JP2008505785A - Coating method and apparatus for forming a coated object - Google Patents

Abstract

  A method and apparatus used to produce a coated object (article) having one or more layers. The layer can be applied by dip coating, spray coating or flow coating. The apparatus and method can produce a coated container, preferably a container containing polyethylene terephthalate, from a coated preform. In certain apparatus configurations, the apparatus and method produce containers or preforms that are coated in an energetically efficient manner that reduces the risk of damage to the coating and thus increases the effectiveness of the final container. Makes it possible to do.

Description

Related Applications This application is incorporated herein by reference in its entirety, provisional application 60 / 586,854 filed on July 9, 2004, provisional application 60 / 644,044 filed on January 14, 2005, And claims priority to provisional application 60 / 672,321 filed April 18, 2005 under 35 USC 119 (e).

Background of the invention
TECHNICAL FIELD OF THE INVENTION The present invention relates to a method and apparatus for producing an object (or article) having one or more layers by dip coating, spray coating or flow coating. In one embodiment, the present invention relates to an apparatus and method for producing a coated container, preferably a container comprising polyethylene terephthalate, from a preform.

Description of Related Art A preform is a product from which a container is manufactured by blow molding. The term “container” is a broad term and includes both preforms and bottle containers made from the preforms, regardless of whether or not they are used in the normal sense. . Various plastics or other materials are used for the containers, many of which are very suitable. Products such as carbonated beverages and foodstuffs require containers that are resistant to permeation of gases such as carbon dioxide or oxygen. Such container coatings have been suggested for many years. A resin that is now widely used in the container industry is polyethylene terephthalate (PET), which is not only a homopolymer formed by polycondensation of β-hydroxyethyl terephthalate. , Other glycols or dibasic acids, for example, copolymerized polyesters containing minor units derived from isophthalate copolymers.

  The production of biaxially oriented PET is well known in the art. Biaxially oriented PET containers are strong and have good resistance to creep. Relatively thin and lightweight containers can be manufactured to withstand the pressures received from beverages such as carbonated liquids, particularly soft drinks including cola, beer, without distortion beyond the desired shelf life.

  Thin-walled PET containers are somewhat permeable to gases such as carbon dioxide and oxygen gas, and therefore carbon dioxide pressure drops that may adversely affect the scent and quality of the contents in the bottle And oxygen gas ingress may occur. In conventional operation, a preform is manufactured by injection injection and then blown into a bottle. With a commercial 2 liter size, a shell life of 12-16 weeks can be expected, but for smaller bottles such as half a liter, a large surface to volume ratio limits the shell life. Carbon dioxide can be pressurized to 4.5 gas volumes, but if this pressure drops below the acceptable product specification level, the product is considered unsatisfactory.

SUMMARY OF THE INVENTION In a first aspect, the present invention relates to a method and apparatus for producing an object (or article), preferably a plastic object, having a coating with one or more layers. These layers can include thermoplastic materials with good gas barrier properties, and these layers can be UV protected, scuff resistant, blush resistant, chemical resistant, and And / or active properties such as O ₂ or CO ₂ scavenging.

  In some embodiments, a method of manufacturing a multilayer object (or multilayer article) is provided. The method includes a process of transporting an object substrate to a transfer device. The substrate of the object is passed along the transfer device to the loading device. The loading device places the object substrate on the carrier itself which is configured to hold the object substrate. The carrier is selectively movable to carry the substrate along the processing line. A first coating material is deposited on a portion of each object substrate to form a first coating on each object substrate. This first coating material is removed from the bottom of the substrate of each object. In some embodiments, after the first coating material is removed from the substrate of the object, a second coating is applied to at least a portion of the substrate of each object.

  In some embodiments, a method of manufacturing a multilayer object is provided. The method includes a process of transporting an object to a transport device. The carrier of the transport device is configured to hold the object substrate. The carrier carries objects along the processing line. A coating material is deposited on at least a portion of the substrate of each object to form a first coating on the substrate of each object. This coating material is removed from a portion of the substrate of each object. In some embodiments, excess material is removed from the substrate of each object. In some embodiments, a material removal device is used to remove material from the substrate of the object.

  In some embodiments, the coating device includes a transfer device and a carousel device. The transfer device conveys the substrate of the object continuously or discontinuously to the carousel device. In some embodiments, the carousel device is fed with a substrate of objects in batches. In some embodiments, the carousel device includes a loading device configured to pick up an object substrate from the transfer device and transfer the object substrate to the carousel device.

  In some embodiments, a substrate of an object having a liquid coating on the outside is provided. At least a portion of the outer coating can be removed by a material removal device. In some embodiments, the material removal device removes a portion of the coating in the end cap region of the object. In some embodiments, the coating material is heated to a sufficiently high temperature to facilitate recoating a portion of the object substrate. In some embodiments, the objects are self-coated due to gravity, causing the liquid coating material to flow over a portion of each object.

  In some embodiments, an apparatus for producing a multilayer object is provided. The apparatus comprises a transfer device configured to receive and carry an object. The loading device includes a plurality of loaders. The loader is movable between a loading position and an unloading position. The plurality of movable carriers can have a gripping mechanism configured to selectively hold a substrate of an object. The loader is configured to receive an object substrate from the transfer device when the loader is in the loading position. The loader is configured to transport the object substrate to a movable carrier when the loader is in the unloading position. The plurality of movable carriers are configured to maintain and carry the substrate of the object along the processing line. The covering unit is located along the side of the processing line. The covering unit is configured to transport the material to the substrate of the object held by the carrier.

  In some embodiments, the movable carrier is attached to a conveyor. The carrier can have one or more gripping mechanisms. Each gripping mechanism is sized to match the inside of the corresponding object substrate (ie, preform or container). Each gripping mechanism is movable between a first position for holding the object substrate and a second position for receiving the object substrate. In some embodiments, the gripping mechanism is in the shape of a mandrel.

  In some embodiments, the coating apparatus is configured to coat a substrate of an object. The coating apparatus comprises a controller connected to a plurality of temperature sensors and a curing device configured to cure (remove) a layer of material on the substrate of the object. The controller controls the output of the curing device in response to at least one temperature signal from the at least one temperature sensor. In some embodiments, the temperature sensor is a pyrometer or a thermocouple.

  In some embodiments, the transfer device transports the substrate of the object to the carousel device. The transfer device comprises at least one star wheel device. The star wheel device has a plurality of peripheral pockets that are sized and dimensioned to receive the substrate of the object. The plurality of peripheral pockets are rotatable about the drive shaft of the star wheel device. In some embodiments, the transfer device comprises a plurality of star wheels. The star wheel is arranged to transport the substrate of the object to the carousel device.

  In some embodiments, an apparatus for producing a multilayer object is provided. The apparatus includes a transport device (transport system) having a carrier. Each carrier is configured to carry at least one substrate along the processing line. A coating device (or coating system) is located next to the processing line. The coating apparatus comprises a conveying device configured to convey a coated substrate held on a carrier moving along a processing line. In some embodiments, the transport device comprises a coating unit. The modular tank device is movable relative to the transport device and can be positioned. In some embodiments, the modular tank apparatus comprises a tank configured to hold the coating material and a pump in communication with the tank. The modular tank device is movable between a remote position and a transfer position. In some embodiments, when the modular tank device is in the transfer position and the pump is operating, the coating material is transferred from the tank to the transfer device. In some embodiments, when the modular tank device is in the transfer position and the pump is operating, the modular tank device is next to the transfer device and the coating material is transferred from the tank to the transfer device. The

  In some embodiments, the modular tank apparatus comprises a transport device (transport system) configured to roll along a support surface. The transport device may comprise one or more wheel assemblies. In some embodiments, the transport device comprises four wheel assemblies mounted on the frame of the modular tank device. In some embodiments, the transport device comprises a linear slider.

  The modular tank device may comprise a filtration device in communication with the tank. The filtration device may comprise a plurality of filters configured to remove objects or impurities from the coating material.

  In some embodiments, a process for producing a coated object is provided. This process provides a container or preform comprising an object, preferably polyethylene terephthalate, applying an aqueous dispersion of a thermoplastic resin to the object, and curing / drying the coating. In some embodiments where the object is a preform, preferably the method further comprises a blow molding operation, the blow molding preferably being suitable for orientation in the bottle / container. Stretching the dried coated preform axially and radially in a blow molding process at a moderate temperature. Within that process, a thermoplastic epoxy resin is applied to the object by dipping, spraying or flow coating, and the coating and drying process is applied in more than one pass, so that the coating properties depend on each coating layer. Be improved. The volume of the coating deposit can vary depending on the body temperature, body angle, solution / dispersant temperature, solution / dispersant viscosity, and number of layers. The preferred multiple coating results in a substantially non-distinctive multilayer between the layers, resulting in improved coating performance and / or reduced surface voids and coating holidays. Furthermore, the preferred multiple coating process produces a continuous layer that is required to reduce the amount of coating material in order to sufficiently cover the object.

  In a preferred embodiment, the coating / drying process provides enhanced surface tension properties. In a further preferred process, the drying process of the object has a repair effect with respect to defects on the surface of the object as a final product. Further, in a preferred process, the drying / curing process produces an object that exhibits substantially no blushing.

  According to an embodiment, there is provided a processing method for producing an object coated with a thermoplastic resin, the processing method comprising applying a first heat to the outer surface of the substrate of the object by dip coating, spray coating or flow coating. Applying an aqueous solution or dispersion of a plastic resin; pulling the object out of the dip, spray coating or flow coating at a predetermined ratio to form a first coherent film; Curing / drying until the film is substantially dry to form the first coating. Optionally, the method further applies an aqueous solution or dispersion of the second thermoplastic resin to the outer surface of the substrate of the object by dip coating, spray coating or flow coating; a second adherent film The object is drawn from the dip coating, spray coating or flow coating at a predetermined ratio; and cured / dried until the second film is substantially dry to form the second coating. In a preferred embodiment, at least one of the first and second thermoplastic resins, which may be the same or different, comprises a thermoplastic epoxy resin.

  In accordance with a preferred embodiment, a method of dip coating an object (article) is provided, the method comprising the following steps: a) achieving sufficient exposure to the flow Immersing the object in an aqueous coating / dispersion contained in either a static vat or flow coater while rotating the object, b) from a static vat or flow coater The object is lifted at the rate at which a coherent film is observed, and c) the infrared heater is irradiated, optionally while cooling the object with air until the film is substantially dry.

  In accordance with a preferred embodiment, an apparatus for dip coating an object (article) is provided, the apparatus comprising an object transporter (conveyor) for transporting the object through the dip coating apparatus; A tank or bat containing a dispersion, wherein the transporter draws or immerses an object through the tank or bat; and a cure comprising an oven or chamber in which a curing / drying source is located And an object is moved by the transporter through the oven or chamber. The curing / drying unit is optionally coupled to a fan or blower that cools the object with air. A preferred apparatus can have a second tank or vat for the coating material and a second curing / drying unit. In other preferred embodiments, the transporter transports the object back through the tank and / or curing / drying unit to provide the object with a second coating. Preferred embodiments can include one or more dip removers located between the coating tank or vat and the curing / drying unit, or located in front of the curing / drying unit.

  According to another preferred embodiment, a method of coating an object (article) is provided, the method comprising the following steps: a) the object to achieve sufficient exposure to the flow Spray the object with an aqueous coating / dispersion while rotating the object; b) spray the object at a rate where a coherent film is observed; c) selectively until the film is substantially dry First, an infrared heater is irradiated while cooling an object with air.

  In accordance with a preferred embodiment, an apparatus for spray coating an object is provided, the apparatus being included in an object transporter that transports the object through the spray coating apparatus; for example, included in a bat One or more nozzles in communication with the aqueous solution / dispersion obtained; a coating material collector for receiving unused coating material; a curing / comprising an oven or chamber in which a curing / drying source is located A drying unit, and the object is moved by the transporter through the oven or chamber. The curing / drying unit is optionally coupled to a fan or blower to cool the object with air. A preferred apparatus further comprises a second tank or vat for the coating material, a second group of one or more spray nozzles, and / or a second curing / drying unit, or When providing two coatings, one or more components of the first spray coating apparatus can be used.

  Suitable apparatus optionally includes one or more dip removers located between the spray unit and the curing / drying unit or placed in front of the curing / drying unit. it can.

  According to another embodiment, a method of flow coating an object is provided, the method comprising the following steps: a) rotating the object so that it is sufficiently illuminated against the flow Flow coated with an aqueous coating / dispersion; b) pulls the object from the flow coated sheet at a rate where a coherent film is observed; c) irradiates the infrared heater with the object and film until the film is substantially dry Optionally, d) cooling the object with air.

  According to a preferred embodiment, an apparatus for flow coating an object is provided, the apparatus comprising an aqueous solution / dispersion of a coating material in communication with an object transporter for transporting the object from the flow coating apparatus and a fluid guide A tank or bat containing a tank or bat that eliminates the flow of fluid guide where the coating material forms a sheet or drops a shower curtain, a coating material collector that receives unused coating material, and curing / drying A curing / drying unit comprising an oven or chamber in which the source is located, and the object is moved by the transporter through the oven or chamber. The curing / drying unit is optionally coupled to a fan or blower that cools the object with air. Preferred embodiments provide a second tank or bat for a covering rod, a second fluid guide, and / or a second curing / drying unit, or a second covering. In some cases, one or more components of the first flow coating apparatus can be used. A suitable apparatus may include a dip remover located between the coating tank or vat and the curing / drying unit, or placed in front of the curing / drying unit.

  In one embodiment, a suitable apparatus comprises means for placing an object in the apparatus, means for dip-coating, spray-coating or flow-coating the object, and optionally, means for removing excess coating, drying or Means for curing, optionally, means for cooling during and / or after the drying / curing means, and means for removing from the apparatus. In one embodiment, the apparatus is a single collective processing line that includes a plurality of stations, each station coating an object, thereby producing an object with multiple coatings.

In another embodiment, apparatus is modular (they become module), in a modular, included in the self by the ability of each processing line is handed off to the other line, a result, how Depending on the many modules, single or multiple coatings are connected to allow maximum processing flexibility.

  In accordance with one embodiment, a multi-layer object is provided, the multi-layer object comprising a substrate and at least one layer, the layer comprising a coated object. A thermoplastic epoxy resin coating disposed on at least a portion of the blower to form, preferably when the coated object is substantially immersed when immersed in water or directly exposed to water. No brushing or whitening occurs on the object. In a preferred embodiment, such objects are also substantially free of brushing or whitening when exposed to high humidity, including 70% or higher humidity. Such exposure to water or humidity occurs during several hours or longer and longer, including about 6 hours, 12 hours, 24 hours, 48 hours, and / or near room temperature. And may occur at low temperatures. In one embodiment, the coated object is about 0-30 ° C, including 5 ° C, 10 ° C, 15 ° C, 20 ° C, 22 ° C, 25 ° C for about 24 hours. There is virtually no brushing or whitening when immersed in water at temperature or when directly exposed to water. In a preferred embodiment, the substrate comprises a polymetric material, preferably a thermoplastic resin selected from the group consisting of polyester, polypropylene, polyethylene, polycarbonate, polyamide, and acrylic. If the object is a preform or bottle having a body portion and a neck portion, preferably the covering is substantially disposed only on the preform body portion. In a preferred embodiment, one or more additional covering layers are disposed on the object. Preferably, the covering layer is disposed on the object. In such three or more layer embodiments, there is substantially no distinction between the coating layers and / or the one or more additional layers comprise a thermoplastic material. The coating layer (s) may, in preferred embodiments, include at least one or more of the following features: gas barrier, UV protection, scuff resistance, brush resistance, chemical resistance.

  Based on the preferred embodiment, a multi-layer container, preferably a preform or bottle having a body portion and a neck portion is produced. Preferably, the container, preform or bottle may comprise a substrate of thermoplastic material and one or more layers of thermoplastic resin coating material. Preferably, the thermoplastic substrate material is selected from the group consisting of polyester, polyolefin, polycarbonate, polyamide and acrylic. Preferably, it may comprise at least one or more of the following features: gas barrier protection, UV protection, scuff resistance, brush resistance, chemical resistance. Preferably, the coating is disposed only on the body portion of the preform. In addition, the opened product preferably has no substantial distinction between layers.

  In a preferred embodiment, the coated object or container formed from the coated preform is water or a low or high temperature (relative to room temperature) for several hours or even longer. Or substantially no brushing or whitening when exposed to high humidity. In one embodiment, the coated object or container is substantially free of brushing or whitening when immersed in water or exposed to water. In related embodiments, flame curing, gas heater, electron beam treatment, or optionally replaced with UV radiation that is followed by or combined with cooling with air. It is done.

  All of these embodiments are intended to be within the scope of the invention disclosed herein. Other embodiments of the invention will be readily apparent to those skilled in the art from the following detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings, and the invention will be described by any particular preferred embodiments disclosed. The present invention is not limited to the embodiment.

A. General Description of Preferred Embodiments A method and apparatus for forming a coating comprising one or more layers on an object will now be described. These layers are good not only for layers or additives that provide active properties such as UV protection, scuff resistance, blush resistance, chemical resistance, and / or oxygen and / or carbon dioxide capture. Thermoplastic materials with gas barrier properties may be included.

  As considered herein, one embodiment of the coated object is a preform of the type used as a beverage container. Alternatively, the coated object embodiments of the present invention may take the form of jars, tubes, trays, bottles that contain products that are sensitive to exposure to liquids, foods, pharmaceuticals, or other gases. However, for simplicity, these embodiments are first described herein as objects or preforms.

  Furthermore, the objects described herein can be specifically described in relation to a specific substrate, polyethylene terephthalate (PET). However, the preferred method is applicable to many other thermoplastic polyester types. As used herein, the term “substrate” is a broad term used in the normal sense, and the material “substrate” is used to form a coated basic object. Including an embodiment. Other suitable object substrates include, but are not limited to, various polymers such as polyesters, polyolefins including polypropylene and polyethylene, polycarbonates, polyamides including nylon, or acrylic resins. These base materials may be used alone or in combination with each other. Examples of more specific substrates include, but are not limited to, polyethylene 2,6- and 1,5-naphthalate (PEN), PETG, polytetramethylene 1,2-dioxybenzoate, and ethylene terephthalate and ethylene isophthalate. Including copolymers.

  In one embodiment, PET is used as the polyester substrate on which the coating is formed. As used herein, “PET” includes, but is not limited to, modified PET as well as PET mixed with other materials. The term “high IPA PET” refers to PET having an IPA content that is preferably greater than about 2% by weight and about 2-10% by weight of IPA.

  One or more layers of coating materials are used in suitable methods and processes. This layer may include a barrier layer, a UV protection layer, an oxygen scavenging layer, a carbon dioxide scavenging layer, and other layers required for a particular application. As used herein, the terms “barrier material”, “barrier resin”, etc. are broad terms and are used in their usual sense, and without limitation, preferably to form a coating on an object. When used, refers to a material that adheres well to the substrate of the object and is less permeable to oxygen and carbon dioxide than the substrate of the object. As used herein, terms such as “UV protection” are broad terms and are used in their ordinary sense, and without limitation, preferably when used to form a coating on an object. , Refers to a material that adheres well to the substrate of the object and has a higher UV absorption than the substrate of the object. As used herein, terms such as “oxygen scavenging” are broad terms and are used in their ordinary sense, and without limitation, preferably when used to form a coating on an object. A material that adheres well to the substrate of the object and has a higher oxygen absorption rate than the substrate of the object. As used herein, terms such as “carbon dioxide capture” are broad terms and are used in their ordinary sense, and without limitation, preferably when used to form a coating on an object. Furthermore, it refers to a material that adheres well to the substrate of the object and has a higher carbon dioxide absorption rate than the substrate of the object. As used herein, terms such as “cross-linked” and “cross-linked” are broad terms and are used in their usual sense, and are not limited, but include a very low degree of cross-linking such as a thermosetting epoxy. Refers to materials and coatings of varying degrees, including even cross-linked materials. The degree of crosslinking can be adjusted to provide an appropriate degree of resistance to chemical or mechanical abuse in a particular environment.

  Once a suitable coating material has been selected, there is a need for an apparatus and method for commercial production of the coated object. One such method and apparatus is described below.

  A preferred method provides a coating that is disposed on the object, in particular a preform that is subsequently blown into a container. Such a method is preferred in many instances for placing the coating on the bottle itself. The preform is then smaller in size and more regular in shape than the blow molded container, making it easier to obtain a uniform and regular coating. Furthermore, bottles and containers of different shapes and sizes can be formed from preforms of similar size and shape. Thus, the same apparatus and process can be used to form a coating on a preform to form several different types of containers. Blow molding may occur immediately after molding and coating formation, or a preform may be formed and stored for later blow molding. If preforms are stored prior to blow molding, their smaller size allows the storage space they occupy to be smaller. While it is often preferred to form a container from a coated preform, the container may also be coated.

  Blow molding processes present several challenges. One process in which the greatest difficulty occurs is during the blow molding process where the container is formed from a preform. During this process, delamination or voids such as delamination, coating cracking and crazing, uneven coating thickness, and discontinuous coating can occur. These difficulties can be overcome by using a suitable coating material and forming a coating on the preform in a manner that provides good adhesion between the layers.

  Thus, preferred embodiments include a suitable coating material. When a suitable coating material is used, the coating adheres directly to the preform without significant delamination and continues to adhere until the preform is blown into a container. The use of a suitable coating material also helps to reduce superficial and structural defects that can occur as a result of the above-described container blow molding.

  One common problem that arises in objects formed by the formation of a coating with a coating solution or dispersion is that the object is directly immersed in water or high humidity (including about 70% relative humidity) (partial immersion). Or “brushing” or whitening when exposed. In preferred embodiments, the objects disclosed herein and the objects produced by the methods disclosed herein have minimal or substantially zero brushing when directly immersed or exposed to water or high humidity. Or indicates whitening. Such exposure may occur for several hours or more, including about 6 hours, 12 hours, 24 hours, 48 hours and more, and / or in a cooler containing ice or ice water. May occur at room temperature and near lowered temperatures, as seen when placing an object on Exposure may also occur at elevated temperatures, including temperatures that do not include temperatures that are normally high enough to cause visible softening of the material forming the container or coating, and temperatures that approach the Tg of the material. . In one embodiment, the coated object is directly at a temperature from 0 ° C. to 30 ° C. for 24 hours, including 5 ° C., 10 ° C., 15 ° C., 20 ° C., 22 ° C. and 25 ° C. Substantially no brushing or whitening when immersed or exposed to water. The treatment used to solidify or dry the coating layer appears to have a cure to the brush resistance of the object.

B. DETAILED DESCRIPTION OF THE DRAWINGS Referring to FIG. 1, a preform 1 is depicted without a suitable coating. The preform is preferably formed from an FDA approved material, such as virgin PET, and may be in any of a wide range of shapes and sizes. The preform shown in FIG. 1 is a 24 gram preform of the type that forms a 16 ounce carbonated beverage bottle, but as will be appreciated by those skilled in the art, it is suitable for the desired shape, properties and end object application. Depending on the shape, other preform shapes can be used. The preform 1 without the coating may be formed by injection molding known in the prior art or other suitable methods.

  Referring to FIG. 2, a cross-sectional view of the preform of FIG. 1 without the preferred coating is depicted. The preform 1 on which no coating is formed has a neck portion 2 and a body portion 4. The neck 2 is also referred to as a neck finish and begins from the opening 18 into the preform 1 and extends to and includes the support ring 6. The neck 2 is further characterized by the presence of threads 8 that provide a means to cap the bottle formed from the preform 1. The body portion 4 has an elongated cylindrical shape that extends from the neck 2 and reaches the rounded end cap 10. The preform thickness 12 depends on the overall length of the preform 1 and the resulting wall thickness and overall size of the container. As the terms “neck” and “body” are used herein, in a container referred to in the colloquium as a “long neck” container, the elongate just below the support ring, the threads, and / or the spout where the cap is closed Note that it is considered part of the “body” of the container, not part of the “neck”.

  Referring to FIG. 3, a cross-sectional view of one type of coated preform 20 having features according to a preferred embodiment is depicted. The coated preform 20 has a neck portion 2 and a body portion 4 like the preform in which the coating of FIGS. 1 and 2 is not formed. The covering layer 22 is disposed on almost the entire surface of the body portion 4 and ends at the bottom of the support ring 6. The covering layer 22 in the embodiment shown in the drawings does not extend to the neck 2 and is preferably not present on the inner surface 16 of the preform formed from an FDA approved material such as PET. . The covering layer 22 may include one layer of one material, one layer of several materials combined, or several layers of at least two materials. The total preform thickness 26 is equal to the initial preform thickness plus the thickness of the coating layer or layers, depending on the overall size of the resulting container and the desired coating thickness.

  FIG. 4 is an enlarged view of the wall section of the preform showing the configuration of the coating layer in an embodiment of the preform. Layer 110 is a preform substrate layer, while 112 includes a preform covering layer. The outer covering layer 116 includes one or more layers of material, while 114 includes the inner covering layer. In preferred embodiments, there may be one or more outer coating layers. As shown here, a coated preform has one inner coating layer and two outer coating layers. Not all preforms in FIG. 4 are of this type.

