1、SBO Universal Process creation 吹瓶工艺 1Agenda 目录 2 Characteristics and properties of P.E.T P.E.T 的特性与特质 Chapter 1 How is a preform made ?瓶胚如何生产？ Chapter 2 What is bi-orientation ?什么是双向拉伸？ Chapter 3 How is a preform heated ?如何加热瓶胚？ Chapter 4 Regulation调整设定 Chapter 5 The bottle 瓶子特性 Chapter 6 How is a b
2、ottle blown ?如何吹制瓶子？ Chapter 7 Cooling phase 冷却 Chapter 8 What about the environment ?环境有那些要求? Chapter 9 Methodology 方法论 Chapter 10 Why are there different types of bottles ?不同类型的瓶子之间有何差异？ Chapter 11 How to react ?怎样改进瓶子品质？ Chapter 12 Bottle defects analysis瓶子缺陷分析 Chapter 13Characteristics and prope
3、rties of P.E.T. P.E.T. 的特性与特质 Chapter 1 第1 章 3Characteristics and properties of P.E.T. P.E.T. 的特性与特质 4 Before Tg. Disordered chains with bonds vitreous state 在Tg.温度前，是无 序的分子链胶合成 的玻璃态 The 3 P.E.T. transition temperatures PET的3个转化点温度 P.E.T. pellets P. E . T. 粒子 Temperature Glass Transition 玻璃态转化点温度 Th
4、is image cannot currently be displayed. mW Exothermic reaction 放热反应 Endothermic reaction吸热反应 Energy 能量 Melting Temperature 熔融态转化点温度 Temperature Crystalline Transition 结晶转化点温度 Temperature Rise 温度升高 (20 C/min) DSC thermal analysis of amorphous of P.E.T. 非结晶态P.E.T.的 DSC热分析 (Differential Scanning Calori
5、metry) Variable depending On material 依材料不同而有所差异Characteristics and properties of P.E.T. PET 的特性与特质 5 Glass transition temperature (Tg) 玻璃态转化点温度(Tg) - The softening point, which is the temperature at which the molecular chains can move around relative to each other (transition from solid phase to ru
6、bbery phase). - 软化点，在该温度下分子链与分子链间能相对运动（由固态转换到橡胶态的温度点） - This temperature may vary depending on the polymers degree of crystallinity. - 该温度取决于该聚合体的结晶度有多少 Crystallization temperature (Tc)结晶温度(Tc) - The temperature at which amorphous, transparent PET develops crystalline zones (spherulites, milky white
7、 color). - 在该温度下无规则的非结晶PET转化为结晶态（球状结晶，乳白色） - PET crystallinity maximum rate is around 55%. - PET最大结晶率为55%左右 Fusion (melting) temperature (Tf)熔融温度(Tf) - The melting point of the polymer. - 聚合体的熔融点 This is the temperature at which the crystallites melt, moving from the solid to the liquid state. 该温度是微
8、晶体熔融，由固态变成液态的温度 - It is crystallite melting ( e.g.: Tm = 270 ). - 这是微晶体的熔化温度（例如：Tm= 270 ) Intrinsic viscosity (I.V.)固有粘度 - The solution viscosity of PET.PET的液态粘度 This is the main feature of the molecular mass, i.e., the average length of the chains. 这是摩尔质量的主要特征，也就是分子链的平均长度。Characteristics and proper
9、ties of P.E.T. P.E.T 的特性与特质 6 Amorphous state非结晶态 - The state of PET when there is no crystalline zone. It is transparent and its density is approximately 1.33; it is also called “tempered“ PET. - 未有结晶的晶体存在，就是所谓的非结晶态。 该状态是透明的，它的密度约为1.33，也被称为“强化”PET Crystalline state结晶态 - A semi-crystalline state mad
10、e up of ordered zones and amorphous zones. We find: - 一种由有序和无序区域组成的半结晶态。我们发现： Spherical crystallization which produces a white color during heating. 加热过程中产生白色球状结晶 Induced crystallization which is transparent and by stretching. 通过拉伸促使诱导结晶(拉伸结晶) Orientation 定向拉伸 - The phase resulting from mono or bi-d
