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 |  موضوع: كتاب Stretch Blow Molding الإثنين 23 سبتمبر 2019, 10:09 pm | |
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Stretch Blow Molding
Third edition
O. Brandau
Member of Society of Plastics Engineers
Member of Mensa Canada
و المحتوى كما يلي :
Acknowledgments
Introduction
1 Short History of Stretch Blow Molding
2 Material Basics
Chapter Outline
2.1 Manufacture and States of PET 5
Manufacture of PET 6
Catalysts 7
PET is a Linear Condensation Polymer 7
Intrinsic Viscosity 7
Copolymer Content 8
2.2 Crystallization of PET 9
“Extended Chain” or “Oriented” Crystallization 10
Summary 10
2.3 Drying of PET 12
2.4 Other Consequences of Insufficient Drying 14
2.5 Behavior in the Injection Mold 14
2.6 Behavior in the Blow Mold 18
Natural Stretch Ratio (or Natural Draw Ratio) 18
Acetaldehyde (AA) in PET Bottles 21
3 Reheat Stretch Blow Machine (RSBM) Types
Chapter Outline
3.1 Overview 27
Semiautomatic Machines 28
Linear Shuttle Type Machines 30
Linear Continuous Motion Machines 34
Rotary Machines 37
3.2 Differences Between Rotary Machines of Different Manufacturers 45
3.3 Orientation of Preforms and Bottles 45
3.4 Movement Actuation 46
3.5 Shape and Location of Oven Section 46
3.6 Blow Mold Actuation 46
3.7 Preform Seal 47
3.8 Synchronization and Crash Protection 48
4 Machine Details
Chapter Outline
4.1 Oven Section 49
Layout 50
Infrared Lamps 53
Different Heating Methods 54
Lamp Control 55
Fan Cooling 57
4.2 Transfer Functions 58
Rotary Machines 58
Linear Machines 61
4.3 Blow Wheel/Blow Clamp 63
Rotary Machines 63
4.4 Machine Timing 63
4.5 Rotary Machines Comparison 66
Changeover Times 68
Air Consumption 70
5 Blow Molds
Chapter Outline
5.1 Design 73
5.2 Base Mold 76
5.3 Making a Mold 76
5.4 Venting 77
5.5 Stretch Rod 78
6 Fundamentals of the Blow Process
Chapter Outline
6.1 Process Overview 81
6.2 Stretch Ratios 81
6.3 Types of Heat Transfer 84
6.4 Light Absorption Characteristics of PET 84
6.5 Optimal Preform Temperature 88
7 The Blowing Process
Chapter Outline
7.1 Reheating Preforms 91
7.2 Blowing Bottles 93
Mold Closed 94
Stretch Rod Engages 95
Preblow Engages 96
Stretch Rod at Base Insert 97
High-Pressure Blow 98
Mold Opening 99
7.3 Air Valve Control 101
8 Injection Stretch Blow
Molding Machines
Chapter Outline
8.1 Four-Station Machines 108
8.2 Machine Controls 112
Melting in Extruder 112
8.3 Injection Controls 114
Injection Pressure and Speed 114
Choosing the Transition Point 116
Hold Pressure and Time 116
Cooling Time 116
Cushion Control 117
A Practical Example 118
8.4 Interaction Between Injection and Blow 118
8.5 Conditioning 120
8.6 Container Blowing 121
8.7 Hot Runners 123
Flow Channel Design 123
Gate Mechanism 128
8.8 Integrated Two-Stage Stretch Blow Molding 130
8.9 Single or Two Stage — That is the Question 131
9 Special Applications
Chapter Outline
9.1 Simulation of the Blow Process 136
Preparations 136
Simulation and Output 137
Applications 139
Costs and Benefits 140
9.2 Stretch Blow Molding of Oriented Polypropylene 140
Process Difference 141
Applications 142
Multilayer 143
9.3 Plant-Based Plastics 145
Processing PLA 147
9.4 Blow Process for Hot-Fill Applications 148
The Hot-Fill Process 148
Demands on the Bottle 149
Heat-Set Blow Process 151
Volume Shrinkage Test 154
Double-Blow or Two-Wheel Process 156
Economic Considerations 160
Cold Aseptic Filling 160
Blow Molds for Hot-Fill Bottles 162
Blow Mold Coating 163
Materials for Hot-Fill Bottles 165
Panel-Less Designs 166
9.5 Preferential Heating 166
9.6 Direct Feeding of Preforms into the Blow Machine 170
General Observations 170
Preform Temperatures 172
Conveyors 176
Layout 177
Operation 178
Economical Considerations 179
Other Automation 180
Conclusions 181
9.7 Vision Inspection 181
System Overview 182