  Referring to FIG. 5, another embodiment of a coated preform 25 is shown in cross section. The main difference between the coated preform 25 and the coated preform 20 of FIG. 3 is that the coating layer 22 is arranged not only on the body part 3 but also on the support ring 6 of the neck part 2. Preferably, any coating, particularly on the upper surface or above the support ring 6, is formed from an FDA approved material such as PET.

  Coated preforms and containers can have layers of varying relative thickness. In view of the present disclosure, the thickness of a given layer and the thickness of the preform or the entire container may be selected to suit the coating forming process or particularly the end use of the container at a given point or throughout the container. it can. Further, as discussed above with respect to the coating layer of FIG. 3, the coating layer in the preform and container embodiments disclosed herein is composed of one material, one layer of several materials, at least two or more materials. It can contain several layers.

  After a coated preform as depicted in FIG. 3 is prepared by a method and apparatus as described in detail below, it is subjected to a stretch blow molding process. Referring to FIG. 6, the preform 20 coated in this process is placed in a mold 28 having a mold space corresponding to the desired container shape. The coated preform is then heated, expanded by stretching, and forced by air inside the preform 20 to fill the mold space of the mold 28 to form a coated container 30. The operation of the blow molding process is usually limited to the body part 4 of the preform, and the neck part 2 including the thread, pilfer ring and support ring retains the shape of the original preform.

  Referring to FIG. 7, an embodiment of a coated container 40 according to a preferred embodiment is disclosed that can be formed by blow molding the coated preform 20 of FIG. The container 40 has a neck portion 2 body portion 4 corresponding to the neck and body portion of the coated preform of FIG. The neck 2 is further characterized by the presence of threads 8 that provide a means for closing the cap on the container.

  When the coated container 40 is viewed in cross-section as in FIG. 8, the configuration can be seen. The covering 42 covers the entire outside of the body part 4 of the container 40 and stops immediately below the support ring 6. Since the inner surface 50 of the container made of FDA approved material, preferably PET, remains uncoated, only the inner surface 50 is filled with a product such as a beverage, food or medicine. Contact with. In one preferred embodiment used as a carbonated beverage container, a 24 gram preform has a coating in the range of about 0.05 to about 0.75 grams, including about 0.1 to about 0.2 grams. Blow molded into 16 ounce bottles.

  Referring to FIG. 9, a preferred three layer preform 76 is shown. This coated preform embodiment is preferably formed by placing two coating layers 80 and 82 on the preform 1 as shown in FIG.

  Referring to FIG. 10, a non-limiting flow diagram illustrating a preferred process and apparatus is shown. Suitable treatments and equipment include entry 84 to the device 84, object dip, spray or flow coating 86, excess material removal 88, drying / solidification 90, cooling 92, removal from the device 94. Include.

  Referring to FIG. 11, a non-limiting flow diagram of one embodiment of a preferred process is shown, where the apparatus includes one coating unit A of the type of FIG. 10 that produces one coated object. . The object is placed in the device 84 before the coating unit and is removed from the device 94 after the coating unit is removed.

  Referring to FIG. 12, there is shown a non-limiting flow diagram of a preferred embodiment, where the apparatus includes one integrated processing line that includes multiple stations 100, 101, 102, each The station forms a coating on the object and dries or solidifies it, thereby producing an object with multiple coatings. The object is placed in the device 84 before the first station 100 and is removed from the device 94 after the last station 102. It should be understood that the embodiments described herein illustrate one integrated processing line having three coating units and that the number of coating units described above and below is also included.

  Referring to FIG. 13, a non-limiting flow diagram of one embodiment of a preferred process is shown. In this embodiment, the device is modular, where each processing line 107, 108, 109 is self-contained with the ability to pass to the other line 103, so that any number of modules are connected. Depending on whether one or more layers can be formed, thereby allowing maximum flexibility. The object first enters the device at one of several points on the device 84 or 120. The object can enter 84 and proceed through the first module 107, after which the object may exit the device at 118, or the following through a hand off mechanism 103 known by those skilled in the art. May continue to module 108. The object enters the next module 108 at 120. The object may continue to the next module 109 or may exit the device. The number of modules may vary depending on the required manufacturing environment. Further, the individual coating units 104, 105, 106 may include different coating materials depending on the needs of a particular production line. Compatibility between different modules and covering units provides maximum flexibility.

  Referring to FIGS. 14, 15 and 16, there is shown an alternate diagram of a non-limiting diagram of one embodiment of a preferred process. In this embodiment, a top view of an apparatus including one flow coater 86 is shown. The preform enters apparatus 84 and proceeds to flow coater 86, where preform 1 passes through a waterfall of coating material. The coating material travels down the angled liquid guide 160 from the tank or from the bat 150 via a gap 155 in the tank, where a waterfall (not shown) as it passes over the preform. Form. The gap 155 in the tank may be widened or narrowed to regulate the material flow. Material is pumped from a reservoir (not shown) to a bat or tank at a rate that keeps the coating material level above the level of the gap. Advantageously, this arrangement ensures a constant flow of coating material. Excess material also reduces fluid fluctuations due to pump rotation. As the preform exits the coating waterfall, excess material will drip into the material collection reservoir 170. A coating material collector (not shown) receives an unused coating waterfall and returns the material to the coating tank or vat. Thereafter, excess material is removed from the bottom of the preform 88. The preform then moves to the drying / solidification unit 90 before being removed from the device 94. As shown here, the preform is stationary prior to removal for cooling. The collection reservoir and the coating material collector are preferably poured into a reservoir feeding a tank or bat so that drainage from the device can be reduced.

  Referring to FIGS. 17A and 17B, a non-limiting view of one embodiment of a suitable infrared drying / solidification unit 90 is shown. As shown in FIG. 17A, the unit 90 is opened. The arrow at the bottom of the unit shows how the unit closes. A series of ten lamps 200 is shown on one side of the processing line. Below the preform is shown an angled reflector 210 that reflects heat to the bottom of the preform for more complete solidification. On the other side of the lamp is a semi-circular reflector 230 that reflects infrared heat back into the preform to allow more complete and efficient solidification. Reflectors with other shapes and sizes may be used.

  Referring to FIG. 17B, an enlarged cross-sectional view detailing the lamp arrangement in one embodiment of a preferred infrared drying / solidification unit 90. The lamp in this embodiment is adjustable 220 and may be moved closer to or away from the preform to allow maximum drying / solidification flexibility.

  Suitable methods and apparatus for forming coated objects, and more particularly preforms, are discussed in more detail below.

C. General Description of Suitable Materials The objects disclosed herein are made from any of a wide range of materials as disclosed herein. Some objects may be specifically described in relation to a particular basic preform material and / or a coating material for these same objects. And the methods used to manufacture the object can be applied to many other thermoplastic resins, including but not limited to polyester, polyolefin, polylactic acid, polycarbonate and the like. Other suitable materials include, but are not limited to, polymeric materials including thermosetting polymers, thermoplastic materials such as polyester, polyolefins including polypropylene and polyethylene, polycarbonate, nylon (eg nylon 6, nylon 66) and MXD6. Polyamides, polystyrenes, epoxies, copolymers, blends, graft polymers and / or modified polymers (monomers or portions thereof having other groups as side groups, such as olefin-modified polyesters). These materials may be used alone or in conjunction with other materials, blends or copolymers that are multilayer structures. And can be combined with different additives such as nanoparticle barrier materials, oxygen scavenging, UV absorbers, foaming agents. More specific examples of materials include, but are not limited to, ethylene vinyl acetate (EVA), linear low density polyethylene (LLDPE), polyethylene 2,6- and 1,5-naphthalate (PEN), polyethylene terephthalate glycol (PETG) ), Poly (cyclohexylenedimethylene terephthalate), polylactic acid (PLA), polycarbonate, polyglycolic acid (PGA), polystyrene, cycloolefin, poly-4-methylenepentene-1, poly (methyl methacrylate), acrylonitrile, Polymeric ionomers such as polyvinyl chloride, polyvinylidene chloride (PVDC), styrene acrylonitrile, acrylonitrile butadiene styrene, polyacetal, polybutylene terephthalate, PET sulfonate omers), polysulfone, polytetrafluoroethylene, polytetramethylene 1,2-dioxybenzoate, polyurethane, and copolymers of ethylene terephthalate and ethylene isophthalate, and one or more of the aforementioned copolymers and / or blends.

  As used herein, the term “polyethylene terephthalate glycol” (PETG) is referenced to a copolymer of PET, and an additional comonomer, cyclohexane dimethanol (CHDM), is effective in a mixture of PET ( For example, about 40% or more by weight) is added. In one implementation, suitable PETG materials are essentially amorphous. Suitable PETG materials can be purchased from a variety of sources. One suitable sales source is a division of Voridian, Eastman Chemical Company. Other PET copolymers contain CHDM at a lower level so that the resulting material remains crystallizable or semi-crystalline. One example of a PET copolymer containing a lower level of CHDM is Voridian 9921 resin. Another example of modified PET is a PET having an IPA content preferably greater than 2% by weight, containing about 2-20% by weight of IPA, and containing about 5-10% by weight of IPA. “High IPA PET” or IPA modified PET. In the specification, all proportions in the formulas and compositions are by weight unless otherwise specified.

  In some embodiments, grafted or modified polymers can be used. In one implementation, the polypropylene or other polymer includes, but is not limited to, maleic anhydride, glycidyl methacrylate, acrylic methacrylate and / or similar compounds to improve adhesion. In other embodiments, polypropylene also refers to clarified polypropylene. As used herein, the term “clear polypropylene” is a broad term and is used according to its ordinary meaning and includes, but is not limited to, a nucleation inhibitor and / or a clear additive. including. Clear polypropylene is generally a transparent material compared to homopolymers or block copolymers of polypropylene. The inclusion of the nucleation inhibitor helps to prevent and / or reduce crystallinity or the effect of crystallinity, and within polypropylene or other materials added to it, it contributes to the haze of polypropylene. Some purifiers work by reducing the total crystallinity that reduces than reducing the size of the crystalline domains and / or counteract the size of large domains that can be formed by lack of purifier. Including the formation of many small domains. Clear polypropylene can be purchased from a variety of sources such as Dow Chemical Co. Nucleation inhibitors may also be added to polypropylene or other materials. One suitable source of nucleation inhibitor additive is Schulman.

  In certain embodiments, suitable materials are unused, pre-use, used, ground recycled material, recycled and / or combinations thereof. For example, the PET can be unused, pre-use, used, recycled, or ground recycled material PET, PET copolymer, and combinations thereof.

  In a preferred embodiment, the final containers and / or materials used therein are beneficial in the next plastic container recycling trend. In a preferred embodiment, a substrate that is an object such as a container, jar, bottle or preform (sometimes referred to as a basic preform) uses the apparatus, methods and materials described herein. Covered. The basic preform or substrate is manufactured by any suitable method. Including but not limited to those well known in the art, with or without subsequent blow molding, injection molding, including single molecule injection molding, inject-over-inject molding, And co-injection molding, extrusion molding, and compression molding. The substrate is made of any material or combination of materials including glass, plastic, metal and the like. Polymers such as thermoplastic materials are preferred. Examples of suitable thermoplastics include, but are not limited to, polyesters (eg, PET, PEN), polyolefins (PP, HDPE), polylactic acid, polycarbonate, and polyamide.

  Each of the one or more layers that coat the substrate is formed by application to the construction of the coating layer according to the methods described herein. Suitable coating layer configurations include solutions, suspensions, emulsions and / or dispersions comprising at least one polymeric material (preferably a thermoplastic material) and optionally one or more additives. The additive is preferably applied to the coating during a dry or cured coating layer (eg, UV resistance, barrier, scratch resistance) and / or treatment (eg, thermal enhancer, non-foaming agent). Provides functionality for the configuration. The polymeric material used in the layer configuration itself provides functional properties such as a gas barrier.

  The construction of the coating layer includes aqueous and / or organic solvents, but it is preferred that the material minimize the amount of volatile organic compounds (low VOC). When multiple layers are used, it is preferred that each layer be sufficiently dried (ie, remove volatile solvents) before the next layer is applied.

In preferred method and processing embodiments, the one or more layers comprise a barrier layer, a UV protective layer, an oxygen scavenging layers, an oxygen barrier layer, a carbon dioxide scavenging layers, carbon dioxide. It can include barrier layers and other layers as required for a particular application. As used herein, the terms “barrier material”, “barrier resin” and the like are broad terms and are used in their ordinary sense, and are not limited, but when used in preferred methods and processes, It refers to one or more other layers of materials and / or final objects (including substrates) that have a low permeability of oxygen and carbon dioxide. As used herein, terms such as “UV protection” are broad terms that are used in their ordinary sense and include, but are not limited to, higher UV absorption than one or more other layers of an object. The material which has. As used herein, terms such as “oxygen scavenging” are broad terms and are used in their ordinary sense and include, but are not limited to, higher oxygen absorption rates than one or more other layers of an object. The material which has. As used herein, terms such as “oxygen barrier” are broad terms and are used in their ordinary sense, including but not limited to, virtually inactive or active, and in objects and / or It refers to a material that delays oxygen transmission to the outside. As used herein, terms such as “carbon dioxide capture” have a broader meaning and are used in their ordinary sense, including but not limited to higher carbon dioxide absorption than one or more other layers of an object. Refers to a material having a rate. As used herein, a term such as “carbon dioxide barrier” refers to a material that, in principle, is inert or active, and delays the permeation of oxygen into and / or out of an object.
Without wishing to be bound by any theory, the Applicant has received carbon dioxide capture in one or more layers of the object in applications where the carbon dioxide product contained in the object, such as a soft drink, is excessively carbon dioxide. Inclusion allows excessive carbonation and saturates the layer containing carbon dioxide capture. Thus, when carbon dioxide escapes from the object to the atmosphere, it first exits the object layer rather than the product contained therein. As used herein, the terms “cross-linked”, “cross-linked” and the like are broadly used and are used in their ordinary sense, and refer to materials and coatings, without limitation. They vary from very slight cross-linking to including fully cross-linked materials such as thermoset epoxies. The degree of cross-linking can be adjusted to provide suitable or appropriate physical properties such as a degree of chemical or mechanical fraud resistance for a particular situation.

  Other functions provided by one or more coating layers, alone or in conjunction with other functions, to colors, substrates and / or other coating layers, including but not limited to dyes and pigments An adhesion promoter for enhancing the adhesion of the coating layer, and an adhesion resistance agent.

D. Examples of preferred coating materials or objects
1. Examples of preferred coating materials In a preferred embodiment, the preferred coating material comprises a thermoplastic material. Further preferred embodiments include “phenoxy-type thermoplastics”. As that term is used herein, phenoxy-type thermoplastics include a variety of materials, including those discussed in WO 99/20462. In one embodiment, the material comprises a thermoplastic epoxy resin (TPE), a phenoxy-type thermoplastic, a subset of phenoxy-type thermoplastic. Furthermore, phenoxy-type thermoplastics and a subset of thermoplastic materials are preferred hydroxyphenoxy ether polymers, and polyhydroxyamino ether copolymers (PHAE) are even more preferred materials. For example, U.S. Pat. Nos. 6,455,116, 6,180,715, 6,011,111, 5,834,078, 5,814,373, 5,464,924, and 5 , 275,853. See also PCT application numbers WO99 / 48962, WO99 / 12995, WO98 / 29491 and WO98 / 14498. In some embodiments, the PHAE is TPE.

Preferably, the phenoxy type thermoplastic used in the preferred embodiment comprises one of the following types:
(1) Poly (amide ether) functionalized with a hydroxy group having a repeating unit represented by any one of the formulas Ia, Ib or Ic:

  Or

(2) Poly (hydroxyamide ether) having a repeating unit individually represented by any one of chemical formulas IIa, IIb, or IIc

  Or

(3) Polyether functionalized with amide and hydroxymethyl groups having repeating units represented by Formula III

(4) Polyether functionalized with a hydroxy group having a repeating unit represented by Formula IV

(5) Poly (ethersulfonamide) functionalized with a hydroxy group having a repeating unit represented by the chemical formula Va or Vb

(6) Poly (hydroxy ester ether) having a repeating unit represented by Chemical Formula VI

(7) Hydroxy-phenoxy ether polymer having a repeating unit represented by chemical formula VII

And
(8) Poly (hydroxyaminoether) having a repeating unit represented by Chemical Formula VIII

  Here, each Ar is individually a divalent aromatic moiety, a substituted divalent aromatic moiety, or a heteroaromatic moiety, or a different divalent aromatic moiety, a substituted aromatic moiety, or a heteroaromatic. Represents a combination of parts. R is individually hydrogen or a monovalent hydrocarbyl group moiety. Each Ar1 is a divalent aromatic moiety or a combination of amide or divalent aromatic moieties having a hydroxymethyl group. Each Ar2 is the same as or different from Ar and individually represents a divalent aromatic moiety, a substituted aromatic moiety, or a heteroaromatic moiety, or a different divalent aromatic moiety, a substituted aromatic moiety, or A combination of heteroaromatic moieties. R1 is individually primarily a hydrocarbylene group moiety, such as a divalent aromatic moiety, a substituted divalent aromatic moiety, a divalent heteroaromatic moiety, a divalent alkylene moiety, a substituted divalent alkylene moiety, or A divalent heteroalkylene moiety or a combination of such moieties. R2 is individually a monovalent hydrocarbyl group moiety. A is an amine moiety or a combination of different amine moieties. X is an amine, arylene oxy, arylene disulfonamide, or an arylene carboxy moiety, or a combination of such moieties. Ar3 is a cardo portion.

  Here, Y is a covalent bond or link group, where suitable link groups include, for example, an oxygen atom, a sulfur atom, a carbonyl atom, a sulfonyl group, or a methylene group, or a similar bond. . n is an integer of about 10 to about 1000. x is 0.01 to 1.0. And y is 0-0.5.

  The term “primarily hydrocarbylene” means a divalent radical that is predominantly a hydrocarbon, but optionally, such as oxygen, sulfur, imino groups, sulfonyl groups, sulfoxyl groups, and the like. Contains a small amount of a heteroatom moiety.

  The poly (amide ether) functionalized with a hydroxy group represented by Formula I is preferably N, as described in US Pat. Nos. 5,089,588 and 5,143,998. N'-bis (hydroxyphenylamido) alkanes or arenes are prepared by contacting diglycidyl ether.

  The poly (hydroxyamide ether) represented by Formula II is, for example, N, N′-bis (3-hydroxyphenyl) adipamide, as described in US Pat. No. 5,134,218, or , N, N′-bis (3-hydroxyphenyl) glutamide, bis (hydroxyphenylamido) alkanes, or arenes, or combinations of two or more of these compounds are prepared by contacting with epihalohydrin.

  Polyethers functionalized with amides and hydroxymethyl, represented by Formula III, can be diglycidyl ethers such as diglycidyl ethers of bisphenol A, for example, pendant amides, N-substituted amides, and / or hydroxylalkyls. Prepared by reacting with a dihydric phenol having a moiety, such as 2,2-bis (4-hydroxyphenyl) acetamide and 3,5-hydroxybenzamide. These polyethers and their products are described in US Pat. Nos. 5,115,075 and 5,218,075.

  Polyethers functionalized with hydroxy groups represented by Formula IV can be synthesized using, for example, diglycidyl ether or a combination of diglycidyl ethers using the process described in US Pat. No. 5,164,472. It is prepared by reacting a dihydric phenol or a compound of a dihydric phenol. Alternatively, polyethers functionalized with hydroxy groups can be obtained by combining dihydric phenols or combinations of dihydric phenols with Reinking, Barnabeo and Hale in the Journal of Applied Polymer Science, Vol. 7, p. 2135 (1963) by reaction with epihalohydrin.

  A poly (ethersulfonamide) functionalized with a hydroxy group, represented by Formula V, is, for example, N, N′-dialkyl, or as described in US Pat. No. 5,149,768, or Prepared by polymerizing N, N'-diallyldisulfonamide with diglycidyl ether.

  The poly (hydroxy ester ether) represented by Formula VI is a diglycidyl ether of an aliphatic or aromatic diacid, such as diglycidyl terephthalate or diglycidyl ether of a dihydric phenol, adipic acid or isophthalic acid. Prepared by reacting with an aliphatic or aromatic diacid. These polyesters are described in US Pat. No. 5,171,820.

  The hydroxy-phenoxy ether polymer represented by formula VII is substituted with, for example, 9,9-bis (4-hydroxyphenyl) fluorene, phenolphthalein, or phenolphthalimidine, or substituted with at least one dinuclear monomer. At least one diglycidyl ether of cardo-bisphenol, such as bis (hydroxyphenyl) fluorene, substituted phenolphthalein, or substituted cardo-bisphenol, such as substituted phenolphthalimidine, and its dinuclear Under conditions sufficient to react the nucleophilic part of the monomer with the epoxy part and form a pendant hydroxy part and a polymer backbone containing ether, imino, amino, sulfonamide, or ester chains , By contacting Te, to prepare. These hydroxy-phenoxy ether polymers are disclosed in US Pat. No. 5,184,373.

  The poly (hydroxyaminoether) ("PHAE" or polyetheramine) represented by Formula VIII is prepared by converting one or more of the diglycidyl ethers of phenols containing two hydroxyl groups to amines having two amine hydrogens and amine chains. Prepared by contacting under sufficient conditions to sufficiently provide an amino moiety that reacts with the epoxy moiety to form a polymer backbone having an ether chain and a suspended hydroxy moiety. These compounds are disclosed in US Pat. No. 5,275,853. For example, the polyhydroxyaminoether copolymer is made from diglycidyl ether, hydroquinone diglycidyl ether, bisphenol A, diglycidyl ether, or combinations thereof.

  Hydroxy-phenoxy ether polymers are polynuclear phenol condensation-reactive products with two hydroxyl groups in the molecule, such as bisphenol A and epihalohydrin, and have repeating units represented by Formula IV, where Then, Ar is an isopropylidene / diphenylene moiety. The process of preparing these is disclosed in US Pat. No. 3,305,528, which is incorporated by reference in all of it.

  In general, preferred phenoxy-type materials form stable aqueous solutions or dispersions. Preferably, the solution / dispersion properties are not adversely affected by contact with water. Preferred materials are distributed from approximately 10% solids to approximately 50% solids, including approximately 15%, 20%, 25%, 30%, 35%, 40%, and 45%, and Such a percentage is distributed. Preferably, the material used is dissolved or dispersed in a polar solvent. These polar solvents are, but not limited to, water, alcohols, and glycol ethers. For example, see US Pat. Nos. 6,455,116, 6,180,715, and 5,834,078, where some preferred phenoxy-type solutions and / or dispersions are described. ing.

  One preferred phenoxy type material is a polyhydroxyaminoether copolymer (PHAE), a dispersion or solution represented by Formula VIII. Dispersions or solutions, when applied to containers or preforms, greatly reduce the permeation rate of various gases through the walls of the container in a predicted and well-known manner. One dispersion or latex made thereby comprises 10 to 30 percent solids. PHAE solutions / dispersions are those other than those containing PHAE in an aqueous solution, preferably containing an organic acid, preferably an acid of lactic acid, malic acid, citric acid, or glycol, and / or combinations thereof, Alternatively, it is prepared by stirring or otherwise stirring with phosphoric acid. These PHAE solutions / dispersions also contain organic acid salts produced by reaction of these acids with polyhydroxyamino ethers.

  In some embodiments, the phenoxy type thermoplastic is mixed or blended with other materials using techniques known to those skilled in the art. In some embodiments, a compatibilizer is added to the mixture. When a compatibilizer is used, preferably one or more properties of the mixture, including but not limited to color, haze, and adhesion between layers comprising the mixture and other layers, Improved. One preferred mixture comprises one or more phenoxy type thermoplastics and one or more polyolefins. A preferred polyolefin comprises polypropylene. In one embodiment, the polypropylene or other polyolefin is a polar molecule or monomer, including but not limited to maleic anhydride, glycidyl methacrylate, acrylic methacrylate, and / or similar compounds that increase compatibility. , Grafted or modified.

  The following PHAE solutions or dispersions may be used as described in WO 04/004929 and U.S. Pat. Or an example of a suitable phenoxy type solution or dispersion used when applied as a liquid by spray coating. One suitable material is a BLOX ™ experimental barrier resin, for example, XU-19061.00 made with phosphoric acid manufactured by Dow Chemical Company. This particular PHAE dispersion is said to have the following typical characteristics. 30% solids, specific gravity 1.30, pH 4, viscosity of 24 centipoise (Brookfield, 60 rpm, LVI, 22 ° C.) and particle size 1,400-1800 angstroms. Other suitable materials include resorcinol-based BLOX ™ 588-29 resin, which also provides excellent results as a barrier material. This particular dispersion is said to have the following typical characteristics: 30% solids, specific gravity 1.2, pH 4.0, viscosity of 20 centipoise (Brookfield, 60 rpm, LVI, 22 ° C.). ) And particle sizes of 1,500 to 2,000 angstroms. Other variations of the chemical nature of the polyhydroxyamino ether prove to be useful, such as a crystalline version based on hydroquinone diglycidyl ether. Other suitable materials include solutions / dispersions of polyhydroxy amino ethers available under the name OXYBLOK by Imperial Chemical Industries (“ICI”, Ohio, USA). In one embodiment, the PHAE solution or dispersion is partially (semi-crosslinked), fully or precisely as required for the application by adding the appropriate crosslinker material. To be cross-linked. The benefits of crosslinking include, but are not limited to, one or more of the following: improved chemical resistance, improved wear resistance, low brushing, low surface tension. Examples of crosslinker materials include, but are not limited to, formaldehyde, acetaldehyde, or others of the aldehyde family of materials. A suitable cross-linking agent also changes the Tg of the material and facilitates the formation of certain containers. Other suitable materials include the BLOX ™ 5000 resin dispersion intermediate, BLOX ™ XUR 588-29, BLOX ™ 0000 and 4000 series resins. Solvents used to dissolve these materials include, but are not limited to, polar solvents such as alcohols, water, glycol ethers, or mixtures thereof. Other suitable materials include, but are not limited to, BLOX ™ R1.