11、irectional stretching of PET under certain conditions. - 在不同条件下，可以使PET有单一方向或双方向的拉伸结晶How is a preform made ? 瓶胚如何生产？ Chapter 2 第2 章 7Preform production 瓶胚生产 8 The preform is the injected article, which serves as transition state to obtain later a bi-oriented bottle. 瓶胚是一种注塑物品。作为后续双向拉伸吹瓶的中间半成品 The pre
12、form neck is defined during the molding phase and its dimensions are not modified by heat or stretch/blow action. 瓶胚的瓶颈在注塑的阶段已经定型，它的尺寸在加热和拉伸/吹制时不会改变 The size, the weight, the wall thickness, the design are very important in regards to the item we blow. 瓶胚的大小、重量、壁厚的设计是我们吹制瓶子时需要非常关注的因素 Body 胚身 Support
13、 ring 支撑环 Neck 瓶颈 Injection point (gate) 注塑口 Sealing surface 密封面 (天面)Preform production 瓶胚生产 9 HEAT 加热 MALAXATION 软化 COMPRESSION 压缩 MELTED STATE 熔融态 60 80 100 120 140 160 180 200 220 240 260 280 Preform Storage 瓶胚 存放 Cooling On robot 机械手中冷却 Cooling in The mold 模具中冷却 Start of the preform solidificati
14、on 瓶胚固化开始 Transformation of cristallized P.E.T. pellets into amorphous preforms 结晶态的P.E.T. 粒子到非结晶态的瓶胚的转化 C TG Mold exit 模具出口 Cristallized Pellets 结晶的粒子 mW ENERGY能量 Thermique and mecanical energy 辐射热和机械能 Very important Critical zone to quickly reach to avoid crystallization 需快速跨过以避免结晶 Injection to ca
15、vities 注入模具内 Pressure 70/90 bar Depending On size 压力范围 70-90 bar 取决于瓶胚大小 T C sufficient for complete Fusion of the cristallites, but not Too high to avoid the AA gas 该温度能充分完成结晶体熔化， 但不可过高以防止AA的产生Preform production 瓶胚生产 10 Dryer 干燥机 Screw / Barrel 螺杆/螺杆腔 Injection press 注射压力 Hot distributer 热流道 Female
16、 part of the mould 模具的母模 Male part of the mould 模具的公模 MOULD 模具Preform production 瓶胚生产 11 INJECTION 注塑 STORAGE 存储（时间） REHEAT 再加热Preform characteristics 瓶胚特性 12 Preform thickness :瓶胚厚度 - average:平均值 about 3.7 mm 3.7 mm左右 - mini:最小值 about 2.5 mm 2.5 mm左右 -m a x i :最大值 about 6 mm with special PET 特殊的PET
17、大约6mm - maxi for SIDEL machine: 4.5 mm对SIDEL的机器最大值为4.5 mm Maximum values do not to exceed in reference to the costumers target : 最大值不能超出客户给出的参考目标值 - Weight variation: - 重量变化 - Length of the injection gate : 1 mm - 注射口的长度为：1mm - Excess of material on part line : 0.05 mm - 合模线溢料：0.05mm With a preform
18、already heated at 100C and then chilled down 一个被加热到100C后被冷却的瓶胚 - Perpendicularity variation 垂直变化 : average 1.5 mm平均1.5mm maximum 3 mm最大3mm - Preform body length reduction : 3 mm - 瓶胚长度减少：3mm PREFORM WEIGHT 重量 0 to 30 30 to 70 70 to 100 100 to 130 130 to 160 160 to 200 TOLERANCE 误差 0,25 g 0.5 g 1 g 1
19、,5 g 2 g 2,5 gPreform characteristics 瓶胚特性 13 All the following defects are considered not acceptable : 以下的这些缺陷都是不可接受的： - Visual.目视缺陷 - Un-melted.未熔融酯粒存在 - Marks.斑点 - Bubbles.气泡 - Impurities.不纯净 - Degraded material visible under polarized light.偏振光下可视材料降解 - Crystallization on the body or the gate.胚身