Applications 183
Beyond Vision Inspection 185
9.8 Barrier Enhancing Technologies 189
Permeation Rate 190
Product Types 191
Methods of Barrier Enhancements 193
Blowing of Multilayer Preforms 193
Internal Plasma Coatings 196
External Coatings 197
Additives in Injection Molding 198
Monolayer Solutions 200
Evaluating Barrier Solutions 202
9.9 Blow-and-Trim Process 203
Capital Costs 206
Process 206
9.10 CSD Bottle Base Failures 207
Preform Production 208
Bottle Production 208
Testing for Stress Cracking 209
9.11 Recycling of PET Bottles 210
Bottle-to-Bottle Recycling 211
9.12 Preform Aesthetics in the Two-Stage Process 217
9.13 Blowing Thick-Walled Preforms 220
10 Troubleshooting of Blowing
Problems
Chapter Outline
10.1 General Guidelines 224
10.2 Starting a New Process 227
10.3 Preblow Pressure Control 231
10.4 Changing Preform Temperatures 232
10.5 Output Control 233
10.6 Troubleshooting of Specific Problems 234
Internal Folding in the Neck Area 235
Excessive Material in the Base of the Bottle “Candle Stick” 236
Off-Center Gate 238
Haze in Bottle Walls 239
Pearlescence or Stress Whitening 241
Deformed Necks 243
Bottle Features not Shaped Properly (Underblown Bottle) 244
Flats on Bottle Split-Line 244
Rings Forming in Bottle Body 245
Wall Thickness Over Circumference of Bottle not Uniform 246
Excessive Changes in Bottle Volume with Age 247
Bottle Fails Burst Test 247
Uneven Axial Wall Distribution 249
Environmental Stress Cracking of CSD Bottles 249
Cracked Gates 251
Drop Impact Failure 252
Top Load Test Failure 253
Panel Sink 253
10.7 Defects Particular to Single-Stage Molding 255
Bottle Cloudiness 255
Bubbles in Preform/Bottle 256
Preform Stringing 256
Sink Marks 258
Gate or Body Splay 259
Short Shots 260
10.8 Summary of Preform Quality Checks 261
11 Economics
Chapter Outline
11.1 Container Types 264
CSD Bottles 264
Water Bottles 265
Heat-Set Bottles 266
Custom Containers 266
Beer Bottles 268
11.2 Business Models 269
11.3 Tooling Costs 270
11.4 Lightweighing of Bottles and Caps 272
Lighter Necks 272
Lighter Caps 273
New Bottle Designs 277
Special Machines 279
11.5 Resin Prices 280
11.6 Bottle Production Costs 282
Preform Costs 282
Bottle Costs 284
11.7 Starting with a New Product 285
Bottle Demands 285
Process Selection 286
Machine Output Considerations 287
Process Flow 288
Putting it all Together 292
11.8 Recommended Laboratory Equipment for RSBM Plants 293
11.9 Western Versus Asian Machinery 293
11.10 Bottle Storage and Transport 298
12 Preform Design for Single- and
Two-Stage Processing
Chapter Outline
12.1 Two-Stage Process Injection Molding 301
12.2 Single-Stage Process Injection Molding 303
12.3 Goals and Conditions 303
12.4 The Mechanics of Preform Design 304
12.5 Putting it all Together 307
13 Auxiliary Equipment
Chapter Outline
13.1 Compressors 317
Function of a Piston Compressor 317
Calculation of Air Requirements 319
Compressor Selection 320
13.2 Chillers 321
Antifreeze 324
Flow in Cooling Systems 326
Calculation of Chilled Water Requirements 327
13.3 Conveyors and Bottle Storage Devices 329
Conveyors 329
Palletizers/Depalletizers 330
Silos 330
Unscramblers 332
14 Training of Operators
Chapter Outline
14.1 Current State of Training 335
14.2 Obstacles to Training Programs 336
14.3 Rethinking Abstract Concepts 337
14.4 Language Structure 337
14.5 Converting Formulas Into Common English Sentences 337
14.6 Substituting Uncommon Arithmetical Operators 338
14.7 Presentation Style 338
14.8 Translating Graphs into Common-Day Language 338
14.9 Choosing Easy-to-Understand Drawings 339
14.10 Computer Simulations 340
14.11 Comprehensive Coverage 340
14.12 Trainees Involvement 340
14.13 Assessments 342
In-Plant or Off-Plant Training 342
14.14 Conclusions 343
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