  In one embodiment, preferred phenoxy-type thermoplastics are soluble in water-soluble acids. The polymer solution / dispersion is a thermoplastic epoxy in a solution of water, preferably acetic acid or phosphoric acid, and also lactic acid, malic acid, citric acid, glycolic acid, and / or their Prepared by stirring or otherwise mixing with the organic acid, including the mixture. In a preferred embodiment, the acid concentration in the polymer solution is preferably in the range of about 5% to 20%, including about 5% to 10% by weight based on the total weight. In other preferred embodiments, the acid concentration may be about 5% or less, or about 20% or more, and may vary depending on factors such as the type of polymer and its molecular weight. In other preferred embodiments, the acid concentration is distributed from about 2.5 to about 5% by weight. In a preferred embodiment, the amount of dissolved polymer ranges from about 0.1% to about 40%. A homogeneous and free flowing polymer solution is preferred. In one embodiment, a 10% polymer solution is prepared by dissolving the polymer in a 10% acetic acid solution at 90 ° C. And while still hot, the solution is diluted with 20% distilled water to give an 8% polymer solution. Higher polymer concentrations tend to make the polymer solution more viscous. One preferred, non-limiting, hydroxy-phenoxy ether polymer, PAPHEN 25068-38-6, is commercially available from Phenoxy Associates, Inc. Another preferred phenoxy resin is available from InChem ™ (Rock Hill, South Carolina) and these materials include, but are not limited to, INCHEMERZ ™ PKHH and PKHW, products Includes line.

  Other suitable coating materials include preferred copolyester materials, as described in Jabarin U.S. Pat. No. 4,578,295. They generally comprise a mixture of at least one reactant selected from isophthalic acid, terephthalic acid, and their C1 to C4 alkyl esters, 1,3-bis (2-hydroxyethoxyl) benzene and Prepared by heating with ethylene glycol. Optionally, the mixture may further comprise one or more ester-forming dihydroxy hydrocarbons and / or bis (4-β-hydroxyethoxyphenyl) sulfone. In particular, preferred copolyester materials are B-010, B-030, and others in this family such as Mitsui Petrochemical Ind. Ltd .. (Japan).

  An example of a preferred polyamide material includes MXD-6 from Mitsubishi Gas Chemical (Japan). Other preferred polyamide materials include nylon 6 and nylon 66. Other preferred polyamide materials include mixtures of polyamide and polyester, including those comprising about 1-20% polyester by weight, more preferably, comprising about 1-10% polyester by weight. Wherein the polyester is preferably PET or modified PET. In other embodiments, preferred polyamide materials include mixtures of polyamide and polyester, comprising about 1 to 20% by weight polyamide, more preferred or about 1 to 10% by weight. Including those comprising polyamide, where the polyester is preferably PET or modified PET. The mixture is a normal mixture or they are compatibilized with an antioxidant or other material. Examples of such materials include those described in US Patent Publication No. 2004/0013833, filed March 21, 2003, which is hereby incorporated by reference in its entirety. Other preferred polyesters include, but are not limited to, PEN and PET / PEN copolymers.

Certain coating materials are preferably applied as part of a topcoat or layer that provides more chemical resistance to, for example, corrosive or acidic materials than the layer immediately below the topcoat. In one embodiment, these topcoats or layers are aqueous based or non-aqueous based polyesters, polyolefins, and partially or fully cross-linked blends thereof. It is. One preferred aqueous-based polyester is polyethylene terephthalate, but other polyesters can also be used.

  One suitable water-soluble based polyester resin is described in US Pat. No. 4,977,191 (Salsman) and is incorporated herein by reference. More specifically, US Pat. No. 4,977,191 is 20-50% by weight of unwanted terephthalate polymer, 10-40% by weight of at least one glycol, and at least one oxyalkylated. Describes a water soluble base polyester resin with 5-25% reactive organisms by weight of the polyol.

  Another preferred water soluble base polymer is a sulfonated water soluble base polyester resin composition, described in US Pat. No. 5,281,630 (Salsman), which is hereby incorporated by reference. Specifically, US Pat. No. 5,281,630 describes an aqueous suspension of a sulfonated aqueous solution, or 20-50% by weight of a terephthalate polymer, 10-40% by weight of at least one glycol, A hydratable polyester resin comprising a reactive organism of 5-25% by weight of at least one oxyalkylated polyol and producing a prepolymer having a hydroxyalkyl function, wherein the prepolymer resin comprises: Furthermore, at approximately 0.10 mol, per 100 g of prepolymer resin is reacted with approximately 0.50 mol of α, β-ethylenically unsaturated dicarboxylic acid, and a resin is produced, α, β-ethylenically unsaturated dicarbonyl acid Of approximately 0.5 moles per mole of α, β-ethylenically unsaturated dicarbonyl acid residue. Are reacted in a substantially 1.5 moles of sulfite agent, describes generating a sulfonated-terminated resin.

  Yet another preferred water-soluble base polymer is the coating described in US Pat. No. 5,726,277 (Salsman), which is hereby incorporated by reference. Specifically, US Pat. No. 5,726,277 comprises at least 50% reaction product by weight of a mixture of waste terephthalate polymer and glycol containing oxyalkylate polyol in the presence of a glycolysis catalyst. A coating composition wherein the reaction product is further reacted with a bifunctional group, an organic acid, and the weight ratio of the acid in the glycol is in the range of 6: 1 to 2: 1. Yes.

  While the above examples are provided as preferred water soluble based polymer coating compositions, other water soluble based polymers are suitable for use in the product and methods described herein. By way of example and not limitation, a further suitable water-soluble based composition is described in US Pat. No. 4,104,222 (Date et al.), Which is hereby incorporated by reference. U.S. Pat. No. 4,104,222 is a dispersion of a linear polyester resin obtained by mixing a linear polyester resin with a surfactant of higher alcohol / ethylene oxide addition type. It describes melting and, in particular, dispersing the lysate obtained by pouring the melt into an aqueous alkaline solution under stirring. This dispersion is obtained by mixing a linear polyester resin with a higher alcohol / ethylene oxide additive type, resulting in melting the mixture and pouring into an aqueous alkaline solution under stirring. It describes the dispersion of the resulting melt. Specifically, this dispersion is obtained by mixing linear polyester with a higher alcohol / ethylene oxide addition type surfactant, melting the mixture and stirring at a temperature of 70-95 ° C. The resulting melt is dispersed by pouring into an aqueous solution of an alkanolamine, wherein said alkanolamine is monoethanolamine, diethanolamine, triethanolamine, monoethyleneethanolamine, monoethylethanol Selected from the group consisting of amine, diethylethanolamine, propanolamine, butanolamine, pentanolamine, N-phenylethanolamine, and glycerinoalkanolamine, wherein the alkanolamine is 0.2-0.5 in aqueous solution. In the amount of% by weight And the surfactant of the higher alcohol / ethylene oxide additive type is a higher alcohol product of an ethylene oxide additive having an alkyl group of at least 8 carbon atoms, an alkyl-substituted phenol, or sorbitan mono It is an acrylate, and the surfactant has at least 12-valent HLB.

Similarly, for example, U.S. Pat. No. 4,528,321 (Allen) discloses dispersion of water-soluble or water-swellable polymer particles in water-immiscible liquids and is immiscible with water. In a liquid, by reverse layer polymerization, C _4-12 alkylene glycol monoethers, their C _1-4 alkanoates, C _6-12 polyalkylene glycol monoethers, and their C _1-4 alkanoates A nonionic compound selected from:

  In some embodiments, the coating material is also utilized as a base preform material.

2. Additives that reinforce the material An advantage of the preferred methods disclosed herein is their flexibility, which allows the use of multiple functionalized additives. Additions known to those skilled in the art for their ability to provide enhanced CO ₂ barrier, O ₂ barrier, UV protection, rub resistance, brush resistance, impact resistance, and / or chemical resistance Things may be used. For the additives listed here, the percentage is the percentage by weight of the material in the solvent's closed coating solution, and all non-solvent materials are not solid, but often , Referred to as “solid”.

  Preferred additives are prepared by methods known to those skilled in the art. For example, the additive is mixed directly with a particular material and they are dissolved / dispersed separately and then added to the particular material, or they add the particular material to the addition of solvent. Combine to form a solution / dispersion of the material. Moreover, in some embodiments, preferred additives are used alone as a layer.

  In a preferred embodiment, the barrier properties of the layer are enhanced by the addition of different additives. Additives are preferably present up to an amount of about 40% of the material and also include about 30%, 20%, 10%, 5%, 2%, and 1% of the weight of the material. In other embodiments, the additive is preferably present in an amount of 1% or less, and the preferred range of materials is, without limitation, about 0.01% to about 1% by weight, about 0.01%. % To about 0.1% and about 0.1% to about 1%. Furthermore, in some embodiments, the additive is preferably stable in an aqueous state.

  Derivatives of resorcinol (m-dihydroxybenzene) are used with various preferred materials as a mixture or as an additive or monomer in the formation of the material. Higher resorcinol includes better material barrier properties. For example, resorcinol diglycidyl ether is used in PHAE, and hydroxyethyl ether resorcinol is used in PET and other polyester and copolyester barrier materials.

  Other additives used are “nanoparticles” or “nanoparticle materials”. For convenience, the term nanoparticle is used herein to refer to both nanoparticles and nanoparticle materials. These nanoparticles are small, micron, or sub-micron in size (diameter), and more twisted so that they penetrate the material because of moving gas molecules such as oxygen or carbon dioxide A material property that enhances the barrier properties of the material by creating a pathway. In a preferred embodiment, the nanoparticulate material is present in an amount that varies from 0.05 to 1% by weight, includes 0.1%, 0.5% by weight, and includes these amounts. It is the range to do.

  One preferred type of nanoparticulate material is a microparticulate clay based on products available from Southern Clay Products. One preferred line of products available from Southern Clay Products is Cloisite ™ nanoparticles. In one embodiment, preferred nanoparticles comprise montmorillonite that is modified with a quaternary ammonium salt. In other embodiments, the nanoparticles comprise montmorillonite modified with a tertiary ammonium salt. In other embodiments, the nanoparticles comprise natural montmorillonite. In a further embodiment, the nanoparticles comprise an organoclay, as described in US Pat. No. 5,780,376, the entire disclosure herein is accepted by reference and Forms part of the disclosure of the specification. Other suitable organic and inorganic microparticle clays based on the product are also used. Artificial and natural products are also suitable.

  Another type of preferred nanoparticulate material comprises a metal composite. For example, one suitable composite is a water-based dispersion of aluminum oxide in nanoparticle form available from BYK Chemie (Germany). This type of nanoparticulate material is believed to provide one or more of the following advantages. Increased wear resistance, scratch resistance, increased Tg, and thermal stability.

  Another type of preferred nanoparticulate material comprises a polymer-silicate composite. In a preferred embodiment, the silicate comprises montmorillonite. Suitable polymer-silicate nanoparticle materials are available from Nanocor and RTP Company. Other preferred nanoparticulate materials include fumed silica, such as Cab-O-Sil.

  In a preferred embodiment, the UV protection properties of the material are enhanced by the addition of different additives. In preferred embodiments, the UV protection material used provides UV protection to about 350 nm or less, preferably about 370 nm or less, more preferably about 400 nm or less. The UV protection material can be used as an additive, with additional functions or layers applied separately as a single layer. Preferably, the additive that provides enhanced UV protection is present in the material up to about 0.05-20% by weight, and about 0.1%, 0.5%, 1%, 2% by weight. 3%, 5%, 10% and 15%, and their ranges. Preferably, the UV protection material is added in a form that is compatible with other materials. For example, a preferred UV protection material is Milliken, Ciba and Clariant. UV390A is an oily liquid whose mixing is preferably assisted by mixing the liquid with water, preferably approximately the same in volume. The mixture is then added to the material solution, eg, BLOX ™ 599-29, and stirred. The resulting solution contains about 10% UV390A and provides UV protection up to 390 nm when applied to a PET preform. As described above, in other embodiments, the UV390A solution is applied as a single layer. In other embodiments, preferred UV protection materials comprise UV grafted, grafted or modified polymers added as a concentrate. Other preferred UV protection materials include, but are not limited to, benzotriazole, phenothiazine, and azaphenothiazine. The UV protection material is added during the dissolution stage process prior to use, for example, prior to injection molding or extrusion, or added directly to the coating material in the formation of a solution or dispersion. It is done. Suitable UV protection materials are available from Milliken, Ciba and Clariant.

Carbon dioxide (CO ₂ ) capture properties are added to the material. In one preferred embodiment, such properties are achieved by including an active amine which reacts with CO ₂ to form a high gas barrier salt. This salt then acts as a passive CO ₂ barrier. The active amine is an additive or it may be one or more portions in one or more layers of thermoplastic material. Any suitable carbon dioxide scavenging material other than an amine is also used.

Oxygen (O ₂ ) scavenging properties are added to preferred materials by including an oxygen scavenger, such as, for example, anthroquinone, and others known in the art. In other embodiments, one suitable oxygen scavenger is the AMOSORB ™ oxygen scavenger available from BP Amoco Corporation and Color Matrix Corporation, which is described in US Pat. No. 083,585, the disclosure of which is fully incorporated herein. In one embodiment, O ₂ scavenging properties are added to the preferred phenoxy type material or other materials by including an oxygen scavenger in the phenoxy type material with a different activation mechanism. Preferred oxygen scavengers can also each act spontaneously, with a slow action, until gradually or until activated by a specific trigger. In some embodiments, the oxygen scavenger is activated via exposure to either UV or an aqueous solution (eg, present in the contents of the container), or a combination of both. The oxygen scavenger is preferably in an amount of about 0.1% to about 20 percent by weight, more preferably in an amount of about 0.5 to about 10%, based on the total weight of the coating layer. Most preferably, it is present in an amount of about 1% to about 5 percent.

  Certain embodiments of the material are cross-linked to enhance thermal stability for various applications, such as hot-fill applications. In one embodiment, the inner layer may comprise a low crosslinkable material, while the outer layer may comprise a high crosslinkable material, or other suitable combination. For example, the inner coating on the PET surface utilizes non-crosslinkable or low crosslinkable materials, such as BLOX ™ 588-29, and the outer coating is made from other materials, such as ICI. Such as EXP 12468-4B, which allows cross-linking to adhere more strongly to the bottom layer, such as a PET or PP layer. Suitable additives capable of cross-linking may be added to one or more layers. Appropriate crosslinkers are selected depending on the chemical nature and functionality of the resin or material to which they are added. For example, amine crosslinkers are useful for crosslinker resins comprising epoxide groups. Preferably, the crosslinking additive, if present, is present in an amount of about 1% to 10% by weight of the coating solution / dispersion, preferably about 1% to 5% by weight, more preferably It is about 0.01% to 0.1% by weight and includes 2%, 3%, 4%, 6%, 7%, 8%, and 9% by weight. Optionally, a thermoplastic epoxy (TPE) is used with one or more crosslinkers. In some embodiments, the agent (eg, carbon black) is coated with and incorporated into the TPE material. The TPE material can form part of the object disclosed herein. It is contemplated that carbon black or similar additives are used in other polymers to enhance material properties.

  The material of certain embodiments may optionally comprise a cure enhancer. As used herein, the term “curing enhancer” is a broad term and is used in its ordinary sense and includes, but is not limited to, chemically cross-linking catalysts, thermal enhancers, and the like. As used herein, the term “thermal enhancer” is a broad term and is used in its ordinary sense and includes, but is not limited to, transition metals, transition metal compounds, radiation absorbing additives (eg, Carbon black). An effective amount of heat enhancer is utilized to enhance the cure process. Suitable transition metals include, but are not limited to, cobalt, rhodium, and copper. Suitable transition metal compounds include, but are not limited to, metal carboxylates. Preferred carboxylates include but are not limited to neodecanoate, octylate, and acetate. Thermal enhancers are used alone or in combination with one or more other thermal enhancers.

  The heat enhancer can be added to the material and significantly increases the temperature of the material during the curing process compared to a material without the heat enhancer. For example, in some embodiments, a heat enhancer (eg, carbon black) is a polymer that has undergone a curing process (eg, IR radiation) and the temperature of the polymer that has undergone the same or similar curing process. Can be added to the polymer so that it is significantly higher than no polymer. The increased temperature of the polymer provided by the heat enhancer can increase the rate of cure and therefore increase the production rate. This is because the process requires less time.

  In some embodiments, the heat enhancer is present in an amount of about 5 to 800 ppm, preferably about 20 to about 150 ppm, preferably about 50 to 125 ppm, preferably about 75 to 100 ppm, About 10, 20, 30, 40, 50, 75, 100, 125, 150, 175, 200, 300, 400, 500, 600, and 700 ppm, including ranges encompassing these amounts. The amount of heat enhancer is calculated based on the weight of the layer comprising the heat enhancer or the total weight of all layers comprising the object.

  In some embodiments, a preferred thermal enhancer comprises carbon black. In one embodiment, carbon black is applied as a component of the coating material to enhance the curing of the coating material. When used as a component of a coating material, carbon black is added to one or more coating materials before, during, and / or after the coating material is applied to an object (eg, permeate, coat, etc.). . Preferably, carbon black is added to the coating material and agitated to ensure thorough mixing. The heat enhancer comprises additional materials to achieve the required material properties of the attached object. In other embodiments where carbon black is used in the injection molding process, the carbon black is added to the polymer mixture in a dissolution stage process.

  In some embodiments, the polymer comprises about 5 to 800 ppm, preferably about 20 to about 150 ppm, preferably about 50 to 125 ppm, preferably about 75 to 100 ppm, about 10, It includes 20, 30, 40, 50, 75, 100, 125, 150, 175, 200, 300, 400, 500, 600, and 700 ppm of hot salt hansar, and covers the total amount of these. In a further embodiment, the coating material is cured using radiation, such as infrared (IR) heating. In preferred embodiments, IR heating provides an effective coating rather than curing using other methods. Other heat and cure enhancers and methods of using them are described in US patent application Ser. No. 10 / 983,150 filed Nov. 5, 2004, entitled “the disclosure of what is her incorporated”. by reference it itss entity ", the disclosure of which is hereby incorporated by reference.

  In some embodiments, the addition of a non-foaming agent is required. In some embodiments utilizing a solution or dispersion, the solution or dispersion forms a foam and / or bubble that interferes with the preferred process. One way to avoid this interference is to add a non-foaming / bubble agent to the solution / dispersion. Suitable non-foaming agents non-foaming agents include, but are not limited to, nonionic surfactants, alkylene oxide based materials, siloxane based materials, and ionic surfactants. Preferably, the non-foaming agent, if present, is present in an amount from about 0.01% to about 0.3% of the solution / dispersion, preferably from about 0.01% to about 0.2%. About 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.1%, 0 .25% and ranges encompassing these amounts.

  In other embodiments, a foaming agent is added to the coating material to foam the coating layer. In a further embodiment, a blowing agent reaction product is used. Useful blowing agents include, but are not limited to, azobisformamide, azobisisobutyronitrile, diazoaminobenzene, N, N-dimethyl-N, N-dinitrosotephthalamide, N, N-dinitrosopentamethylene-tetramine Benzenesulfonyl-hydrazide, benzene-1,3-disulfonylhydrazine, diphenylsulfone-3-3, disulfonylhydrazine, 4,4′-oxybisbenzenesulfonylhydrazine, P-toluenesulfonyl semicarbazide, barium azodicarboxylate, Includes butylamine nitrile, nitrourea, trihydrazinotriazine, phenyl-methyl-urethane, p-sulfone hydrazine, peroxide, ammonium bicarbonate, and sodium bicarbonate. Currently considered, commercially available foam materials include, but are not limited to, EXPANCEL ™, CELOGEN ™, HYDROCEROL ™, MIKROFINE ™, CEL SPAN ™ and PLASTRON Includes FOAM ™. The foaming agent and the foamed layer are described in more detail below.

  The blowing agent is about 1 to about 20% by weight, more preferably about 1 to about 10% by weight, and most preferably about 1 to about 5% by weight, based on the weight of the coating layer. In the coating material. New foaming techniques known to those skilled in the art using compressed gas are also used as an alternative means for generating foam, replacing the conventional blowing agents listed above.

3. Examples of preferred objects In a preferred embodiment, the finished object comprises two or more layers applied in sequence on a base object, forming a preform or other type of bottle or container. Formed from the process in The base object is manufactured from a thermoplastic whose gas barrier properties and / or other functional properties are smaller than those sequentially applied with a coating layer, and comprises PET, but in other embodiments also PEN, PLA, PP, polycarbonate, or other materials described herein. In another embodiment, the base preform or object is preferably an oxygen scavenger that is benign to the next recycle stream after the finished object is discarded. scavenger).

  The coating layer applied on the base object preferably has improved gas and / or aroma barrier properties that exceed only the base object when applied in a layer having a low thickness compared to the base substrate. A thermoplastic material is provided. Suitable materials for use in the first coating layer are thermoplastic epoxy, PHAE, phenoxy-type thermoplastics, blends containing phenoxy-type thermoplastics, MXD6, nylon, nano Particles, or nanocomposites, and blends thereof, PGA, PVDC, or other materials disclosed herein. The material is preferably applied in the formation of a water-based solution or dispersion, but is also applicable as a solvent-based solution or dispersion and preferably exhibits a low VOC. The material is preferably one that has been approved by the FDA for direct food contact, but that approval is not required. Additives to the initial coating layer include a UV absorber, a coloring agent, and an adhesion promoter that enhances the adhesion of the coating to the substrate. In order to achieve the desired properties, the appropriate material is partially heat cured and / or crosslinked to varying degrees depending on its application. The material of the coating layer is preferably applied by dip, spray or flow coating, as shown here, then dried and / or preferably, Cure at IR if necessary. When the coating material is applied in the formation of a solution, dispersion, or the like, the coated substrate is applied before the second or top coating layer is applied. Preferably, it is completely dried.

  In one embodiment, one or more coating layers are further applied, and the additional coating layers preferably have a chemical resistance and / or abrasion resistance that exceeds only the base object. Providing thermoplastic material. In order to achieve the desired properties, suitable materials are partially heat cured and / or crosslinked to varying degrees depending on the application. The material is preferably applied in the formation of aqueous or solvent-based solutions or dispersions and preferably exhibits a low VOC. Additives to further coating layers include lubricants, thermal enhancers, UV absorbers, and adhesion promoters. The application is preferably accomplished by dip, spray or flow coating on a hot preform and is accomplished by drying or curing, preferably with IR. Is done.

E. Preferred foam material In some embodiments, the foam material is used in a substrate (base object or preform) or coating layer. As used herein, the term “foam material” is a broad term and is used according to its ordinary meaning and includes, but is not limited to, a blowing agent, a mixture of blowing agents, and a binder or carrier. Materials, expandable cellular materials, and / or materials with voids. The terms “foam material” and “expandable material” are used interchangeably herein. Preferred foam materials exhibit one or more physical properties that improve the thermal and / or structural properties of an object (eg, a container) and are typically experienced by the container, Allows preferred embodiments to withstand the process and physical stress. In one embodiment, the foam material provides structural support for the container. In other embodiments, the foam material forms a protective layer that reduces damage to the container during the process. For example, the foam material provides abrasion resistance that reduces damage to the container during shipping. In one embodiment, the foam protective layer increases the shock or impact resistance of the container and therefore prevents or reduces container breakage. Furthermore, in other embodiments, the foam can enhance the easily gripping surface and / or the aesthetics or attractiveness of the container.