20、或注射口部位结晶 - Material flow problem visible under polarized light.偏振光下可视的材料流动纹路 As well as out of ranges specificities : 以及明显超出规格范围： - Weight.重量 - Length.长度 - Thickness.厚度 - Diameter.直径Control under polarized light 偏振光下的控制 14 1. Thermal degradation热降解 2. Insufficient mold cooling冷却不充分 3. Crystallizatio
21、n at ejection point注塑点处结晶 4. Non-optimized drying干燥不良 5. Bubbles气泡 6. Turbulences in the polymer flux聚合体（形状）混乱 7. Sinking凹陷 8. Stains不洁 9. Condensation冷凝状(水环) 10. Flashing 注塑材料飞边 11. Incomplete neck胚颈注塑不全 Natural light 钠气灯 Polarized light 偏振光 1 2 3 4 5 6 7 8 9 10 11 12 Preform characteristics 瓶胚特性 1
22、5 The AA(acethal dehyde acid) appears for the following reasons :AA（乙醛）出现有以下几种原因： - Its an acid created by degradation of PET. - 它是PET降解产生的一种酸 - During the preform injection, inside the screw/barrel. - 在注塑瓶胚时存在于挤压机螺杆和螺杆舱内 - Inside the barrel or hot block of the injection m/c, if the temperature is t
23、oo a high or if the PET stays too long into the stagnation period. - 在螺杆舱或注射室内的温度过高或PET滞留时间过长时产生 - An incorrect drying before injection or the excessive speed of the screw that shears the molecular chains. - 注射前干燥不好或挤压机螺杆转速过高造成剪切热过多，温度过高，也会产生AA NOTE :备注： The concentration of AA inside the bottle is
24、not toxic, but it gives a fruity taste (apple) to the drink. Water is especially sensitive to AA. 瓶子内的AA没有毒性，但是会有水果(苹果)气味 水对AA尤其敏感(包装饮用水无色、无味，无法掩盖味道) Maximum AA:最大AA值： - Pellet粒子: 0.5 1 ppm - Preform瓶胚 : 2 3 ppm for water 包装饮用水 4 6 ppm for C.S.D.( more) 汽水或其它 - Bottle 瓶子: 1 2 gr./ L for water 包装饮用水瓶
25、 2 3 gr./ L for C.S.D. 汽水瓶 ppm : particles per million.百万分之一 gr./ L : micro grams per liter of air inside an empty bottle hermetically sealed for 24 hours. gr./ L : 密封24小时的空瓶内气体 微克/每升Preform characteristics 瓶胚特性 SIDEL recommendation for storage of material and preform. SIDEL对于PET酯粒和瓶胚的存放建议 - Water p
26、ick-up 吸收水分 Water pick-up by the amorphous material. 非结晶态易的分子会吸收水分 Water pick-up depends on temperature, humidity level and crystallinity. 吸水量及速度，取决于温度、湿度、结晶度 Water pick-up affects preform reheat and blowing. 吸水影响瓶胚的再加热和吹制 The maximum water pick-up level acceptable to blow good bottles is 2000 - 250
27、0 ppm. 能吹出好瓶子的最大含水量为2000-2500ppm Optimum storage conditions: 最佳储存条件: - 2000 ppm is reached after 3 months at 22C and 50% of relative humidity (see curve), and 2500 ppm after 5 months. - 在 22C 、50%相对湿度情况3个月会达到 2000ppm ，5个月达到2500ppm - Above these values, the humidity level affect IR absorption and mat
28、erial distribution (water has a lubricating effect). - 超过标准，水分会影响瓶胚对红外线的吸收和材料分布（水有润滑作用） 16Preform characteristics 瓶胚特性 17 0 500 1000 1500 2000 2500 3000 3500 024681 01 2 Time (month)时间（月） H2O (ppm) Absorption of water in P.E.T. at 22C and 50% of relative humidity PET在温度22C 和相对湿度为50% 时的吸水过程 Amount of
29、 humidity in the preform over time 瓶胚含水量与时间的关系 Degradation process 降解过程Preform production 瓶胚生产 18 Weight increase in % 重量增加% Days 天 Storage with a relative humidity level of 75% 在相对湿度75%时存放 45 C 35 C 23 CPreform production 瓶胚生产 19 23 C - 5 % RELATIVE HUMIDITY (R.H.) 23 C 、 5 % 相对湿度 23 C - 50 % R.H.
30、23 C 、 50 % 相对湿度 IV ( dl/gr ) Months 月 59 gr PREFORM - 4 mm thickness 重50克 厚4mm的瓶胚Preform production 瓶胚生产 20 P.E.T. colored pelletsPET色母粒 - 1 2 % mixed to classic P.E.T. -12 %混入标准的P.E.T. - Dried separately in a hopper in to avoid sticking and humidity. - 在料斗中分开干燥，避免粘附和受潮 - Proportioned at the right
31、percentage to obtain the right color ( amber, green, blue ). - 用适当的比例获得正确的颜色（黄色、绿色、蓝色） - Mixed with a screw and blended at the arrival of the melted P.E.T. - 通过螺杆的挤压达到的PET熔融混合 - Depending on the type of color and pellet size, visible flames in natural light can appear. - 在自然光下显现艳丽色彩，取决于颜色的类型和粒子的大小 L
32、iquid coloring agent 色母液 - Inserted in the hopper of the injection press through a batching system. Heavily colorizes the P.E.T. - 通过批量系统用注入料斗，充分的给PET染色 - It is recommended not to use it.这种不建议使用Preform production 瓶胚生产 21 Incorporation of a coloring agent 色母液的注入 - Inserted in the hopper of the ejecti
33、on press through a pump. If the agent does not blend in, it acts as a lubricant and the P.E.T. gets degraded. - 通过泵将色母液注入料斗。如果色油未充分混合易造成螺杆打滑、及PET降解 Extrusion of colored and re-pelleted P.E.T. 加色母液后再一次的造粒 - Completely colored material, no blending. - 酯粒已完成配色，不需另外混合配色 Inconvenient : 坏处 - Especially fo
34、r mineral water, the proportion of AA may be too great, because of the double extrusion to obtain the colored pellet. -因为是靠双重挤出获得的彩色粒子，对矿物质水来说，AA存在风险大 Note :备注: - The colored P.E.T. pigments modify the level of IR absorption. In general, less energy is needed to heat up colored material, about 5% le
35、ss depending on the nature and color of the pigment. -着完色的PET对红外线辐射的吸收有所变化。通常说来，染完色的原料被加热时需要相对少的能量， 取决于颜料本身，相差大约5%Preform characteristics 瓶胚特性 22 The quality of the bottle is largely dependent on the quality of the preform. 瓶子的质量很大程度上取决于瓶胚的质量 - With a good preform, the features of the bottle depend
36、on: - 除了瓶胚质量，瓶子质量还取决于: IR profile.红外线灯管的分配 Preform temperature.瓶胚温度 Stretch / preblow / blow relations.拉伸 /预吹/吹制之间的关系Process cycle 工艺循环 23 First step 第一步 Second step 第二步 Storage 存储What is bi-orientation ? 什么是双向拉伸？ Chapter 3 第 3 章 24Performances obtained by stretching 拉伸成形 25 Axial stretching 轴向拉伸 Ax
37、ial and radial stretching 轴向和径向拉伸 Radial stretching 径向拉伸Bi-orientation ratio preform/bottle 瓶胚/瓶子双向拉伸比率 26 Axial Stretching ration in and L defined By the preform and bottle dimensions 轴向和径向的拉伸比取决于瓶胚与瓶子的尺寸 Stretching speed : 0,8 1,5 m/s 拉伸速度： 0.8 1.5 m/s AXIAL L 轴向 RADIAL 径向 Blow and preblow Pressur
38、e parameters 高压吹和预吹压力参数 Bi-stretching temperatures 20 25 C Tg 双向拉伸温度大于Tg温度2025度 Heating profile 加热灯管配置 Variable parameters Independent of the process 可变的参数之个别的影响 I.V. Function of 的方程式 (e) Function of 的方程式Bi-orientation ratio ( ) 双向拉伸率 27 L l D d p Longitudinal stretching ratio: 轴向拉长率 Bottle L 瓶长 Len
39、gth 长度= - average pref. l. 平均瓶胚长 Generally Length = about 3 for spring bottle 3 for CSD bottle 通常 长度=水瓶大约为3， 气水瓶小于3 Radial stretching ratio:径向拉伸率 Bottle D 瓶子直径 diam = - Preform ( d.- Thickness)瓶胚直径 - 壁厚 Generally diameter = about. 3,75 通常 直径 = 3.75 左右 Bi-orientation = Axial stretching x Radial stret