  In one embodiment, the foam material comprises a foaming agent or foaming agent and a carrier material. In one preferred embodiment, the blowing agent comprises an expandable structure (eg, a microsphere) that is expanded and cooperates with the carrier material to produce a foam. For example, the blowing agent is a thermoplastic microsphere, such as EXPANCEL ™ microsphere sold by Akzo Nobel. In one embodiment, the microspheres are thermoplastic hollow spheres with a thermoplastic shell that encapsulates a gas. Preferably, when the microspheres are heated, the thermoplastic shell becomes soft and the gas increases the pressure that causes expansion of the microspheres from the initial position to the expanded position. The expanded microspheres and at least a portion of the carrier material form part of the foam of the object described herein. The foam material can be a single material (eg, a generally homogeneous mixture of blowing agent and carrier material), a mix or blend of materials, a substrate formed by two or more materials, two or more layers, A plurality of microlayers (thin plates) are provided, and preferably a layer containing at least two different materials is formed. Alternatively, the microspheres are suitable for other controllable, expandable materials. For example, a microsphere is a structure comprising a material that generates gas from or within the structure. In one embodiment, the microspheres are hollow structures that contain chemicals that generate or contain gas, and where an increase in gas pressure results in a structure that expands and / or ruptures. In other embodiments, the microspheres are manufactured from one or more materials that decompose or react to expand and / or rupture the microspheres to produce gas, and / or Or it is the structure which contains. Optionally, the microspheres are generally hard structures. Optionally, the microsphere is a shell filled with a solid, liquid, and / or gas. The microspheres have any configuration and shape suitable for forming a foam. For example, the microsphere is generally spherical. Optionally, the microspheres are elongated or oblique spheroids. Optionally, the microspheres can comprise any gas or gas mixture suitable for expanding the microspheres. In one embodiment, the gas can comprise an inert gas, such as nitrogen. In one embodiment, the gas is generally non-flammable. However, in certain embodiments, a non-inert gas and / or a combustible gas can fill the shell of the microsphere. In some embodiments, as is well known in the art, the foam material may comprise a foaming agent or a blowing agent. Moreover, the foam material may be almost or completely a blowing agent.

  Some preferred embodiments generally comprise microspheres that do not break or rupture, while other embodiments have microspheres that break, rupture, tear, and / or become such. It has a sphere. Optionally, the portion of the microsphere may be broken while the remaining portion of the microsphere is not broken. In some embodiments, about 0.5%, 1%, 2%, 3%, 4%, 5%, 10%, 20%, 30%, 40%, 50% by weight of the microspheres. , 60%, 70%, 80%, 90%, and the range including these amounts. In one embodiment, for example, a substantial portion of the microsphere ruptures and / or tears when the microsphere is expanded. In addition, various mixtures and mixtures of microspheres are used to form the foam material.

  The microspheres are formed of any material that is suitable for causing expansion. In one embodiment, as described herein, the microsphere has a shell comprising a polymer, resin, thermoplastic, thermosetting resin, and the like. The microsphere shell may comprise one material or a mixture of two or more different materials. For example, the microspheres comprise ethylene vinyl acetate (EVA), polyethylene terephthalate (PET), polyamide (eg, nylon 6 and nylon 66), polyethylene terephthalate glycol (PETG), PEN, PET copolymer and combinations thereof. Has an outer shell. In one embodiment, the PET copolymer comprises CHDM comonomer at a level between what is commonly referred to as PETG and PET. In other embodiments, comonomers such as DEG and IPA are added to PET to form a microsphere shell. The specific combination of material type, size, and inert gas is selected to achieve the required expansion of the microspheres. In one embodiment, the microsphere is preferably a shell formed of a high temperature material (eg, PETG or similar material) that is capable of expanding when the microsphere does not cause rupture, subject to high temperatures. It comprises. If the microsphere has a shell made of a low temperature material (eg, as EVA), the microsphere is suitable for processing a specific carrier material (eg, PET or polypropylene having a high melting point). It breaks on condition of high temperature. In some situations, for example, EXPANCEL ™ microspheres break when processed at relatively high temperatures. Advantageously, intermediate or hot microspheres are used with a carrier material having a relatively high melting point to produce a controllably expandable foam material without breaking the microspheres. For example, the microspheres can comprise a medium temperature material (eg, PETG) or a high temperature material (eg, acrylonitrile) and are suitable for relatively high temperature applications. Therefore, the blowing agent for foaming the polymer is selected based on the processing temperature used.

  The foam material is a matrix with a carrier material, preferably a material that can be mixed with a blowing agent (eg, microspheres) that forms an expandable material. The carrier material is thermoplastic, thermosetting resin, or polymerized material, such as ethylene acrylic acid (EAA), ethylene vinyl acetate (EVA), linear low density polyethylene (LLDPE), polyethylene terephthalate. Glycol (PETG), poly (hydroxyaminoether) (PHAE), PET, polyethylene, polypropylene, polystyrene (PS), pulp (eg wood or fiber paper pulp, or mixed with one or more polymers) Pulp), mixtures thereof, and the like. However, other materials suitable for carrying the blowing agent are used to achieve one or more of the required thermal, structural, optical, and / or other characteristics of the foam. In some embodiments, the carrier material has properties (eg, high melt index) for easy and rapid expansion of the microspheres, thus reducing cycle time and thereby reducing production. Result in an increase.

  In a preferred embodiment, the moldable material comprises two or more components, each including a plurality of components having different process windows and / or physical properties. The components are combined so that the moldable material has one or more required attributes. The proportions of the components are varied to provide the required process window and / or physical properties. For example, the first material has a process window that is similar to or different from the process window of the second material. The process window is based on pressure, temperature, viscosity, etc., for example. Therefore, the components of the moldable material are mixed to achieve the pressure or temperature range that is desirable to shape the material.

  In one embodiment, the combination of the first material and the second material results in a material having a process window that is more desirable than the process window of the second material. For example, the first material is suitable for processing over a wide temperature range, and the second material is suitable for processing over a narrow temperature range. A material having a portion formed by the first material and another portion formed by the second material is suitable for processing over a wider temperature range than a narrow range of processing temperatures of the second material. . In one embodiment, the process window for the multi-component material is similar to the process window for the first material. In one embodiment, the moldable material comprises a multilayer sheet or a tube comprising a layer comprising PET and polypropylene. Materials formed from both PET and polypropylene can be processed (eg, extruded) over a wide temperature range similar to the processing temperature range suitable for PET. The process window is for one or more parameters, such as pressure, temperature, viscosity, etc.

  Optionally, the amount of each component of the material is varied to achieve the desired process window. Optionally, the materials are combined to produce a moldable material suitable for processing over the desired range of pressure, temperature, viscosity. For example, the percentage of material having a more desirable process window is increased and the percentage of material having a less desirable process window is reduced to have a process window substantially similar to the process window of the first material. As a result. Of course, if the more desirable process window is between the first process window of the first material and the second process window of the second material, the proportion of the first and second materials can be molded. Selected to achieve the required process window of the material.

  Optionally, each of a plurality of materials having similar or different process windows are combined to obtain the desired process window for the resulting material.

  In one embodiment, the rheological properties of the moldable material are altered by changing one or more components having different rheological properties. For example, a substrate (eg, PP) has a high melt strength and is sensitive to extrusion. PP has a low melt strength that makes extrusion difficult to form a material that is suitable for the extrusion process, for example in combination with other materials such as PET to make a material suitable for the extrusion process. Form. For example, a layer of PP or other strong material supports the PET layer during coextrusion (eg, horizontal or vertical coextrusion). Therefore, moldable materials formed of PET and polypropylene are generally processed, eg, extruded, in a temperature range that is suitable for PP and generally not suitable for PET.

  In some embodiments, the composition of the moldable material may be selected to affect one or more properties of the object. For example, thermal properties, structural properties, barrier properties, optical properties, flow properties, preferred flavor properties, and / or other properties, or properties disclosed herein, use the moldable materials described herein. Obtained.

F. Preferred objects In general, preferred objects here include preforms or containers having one or more coating layers. The coating layer is preferably barrier protection, UV protection, impact resistance, scuff resistance, blush resistance, chemical resistance. It provides functions such as (chemical resistance) and antimicrobial propertie. The layers are applied as multiple layers, each layer having one or more functional properties or applied as a single layer containing one or more functional components. The layer is applied sequentially as a respective coating layer, partially or fully dried / cured, before the next coating layer is applied.

  A preferred substrate is a PET preform or container as described above. However, other substrate materials can also be utilized. Other suitable substrate materials include, but are not limited to, polyester, polypropylene, polyethylene, polycarbonate, polyamide, acrylic.

For example, in one multilayer object, the inner layer has a primer layer that has functional properties for PET, O ₂ capture, UV resistance, and strong adhesion to a passive barrier, Alternatively, it is a base coat and the one or more outer coatings comprise a passive barrier and a scuff resistance. As described herein for the coating layer, the inner is brought closer to the substrate and the outer is brought closer to the surface of the container. The layer between the inner and outer layers is generally described as intermediate or middle. In other embodiments, the plurality of coated objects comprise an inner coating layer comprising an O ₂ scavenger, an intermediate active UV protection layer, followed by an outer layer of partially or highly cross-linked material. . In another embodiment, the multilayer coated preform comprises an inner coating layer comprising an O ₂ scavenger, an intermediate CO ₂ capture layer, an intermediate active UV protection layer, and a partially or highly crosslinkable material Followed by.
These combinations provide a hard increased cross-linked coating, suitable for carbonated beverages such as beer, and in another embodiment are utilized for carbonated soft drinks, the inner coating layer of which It is a UV protection layer followed by an outer layer of cross-linked material. Although the above embodiments have been referred to in the context of a particular beverage, they can be used for other purposes, and different layer arrangements can be used for that refreshed beverage. Good.

  In a related embodiment, the final coating and drying of the preform provides the preform with a scuff resistance, and the container in the solution or dispersion is diluted or suspended. Containing reduced paraffin or wax, slipping agent, polysilane, or low molecular weight polyethylene to reduce the surface tension of the container.

G. Method and apparatus for manufacturing a coated object Once a suitable coating material has been selected, a coating is preferably formed on the preform in a manner that promotes adhesion between the two materials. Although the following discussion relates to preforms, such discussion should not be considered limiting, and the methods and apparatus described therein may be applied or adopted for containers and other objects. In general, adhesion between the coating material and the preform substrate increases as the surface temperature of the preform increases. For this reason, the preferred coating material adheres to the preform at room temperature, but preferably forms a coating on the heated preform.

  In general, plastics, and in particular PET preforms, have static electricity, which results in the preforms becoming dirty immediately after attracting dirt. In a preferred embodiment, the preform is removed directly from the injection molding apparatus and a coating is formed, including still warm. It is believed that the coating is formed immediately after the preform is removed from the injection molding apparatus, thereby avoiding the dust problem and also that the warm preform enhances the coating forming process. However, the method also allows for coating of preforms that are stored prior to coating. Preferably, the preform is substantially clean but does not require cleaning.

  In a preferred embodiment, an automated device is used. Preferred methods include entry of the preform into the device, immersion of the preform, spraying or flow coating, removal of any excess material, drying / curing, cooling, ejection from the device. The apparatus may optionally include a recycling process. In one embodiment, the apparatus has one integrated process line that includes two or more dipping, flow or spray coating units and two or more drying / curing units, and is coated in multiple layers Manufactured preforms. In another embodiment, the device has one or more coating modules. Each coating module has a process line that is self-included with one or more dipping, flow or spray coating units and one or more drying / curing units. Depending on the configuration of the module, the preform can be coated with one or more layers. For example, one configuration has three coating modules where the preform moves from one module to the next. In other configurations, there are also three modules, but the preform moves from the first module to the third module, skipping the second module. This ability to switch between different module configurations allows flexibility. In a further preferred embodiment, the modular and integrated device may be directly coupled to the preform injection molding device and / or the blow molding device. The injection molding apparatus produces a preform for use in the present invention.

  A preferred embodiment of a fully automated coating apparatus will now be described. While this device is described with respect to presently preferred materials, those skilled in the art will appreciate that the parameters will vary depending on the material used and the specific physical structure of the desired final product preform. This method is described for a coated 24 gram preform, the preform being deposited on the surface, totaling about 0.07,0,09,0.10,0.15,0.20, About 0.05 to about 0 including 0.25, 0.30, 0.35, 0.40, 0.45, 0.50, 0.55, 0.60, 0.65 and 0.70 grams .75 grams of coating material. In the method described below, the coating solution / dispersion is about 0.07, 0.08, 0.09, 0.1, 0.11, 0.12 per coating layer on a 24 gram preform. , 0.13, 0.14, 0.15, 0.16, 0.17, 0.18 and 0.19 grams of coating material from about 0.06 to about 0.20 grams per coating layer Temperature and viscosity suitable for depositing. The preferred amount of deposition for different sized objects may be estimated as a function of the increase or decrease in surface area when compared to a 24 gram preform. Accordingly, objects other than the 24-gram proform may be outside the above range. Further, in certain embodiments, it may be desirable to have a total coverage on a single layer or 24 gram preform that falls outside the above range.

  The apparatus and method may be used for other similarly sized preforms and containers, or for other sized objects, as will be apparent to those skilled in the art in the following discussion. It may be adopted. The presently preferred coating material comprises TPE, preferably a phenoxy type resin, more preferably a PHAE containing the above-mentioned BLOX resin. These materials and methods are given by way of example only and are not intended to limit the scope of the invention in any way.

1. An entry preform to the device is first brought to the device. An advantage of one preferred method is that conventional preforms such as preforms commonly used by those skilled in the art may be used. For example, a 24 gram monolayer preform of the type commonly used to form a 16 ounce bottle can be used without any modification prior to entry into the device. In one embodiment, the device is directly coupled to a preform injection molding device that provides a warm preform to the device. In another embodiment, the stored preform is added to the device by methods well known by those skilled in the art, including methods of loading the preform into an additional process device. Preferably, prior to entry into the device, the stored preform is pre-warmed to about 100 ° F to 130 ° F, including about 120 ° F. The stored preform is preferably clean, although no cleaning is required. While other preforms and container substrates can be used, PET preforms are preferred. Other suitable object substrates include various polymers such as, but not limited to, polyesters, polyolefins including polypropylene and polyethylene, polycarbonates, polyamides including nylon or acrylic resins.

2. Once a suitable coating material has been selected for immersion, spraying or flow coating , it can be prepared and used for either immersion, spraying or flow coating. Material preparation is essentially the same as dipping, spraying and flow coating. The coating material has a solution / dispersion formed from one or more solvents in which the resin of the coating material is dissolved and / or suspended.

  The temperature of the coating solution / dispersion can have a profound effect on the viscosity of the solution / dispersion. As the temperature increases, the viscosity decreases and vice versa. Furthermore, as the viscosity increases, the rate of material deposition increases. Therefore, temperature can be used as a mechanism for controlling deposition. In one embodiment using flow coating, the temperature of the solution / dispersion is maintained in a range that is low enough to minimize curing of the coating material, but high enough to maintain a suitable viscosity. The In one embodiment, the temperature is between about 60 ° F. and 80 ° F., including about 70 ° F. In some cases, solutions / dispersions that are too viscous for use in spray or flow coating may be used in dip coating. Similarly, higher temperatures may be utilized in spray coatings than are recommended for dipping or flow coating due to curing issues because the coating material may spend less time at elevated temperatures in spray coating. . In any case, the solution or dispersion may be used at any temperature at which it exhibits suitable properties for application. In a preferred embodiment, a temperature controller is used to ensure a constant temperature of the coating solution / dispersion during the coating process. In certain embodiments, the addition of water may decrease the viscosity of the solution / dispersion as the viscosity increases. Other embodiments also provide a water content monitor and / or that signal when the viscosity is outside the desired range and / or automatically add water or other solvents to achieve the desired range of viscosity. Or a viscosity monitor may be included.

  In a preferred embodiment, the solution / dispersion is 0.07, 0.08, 0.09, 0.1, 0.11, 0.12, 0.13, 0. Suitable temperature and viscosity to deposit from about 0.06 to about 0.2 grams per application, including 14,0.15, 0.16, 0.17, 0.18 and 0.19 grams . The preferred amount of deposit for various sized objects may be estimated as a function of the increase or decrease in surface area when compared to a 24 gram preform. Therefore, it can be outside the above range for objects other than 24-gram preforms. Further, in certain embodiments, it may be desirable to have a single layer that is outside the above range on a 24-gram preform.

  In one embodiment, a preform made from dipping, spraying or flow coating is of the type seen in FIG. The coating 22 is deposited on the preform body 4 and the neck 2 is not coated. The inner side of the coated preform 16 is preferably uncoated. In a preferred embodiment, this is accomplished through the use of a retention or gripping mechanism having an expandable collet that is inserted into the preform in combination with a housing that surrounds the outside of the preform neck. The collet expands, thereby holding the preform between the collet and the housing. The housing covers the outside of the neck, including the threads, thereby protecting the inside of the preform as well as protecting the neck from the covering.

  In a preferred embodiment, a coated preform made from dipping, spraying or flow coating produces the final product with substantially no distinction between layers. Furthermore, it has been discovered that in dipping and flow coating procedures, the amount of coating material deposited on the preform is slightly reduced with each successive layer.

a. Dip coating In a preferred embodiment, the coating is applied through a dip coating process. The preform is immersed in a tank or other suitable container that contains the coating material. The soaking of the preforms in the coating material can be performed with each other by the use of a holding shelf or the like, or can be performed in a fully automated process. While the apparatus shown in FIG. 14 depicts one embodiment of an automated flow coating unit, in some embodiments utilizing automated dip coating, the flow coater 86 may be a dip coating tank or other containing coating material. The appropriate container position is indicated.

  In a preferred embodiment, the preform rotates while immersed in the coating material. The preform preferably also includes 50, 60 and 70 RPM and rotates at a speed of about 30-80 RPM, more preferably 40 RPM. This allows complete coverage of the preform. Other speeds may be used, but are preferably not high enough to cause loss of coating material due to centrifugal forces.

  The preform is preferably soaked for a sufficient amount of time to allow complete coverage of the preform. This is generally in the range of about 0.25 to about 5 seconds, including the upper and lower ranges. Without wishing to be bound by theory, long residence times do not seem to provide any added coating benefits.

  The opacity of the coating material should also be taken into account in determining the soaking time and hence the speed. If the speed is too fast, the coating material will wave and splash and cause loss of the coating. Another consideration is that many coating material solutions or dispersions form bubbles and / or bubbles that can interfere with the coating process. In order to avoid this hindrance, the soaking speed is preferably chosen so as to avoid excessive stirring of the coating material. If necessary, antifoam / bubble agents may be added to the coating solution / dispersion.

b. Spray Coating In a preferred embodiment, the coating is performed through a spray coating process. The preform is sprayed with a coating material that is fluidly connected to a tank or other suitable container containing the coating material. Spraying the preform with the coating material can be performed manually using a holding shelf or the like, or can be performed in a fully automated process. Although the apparatus shown in FIG. 14 depicts one embodiment of an automated flow coating unit, in certain embodiments that utilize automated spray coating, the position of the flow coater 86 indicates the position of the spray coating apparatus.

  In a preferred embodiment, the preform is rotating while being sprayed with the coating material. The preform preferably includes about 50, 60 and 70 RPM and rotates at a speed of about 30-80 RPM, more preferably 40 RPM. Preferably, the preform rotates at least about 360 ° as it proceeds through the coating spray. This allows complete coverage of the preform. However, the preform may remain stationary while the spray is directed at the preform.

  The preform is preferably sprayed for a time sufficient to allow complete coverage of the preform. The length of time required for spraying depends on several factors, including spray rate (spray deposition per unit time), the area surrounded by the spray, and the like.

  The coating material is contained in a tank or other suitable container that is in fluid communication with the production line. Preferably, closed equipment is used in which unused coating material is recycled. In one embodiment, this may be accomplished by collecting unused coating material in a coating material collector that is in fluid communication with the coating material tank. Many coating material solutions or dispersions produce bubbles or bubbles that can interfere with the coating process. In order to avoid this hindrance, the coating material is preferably removed from the bottom or middle of the tank. It is also preferred to slow down the material flow before returning to the coating tank in order to further reduce bubbles and / or bubbles. This can be done by means known to those skilled in the art. If necessary, antifoam / bubble agents may be added to the coating solution / dispersion.

  The properties of the coating material should also be taken into account in determining the spray time and related parameters such as nozzle size and shape. If the speed is too high and / or the nozzle size is not correct, the coating material can be splattered causing coating loss. If the speed is too slow or the nozzle size is not correct, the coating material may be applied thicker than desired. Suitable spraying equipment includes those sold by Nordson (Westlake, Ohio). Another consideration is that many coating material solutions or dispersions produce bubbles or bubbles that can interfere with the coating process. In order to avoid this hindrance, the spray rate, the nozzle used and the fluid coupling are preferably selected in order to avoid excessive stirring of the coating material. If necessary, antifoam / bubble agents may be added to the coating solution / dispersion.

c. Flow coating In a preferred embodiment, the coating is performed through a flow coating process. The purpose of the flow coating is to provide a sheet of material through which the preform passes for complete coating, such as a falling shower curtain or waterfall. Advantageously, the preferred method of flow coating allows for a short residence time of the preform in the coating material. The preform need only pass through the sheet for a time sufficient to coat the surface of the preform. Without wishing to be bound by theory, long residence times do not seem to provide any added coating benefit.

  Referring to FIGS. 14, 15 and 16, there is shown an alternating diagram of a non-limiting diagram of one embodiment of a preferred flow coating process. In this embodiment, a top view of an apparatus having one flow coater 86 is shown. The preform enters the device 84 and travels to the flow coater 86 where the preform 1 passes through a waterfall (not shown) of the coating material. The coating material travels down the angled liquid guide 160 from the tank or from the bat 150 via the gap 155 in the tank, where it forms a waterfall as it passes over the preform. Other embodiments may have a fluid guide that is substantially horizontal. The gap 155 in the tank 150 may be widened or narrowed to regulate the material flow. The material is pumped from a reservoir (not shown) to the bat or tank 150 at a rate that keeps the coating material level above the level of the gap. Advantageously, this arrangement ensures a constant flow of coating material. Excess material also reduces fluid fluctuations due to pump rotation.

  In order to provide a uniform coating, the preform is preferably rotating while the preform proceeds through the sheet of coating material. The preform preferably includes about 50, 60 and 70 RPM and rotates at a speed of about 30-80 RPM, more preferably 40 RPM. Preferably, the preform rotates at least two full revolutions or about 720 ° while traveling through the sheet of coating material. In one preferred embodiment, the preform is rotated at an angle while traveling through the sheet of coating material. The angle of the preform is preferably acute with respect to the plane of the sheet of coating material. This advantageously allows complete coverage of the preform without coating the neck or inside of the preform. In another preferred embodiment, the preform 16 shown in FIG. 16 is perpendicular or perpendicular to the floor while traveling through the sheet of coating material. It has been found that when a sheet of coating material comes into contact with the preform, the sheet tends to climb up the preform wall from the initial position of contact. One skilled in the art can control the effect by adjusting parameters such as flow rate, coating material viscosity and physical positioning of the coated sheet material relative to the preform. For example, as the flow increases, the glaring effect also increases, which can cause the coating material to coat the preform more than desired. As another example, the angle adjustment is removed to the bottom of the preform by gravity, reducing the amount of material replaced, so that more material is retained in the center or body of the preform. By reducing the angle of the preform relative to the material sheet, the thickness of the coating can be adjusted. The ability to skillfully handle this craving effect advantageously allows complete coverage of the preform without coating the neck or interior of the preform.

  The coating material is contained in a tank or other suitable container in fluid communication with the production line in a closed device. It is preferable to recycle unused coating materials. In one embodiment, it may be accomplished by collecting a waterfall flow stream returning to the coating material collector in fluid communication with the coating material tank. Many coating material solutions or dispersions produce bubbles or bubbles that can interfere with the coating process. In order to avoid this hindrance, the coating material is preferably removed from the bottom or middle of the tank. It is also preferred to slow down the material flow before returning to the coating tank in order to further reduce bubbles and / or bubbles. This can be done by means known to those skilled in the art. If necessary, antifoam / bubble agents may be added to the coating solution / dispersion.

  In selecting an appropriate flow rate for the coating material, several variables should be considered to provide reasonable sheeting, flow rate, preform length and diameter, including the viscosity of the coating material.

  The flow rate determines the accuracy of the sheet of material. If the flow rate is too fast or too slow, the material may not accurately coat the preform. If the flow rate is too high, the material may splash and force the production line, causing incomplete coating of the preform, waste of the coating material, and increased foam and / or bubble problems. If the flow rate is too slow, the coating material may only partially coat the preform.

  The length and diameter of the preform to be coated should also be considered when selecting the flow rate. The sheet of material should completely cover the entire preform, and therefore flow rate adjustment may be necessary when the length or diameter of the preform changes.

  Another factor to consider is the spacing on the preform line. As the preform travels through the sheet of material, a so-called wake effect can be observed. If the next preform passes through the sheet at the location where the previous preform has passed, it may not be properly coated. It is therefore important to monitor the speed and centerline of the preform. The speed of the preform depends on the throughput of the specific equipment used.

3. Removal of excess material Advantageously, the preferred method provides sufficient deposition so that virtually all of the coating on the preform is utilized (ie, there is virtually no excess material to remove). However, there are situations where it is necessary to remove excess coating material after being applied to the preform by dipping, spraying or flow methods. Preferably, both rotational speed and gravity act to normalize the sheet on the preform and remove excess material. Preferably, the preform is allowed to normalize for about 5 to about 15 seconds, more preferably for about 10 seconds. If a tank holding the coating material is arranged to allow the preform to pass over the tank after coating, the rotation and gravity of the preform will cause excess material from the preform to the coating material tank. May cause back dripping. This allows excess material to be recycled without additional effort. If the tank is in a situation where excess material does not drip back into the tank, other materials such as a coating material collector or reservoir in fluid communication with the coating tank or bat can be captured and returned for reuse. Any suitable means may be employed.

  If the above method is impractical due to manufacturing environment or inappropriate and various methods and apparatus, a drip remover 88 or the like may be used to remove excess material. See Figures 14, 15 and 16. For example, a suitable drip remover includes one or more of the following: wipers, brushes, sponge rollers, air knives or air currents used alone or in combination with each other. In addition, any of these methods may be combined with the rotation and gravity methods described above. Preferably, excess material removed by these methods is recycled for further use.

4). After the coating is formed on the drying and curing preform 1 and excess material is removed 88, the coated preform is then dried and cured 90. The drying and curing steps are preferably performed by infrared (IR) heating 90. See FIGS. 14, 15, 17 (A) and 17 (B). In one embodiment, a 1000 W quartz infrared lamp 200 is used as the source. A preferred source is a General Electric Q1500 T3 / CL quartz line tungsten-halogen lamp. This particular source and equivalent source can be purchased commercially from a number of sources including General Electric and Philips. The source may be used in full volume, or it may be used in partial volumes such as about 50%, about 60%, about 75%. Preferred embodiments may use a single lamp or a combination of multiple lamps. For example, six infrared lamps may be used with a capacity of 70%.

  Preferred embodiments may also use lamps with adjustable physical orientation relative to the preform. As shown in FIGS. 17A and 17B, the ramp position 200 may be adjusted to a position that approaches or moves away from the preform. For example, in one embodiment having multiple lamps, it may be desirable to move one or more lamps located below the bottom of the preform closer to the preform. This advantageously allows for complete curing of the bottom of the preform. Embodiments with adjustable lamps may also be used for preforms with various widths. For example, if the preform is wider at the top than the bottom, the lamp may be closer to the preform at the bottom of the preform in order to further ensure curing. The lamp is preferably oriented to provide a relatively uniform illumination of the entire surface of the coating.

  In other embodiments, a reflector is used in combination with an infrared lamp to provide complete curing. In a preferred embodiment, the lamp 200 is disposed on one side of the process line, while one or more reflectors 210, 230 are disposed opposite or below the process line. This advantageously allows for a more complete curing that reflects the lamp output back onto the preform. More preferably, an additional reflector 210 is disposed below the preform to reflect heat from the lamp upwards toward the bottom of the preform. This advantageously allows for complete curing of the bottom of the preform. In other preferred embodiments, various reflector combinations may be used depending on the characteristics of the object and the infrared lamp used. More preferably, the reflector is used in combination with the adjustable infrared lamp described above.

  FIG. 17 depicts a diagram of a non-limiting embodiment of a preferred infrared drying / curing unit. A series of lamps 200 is shown on one side of the process line. Below the preform is shown an angled reflector 210 that reflects heat toward the bottom of the preform for more complete curing. On the other side of the lamp is a semi-circular reflector 230 that reflects back infrared heat, allowing more complete and efficient curing. FIG. 17B is an enlarged cross-sectional view of the lamp showing an embodiment in which the lamp arrangement is adjustable 220. The lamp may be moved closer to or away from the preform, allowing maximum drying / curing flexibility.

  In addition, the use of infrared heat allows the thermoplastic epoxy (eg, PHAE) coating to dry without excessive heating of the PET substrate and can be used during heating of the preform prior to blow molding, thus Useful for energy efficient devices. It has also been discovered that the use of infrared heating reduces brushes and improves chemical resistance.

  Although this step can be performed without additional air, infrared heating is preferably combined with forced air. The air used may be hot, cold or ambient. The combination of infrared and air curing provides the unique properties of the preferred embodiment, excellent chemistry, brush and scuff resistance. Furthermore, without wishing to be bound by theory, the chemical resistance of the coating appears to be a function of crosslinking and curing. The more complete the curing, the greater the chemical resistance.

  To determine the length of time required to completely dry and cure the coating, several factors such as the coating material, the thickness of the deposit, and the substrate material should be considered. Different coating materials cure faster or slower than others. Further, as the solid content increases, the curing speed decreases. In general, longer and shorter times than this range may be used for infrared curing of a 24 gram preform with about 0.05 to about 0.75 gram of coating material formed, The time is about 5-60 seconds.

  Another factor to consider is the surface temperature of the preform, as it is related to the glass transition temperature (Tg) of the substrate and coating material. In the drying / curing step, the surface temperature of the coating preferably exceeds the Tg of the coating material without heating the substrate beyond the Tg of the substrate. This results in the desired film formation and / or crosslinking without deformation of the preform shape due to excessive heating of the substrate. For example, if the coating material has a higher Tg than the preform substrate material, the substrate temperature remains at or below the substrate Tg and the preform surface is heated to a temperature above the coating Tg. It is preferred that One way to adjust the drying / curing process to achieve this balance is to combine infrared heating and air cooling, although other methods may be used.

  The advantage of using air in addition to infrared heating is that air adjusts the surface temperature of the preform, thereby allowing flexibility in controlling radiant heat penetration. If a particular embodiment requires a slower curing rate or deeper infrared penetration, this can be controlled by air alone, the time spent in the infrared unit, or the frequency of the infrared lamp. These can be used alone or in combination.

  Preferably, the preform rotates while traveling through the infrared heater. The preform preferably rotates at a speed of about 30-80 RPM, more preferably about 40 RPM. If the rotational speed is too fast, the coating will scatter and cause uneven coating of the preform. If the rotational speed is too slow, the preform will dry unevenly. More preferably, the preform rotates at least about 360 ° while traveling through the infrared heater. This advantageously allows for complete curing and drying.

  In other preferred embodiments, instead of infrared heating or other methods, electron beam processing may be employed. Electron beam processing (EBP) is used primarily for injection molded preforms and containers due to its large size and high cost and has not been used for the curing of associated polymers. It was. However, recent advances in this technology are expected to lead to smaller and less expensive devices. An EBP accelerator is characterized by its energy and power. For example, an accelerator with an energy of 150-500 keV is usually used for curing and crosslinking of food film coatings.

  EBP polymerization is the process by which several individual groups of molecules combine to form one large group (polymer). When a substrate or coating is exposed to rapidly accelerated electrons, a reaction occurs in which chemical bonds in the material break and a new modified molecular structure is formed. This polymerization can cause significant physical changes in the product and can result in desirable properties such as high gloss and abrasion resistance. EBP can be a very efficient way to initiate the polymerization process in many materials.

  Similar to EBP polymerization, EBP crosslinking is a chemical reaction that modifies and enhances the physical properties of the material being processed. It is a process whereby a chemical bond or a network of internal bonds is developed between large polymer chains to form a stronger molecular structure. EBP may be used to improve the thermal, chemical, barrier, impact, abrasion and other properties of inexpensive product thermoplastics. Crosslinkable plastic EBP creates materials with improved dimensional stability, reduced stress cracking, higher set temperature, reduced solvent and water permeability and improved thermomechanical properties Can do.

The effect of the ionization reaction of the polymerized material appears in one of three: (1) spontaneously increasing molecular weight (crosslinking); (2) spontaneously decreasing molecular weight (division); (3) radiation resistance No significant change in molecular weight is observed for certain polymers. Some polymers may experience a combination of (1) and (2). During irradiation, chain splitting occurs simultaneously and competitively with cross-linking, and the final result depends on the yield ratio of these reactions. Polymers containing halogen atoms on each carbon atom experienced mainly crosslinked, whereas the polymer and -CX ₂ -CX ₂ containing a quaternary carbon atom in the - type (X is a halogen) When the polymer chain split Is dominant. Aromatic polystyrene and polycarbonate are relatively resistant to EBP.

  For polyvinyl chloride, polypropylene and PET, alterations in both directions are possible; certain conditions exist for each advantage. The ratio of crosslinking to splitting depends on several factors including total radiation dose, dose rate, oxygen, stabilizers, presence of radical scavengers, and / or hindrance derived from structural crystal forces.

  Especially in copolymers and mixtures, the effect of the overall properties of crosslinking can be contradictory. For example, after EBP, highly crystallized polymers such as HDPE may not show significant changes in tension, a property derived from the crystal structure, but of amorphous structures such as impact and stress crack resistance. Significant improvements in behavior related properties can be demonstrated.

  Aromatic polyimide (nylon) is quite sensitive to ionizing radiation. After exposure, the tension of the aromatic polyamide is not improved, but for a mixture of aromatic polyamide and linear aliphatic polyamide, an increase in tension is led with a substantial decrease in length.

  EBP can be used as an alternative to infrared for more accurate and faster curing of TPE coatings applied to preforms and containers.

  When used with dipping, spraying or flow coating, EBP appears to have the potential to provide lower cost, improved speed and / or improved cross-linking control compared to infrared curing. EBP is also beneficial in that the changes it produces occur in the solid phase as opposed to alternative chemical and thermal reactions applied to the dissolved polymer.

  In other preferred embodiments, gas heaters, ultraviolet radiation, flames may be employed in addition to or instead of infrared or EBP curing. Preferably, the drying / curing unit is arranged at a sufficient distance or separated from the coating material tank and / or flow coating sheet to avoid unwanted curing of the unused coating material.

5. The cooling preform is then cooled. The cooling process is combined with a curing process to provide enhanced chemistry, brush and scuff resistance. It can be attributed to the removal of solvent and volatiles after one layer of coating or during successive coatings.

  In one embodiment, the cooling step is performed at ambient temperature. In other embodiments, the cooling process is accelerated by the use of forced ambient or cold air.

  There are several factors to consider during the cooling process. The surface temperature of the preform is preferably lower than the lower Tg of the preform substrate or coating. For example, some coatings have a lower Tg than the preform substrate material, and in this example the preform should be cooled to a temperature below the Tg of the coating. If the preform substrate has a lower Tg, the preform should be cooled below the Tg of the preform substrate.

  The cooling time is also affected by where in the process cooling takes place. In a preferred embodiment, a multilayer coating is applied to each preform. When the cooling step is prior to subsequent coating, the cooling time may be shortened because the elevated preform temperature is believed to improve the coating step. While the cooling time varies, they are typically about 5-40 seconds for about 0.05 to about 0.75 grams of a coated 24 gram preform.

6). Ejection from the device In one embodiment, once the preform has cooled, it is removed from the device and ready for packaging. In another embodiment, the preform is removed from the coating apparatus and sent to a blow molding apparatus for further processing. In yet another embodiment, the coated preform is passed to another coating module where an additional coating or multiple coatings are formed. This further device may or may not be connected to a further coating module or blow molding device.

7). Recycling Conveniently, bottles formed or as a result of the preferred method described above can be easily recycled. Using current recycling processes, the coating can be easily removed from the recovered PET. For example, a polyhydroxyaminoether-based coating applied by dip coating and cured by infrared heating can be removed in 30 seconds when exposed to an aqueous solution at 80 ° C. at pH 12. Also, an aqueous solution with a pH equal to or lower than 4 can be used to remove the coating. The diversity of acid salts formed from polyhydroxyaminoethers changes the conditions required for removal of the coating. For example, the resulting acid salt from an acetic acid solution of a polyhydroxyaminoether resin can be removed using an aqueous 80 ° C. solution at a neutral pH. Instead, the recycling method described in US Pat. No. 6,077,097, entitled Recycling Method for Objects Having Hydroxyphenoxy Ether Polymers, may be used. The method disclosed at this occurrence is incorporated herein by reference.

8). Example I
A laboratory scale flow coater was used to form a coating on a 24 gram PET preform. A device as illustrated in FIGS. 14-16 and having one flow coating unit and an infrared curing / drying unit was used. The preform was manually loaded into the process line. The collets used to hold the 24 gram preform were centered at 1.5 "spacing from each other. This avoids wake effects when the preform passes through a coated waterfall or sheet. The distance was found to provide the proper spacing, and the coating material was pumped into the tank using a non-shearing pump, which then flowed out of the tank to form a waterfall or sheet. It formed a coating on the preform as it passed through the sheet, while the preform was lined at a rate of 3 inches per second while passing through the coating sheet to ensure two full rotations. Once it has passed through the sheet, the line speed allows the excess coating material to be removed at the bottom of the preform. The preform was allowed to drip for about 10 seconds before passing over the sponge roller, and then the preform was transferred to an infrared curing / drying unit with 5 1000W general as a source. An Electric Q1500 T3 / CL quartz line tungsten-halogen lamp was used at a capacity of 60%, the lamp was arranged at 0.6 inches in the center line, and the preform was held for 10 seconds in an infrared curing / drying unit. When the preforms came out of the curing / drying unit, they were cooled with forced ambient air before being removed from the apparatus.

  The coating material used in this example was a PHAE dispersion with 30% solids of BLOX ™ XUR 588-29 (from Dow Chemical). The average deposit (one layer on a 24 gram preform) was about 97 mg.

9. Example II
FIG. 18 is a schematic diagram illustrating one embodiment of a coating apparatus. The coating apparatus 300 is preferably an automated apparatus for rapidly coating a preform. The illustrated coating apparatus 300 includes a transfer device 310, a transfer device or carousel device 312, a coating unit 316 (ie, a transfer device, a flow coating unit, etc.), a material removal device 318, and a temperature control device. 320 and a preform removing device 346. In the illustrated embodiment, the temperature controller 320 includes a pair of curing units 330 and 332 and a cooling device 336.

  The coating apparatus 300 can be used, for example, for coating a substrate article (substrate article or article substrate) such as a container or a preform. For simplicity, the embodiments described below will be described with reference to a preform that is blow molded into a container. In general, the transfer device 310 can supply the preform to the carousel device 312. The carousel device 312 can move the preform along the processing line so that the preform is coated by the coating unit 316 and processed by the material removal device 318 and then through the temperature controller 320. Passed and the coating layer is cured. The coated preform is then cooled by cooling device 336 and removed from carousel device 312.

  In some embodiments, the coating apparatus 300 can receive a warm worm preform for assistance in the curing process. In the embodiment illustrated in FIG. 18, the coating apparatus 300 can receive a worm preform from the substrate manufacturing apparatus 340. The illustrated base material manufacturing apparatus 340 is, for example, an injection molding machine such as a Gaylord injection molding machine or another injection molding machine. The preform manufactured by the injection molding machine can be quickly transported to the coating apparatus 300 via the transport apparatus 342. Since the conveying apparatus 342 can use a typical apparatus used for removing the preform from the injection molding machine, detailed description will not be given.

  The natural heat of the worm preform provides one or more of the following: Ie, a coherent coating that shortens the curing time, generally produces a completely cured layer, minimizes the number of blisters formed in the coating layer Promotes and / or provides similar ones. In a non-limiting embodiment, the temperature of the worm preform is about 30 ° C. to about 70 ° C. when the preform is coated by the coating unit 316. The temperature of the preform is preferably generally greater than about 30 ° C. when the preform is being coated by the coating unit 316. Beneficially, there is less presence of contaminants (eg, dust) on the surface of the preform due to rapid transfer between the substrate manufacturing device 340 and the coating device 300. A low degree of contamination can promote adhesion between the coated layer and a preform made by injection molding. The preform output from the injection molding machine is cooled to a desired temperature before being processed by the coating apparatus 300.

  The substrate manufacturing apparatus 340 can use any suitable apparatus for manufacturing a substrate. In some embodiments, the substrate manufacturing device 340 is an extrusion blow molding machine. The extrusion blow molded container is output from the substrate manufacturing apparatus 340 and conveyed to the coating apparatus 300 to coat the layer. Alternatively, the substrate manufacturing device 340 may use a compression injection machine or other type of device for manufacturing an object substrate.

  In other embodiments, the preform can be supplied indirectly from an apparatus for manufacturing the substrate of the object, eg, from an injector to a coating apparatus 300. For example, the preform can be manufactured and stored for an extended period of time before the preform is processed by the coating apparatus. If the preform is dirty or contaminated, the preform may be cleaned, for example, by a cleaning process. Any suitable clean can be used to clean the preform. For example, detergents, water, chemicals, surfactants, combinations of them, etc. can be used to clean the preform, and the surface of the preform is suitable for coating the layer. Make sure that there is. The preform is cleaned with water before and / or after it is placed in the coating apparatus 300. A water cleaning unit (not shown) can be placed along the processing line between the transfer device 310 and the coating unit 316. It will be appreciated that the preform is cleaned with water at any location in the processing line. Preferably, any excess liquid from the cleaning process is removed before entering the flow coating apparatus 312. Of course, the preform is coated by the coating apparatus 300 with or without a cleaning process or with or without other types of preparatory processes.

  Optionally, a temperature control unit can be positioned along the processing line to heat the preform before depositing the coating material on the preform. A temperature control unit (not shown) can be placed along the processing line between the transfer device 310 and the coating unit 316. The temperature control unit may include an oven, an energy distribution device (eg, one or more heating lamps), or other suitable device that can be controlled to heat and / or cool the preform. it can. In some embodiments, the temperature control unit can preheat the preform immediately after the preform is coated by the coating unit 316.

  18 and 19, the transfer device 310 can receive the preform and then supply it to the carousel device 312 at any desired supply speed. In some embodiments, the transfer device 310 can supply preforms to the carousel device 312 either batchwise or continuously. Additionally, multiple transfer devices 310 can be used to receive multiple preforms and transport them to the carousel device 312.

  The illustrated transfer device 310 continuously supplies the preform to the carousel device 312. The transfer device 310 can carry the preform, preferably one preform at a time, in a common fixed ratio or in a variable ratio. However, multiple preforms can be transported to the carousel device 312 simultaneously and sequentially. Beneficially, the preform can be passed through the coating unit 316, preferably at a somewhat constant line speed, without stopping the movement of the carousel device 312. Variations in line speed can cause unexpected distribution to the preform. Additionally, the continuous preform supply increases the output of the coating apparatus 300 and ensures that the coating material flowing from the coating unit 316 is used effectively.

  In the embodiment illustrated in FIG. 19, the transfer device 310 includes one or more gates 348, a starwheel 350 attached to a drive shaft 352, and an outer guide member 354. The star wheel 350 and the outer guide member 354 can cooperate to carry the preform to the carousel device 312.

  The gate 348 is configured to prohibit or permit the conveyance of the preform to the star wheel 350. The gate 348 has a rod 360, which is in an open (open) position that allows the preform to be transferred to the star wheel 350, and no preform is transferred to the star wheel 350. It is possible to move between closed positions. When the rod 360 occupies the closed position, the end of the rod 360 stops the preform to be transferred to the star wheel 350. The preform can be transferred to the star wheel 350 when the rod 360 occupies the open position. An air line may provide compressed air that is used to drive the gate 348. In some embodiments, the gate 348 may be driven manually, electrically, mechanically, with compressed air (as illustrated), and / or by any other suitable means.

  The star wheel 350 can have a groove or pocket 362 configured to couple with the preform, as illustrated in FIG. The star wheel 350 can have a plurality of pockets 362 located around its periphery. Each pocket 362 is configured to surround at least a part of the body (main body) of the preform. In the embodiment illustrated in FIGS. 18 to 20, it is a curved segment, which has the same radius of curvature as the upper radius of the body 4 of the preform 1. The preform 1 in the pocket 362 is captured between the outer guide member 354 and the star wheel 350, as illustrated in FIG. As illustrated in FIGS. 20 and 21, the bottom surface 363 of the support ring 6 can slidably engage the top surface 364 of the star wheel 350 and the top surface 368 of the outer guide member 354.

  The drive shaft 352 can rotate at a general speed for continuously feeding the preform to the carousel device 312. In some embodiments, the drive shaft 352 rotates at a constant or variable speed during the manufacturing cycle. When the drive shaft 352 is rotating, each pocket 362 and the corresponding preform of its capture rotate together. As the preform moves, the preform support ring 6 slides along the stationary upper surface 368 of the outer guide member 354. Thus, the preform can move along a curved path extending from the transport device 342 toward the carousel device 312, for example.

  The rotational speed of the star wheel 350 can be determined by the desired output of the coating apparatus 300 and the size and configuration of the star wheel 350. For example, a star wheel with a large radius can rotate at a lower speed than a star wheel 350 with a small radius. In a non-limiting embodiment, the star wheel 350 can be transported to the coating apparatus 300 at 5,000-15,000 preforms / hour. In other non-limiting embodiments, the star wheel 350 can be transported to the coating apparatus 300 at about 45,000 preforms / hour. Alternatively, the rotational speed of the star wheel 350 can be based on the output capability of the injection molding machine 340 (FIG. 18) to optimize preform manufacturing.

  The star wheel 350 may have any number of pockets 362 disposed around its periphery. The number of pockets 362 can be selected according to the dimensions and configuration of the preform 1 that is not yet coated. Preferably, the transfer device 310 is tolerated so that preforms of various dimensions can be transferred by the transfer device 310 without any adjustments or changes.

  FIG. 22 illustrates another embodiment of the transfer apparatus in which the coating apparatus 300 is used. The transfer device 370 can supply the preform to the carousel device 312 in a batch mode. For example, a set number of preforms can be simultaneously conveyed to the carousel device 312. The carousel device 312 can receive and transport the preform along the processing line. After a predetermined time has elapsed, another batch is conveyed to the carousel device 312.

  The transfer device 370 can have a plurality of grippers 372, each gripper configured to hold an uncoated preform 1. The gripper can be any suitable gripping mechanism or a device that can selectively hold or release the preform. The transport device 342 (FIG. 18) can supply one or more preforms to the transfer device 370 at a time. After the transfer device 370 receives the preform 1, the transfer device 370 can move the preform to any desired position. For example, the transfer device 370 can move the preform in the horizontal and vertical directions, illustrated as arrows 374 and 376, respectively. The transfer device 370 can also move the preform in the traverse direction (lateral direction) depending on the configuration of the carousel device 312.

  A transfer device, such as the transfer device as described above, carries the preform and transports the preform 1 to a loading device 377 (FIG. 24A) that is configured to cause the carousel device 312 to load the preform. Can do. In some embodiments, the transfer device can transport multiple preforms 1 to the loading device 377 simultaneously. However, in other embodiments, the transfer device can transport the preforms to the loading device 377 in order.

  With reference to FIG. 18, the carousel device 312 can include one or more carriers 374 configured to receive a preform from the transfer device 310. The carrier 374 moves along the carousel device 312 while carrying one or more preforms. In one embodiment, each carrier 374 holds and transports a single preform. In other embodiments, including the illustrated embodiment, each carrier 374 holds and transports one or more preforms, preferably at least two preforms. The carousel device 312 can have a motor (not shown) that drives the carrier 374 around the carousel device 312. Optionally, the carrier 374 can rotate the preform as the carrier moves along the circumference of the carousel device 312. For example, each carrier 374 can continuously rotate one or more preforms as the carrier 374 moves along the processing line. Optionally, the carrier 374 can move or rotate the preform in an outward and / or inward direction relative to the carousel device 312.

  In connection with FIG. 24A, the loading device 377 of the carousel device 312 can be used to place the preform on the carrier 374. The illustrated loading device 377 includes one or more loaders 376 disposed below the carrier 374. The illustrated loader 376 is movable in the axial direction in the vertical direction between the loading position and the unloading position. In one embodiment, loader 376 receives one or more preforms 1 conveyed by transfer device 310 when loader 376 occupies a loading position. The loader 376 can be displaced vertically toward the unloading position to raise the preform to the movable carrier 374. The carrier 374 can accept the raised preform. The carrier 374 can then hold and carry the preform along the processing line.

  Each loader 376 has a corresponding carrier 374 preferably moving integrally along at least a portion of the processing line. Each loader 376 may comprise a cam riser, follower, or other suitable mechanism for transporting the preform to the carrier 374.

  A curved guide member 380 (illustrated as a shadow in FIG. 24B) is used to position the preform 1 between the pair of retaining members or prongs 386 of the loader 376 in order to position the preform 1. Contact can be made with the uncoated preform 1 held in the pocket 362. The support ring 6 of the preform 1 can rest on the upper surface 389 of the loader 376 and is raised to the carrier 374 in turn. When the loader 376 reaches the unloading position, the preform is separated from the carrier 374.

  In this way, one or more preforms 1 can be transferred from the star wheel 350 to the carrier 374. The loader 376 is adapted to carry any number of preforms 1. In one embodiment, for example, loader 376 is configured to carry only one preform 1. In other embodiments, the loader 376 is configured to carry a plurality of preforms 1.

  Referring to FIG. 24B, loader 376 can move in the direction indicated by arrow 388 and star wheel 350 can rotate in the direction indicated by arrow 390. Loader 376 and star wheel 350 can be synchronized so that each pair of prongs 386 coincides with a corresponding pocket 362 on star wheel 350. Preferably, member 380 is positioned in a stationary position at the top relative to loader 376 and star wheel 350.

  Referring to FIG. 24A, the loader 376 carries and lifts the preform to the corresponding carrier 374. The carrier 374 then receives and holds the preform for further transport along the carousel device. In some embodiments, each loader 376 includes a rail 400, a carriage 402, and an extending member 404 coupled to the carriage 402. The end of the extending member 404 includes a roller 408 that is configured to pass along a slot or cam 412. The loader 376 is movable along the carousel device 312 and can be moved vertically as the roller 408 rotates along the bent slot 412. After the loader 376 holds the preform 1, the carriage 402 of the loader 376 can slide vertically up along the rail 400 to raise the preform toward the carrier 374. When the carriage 402 reaches a raised position (eg, an unloading position), the carrier 374 receives and holds the preform neck 2. Carriage 402 can then be moved vertically downward, thereby moving prong 386 away from the preform.