40、ching = 10 12 双向拉伸率 = 轴向拉伸 x 径向拉伸 = 10 12Bi-orientation ratio ( ) 双向拉伸率 28 Stretching rates of this table were validated for Series 2. 下列的拉伸率范围仅适用于Sidel 2代吹瓶机 CSD / Flat 气水瓶及水瓶 HR 热充瓶 Axial stretching rate 轴向拉伸率 Flat 2.5 3 CSD 2.5 3.5 2.5 3 Radial stretching rate 径向拉伸率 3.3 4.2 3.3 4 Bi-orientation r
41、ate 双向拉伸率 10 12 8.25 11.7Material 材料 29 Each application is unique:每一个应用都具独特性： - The customer should carefully choose the quality of his resins (I.V.) to find out the best compromise between mechanical and thermal properties of his bottle. - 用户应慎选使用的PET酯粒，以符合瓶子的机械特性和耐热性需求 - The choice will be guided
42、 by the product that will fill the bottles (spring water, CSD, HR, oil). - 依所要充填的内容物特性（矿泉水、汽水、热充饮料、食用油)来作出选择How is a preform heated ? 如何加热瓶胚？ Chapter 4 第4 章 30Preform 瓶胚 31 From feeding system.进胚系统 Orientating rollers.取向辊 Feeder rail.进胚导轨 Preform neck up.瓶口向上 Infeed wheel. 进胚星轮 Preform load by spind
43、les. 芯轴加载瓶胚 Preform up side down. 瓶胚翻转瓶口向下 Oven infeed.烘炉进给 Preform heating by IR lamps. 红外灯管加热瓶胚 Preform neck up. 瓶胚翻转瓶口向上 Oven outfeed.烘炉送出 Spindles unloading. 芯轴卸载 Preform transfer.瓶胚传送 Mould.模具Oven 加热炉 32Oven setting 加热炉调整 33Oven cooling 加热炉冷却 34Oven 加热炉菜单 35Lamp position 灯管位置 36 F0020 3DF0039 3
44、DF0044 3DF0045Oven 加热炉 37 Configuration oven IR: 烘炉灯管配置 ： - 9 zones, with progressive steps 分为9区, 采步阶式 Zone 1 zone 2 = 14 mm. 1区 2区 = 14 mm Zone 2 zone 3 = 15 mm. 2区 3区 = 15 mm Zone 3 zone 4 = 17 mm. 3区 4区 = 17 mm Zone 4 zone 5 = 19 mm. 4区 5区 = 19 mm - Different power by zones 区域间灯管功率不同 Zone 1 = 300
45、0 Watts. 1区=3000 瓦 Zone 2 zone 9 = 2500 Watts.2- 9 区=2500 瓦 Profiled cooling shields to protect the neck冷却支架保护瓶胚颈部 Options: 选项： - Quartz Bar.石英棒 - Reflectors. 反光板Cooling shields 冷却档板 38 L-shaped shield L 型板 Often used for HR or Heat Set with crystallized neck 常用作热充填或结晶瓶口的加热 Shoulder-shaped Shield 肩型
46、板 Often used for refillable bottles and high diameter neck 常用作可回收瓶和大直径瓶口的加热 CB2 shieldCB2板 Actual standard for any application 实用标准型Reflectors 反光板 39 Short reflectors make it possible to isolate one heating area. They must be used in specific cases. They age badly, become dull and are likely to melt
47、 if not placed between two areas at 100%. 短的反光板可以隔绝一个加热区。它必须被应用在特殊的情况下。反光板的寿命很短，容易变脏 且如不放置在两区域正中位置容易受热熔化Quartz bar 石英棒 40 Quartz bar is used in area 1. It makes it possible to focus infrared rays. Has double advantage: heating concentration allows better under-neck stretching and limits radiation em
48、ission on the neck which is thus better protected. Quartz bar must be used on 25% to 50% oven modules. 石英棒被用在1区。它用于聚焦红外线。有两个优点：集中加热使瓶颈下方部位能更好的被拉伸，减 少瓶颈上的辐射能保护瓶颈 25%-50%的烘炉单元中必须使用石英棒Lamp configuration 灯管配置 41Oven 烘炉 42 Penetration oven 穿透炉 Distribution oven 分布炉 Stabilized time 稳定区Oven 烘炉 43 Ventilation通风 IR lamps 红外灯管 Spindle 芯轴 IR lamps 红外灯管 Cooling shield 冷却档板 Combination of IR ray and ventilation : 红外线和通风的结合： - IR penetration up to the preform heart. 红外线穿透瓶胚的内部 - Chilling of