  After the plurality of carriers 374 receive the plurality of preforms, the plurality of carriers 374 transport these preforms around the periphery of the carousel device 312 in the direction indicated by arrows 375 in FIGS. . The plurality of carriers 374 can be connected to each other so as to move together. Belts, coupling members, rods, or similar means can be used to connect the plurality of carriers 374 together. In one embodiment, all or a substantial number of carriers 374 of the coating apparatus 300 are interconnected with adjacent carriers 374. In order to hold the preform, the carrier 374 can bond both inside and outside the preform. For example, each carrier 374 can couple the inner surface 16 of the neck 2 and the outer thread 18. In other embodiments, each carrier 374 can engage only the outer surface of the preform (eg, the exterior of the neck 2). Preferably, each carrier 374 does not extend downward past the outer surface of the support ring 6 so that the body 4 is completely covered by the material.

  With reference to FIGS. 24A and 25, the carrier 374 is configured to fit and extend within the interior of the preform as illustrated in FIG. 42. A mechanism 420 may be included. The gripping mechanism can comprise a mandrel or other suitable device for securely holding the preform. The illustrated gripping mechanism has a mandrel shape. As used herein, the term “mandrel” is in a broad sense and is used in its ordinary sense and may include, without limitation, collets, spindles, preform holders, and the like. The mandrel can be used to selectively hold the preform. In some embodiments, the mandrel is movable between a holding position and a release position. The mandrel can hold the preform when in the holding position and release and accept the preform when in the releasing position. In some embodiments, the mandrel 420 is a generally cylindrical elongated body that is sized to fit into an opening in the preform. Optionally, the mandrel 420 can extend into and along a substantial portion of the neck of the preform. In other embodiments, the mandrel 420 can extend in many portions inside the preform and terminate along the body 4 of the preform. Preferably, at least a portion of the mandrel 420 is configured to extend the inner surface of the preform.

  In some embodiments, at least a portion of the mandrel 420 is moved to hold and / or release the preform. Preferably, at least a portion of the mandrel 420 is moved radially inward and outward as desired. For example, the mandrel 420 can be moved radially or outward to engage and hold the inner surface 16 of the preform. The mandrel 420 can be moved radially or inward to release the preform from the mandrel 420.

  Continuing with reference to FIG. 24A, the mandrel 420 may have an inflatable slip ring 424, such as a split. In one embodiment, the ring 424 is an annulus with a gap so that the ring can conveniently extend in the radial direction. The slip ring 424 can be biased inwardly (displaced) to secretly surround the body of the mandrel 420.

  Referring to FIG. 25, the mandrel 420 may have an upper lip 430, a body 432, and a groove 436. The upper lip 430 has a lower surface 431 suitable for contacting the upper edge of the preform so that the preform can sit securely against the upper lip 430. When the loader 376 is transporting the preform to the carrier 374, the loader 376 can raise the preform until the preform contacts the lower surface 431 or is located near the lower surface 431.

  Groove 436 is suitable to receive at least a portion of slip ring 424 (illustrated as a cross-section). At least one or more openings 440 along the groove 436 can cooperate with one or more protrusion 444 to selectively drive the slip ring 424. The protrusion 444 can be a generally spherical body that can extend from a cooperating circular opening 440. When the protrusion 444 extends from the opening 440, the protrusion 444 pushes the slip ring 424 outwardly, thereby applying sufficient pressure to the inner surface so that the outer surface of the slip ring 424 holds the preform. Can do. The protrusion 444 is retracted into the body (body) 432 of the mandrel 420 so that the protrusion 444 generally does not apply a force to the slip ring 424 so that the slip ring 424 is ) Allows biasing inward (biased inward) to tightly surround 432. Therefore, the protrusions 444 can be moved between an extended position and a retracted position to hold or release the preform, respectively. Since the protrusion 444 engages the inner surface of the slip ring 424, it can take any suitable shape. In the illustrated embodiment, the mandrel 420 has four openings 440 and four corresponding protrusions 444. However, any number of protrusions 444 and openings 440 can be used.

  With reference to FIGS. 26A and 26B, each carrier 374 may have a lever device 450 that is adapted to selectively control the slip ring 424. The mandrel is not shown.

  The lever device 450 is arched so that a mandrel 420 (not shown) holds the preform firmly or releases the preform. For example, when the mandrel 420 occupies the first position, the mandrel 420 holds the preform firmly. When the mandrel 420 occupies the second position, the mandrel 420 releases and / or accepts the preform. The mandrel 420 is driven between as many positions as desired. The illustrated lever device 450 is attached to the body 452 of the carrier 374 and preferably includes a lever 454, a base 455, and rods 456, 458.

  As illustrated in FIG. 26B, lever 454 extends from pivot 462 and is rotatable in the direction illustrated as arrow 460. The end of the lever 454 can have a roller 464 for engaging the first track of the carousel device 312. The contact pads 468, 470 (FIG. 26A) of the lever 454 can contact the upper ends of the rods 456, 458, respectively.

  Base 455 can be rotated in the direction indicated by arrow 478 and extends from pivot 482 as illustrated in FIG. 26B. The end of the base 455 can have a roller 484 that engages the second track of the carousel device 312. As illustrated in FIGS. 26A and 26B, each of the rods 456 and 458 extends through a hole in the base 455.

  Referring again to FIG. 26A, the upper ends 490, 492 of the rods 456, 458 can contact each of the contact pads 468, 470 and move the rods 456, 458 relative to the base 455. Springs 494 and 496 disposed around a portion of the rods 456 and 458 bias (bias) the ends 490 and 492 toward the lever 454, respectively. When the carrier 374 is moving along the carousel device 312, each of the rollers 464, 484 can be disposed in a corresponding track of the carousel device 312. As the carrier 374 moves along the track, the distance between the tracks increases or decreases and the rollers 464, 484 move away from each other or closer together. When the rollers 464, 484 are sufficiently close, the lever 454 applies a force sufficient to overcome the bias of the springs 494, 496, thereby moving away from the respective ends of the cylindrical housings 500, 502. The rollers 456 and 458 are pushed. Each of the cylindrical housings 500, 502 can be disposed through a corresponding mandrel 420. In operation, a mandrel can be attached to each cylindrical housing 500,502.

  The diameters of the rods 456, 458 are changed at different locations on the housings 500, 502 so that the protrusions 444 (not shown) are extended or retracted.

  26A, 26B, the carrier 374 may have a drive mechanism that engages a portion of the carousel device 312 and rotates the mandrel. In the illustrated embodiment, the drive mechanism 503 (not shown) includes a drive gear 505, which is a gear, gear, chain, brush, and / or other structure of the carousel device 312. Engage with things. As the carousel motor moves all of the carrier 374 along the carousel device 312, the drive gear 505 of the drive mechanism 503 rotates the rods 456, 458 and then the corresponding mandrels. Optionally, the rods 456, 458 can be interconnected by a belt. Alternatively, the rod is driven independently by one or more drive mechanisms. For example, each rod 456, 458 is driven by a brush gear.

  As illustrated in FIG. 24A, the mandrel 420 can be disposed under the cylindrical housings 500, 502, so that the rods 456, 458 can extend from the lower end of the mandrel 420. For example, the housing 500 may be disposed in the passage 515 (shown in FIG. 25 with a shadow) of the mandrel 420. Preferably, the housing 500 and the mandrel 420 are aligned so that one or more openings 510 in the housing 500 are aligned with the openings in the mandrel 420. The protrusion 444 can therefore pass away from the openings 440, 510. The housing 502 can be aligned like other mandrels 420.

  Referring to FIG. 26A, the body 452 of the carrier 374 may have mounting holes 516, 518 that are configured to receive fasteners for attaching the carrier 374 to a movable portion of the carousel device 312.

  18 and 27, the coating apparatus 300 may include one or a plurality of coating units 316. The illustrated coating unit 316 is in the form of a flow coating device. It will be appreciated that the flow coating device 316 can be replaced by a dip device or a spray device depending on the application.

  As illustrated in FIGS. 27 and 28, the flow coating device 316 can comprise a tank or bat 550 that is preferably in fluid communication with a fluid source. The fluid in the tank 550 can be transferred to the preform 1 by the flow coating device 316 and passes through the preform. The fluid in tank 550 includes, but is not limited to, barrier materials (eg, gas barrier materials, eg, phenoxy thermoplastic), additive (eg, anti-foaming agents), colorants, thermoplastics, polymers, etc. Can be included. Any desired fluid can be retained in tank 550.

  In the embodiment illustrated in FIG. 28, the tank 550 includes a housing 552 and a flow control device 558. The housing 552 has a wall 556 that defines a chamber 554 suitable for holding a coating material (eg, fluid coating material). Embodiments of housing 552 can take any shape suitable for containing a coating. Chamber 554 is dimensioned to hold a desired amount of coating material, preferably a desired amount of coating material in liquid form. It will be appreciated that the dimensions of the chamber 554 may be selected depending on, for example, the output of the coating apparatus 300, the dimensions and configuration of the preform, the characteristics of the coating material, the amount of coating material to be applied, and / or the like. Like.

  The fluid control device 558 can be used to selectively control the flow rate of the coating material conveyed from the flow coating device 316. The fluid control device 558 provides the coating material at a typical fixed flow rate or variable flow rate during the manufacturing cycle. In one embodiment, the fluid control device 558 includes a movable gate 562 and a gate positioning assembly 5543 (FIG. 27) configured to selectively move the gate 562 relative to the fluid guide 566. It has. As illustrated in FIG. 29, the edge 568 of the gate 562 and the fluid guide 566 define a gap or passage 570. The edge 568 of the gate 562 can be generally straight along the length of the gate 562. In other embodiments, the edge 568 can be curved or take any other suitable shape to provide one or more gaps between the gate 562 and the fluid guide 566. Optionally, edge 568 beneficially facilitates laminating the coating material along the surface of fluid guide 566 and over the preform. The tank 550 can have other means of reducing the disturbance of the coating material.

  The edge 568 has a surface 574 that is generally parallel to the surface of the fluid guide 566. In other embodiments, the gap 570 can have a height that varies along its length and / or width. Additionally, the surface 574 can be curved or oriented at an angle relative to the fluid guide 566. The size of the gap 570 is increased or decreased to increase or decrease the amount of fluid flowing down the fluid guide 566 and over the preform. As the coating material flows out of the flow coating device 316, the top surface of the coating material in the tank 550 is preferably higher than the gap 570. If the coating material is foam or foam, the foam or foam is present on the surface of the coating material. Beneficially, the coating material flowing through the gap 570 can be substantially free from bubbles, blisters, or contaminants that tend to flow into the coating material.

  The gate positioning assembly 564 illustrated in FIGS. 27 and 30 can selectively position the gate 562 to obtain a gap 570 of any desired dimensions. The gate positioning assembly 564 may have one or more nuts 580 that engage one or more bolts 581 for threading. When the nut 580 is rotated, the nut 580 moves the bracket 582 attached to the gate 562 in the vertical direction. The gate positioning assembly 564 can be supported by a member 560 that is coupled to the housing 552 of the tank 550. In other embodiments, the gate positioning assembly 564 rotates the gate 562 and / or provides a transverse movement of the gate 562. Also, the gate positioning assembly 564 can move the gate 562 continuously and / or incrementally. In certain embodiments, the gate positioning assembly 564 can be used to move the gate 562, such as one or more motors (eg, stepper motors), solenoids, screw-driven actuators, and / or the like. Can be provided. It will be appreciated that the gate positioning assembly 564 is passively or automatically controlled. For example, the gate positioning assembly 564 can be numerically controlled by a controller (eg, a digital controller).

  Optionally, at least one gate 562 and fluid guide 566 may have means for providing laminar flow. For example, the gap 562 and the fluid guide 566 can have fins, coatings, surface treatments, or other structures that reduce the disturbance of the coating material conveyed by the flow coating device 316.

  With continued reference to FIG. 28, the tank 550 optionally includes a lid or top 593 that covers the tank 550 to prevent or limit contamination of the coating material in the chamber 554. it can. The lid 593 can be removably coupled to the housing 552 to facilitate separation and access from the chamber 554. In some embodiments, a fastener can be used to permanently or temporarily couple the lid 593 to the housing 552.

  In some embodiments, the tank 550 includes an overflow device 592 to adjust the amount of material in the tank 550. Overflow device 592 maintains the desired amount of coating material in tank 550. If the level of coating material preferably rises beyond the opening 594 of the overflow device 592 comprising the tube 591, the coating material flows into the opening 594 and out of the tank 550 via the tube 592. Thereby, the amount of coating material in the tank 550 is reduced. In the illustrated embodiment, the tube 591 extends upward from the bottom of the tank 550 and extends into the chamber 554. Optionally, tank 550 may include a level sensor 596 that is used to determine the level of tank 550. The overflow sensor 596 may be in communication with one or more pumps, valves, and / or other devices that maintain a desired level of coating material. For example, the valve can be actuated to drain the coating material of tank 550, which depends directly or indirectly on the signal from sensor 596.

  Referring to FIG. 31, fluidic device 530 is in fluid communication with tank 550. The fluid device (system) 530 is a closed system for recycling the coating material in order to efficiently reuse the unused coating material. However, the fluidic device 530 can be an open system. Additionally, the fluidic device 530 can be both a closed system for one or more parts of the manufacturing cycle and an open system for one or more parts of the manufacturing cycle.

  With continued reference to FIG. 31, the fluidic device 530 may comprise one or more lines, tanks, pumps, and / or filtration systems (devices). In the illustrated embodiment, the fluidic device 530 includes a tank device 600. The overflow line 604 and the drain line 606 extend between the tank 550 and a reservoir (storage tank) or tank 610. The pump 614 extends between the storage tank 601 and the tank 550.

  In one embodiment, the tank apparatus 600 includes a collection tank 620 that receives unused material from the flow coating apparatus 316. As illustrated in FIG. 33, the collection tank 620 is disposed under the preform covering the end of the fluid guide 566 and / or under the fluid guide 566. The collection tank may take the form of a basket, catch tank, or other structure configured to receive unused coating material.

  Optionally, the collection tank 620 can have means for reducing bubbles and / or blisters in the collected coating material. Foams and / or blisters in the coating material can make the coating of the manufactured multilayer preform non-uniform or incomplete. The coating material collected in tank 620 can be reused to coat the preform. It is therefore beneficial to prevent or limit the formation of bubbles and / or blisters in the tank 620.

  As illustrated in FIG. 32, the collection tank 620 has a baffle 622 to prevent or limit the formation of bubbles and / or blisters. Unused portions of the curtain of the coating material 624 (ie, the coating material that does not remain on the preform) can flow to and along the baffle without creating substantial turbulence. it can. In other embodiments, a plurality of baffles reduces the foam of the coating material. Although not shown, other configurations may be used which are used to limit the formation of bubbles / foam in the coating material. For example, various inclined surfaces, fins, channels, and / or appropriate structures can be used to reduce bubbles. It will be appreciated that the location and type of structure where no bubbles are generated is selected to achieve the desired amount of flow from the collection tank 620 and into the collection tank 630. Additionally, the collection tank 620 can have a structure that creates a vortex and accelerates the flow of unused coating material to the tank 630 to prevent foam generation. Collection tank 620 does not have any means for reducing foam / foam formation. Of course, the structure of the collection tank 620 is selected depending on the properties of the coating material.

  The distance between the tank 550 and the collection tank 620 depends on the desired sheet action of the coating material, the characteristics of the coating material (eg, foam properties, viscosity, etc.), the flow ratio, the line speed of the carousel device 312 and the preform space. And / or other processing parameters.

  Collection tank line 630 extends between collection tank 620 and storage tank 610. The material collected by the collection tank 620 is conveyed to the storage tank 610 via the collection tank line 630.

  Referring to FIG. 31, an overflow tank 604 extends from the tank 550 to the storage tank 610. Fluid passing through the overflow tube 591 substantially passes through the overflow line 604 and reaches the overflow line 604. In some embodiments, material from collection tank 620 is not transferred to storage tank 610. For example, the overflow line 604 can carry the coating material to an off-line storage tank.

  Optionally, the fluidic device 530 can have a drain line 606 extending from the tank 550 to the reservoir 610. In some embodiments, the drain line 606 may drain the tank 550 to prevent the coating material in the tank 550 from being cured when the pump is not operating. used. Additionally, the tank 550 can be drained to clean the inner surface of the tank 550 or to perform other maintenance. A flow regulator (eg, a valve system) is disposed along the drain line 606. The flow regulator can be used to inhibit or allow fluid flow out of the tank 550 via the drain line 606.

  The reservoir 610 can store the coating material, and in particular can have an appropriate size or structure for an extended period of time and to hold the coating material. For example, reservoir 610 may be a container having a volume greater than about 5 gallons, 10 gallons, 15 gallons, 20 gallons, 30 gallons, and ranges including such volumes. In some embodiments, the reservoir 610 can have a volume of about 15 gallons, about 25 gallons, about 35 gallons or more. In some embodiments, the coating apparatus 300 can include a plurality of storage tanks 610. One of the plurality of storage tanks 610 can be online when the other storage tank 610 is offline. After a certain amount of coating material from the online tank 610 has been used, the online storage tank 610 can be replaced with an offline storage tank 610, preferably a storage tank 610 that is full of coating material. The emptied storage tank 610 is then filled, preferably filled and taken offline. In this way, the coating material is quickly added to the coating apparatus 300, thereby increasing the output of the preform.

  With continued reference to FIG. 31, the pump 614 is disposed at a position along the output line 612. The pump 614 can withdraw the coating material from the reservoir 610 and applies pressure to the coating material so that the coating material flows to the tank 550 via the output line 612. Pump 614 can be a suitable device to sufficiently pressurize the coating material. For example, the pump 614 can be a diaphragm pump, a screw-type pump, or the like, and can have a fixed or variable displacement. In one embodiment, for example, the pump 614 is a diaphragm pump, and preferably the diaphragm pump causes little or no shearing. Beneficially, the diaphragm pump 614 can be used with a shearsensitive coating material and can include one or more diaphragms. In one non-limiting embodiment, the pump 614 is a double diaphragm pump. Optionally, multiple pumps can be used at various locations along the fluidic device 530 to pressurize the coating material.

  As shown in FIGS. 31 and 34, the inlet 632 of the output line 612 is connected to the lower part of the storage tank 610. The illustrated inlet 632 is connected to the bottom half of the storage tank 610. In a non-limiting embodiment, the inlet 632 is less than 2 inches from the bottom of the storage tank 610. In an unrestricted embodiment, the inlet 632 is disposed along the bottom of the storage tank 610. Beneficially, the inlet 632 can be positioned below the surface of the coating material in the reservoir 610, thereby pulling the coating material with the least amount of bubbles or blisters. However, the inlet 632 can be connected at any location along the reservoir 610 that is suitable for receiving the coating material.

  Optionally, the fluidic device 530 can include a filtration device. With reference to FIG. 31, the filtration device 650 is configured to remove unwanted material present in the coating material circulating through the fluid device 530. For example, the filtration device 650 can include, for example, cured portions of the coating material, contaminants (eg, dust present in the preform coating and unused coating material captured by the collection tank 620), and Alternatively, selected impurities such as any other material can be captured. The filtration device 650 can include one or more filters suitable for removing various unexpected materials.

  The illustrated filtration device 650 includes an input line 652, a pump 654, a pump line 656, a filtration unit 660, and an output line 666. The input line 652 extends from the storage tank 610 with a pump 654. Pump 654 can be similar to or different from pump 614. Pump 656 extends between pump 654 and filtration unit 660. The fluid in storage tank 610 flows via lines 652, 656 and filtration unit 660, then flows via output line 666 and returns to storage tank 610.

  Filter device 650 is positioned at other locations within fluidic device 530. For example, the filtering device 650 can be positioned along the output line 614 rather than withdrawing fluid from the reservoir 610. The filtration device 650 can be located in any other suitable location for effectively filtering the coating material.

  The filtration unit 660 can have one or more filters. The illustrated filtration unit 660 includes a pair of filters 662, 664 having the same or different filter ratings. In some non-limiting embodiments, the filter 662 can have a rating (eg, a micron rating) in the range of about 30-70 microns. In one embodiment, filter 662 has a micron rating of about 50 microns. Filter 662 may have a micron rating of less than 10 microns. In an unrestricted embodiment, the filter 662 may have a micron rating of less than 5 microns. The upstream filter 662 can filter relatively large contaminants so that the filter 664 can filter small contaminants without clogging with large particles. Filters 662, 664 can have bags, cartridges, and / or other filter structures that can be periodically replaced or cleaned (eg, particles can be removed from the filter structure).

  The flow of coating material through the filtration device 650 is reduced and preferably stopped to change the filter offline. Optionally, valves can be disposed along lines 652 and 656 to control the flow rate through filter 650. Beneficially, the coating device 300 can bypass the filtration device 650 to continuously coat the preform while the filtration device 650 is in use. However, the covering device 300 may be completely shut off during the period in which the filtering device 650 is in use.

  During operation, the coating material can flow from the reservoir 610 to the input line 652. Pump 654 can draw the coating material via input line 652 and flow the material through both pump line 656 and filtration unit 660. Filtration unit 660 removes unexpected substances from the coating material. The filtered coating material then flows via output line 666 and returns to storage 610.

  Referring to FIG. 18, after the preform is coated by the flow coating device 316, the carousel device 312 passes the preform to the material removal device 318 that is configured to remove excess coating material on the preform. Move. Typically, when the coated preform arrives at the material removal device 318, the coating material is still a liquid.

  The coating apparatus 300 is an effective deposition in which virtually all of the coating material on the preform (ie, there is no excess material to be removed) is used to form a multi-layered preform as a result. (Deposition) can be provided. In some embodiments, many or all of the coating material deposited on each preform is cured to produce a multilayer preform. However, there are situations where it is desirable to remove excess coating material after the preform has been coated. In one embodiment, the rotation and gravity of the preform work together to generally clean the sheet of coating material on the preform and remove at least a portion of excess material.

  In some embodiments, the material removal device 318 is used to remove additional unexpected material. If the preform has surplus material, the surplus material may blisters, burn, or produce incomplete materials, so the preform Subsequent blow molding may make it inappropriate and unsuitable for use.

  FIG. 35 is a perspective view of one embodiment of a material removal device 318. Since the material removal device 318 produces the preform with a somewhat uniform coating, it can remove at least a portion of the coating layer on the preform. Preferably, the coating layer is cured when the coated preform arrives at the material removal device 318. The illustrated material removal apparatus 318 is a de-tear device having a surface 700 suitable for contacting and removing material from the preform. The material removal device 318 can have an absorbent component that pulls the coating material from the preform as it passes through it. The absorbent element can be rotated to further enhance the removal of the coating material.

  Referring to FIGS. 36 and 37, the surface 700 is defined by a sponge roller or belt 702 that engages a drive wheel 704 (FIG. 37) driven by a motor 706. One or more wheels 704 can tension belt 702. The surface 700 of the belt 702 can preferably include an absorbent material such as an open cell foam (eg, an open cell polyethylene foam). In other embodiments, the belt 702 includes a non-absorbing material. The material forming the belt 702 is selected based on the desired amount of material absorbed by the belt 702.

  The illustrated material removal device 318 includes a removal device cleaner 711 that is configured to extract material from the material removal device 318. The removal device cleaner 711 has wheels 712 that can compress the belt 702 between the wheels 704 to remove the coating material from the belt 702. In the illustrated embodiment, belt 702 is compressed between wheels 704, 712 to squeeze out the liquid coating material. Such a removal device cleaner is used to prevent saturation of the belt 702.

  In operation, after the flow coating device 316 coats the preform, the coated preform moves along a processing line in the direction indicated by arrow 720 illustrated in FIG. As the preform moves and engages the material removal device 318, the motor 706 rotates the drive wheel 704 to move the belt 702 and its surface 700. The surface 700 may have a line speed that is the same as or different from the line speed of the carousel device 312. The surface 700 is pressed against one or more preforms to remove material from the preform. In the illustrated embodiment, the material removal device 318 simultaneously removes at least a portion of the coating material present in the plurality of preform bodies.

  Fluid is supplied to the belt 702 to further enhance the removal of the coating material. In some embodiments, including the embodiment illustrated in FIG. 36, the line 715 carries liquids such as water, solvents, coating materials, etc. on the belt 702. Any number of lines can be used to transport liquid to the material removal device 318. The liquid can help clean the belt 702 and improve the efficiency of the belt 702.

  Optionally, surface 700 can also be a stationary surface that engages and removes excess material from the preform. The preform can be dragged across the stationary surface 700.

  The material removal device 318 can remove material from at least a portion of each preform. A substantial portion of the surface of the rounded end cap, preferably in the liquid state, can be removed by the material removal device 318. In some embodiments, the material removal device 318 can remove most or all of the coating material on the rounded end cap. The material removal device 318 can then remove the thin film of coating material disposed on the surface of the end cap. Material removal device 318 can also be used to remove coating material from other parts of the preform.

The material removal device 318 can be moved relative to the preform to adjust the amount of material removed from the coated preform. As shown in FIG. 35, the material removal device 318 can remove material from the end 716 of the preform having a length L _1. End 716 is the portion of the preform from which material removal device 318 is removing material. Preform is L ₂ overall length. In some non-limiting embodiments, the end 716 has a length L ₁ that is generally less than the radius, r, of the end cap 10. In some non-limiting embodiments, the end 716 has a length L ₁ that is generally equal to the radius of the end cap 10. In some non-limiting embodiments, the end 716 has a length L ₁ that is generally less than about ½ of the length L ₂ . In other embodiments without other restrictions, the length L ₁ is in the range of 5-30% of the length L ₂ . In yet another non-limiting embodiment, the length L ₁ is in the range of 10% to 40% of the length L ₁ . In some embodiments non-limiting, the length _{L 1} is 5% of the length _{L 2, 10%, 20%} , 30%, 40%, 50%, and, in a range containing these Pasentiji . In some non-limiting embodiments, the material removal device 318 is 2.5%, 5%, 10%, 20%, 30%, 40%, 50% of the preform coating material and its Remove ranges that contain such percentages. It will be appreciated that any percentage of material 714 may be removed by material removal device 318.

  Any number of material removal devices 318 can be used to remove from the preform. For example, the first material removal device 318 can remove a first amount of material from each of the preforms moving along the processing line. The second material removal device 318 can continuously remove a second amount of material from each of the preforms. The first amount of material is generally equal to or different from the second amount of material. In one embodiment, the first amount of material is greater than the second amount of material. Each material removal device 318 can remove material from the same and / or different parts of the preform. In one embodiment, the first material removal device 318 can remove material from the first portion of each preform. The second material removal device 318 can remove material from the second portion of each preform. In one embodiment, the first portion has a generally longer length than the length of the second portion. It will be appreciated that any number of material removal devices 318 can be used at various suitable locations to remove material from the preform held by the carrier 374.

  The particular location of the material removal device 318 may include, for example, the viscosity of the coating material, the rotational speed of the preform, the line speed, the setting of the temperature controller 320, the desired quality of the coated preform, and / or similar factors Can be selected. For example, if an unexpected number of water bubbles are formed during the curing process period, the material removing device 318 can remove excess (excess) material that contributes to generating water bubbles. For example, if the formation of water bubbles on the end cap 10 during the curing process, the material can be removed from the end cap 10 before the coated preform enters the temperature controller 320. The coating material adhering to the preform is then re-coated on the end cap to form a relatively thin layer of material across the end cap 10. Such thin layers can preferably be cured without the formation of an unexpected number of water bubbles.

  As the coated preform enters the temperature controller 320, the temperature controller 320 heats the coated preform, thereby reducing the viscosity of the coating material and causing the coating material 714 to move to the end of the preform. Spread towards. A material removal device 318 is positioned relative to the preform to compensate for changes in the viscosity of the coating material. In some embodiments, the coating material 714 can cover the portion 716 before and / or after the curing process such that the cured coating material covers the end cap 10.

  The preform can be oriented vertically or oriented at a predetermined angle with respect to the vertical axis. In the illustrated embodiment, the preforms are passed along a material removal device 318, but the preforms are angled from the vertical axis so that portions of the end cap 10 are removed from the material. Contact device 318. In some non-limiting embodiments, the preform longitudinal axis 722 (FIG. 38) is at an angle of less than 90 ° with the vertical axis. In one non-limiting embodiment, the preform longitudinal axis 722 is at an angle in the range of about 20 ° to about 70 ° with the vertical axis. In one non-limiting embodiment, the preform longitudinal axis 722 is at an angle in the range of about 40 ° to about 60 ° with the vertical axis. In some embodiments, a generally vertically oriented preform passes through a sheet of coating material produced by the flow coating device 316 and the orientation of the preform is illustrated in FIG. As such, the preform is changed before reaching the material removal device 318. Additionally, when the preform is advanced along the material removal device 318 to enhance the dispersion and / or removal of the material on the surface of the preform, the preform is rotated about the longitudinal axis 733. Can be rotated. For example, the preform is angled and rotated to further maintain the coating material on the body. For example, in one embodiment, the orientation and rotation of the preform causes the retention of the coating material at the top and / or center of the preform body 4 to form a uniform layer of coating material. Facilitate. However, in other embodiments, when the preform is moving down the processing line, the preform is not rotated. In some embodiments, the preform can rotate continuously or periodically as the preform passes along one or more material removal devices 318.

  The surface 700 of the material removal device 318 may have any size and configuration suitable for removing material from the preform being conveyed along the carousel device 312. Referring to FIG. 39, the surface 700 can be a surface treatment or surface structure 730. The surface structure 730 can include one or more serrations, ridges, protrusions, grooves, channels, and / or coating materials that are easy to remove and / or diffuse, and any other structure. May be included.

  Referring to FIG. 39B, the surface 700 has one or more grooves 730 to facilitate removal of the coating material attached to the preform. The coating material is received in the groove 730 and passes along to leave the preform. Depending on the embodiment, the groove 730 can be parallel or perpendicular to the arrow 720 of FIG. In addition, the removal device 318 may have one or more tubes 715 to supply fluid (eg, water, solution, dilute solution, coating material, surfactant, mixtures thereof, etc.) to the surface. . The combination of grooves 730 and the liquid quickly pull away the excess coating material of the preform.

  The surface 700 may be a smooth surface. Preferably, a liquid flow is supplied from tube 715 to pull away the uncured coating material from the preform and flat surface 700. Any amount of liquid (eg, drops, pools, and / or fluids) can be used to remove excess material from the preform.

  The preform may or may not be in contact with the surface 700. In one embodiment, the surface 700 is spaced from the preform even though the liquid on the surface 700 is in contact with the preform. Of course, the surface 700 may be in contact with the preform during the removal process.

  The removal device 318 may extend along a row of preforms on the carousel device 312 so that the coating material can be continuously removed from the plurality of preforms. However, the size may be designed to remove material from one preform at a time.

  Tube 715 optionally transports the coating material to removal device 318. The coating material can also be used by bringing a similar or different coating material removed from the preform. For example, the coating material is transported to surface 700 by tube 715. If the coating material is flowing even along part of the surface 700, preferably the material attached to the preform surface is removed while still in the liquid state. In one embodiment, the coating material can simultaneously remove excess material from the preform while maintaining a thin layer of the coating material of the preform.

  Referring to FIG. 39C, the removal device 318 defines the flow of fluid to be removed and / or retransmitted on the preform 20. The illustrated removal device 318 includes a liquid source 750 that directs a high-speed fluid stream toward one or more preforms. The fluid can be air, nitrogen, oxygen, and / or other gases. In some embodiments, the liquid source 750 may extend along a row of preforms on the carousel device 312 so that the coating material attached to each preform can be continuously removed.

  The illustrated liquid source 750 is an air knife. The tube 752 transports air to the air knife 750, expells air from a nozzle 756 that faces the preform, and blows away excess material from the preform. Although not shown, the liquid source 750 can be configured as a plurality of liquid sources, for example, an air knife. Optionally, the liquid source 750 can spray a liquid that removes the coating material from the preform.

  Referring to FIG. 39D, the removal device 318 can utilize energy, such as potential energy, to remove the coating material from the coated preform. As in the illustrated embodiment, the removal device 318 includes an energy source 760 that generates charge. The charge pulls the uncured material away from the preform. The electric wire 762 supplies power to the energy source 760. Although not shown, the energy source 760 can be composed of a plurality of energy sources.

  Referring to FIG. 39E, the removal device 318 is a liquid reservoir 764 that stores one or more of the following liquids. : Water, coating materials, surfactants, mixtures thereof, etc. When at least a portion of the coated preform 20 touches the reservoir 764 of the tank 766, material is removed from the preform. For example, when the preform is in a position where the end of the preform is immersed in the liquid, at least the covering portion at the end is removed. Alternatively, the sump 764 can be used to deposit a coating material on the preform.

  One or more of the removal devices 318 described herein may be disposed along any location on the processing line. For example, one or more removal devices 318 can be disposed between the curing machines 330 and 332 of the temperature control device 320.

  The removal device 318 may be a liquid removal device that reuses the liquid removed from the preform. As shown in FIG. 40, the liquid removal device 800 may be one in which the illustrated fluid device 530 and liquid are connected. The liquid device 800 includes a collection tray 802, a discharge pipe 804, and a tank 806. The tray 802 collects excess liquid removed from the removal device 318. Preferably, tray 802 is sized to receive fluid falling from the preform and / or removal device 318 (eg, water, solution, thinning liquid, coating material, surfactant, mixtures thereof, etc.). Configure. If the removal device 318 uses the coating material to remove material from the preform, the material can be reused and then used in the flow coating device 316 and / or the removal device. it can. The tray 802 can be anywhere below the processing line. The collection tray 802 can be placed in the downstream line of the flow coating device 316 below the removal device 318.

  The discharge pipe 804 extends between the tray 802 and the tank 806. The liquid received by the tray 802 flows through the pipe 804 and flows to the tank 806. A pump 810 that is the same as or different from the pump 816 sends liquid from the tank 806 to the pumping tube 715. Pump 806 can apply pressure to the fluid and exhaust it through tube 715.

  The tank 806 may optionally have a stirrer 811 that stirs and mixes the liquid stored in the tank 806. The stirrer 811 promotes mixing of the material accumulated in the tank 806 and promotes uniformity of mixing.

  Continuing with reference to FIG. 40, the liquid removal device 800 may connect the fluid device 530 and the liquid. In one embodiment, the liquid can move back and forth between the devices 530, 800, and one or both of the liquid devices 530, 800 can optimize the amount of liquid. In one embodiment, the liquid tube 814 allows the tank 806, the reservoir 610, and the liquid to be connected. Optionally, a filter 660 is placed along the tube 814 to remove dirt from the liquid passing therethrough. The pump 614 is disposed along the pipe 814 and pressurizes the liquid between the tank 610 and the tank 806. In one embodiment, at least one of the tanks 610, 806 may have one or more sensors 816 for determining the amount of liquid in the tank. When the amount of one liquid in the tank reaches a level other than a predetermined level, the pump 614 is used to replace the liquid between the tanks 610 and 806 to a predetermined level.

  The sensor 816 detects and sends a signal indicating the liquid flow state. The signal from sensor 816 is used to adjust the material composition percentage. Additives can be added to the flowing liquid to achieve the desired mixing based on the signal. For example, the sensor 816 can be designed to measure the properties of the coating (eg, viscosity, concentration, amount of foam, optical properties, refractive index, etc.) to determine whether the additive is added to the liquid. For example, if the sensor 816 detects that there is less non-foaming agent in the liquid, the non-foaming agent is added manually or automatically. In some embodiments, the sensor 816 has one suitable for determining the concentration of various components of the coating material, such as an optical analyzer (eg, spectroscopic device, colorimetric device, etc.), refractometer. May be. In some embodiments, one or more sensors 816 can send a signal to the controller. The controller may be used to selectively control the amount of fluid components. The devices and methods described in US Pat. Nos. 6,067,151 and 5,309,288, which are used here by reference in their entirety, can be used. The sensor 816 can also be designed to measure other parameters of the coating material. The sensor 816 measures the parameter of the liquid flowing continuously or completely depending on the predetermined usage. In some non-limiting embodiments, the sensor 816 can measure the temperature, speed, concentration, amount of ingredients, etc. of the coating material.

  In some embodiments, the fluidic device 530 includes a fluid temperature control device 817 that selectively controls the temperature of the coating material. The fluid temperature control device 817 may be anywhere along the fluid device 530, for example, one or more fluid temperature control devices 817 may change the temperature of a liquid line, in a tank, or other coating material. Can be placed in a suitable location. In the embodiment including the embodiment shown in FIG. 40, the fluid temperature control device 817 is a heat exchanger that quickly changes the temperature of the fluid material in the tank 610. The fluid temperature controller 817 operates to ensure the temperature of the coating material to keep it within a desired temperature that reduces, for example, material degradation, curing and the like. Any suitable heat exchanger can be applied.

  Referring again to FIG. 18, after the coating material is removed from the preform, the preform traverses the temperature control device 320 and cures the coating layer. The temperature controller 320 cures at least a portion of the coating material deposited on the outer surface of the preform. The temperature controller 320 preferably cures a substantial portion of the coating material on each preform.

  The physical configuration of the temperature control device 320 can be adjusted according to the preform. As shown in FIG. 41, one or more ramps 736 can move in response to a preform held on a mandrill 520. As in the illustrated embodiment, each ramp 736 can move toward and / or away from the preform, respectively. It is desirable to place one or more lamps 736 near edge 10 as shown in FIG. Thereby, the curing of the bottom of the preform can be completed. For example, the coating material 714 (FIG. 38) may sag from the body 4 toward the end 10 due to gravity. The coating material collects at the edge 10. The collected coating material is completely cured by the space between the preform and the lamp on the lower side of the curing machine 330. The embodiment applying the lamp can also be used for preforms with varying widths. For example, in the case of a preform whose upper part is wider than the lower part, the lamp can be arranged close to the lower part of the preform in order to ensure uniform curing. The lamp is appropriately tilted so that it illuminates the entire surface of the coating substantially uniformly. One or more lamps can be placed almost evenly from the coated preform. The preform can then be tilted or bent perpendicular to the longitudinal axis. The preform rotates about the major axis 722 so that a substantially uniform curing of the coating material can be achieved as it passes through the ramp 736.

  In some embodiments, the coating material on the substrate object may include a curing accelerator. For example, the coating material can include carbon black and / or other curing promoters that help crosslink the coated member. A sufficient amount of a curing accelerator can be added to the coating material depending on the design of the cure part, the desired production time, and the like. Any cross-linking agent can be used to facilitate the curing process.

  Continuing to refer to FIG. 41, the cure sections 330, 332 have one or more reflectors 740 that reflect the output from the lamp 736 directed at the preform. The reflector 740 is used with an infrared (IR) lamp 736 to increase the curing of the preform. The lamp 736 is placed on one side of the process line and the reflector 740 is placed on the opposite side of the process line. The design appropriately reflects the output from the lamp 736 back to the preform for a quicker and more complete cure, and effectively uses the output of the lamp 736. Although not shown, an additional reflector is placed at an appropriate position with respect to the preform to reflect infrared light from the lamp to the preform. The reflector 740 is usually made of a flat surface, a curved surface, a surface-treated material, and / or a material capable of obtaining an appropriate amount of reflected energy.

  The temperature controller 320 controls the temperature of the preform using one or more of the following: conduction, convection, and radiation. In order to control the temperature of the preform, any heating / cooling method can be adopted. For example, conduction is used to selectively define the surface temperature of the preform, thereby providing flexibility in controlling the penetration of radiant heat. In some embodiments, the temperature control device 320 includes a flow device that delivers a fluid flow (eg, a gas flow) to control the surface temperature of the preform. The fluid there can be heated or cooled. Preferably, a cooling gas is used to form a cold boundary layer along the preform surface to reduce the surface temperature of the coating layer. The boundary layer isolates the surrounding heated air from the preform and promotes thermal insulation. This allows for rapid and complete curing of the preform coating without overheating the coated preform surface. The decrease in the surface temperature of the coating layer can be appropriately delayed by forming a film on the coating layer. When a film is formed on the coating material, the accumulated fluid (for example, water, air, etc.) may move from the film material or be damaged from the film. Of course, when a special embodiment requires slow curing or deep infrared penetration, the cure rate can be controlled with one or more of the following: : Cooling gas, temperature controlled gripping mechanism (eg, temperature controlled mandrel), time lapse in infrared unit, frequency of infrared lamp, and combinations thereof.

  The temperature control device 320 and the transport unit 374 can be operated alone or in combination to control the temperature of the preform. In one embodiment, the surface temperature of the coating may exceed the coating material temperature Tg, and the substrate is not heated above the substrate temperature Tg in the curing / drying step. As a result, generation of an appropriate film and / or cross-linking is performed, and deformation of the preform shape due to overheating of the substrate does not occur. For example, if the Tg and cross-linking temperature of the coating material is higher than the material of the preform substrate, the surface of the coating will be properly heated to the temperature at which the cross-linking of the coating will occur and the temperature of the substrate will be It is kept at Tg or below. One method of performing the drying / curing process to achieve this balance is a combination of infrared heating and air cooling (as described above), but other methods can be employed. In this way, the substrate can be kept at the desired temperature, and at least the portions of the coating material can be kept at different temperatures.

  In one embodiment of FIG. 42, the mandrel 420 has a means for controlling the temperature of the preform disposed therein. The mandrel 420 has a path 744 that controls the temperature of one or more preforms, preferably at the neck of the preform. The body 432 of the mandrel 420 extends to the interior space portion of the preform. The heated or cooled fluid passes through the mandrel 420 to adjust the temperature of the preform 20 held therein. The cooled fluid (eg, coolant, water, air, etc.) moves heat from the preform through path 744. The lamp 736 and the mandrel 420 are used in combination to crystallize the neck end of the preform. Then, as the preform 20 and the corresponding mandrel 420 travel along the processing line by the temperature controller 320, the mandrel 420 and the preform 20 rotate relative to the shaft 722 and become more uniform throughout the body of the preform 20. Heat distribution is ensured.

  The temperature control device 320 may have a structure that blocks or reduces radiant heat penetrating the preform and / or the coating layer. As shown in FIG. 43, the shield 750 shields at least the radiant heat emitted from the lamp 736. The shield 750 blocks most or all of the radiation emitted from the one or more lamps 736. The shield 750 can block radiation emitted from the lamp 736 such as metal or plastic. The shield can be sized, for example, to extend along the top of the preform so as to prevent radiation penetrating into the neck 2 of the preform. The shield 750 can extend over the entire length of the lamp 736. The shield 750 can then include an opaque material that allows some of the radiant energy emerging from the lamp 736 to pass. A plurality of shields 750 can be used to stop or prevent radiation from penetrating into different parts of the preform. One or more curing machines (eg, curing machines 330 and 332) may have one or more shields 750 depending on usage.

  The curing machines 330 and 332 are maintained at any temperature suitable for curing the preform coating. The temperature in the coating machine is appropriately lowered along the processing line. The upstream line curing machine 330 emits a large amount of radiant energy that penetrates the coating layer when no coating is formed on the outer surface of the coating layer. As the preform progresses to the downstream line, the downstream line curing machine 332 reduces the amount of radiant energy emitted from the upstream line curing machine and prevents the formation of scratches and other defects. However, one or more curing machines may produce a substantially constant amount of radiant heat. And the lamp 736 near the preform end 10 of the downstream line can produce a small amount of radiant energy to reduce the damage to the coating layer.

  When the preform reaches the curing process, the preform is cooled. In some embodiments, the preform is cooled after it exits all cure machines. However, you may reach a cooling process between curing machines. The cooling process may have ambient air with or without convection. In some embodiments, the cooling process is facilitated using forced cooled air. In the embodiment shown in FIGS. 18 and 44, the cooling device 336 has a path 770, and a blower or a fan (not shown) circulates the surrounding air (preferably cooling air). Air is held by the transport 374 and cools the preform carried down the path 770 length. Any means for cooling the cured coating on the preform can be used. When the preform is cooled by a desired amount, it is released from the transport unit 374 and carried out by a removing device 346 that also serves as a transport device.

  And the coating | coated apparatus 300 has one or more temperature sensors. In one embodiment, the temperature sensor is an optical pyrometer 824 and is carefully placed along the processing line to measure the temperature of the preform. Preferably, pyrometer 824 directly determines the temperature of the preform by measuring the radiation emitted from the preform. Thus, the pyrometer can measure the temperature of the liquid coating material without touching or disturbing the coating material. In the illustrated embodiment, the coating apparatus 300 has four pyrometers 824. The first pyrometer 824 is placed between the transport device 310 and the flow coating device 316. The second pyrometer 284 is placed between the material removal device 318 and the temperature control device 320. The third pyrometer 284 is placed between the temperature control device 320 and the cooling device 336. The fourth pyrometer 284 is placed in the downstream line of the cooling device 336. The coating apparatus 330 may have any number of pyrometers 824 anywhere, and measures the construction temperature of the coating apparatus and the temperature of the preform being processed. However, other temperature devices may be used to measure the temperature of the preform and / or the coating device configuration. For example, one or more thermocouples can be used to measure the temperature of a preform or coating device configuration.

  The temperature control device 320 is a closed loop or open loop mechanism. For example, the temperature control device 320 is controlled as a closed loop mechanism based on feedback from one or more temperature sensors (eg, pyrometer 824) to the lamp 736. Then, these signals are read to adjust the amount of radiant heat emitted from the lamp 736. Further, the temperature control device 320 determines the amount of radiant heat emitted from the lamp 736 as an open loop mechanism based on a user input. For example, the lamp 736 can be set to a fixed power mode. Each of the lamps 736 is set to a desired target temperature and output. The temperature controller 320 may be switched between a closed loop mode and an open loop mode. In some embodiments, the controller is connected to a plurality of sensors and the temperature controller 320. The controller selectively controls the output of the temperature controller 320 in response to at least one signal from at least one temperature sensor.

  Referring to FIG. 18, the coating apparatus 300 includes one controller 860, and the user controls the configuration of one or more apparatuses 300. The controller 860 receives and displays an indication from the pyrometer 824, for example. The controller 860 stores and executes the program, and controls the control device 300, and the control device 300 coats preforms having different sizes. Each of the programs is used to run one or more coating apparatus 300 configurations. Various configurations of the coating apparatus 300, such as the transport apparatus 310, the flow coating apparatus 316, the material removal apparatus 318, and / or the temperature control apparatus 320, have a mechanism for installation. For example, a typical device for movement consists of a linear slide and an actuating device (eg, a screw-driven actuating device). The controller 860 operates an operation mechanism (for example, one or more coils, a motor including a drive motor or a step motor), and moves the configuration of the coating apparatus 300 to a desired position. These components are numerically controlled by a controller 860 (for example, a digital controller). In some embodiments, each of the configurations has one or more degrees of freedom of configuration location at a desired location. Thus, the configuration of the coating apparatus 300 can be installed at a desired position along the processing line. Each configuration can be in a different position based on the size and shape of the preform being processed. The controller 860 has a preset and stored program that is based on the shape of the preform, the type of coating material, the control conditions (eg, ambient temperature, humidity, etc.), or other parameters known in the art. To select and execute. The coating apparatus 300 can thus be used to coat a variety of different types of preforms.

10. Example III
FIG. 45 shows another embodiment of the coating apparatus, which is substantially the same as the embodiment described above, except as further described below. As much as possible, similar configurations are the same as those in the above description of the embodiment.

  The coating apparatus 1000 includes a supply apparatus 1002 that conveys the preform to a conveyance apparatus 1004 that sequentially conveys the preform to the carousel apparatus 312. As the preform is conveyed along the processing line by the carousel device 312, the coating device 1010a deposits material on the preform flowing in the direction indicated by arrow 375 along the processing line.

  Referring to FIGS. 45 and 46, the supply device 1002 can be constituted by a plurality of conveyors and sliders that convey the preform to the conveying device 1004. As shown in FIG. 46, the supply device 1002 includes an upper conveyance line and a lower conveyance line (not shown) extending downward from the coating device 1000 to the conveyance device 1004. Although not shown, the supply apparatus 1002 can include a gate or the like that performs control to convey the preform from the supply apparatus 1002 to the conveyance apparatus 1004.

  The transport apparatus 1004 can include a plurality of star wheels. The illustrated conveying device 1004 includes a first star wheel 1016 and a second star wheel 1018. The star wheel 1016 has an outer periphery receiving port 1020 for receiving and holding the preform carried by the supply device 1002. The star wheel 1016 rotates so that the preform can be passed to the receiving port 1022 of the star wheel 1018. The star wheel 1018 rotates and conveys the preform to the carousel device 312. Any number of star wheels can be used depending on the design of the coating apparatus.

  As described above, the transport unit 374 receives and holds the preform carried by the transport device 1004. The carousel device 312 moves the transport 374 to carry the supported preform to the coating device 1010a. The coating apparatus 1010a is a flow coating apparatus and is preferably detachably attached to the main body 1023 (FIG. 46) of the carousel apparatus 312. The main body 1023 can surround and protect the coating apparatus 1000.

  As shown in FIGS. 45 to 47, the flow coating apparatus 1010a preferably includes a tank apparatus 1030 and a transfer apparatus 1032. The tank apparatus 1030 has a module structure, and is constituted by a frame 1036 and a tank 1038 installed therein. The module of the modular tank apparatus 1030 is preferably adapted to be removed from the coating apparatus 1000. As used herein, “module” is a broad term and is used in a general sense and includes independent devices and systems that are not limited. In some embodiments, the modular tank device can be moved between a remote position and a transport position. When the tank apparatus 1030 is in the transfer position, the tank-type module can be placed next to the transfer apparatus, and the coating material is transferred from the tank 1038 to the transfer apparatus when the pump 1065 of the tank apparatus 1030 is operated.

  In some embodiments, the tank 1038 is installed within the framework 1036 and the fluid path is connected to the transport apparatus 1032. The frame 1036 can be a frame and surrounds and supports the tank 1038 for convenient transportation. The tank 1038 is generally similar or identical to the tank, or can be a storage tank 610. Therefore, it will not be described in more detail.

  The frame 1036 is preferably detachably connected to the main body 1023 so that the tank device 1030 can be attached and removed. The tank device 1030 can include a moving device 1039. The illustrated moving device 1039 has a plurality of wheel devices 1040 connected to the tank device 1030. Thus, the tank device 1030 can be moved freely on the support surface. In the illustrated embodiment, the wheel device 1040 is attached to the lower part of the frame 1036. Although not shown, the frame 1036 can rest on other suitable means for moving the tank apparatus 1030. For example, the framework 1036 can be placed on a slider (eg, a linear slide device), on a gantry device, on a roller, or on other known moving means.

  Continuing with reference to FIG. 46, the main body 1023 of the coating apparatus 312 may have a storage portion (for example, an opening) for storing the tank apparatus 1030. When the frame 1036 is connected to the main body 1023, one or more lock mechanisms 1050 can be employed to temporarily connect the tank device 1030 to the main body 1023. In addition, an alignment mechanism can be employed to align the tank device 1030 with the main body 1023. Tank 1038 stores the coating material that is carried on the preform surface carried by carousel device 312.

  Preferably, when the liquid level of the coating material in the tank 1038 reaches a predetermined low position, the tank device 1030 is easily detached from the main body 1023 and another tank device 1030, preferably a tank device fully loaded with the coating material. It can be replaced with 1030. Thus, the module of the tank device 1030 can be quickly replaced and attached to the main body 1023. When the empty tank apparatus 1030 is removed from the coating apparatus 1000, the tank 1038 can be used to refill the coating material and again supply the tank apparatus 1030 to the transport apparatus 1032. The transport apparatus 1032 can have a coating that includes a flow coating apparatus, a dip coating apparatus, a spray coating apparatus, and combinations thereof. One skilled in the art can select the size, configuration, moving means of the tank device 1030, etc., depending on the amount of coating material that fills the tank 1038.

  The tank apparatus 1030 may include an upper tank 1060 installed on the upper part of the tank 1038. Material in tank 1038 is conveyed through fluid line 1062 to tank 1060. The coating material from the upper tank 1060 is poured onto the preform surface moving along the processing line by the coating apparatus 1032. In some embodiments, the tank device 1030 can include at least some of the elements of the fluidic device 530 shown in FIG. For example, the filtration unit 660 can be attached to the tank device 1030. In some embodiments, the total fluid device 530 can be attached to the tank device 1030. Thus, the tank device 1030 can include one or more sensors 816, a liquid temperature control device 817, a fluid line, and the like.

  The coating apparatus 1000 illustrated in FIG. 45 is configured to deposit a plurality of layers on a preform held by a corresponding carrier. The first layer can be deposited on each preform by the coating apparatus 1010a. The second coating apparatus 1010b can deposit the second layer on the coated preform. The coating device 1010b can be similar to the coating device 1010a. Each coating device 1010a, 1010b can have one or more transport devices 1032. The modular tank device of the coating device can be configured similarly to the corresponding transport device.

  In some embodiments, the preform is coated on the first layer by a coating device 1010b. The coated preform traverses the material removal device 318 and passes through the temperature control device 320. The temperature control device 320 warms the coated preform and at least cures the coating material. The coated preform moves along the processing line and is carried to the second coating apparatus 1010b. The second layer is deposited on the preform coated by the second coating apparatus 1010b.

  The coated preform that has passed through the temperature controller 320 is warmed. The heat trapped in the preform promotes the sticking, curing, and / or drying of the material deposited by the second coating apparatus 1010b. Also, the coated preform that has passed through the temperature control device 320 is cooled before being conveyed to the second coating device 1010b.

  Depending on the embodiment, the first and second coating apparatuses 1010a and 1010b can be installed adjacent to each other along the processing line. By doing so, the coating layer deposited by the coating apparatus 1010a can be prevented from being cured when the second coating apparatus 1010b deposits the second layer on the material on that layer. Any number of coating devices can be used to form multiple layers having any number of layers.

  Referring to FIG. 48, the transport device 1032 is configured to transport the coating material to the preform carried by the conveyor 374. The transfer device 1032 preferably includes a fluid guide 1070 that carries material to the preform passing from the tank 1060. The preform moving along the processing line passing through the opening 1061 is coated with a coating material 1063.

  In order to catch the coating material 1063 falling from the preform, a receiving tank 1074 is placed under the preform just coated. Thus, the receiving tank 1074 can transport the coating material to a tank 1038, ie an off-line tank, and / or a disposable system. The receiving tank 1074 can be any type of collection tank.

  The fluid guide 1070 and / or the receiving tank 1074 are installed to move to the support structure 1080. The alignment device 1082 is used to move the fluid guide 1070 and / or the receiving tank 1074. The alignment device 1082 can be configured by a drive screw device, linear actuator, control mechanism, and / or other suitable means to align the fluid guide 1070 and / or the receiving tank 1074. In the illustrated embodiment, the support structure 1080 is a vertically extending linear slide that moves the fluid guide 1070 and the receiving tank 1074 vertically. The alignment device 1082 is operated to move the fluid guide 1070 and / or the receiving tank 1074 to a desired position.

  Referring again to FIG. 47, a collection tray 1086a in the shape of a ridge is installed to receive the coating material falling from the preform. The trough 1086a can be a tank that extends below the coated preform and preferably extends from the down line of the receiving tank 1074 along the processing line. As shown in FIG. 45, the ridge 1086a extends toward the material removing device 318. The trough 1086a preferably extends at least to the middle of the flow coating device 1010a and the material removal device 318. In some non-limiting embodiments, the heel 1086a is 2 feet, 3 feet, 4 feet, 6 feet, and longer than that range. In some embodiments, the trough 1086a is more than half the distance between the flow coating device 1010a and the material removal device 318. In addition, the fluid line can be connected to the saddle 1086a to carry the coating material stored therein to the tank 1038 or storage tank. Thus, the coating material that falls from the preform and falls into the ridge 1086 is reused and can be used to coat the preform to efficiently use the coating material.

  Referring to FIG. 49, the carrier described above has a holding mechanism having the shape of a mandrel 1100 configured to grip the preform. The mandrel 1100 has a stretched body 1102 and is controlled to selectively hold the preform 1103. The illustrated mandrel 1100 is in the first position. The stretched body 1102 has a plurality of members that are movable relative to each other. The illustrated stretched body 1102 is divided into a first member 1106 and a second member 1108. As shown in FIG. 49, the preform 1103 moves vertically above the stretch 1102 (indicated by the arrow 1120). Once the stretched body 1102 comes into the preform 1103, the first member 1106 and the second member 1108 move away from each other to hold the preform 1103 firmly. Thus, the mandrel 1100 in the first position (FIG. 49) receives the preform. To hold the preform 1103, the mandrel 1100 moves to the second position (FIG. 50).

  Referring to FIG. 50, the mandrel 1100 includes one or more actuators 1130 that move the first member 1106 and the second member 1108 away from each other. In addition, the mandrel 1100 may have an introduction 1136 that facilitates the preform 1103 to slide into the mandrel 1100.

  FIG. 51 shows another form of mandrel 1050. The mandrel 1050 includes an elongated body 1152 having a mechanism 1154 that restrains and holds the preform. The mechanism 1154 moves between a holding position and an open position. The illustrated elongated body 1152 has a groove 1156 configured to accommodate at least a portion of the movable member 1161 (eg, split ring) of the mechanism 54. The drive mechanism 1160 of the mechanism 1154 selectively moves the split ring 1161 in the desired outward and / or inward direction. The split ring 1161 moves outward and becomes a holding position for holding the preform. The split ring 1161 moves inward to receive the preform or to open the preform. In some embodiments, the drive mechanism 1160 includes a protrusion 1162 and a spring 1164. The spring 1164 moves the protrusion 1162 outward with respect to the split ring 1161. Any number of drive mechanisms 1160 can be used. As the preform advances onto the stretched body 1152, it slides to the stretched body 1152 until the opening of the preform contacts the lower surface of the split ring 1161. As the preform advances further along the mandrel 1050, the preform overcomes the distortion of the spring 1164, the split ring 1161 moves inward, and the preform continues to advance upward along the mandrel 1150.

  The driving device 1181 is connected to the mandrel 1150. The illustrated drive 1181 includes a device suitable for transmitting rotational movement to a gear, chain gear, brush, or other mandrel 1150. For example, the drive 1181 can have a gear or a gear that mates with a chain of carousel devices. Further, the driving device 1181 can be a brush that restrains the brush of the transport system. In other embodiments, the drive 1181 can be a brush gear configured to rotate the mandrel 1150. Thus, the mandrel 1150 rotates in the major axis direction as it moves through the processing line.

  The driving device 1181 is directly or indirectly connected to the mandrel 1150. The illustrated driving device 1181 is connected to the mandrel 1150 by a connecting member 1183.

  Referring to FIG. 52, the preform 1170 is fully inserted into the mandrel 1150. The drive mechanism 1160 applies a force to the split ring 1161 in the outward direction. The elastic interaction between the outer surface of the split ring 1161 and the inner surface of the preform 1170 is sufficient to hold the preform. Preferably, the preform 1170 can be easily removed from the mandrel 1150 so that it can be held without the use of complex mechanisms. That way, you can reduce the number of parts that need to be broken or maintained. In order to remove the preform 1170 from the mandrel 1150, the preform 1170 may be pulled slightly from the mandrel 1150. For example, when the transport portion 374 of the carousel device 312 moves, the coated preform moves by a removal mechanism that pulls the preform 1170 downward. The removal mechanism applies a force that overcomes the elastic force between the mandrel 1150 and the preform. In some embodiments, the removal mechanism has a cam surface that is shaped to mate with the upper surface of the auxiliary ring of the passing preform and pushes the preform away from the mandrel 1150.

  Referring to FIG. 53, the gripping mechanism 1200 holds the outside of the neck portion at the end of the preform. The gripping mechanism 1200 is a preform holding machine, and has a structure 1202 (for example, a protrusion, a ring edge, etc.) that meshes with a part of the preform, preferably the end (for example, a thread) of the neck portion of the preform. The preform is connected to the mandrel or gripping mechanism 1200 by advancing the preform in a vertical direction toward the opening and the gripping mechanism 1200. The gripping mechanism 1200 has a separated annular member 1204 that defines a portion for pressing the end of the neck portion. In order to remove the preform from the gripping mechanism 1200, the preform is pulled downward, and the preform is slid out of the holding mechanism 1200. In some embodiments, the gripping mechanism 1200 moves to the starting position and drops the preform. Of course, the mandrel may or may not rotate as the preform moves through the processing line.

  The configuration of the coating device can be designed to facilitate removal of the coating material. A release body is applied to the surface of the coating apparatus to facilitate cleaning of the coating apparatus. For example, the surface of the coating device that comes into contact with the coating material can be composed of a release material that can easily remove the coating material. The release body can be composed of one or more of the following release materials: Teflon®, polyvinyl, bleached powder (PVC), polypropylene, polyethylene, oriorphine (eg, nylon). For example, the inner surface of the collection tray 1086a can easily remove uncured coating material (eg, a thermoplastic material such as a phenoxyl-type thermoplastic) that falls from a preform traveling through the processing line. It can be covered by a possible release body. Release material can be included in all configurations of the coating apparatus. For example, the collection tray 1086a can be molded into a PVC tray. All surfaces in contact with the coating material can be formed by a release material, and removal of unused coating members can be performed.

  All patents and publications cited herein are incorporated by reference below. Here, except as further described, certain embodiments, features, apparatus, devices, materials, methods, and technical matters described herein may vary from US Pat. No. 6,109,006, depending on the embodiment. 6, 808, 820; 6, 528, 546; 6,312, 641; 6,391,408; 6,352,426; 6,676,883; U.S. Patent Application No. 09 / 745,013 (publication number 2002); 10 / 168,496 (publication number 2003-0220036); 09 / 844,820 (2003-0031814); 10 / 090,471 (publication number 2003-0012904); 10 / 395,899 (publication number 2004) -0013833); 10 / 614,731 (publication number 2004-0071885), 2 Provisional application 60 / 563,021, filed on April 16, 2004 provisional application 60 / 575,231, filed July 7, 2004 provisional application 60 / 563,021,2004 586, 399, provisional application 60 / 620,160, filed October 18, 2004, provisional application 60 / 621,511, filed October 22, 2004, and filed January 11, 2005. US patent application Ser. No. 11 / 108,342, entitled “Single / Multilayer Object and Compression Method for Manufacturing the Object,” filed Apr. 18, 2005, provisional application 60 / 643,008. US patent application Ser. No. 11 / 108,345, filed Apr. 18, 2005, entitled “Single / Multilayer Object and Injection Method for Manufacturing the Object” filed Apr. 18, 2005. Embodiments described in US patent application Ser. No. 11 / 108,607, entitled “Single / Multiple Layered Objects and Stretching Method for Producing the Objects,” which are incorporated by reference in their entirety. , Features, apparatus, devices, materials, methods, and similar to one or more of the described technical matters. The embodiments, features, apparatuses, devices, materials, methods, and the technical matters described there are, depending on the embodiments, the embodiments, characteristics, apparatuses, devices, materials, methods, and the above-described embodiments. It can be applied to or used in technical matters disclosed in patents and applications.

  The various methods and techniques described above provide a number of ways to implement the invention. Of course, it will be appreciated that not all described objects and advantages will necessarily be achieved in accordance with certain specific embodiments described herein.

  Further, those skilled in the art can find various feature variations from different embodiments. Similarly, the various features and processes described above may be combined and adapted by those of ordinary skill in the art to implement the methods of the technology, along with other known features and process equivalents, according to the techniques described herein. be able to.

  Although the present invention has been disclosed in the context of certain embodiments and examples, the present invention may be further modified by those skilled in the art beyond the specifically described embodiments, and It can also be seen that it can be used, deformed, and the like. Accordingly, the present invention is not limited to that specifically disclosed in the preferred embodiment herein.

FIG. 1 is an uncoated preform used as a starting material in a preferred embodiment. FIG. 2 is a cross section of a suitable uncoated preform of the type coated according to the preferred embodiment. FIG. 3 is a cross-section of a preferred embodiment coated preform. FIG. 4 is an enlargement of a portion of the wall portion of the coated preform. FIG. 5 is a cross section of another embodiment of a coated preform. FIG. 6 is a cross-section of a preferred preform within the cavity of a blow molding apparatus of the type that can be used to produce a preferred coated container of the present invention. FIG. 7 is a coated container prepared based on a blow molding process. FIG. 8 is a cross-section of a preferred embodiment coated container having features according to the present invention. FIG. 9 shows a three-layer embodiment of the preform. FIG. 10 is an unrestricted flow diagram illustrating a preferred process. FIG. 11 is an unrestricted flow diagram for one preferred process, where the apparatus comprises a single coating unit. FIG. 12 is an unrestricted flow diagram for a preferred process, where the device comprises a number of coating units within a single integrated device. FIG. 13 is an unrestricted flow diagram for a preferred process, where the device comprises a number of coating units within a modular device. FIG. 14 is an unrestricted plan view of a preferred process, where the apparatus comprises a single flow coating unit. FIG. 15 is an unrestricted front view of a preferred process, where the apparatus comprises a single flow coating unit. FIG. 16 is an unrestricted cross-sectional view of one preferred process, where the apparatus comprises a single flow coating unit. FIGS. 17A and 17B illustrate an unrestricted view of a suitable IR drying / curing unit. FIG. 18 is a plan view of the coating apparatus according to one embodiment without limitation. FIG. 19 is an unrestricted perspective view of one embodiment of the transfer apparatus of the coating apparatus illustrated in FIG. 18, wherein the transfer apparatus is not loaded with a preform. FIG. 20 is an unrestricted partial plan view of the transfer apparatus illustrated in FIG. 19, wherein the transfer apparatus is engaged with a preform. FIG. 21 is an unrestricted partial side view of the transfer apparatus illustrated in FIG. 19, wherein the transfer apparatus is engaged with a preform. FIG. 22 is a diagram showing no limitation on one embodiment of the transfer device of the coating apparatus. FIG. 23 is a non-restrictive view showing a portion of one embodiment of the carousel device of the coating apparatus of FIG. FIG. 24A is an unrestricted side view of a portion of the loading device, where the loading device is not loaded with a preform. FIG. 24B is an unrestricted side view of a portion of the loading device and transfer device, where the coating device is not loaded with a preform. FIG. 25 is a side view of a gripping mechanism according to an embodiment without limitation. FIG. 26A is an unrestricted rear view of one embodiment of a carrier for a carousel device. FIG. 26B is an unrestricted aspect of one embodiment of a carousel device carrier. FIG. 27 is a perspective view without limitation of one embodiment of the flow coating apparatus of the coating apparatus. FIG. 28 is a cross-sectional view of the tank of the flow coating apparatus illustrated in FIG. 27 without restriction. FIG. 29 is an enlarged cross-sectional view taken along line 29-29 in FIG. FIG. 30 is an enlarged view showing a part of the tank of the coating apparatus. FIG. 31 is an unrestricted schematic diagram of one embodiment of a fluid device of a coating apparatus. FIG. 32 is a cross-sectional view of an embodiment of the collect tank of the coating apparatus without limitation. FIG. 33 illustrates, without limitation, a carousel device for carrying a preform and a portion of a coating device for coating the preform. FIG. 34 is a view without limitation of the reservoir of the fluidic device of FIG. FIG. 35 is a diagram showing no restrictions on a part of the carousel device and the removing device according to one embodiment. FIG. 36 is a plan view of an embodiment of the removing device without limitation. FIG. 37 is a side view of the removing device of FIG. 36 without limitation. FIG. 38 is an unrestricted side view showing one embodiment of a preform that is partially coated with a coating material. FIG. 39A to FIG. 39E are diagrams showing no limitation on various removal apparatuses. FIG. 40 is a non-limiting diagram illustrating the removal of one of the coating device removal devices. FIG. 41 is an unrestricted side view of the preform in the curing unit. FIG. 42 is an unrestricted side view of an embodiment of a gripping mechanism for holding a preform. FIG. 43 is an unrestricted view showing another embodiment of the preform in the curing unit. FIG. 44 is a perspective view of the cooling device without limitation. FIG. 45 is an unrestricted side view of another embodiment. FIG. 46 is a perspective view of a part of the coating apparatus illustrated in FIG. FIG. 47 is a perspective view showing a part of the coating apparatus illustrated in FIG. FIG. 48 is a side view of the coating apparatus illustrated in FIG. FIG. 49 is a side view illustrating the gripping mechanism and the preform, and shows a state where the gripping mechanism is in the first position for receiving the preform. FIG. 50 is a side view of the gripping mechanism shown in FIG. 49 in the second position for holding the preform. FIG. 51 is a cross-sectional view of a gripping mechanism according to another embodiment. FIG. 52 is an unrestricted side view of the holding mechanism illustrated in FIG. 51 that holds the preform. FIG. 53 is a side view of the gripping mechanism holding the preform without limitation.

Claims (34)

An apparatus for producing a multilayer object (or multilayer object), the apparatus comprising:
A transfer device configured to receive and carry a substrate of an object;
A loading device having a plurality of loaders that are movable between a loading position and an unloading position;
A plurality of movable carriers having a gripping mechanism configured to selectively hold a plurality of object substrates, wherein the plurality of loaders are positioned at the loading position. And is configured to receive the object substrate from the transfer device when the loader is in position, and transports the object substrate to the movable carrier when the loader is in the unloading position. A plurality of movable carriers, configured as
A coating unit located along a processing line and configured to transport a coating material onto a substrate of the object held by the carrier;
A device for producing multilayer objects. The gripping mechanism includes a plurality of mandrels, and each of the plurality of mandrels is configured to fit into the inside of a corresponding object base, and each of the plurality of mandrels is an object. Movable between a first position for holding the substrate and a second position for receiving the object substrate;
The apparatus of claim 1. The transfer device comprises at least one star wheel, the star wheel having a plurality of peripheral pockets sized to receive a substrate of the object; The plurality of peripheral pockets are rotatable about a drive shaft of the star wheel;
The apparatus of claim 1. The transfer device includes a plurality of star wheels, and an object substrate is transferred between the plurality of star wheels when the star wheel is operating.
The apparatus of claim 1. Each gripping mechanism is movable between a holding position for holding the object substrate and a release position for releasing the object substrate;
The apparatus of claim 1. The apparatus further comprises a material removal device positioned along the processing line, wherein the material removal device is carried by the carrier along the processing line through the material removal device. Configured to receive a coating material disposed on a substrate of the object when
The apparatus of claim 1. The object substrate includes a plurality of preforms, each preform having a neck, a body, and an end cap, and the material removing device is not attached to the end cap of the preform. Configured to remove a substantial portion of the treatment coating material at a location where it is removed;
The apparatus according to claim 6. Further comprising a heat exchanger configured to effectively control the temperature of the coating material;
The apparatus of claim 1. Further comprising a sensor configured to continuously detect the viscosity of the coating material;
The apparatus of claim 1. A fluid device having a tank and a filtration device; the tank is configured to hold a coating material; the tank is in fluid communication between the filtration device and the coating unit; Is configured to receive and filter the coating material from the tank,
The apparatus of claim 1. The movable tank assembly further comprises a movable tank assembly in fluid communication with the coating unit, the movable tank assembly including a housing containing the tank, the tank being conveyed to the coating unit. Configured to hold material,
The apparatus of claim 1. The movable tank assembly is attached to a plurality of handle assemblies;
The apparatus of claim 11. Further comprising a tank in fluid communication with the coating unit, the tank being sized to hold at least 10 gallons of coating material;
The apparatus of claim 1. At least one temperature sensor, the at least one temperature sensor being arranged to measure the temperature of the substrate of the object moving along the processing line;
The apparatus of claim 1. A controller connected to the at least one temperature sensor; and a curing device configured to process a coating material on a substrate of the object, the controller comprising the at least one temperature sensor. Selectively controlling the output of the curing device in response to at least one temperature signal from a temperature sensor;
The apparatus according to claim 14. The at least one temperature sensor comprises a pyrometer;
The apparatus according to claim 14. An apparatus for producing a multilayer object (multilayer article), the apparatus comprising:
A transport device having a carrier, each of the carriers configured to carry at least one substrate along a processing line; and
A coating apparatus located following the processing line, the coating apparatus comprising:
A coating apparatus configured to convey a coating material to the substrate held by the carrier moving along the processing line;
A modular tank device that is movable and located with respect to the conveying device, the modular tank device comprising:
A tank configured to hold a coating material;
A pump in communication with the tank,
The modular tank apparatus is movable between a remote position and a transfer position, and when the modular tank apparatus occupies the transfer position and the pump is operating, the modular tank apparatus Is next to the transport device, and the coating material is transported from the tank to the transport device.
A device for producing multilayer objects. The apparatus further comprises a second conveying device positioned along the processing line, and the second conveying device conveys the coating material to the base material held by the carrier moving along the processing line. Configured to,
The apparatus of claim 17. The modular tank device has a transport device configured to rotate along a support surface;
The apparatus of claim 17. The apparatus of claim 17, wherein the modular tank apparatus further comprises a filtration device in fluid communication with the coating material in the tank. The apparatus further comprises a second coating apparatus, and the second coating apparatus includes:
A second transport device;
A second modular tank device that is movable relative to the transport device and is positioned so that the second modular tank device matches the second transport device. The coating material from the second modular tank device is attached to the substrate via the second transport device,
The apparatus of claim 17. A transfer device configured to receive and carry the substrate;
A loading device having a plurality of loaders, the loader being movable between a loading position and a covering loading position, and the loader removes a substrate from the transfer device when the loader is in the loading position. A loading device configured to receive and configured to transport a substrate to the transport device when the loader is in an unloading position;
At least one curing unit disposed along the processing line, wherein the at least one curing unit is configured to remove coating material adhering to the substrate;
The apparatus of claim 17. A method for producing a multilayer object (multilayer article) comprising:
Transport the substrate of the object to the transfer device,
Passing the substrate of the object along the transfer device to a loading device, the loading device placing the substrate of the object in a carrier configured to hold the substrate of the object, Movable to carry the substrate along a processing line;
Depositing a first coating material on at least a portion of the substrate of each object so as to form a first coating on the substrate of each object;
Providing a material removal apparatus disposed along the processing line;
The material removal device removes the first coating material from the bottom of the substrate of each object;
A method of manufacturing a multilayer object. 24. The method of claim 23, further comprising applying a second coating to at least a portion of the lower portion of each object substrate after the first coating material has been removed from the object substrate. The process of applying the second coating comprises a process of heating the first coating material to a sufficiently high temperature so that the first coating material flows past the bottom of the substrate of each object. And the second coating is formed,
25. A method according to claim 24. The process of applying the second coating comprises a self-coating treatment of the substrate of the object due to gravity, causing the first coating material to flow past the bottom of the substrate of each object;
25. A method according to claim 24. Further comprising rotating the substrate of the object when the first and second coatings are removed;
25. A method according to claim 24. The substrate of the object is preformed and each lower part is at least part of one end cap region of the preform;
24. The method of claim 23. The transfer device continuously conveys the material of the object to the loading device;
24. The method of claim 23. The transfer device supplies the object substrate in batches to the loading device,
24. The method of claim 23. The loading device includes a plurality of loaders, and the loaders are movable between a loading position and an unloading position.
24. The method of claim 23. Placing the object substrate in the loader at the loading position;
Moving the loader to the unloading position;
Further comprising transferring the substrate of the object to the loader when the loader is in a loading position;
32. The method of claim 31. The first coating material comprises a phenoxy-type thermoplastic material;
24. The method of claim 23. The first coating comprises carbon black;
24. The method of claim 23.

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