(WO/2001/002263) SYNTHETIC BOTTLE STOPPER
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SYNTHETIC BOTTLE STOPPER Field of the Invention The present invention relates to a synthetic bottle stopper. More in particular, the present invention relates to a bottle stopper made from a foamed thermoplastic elastomer comprising one or more thermoplastic block copolymers and a blowing agent.
Background of the invention
Cork is a natural occurring material regularly used
for the production of stoppers for casks, vials and
bottles (also referred to as"bung"or"moulded closure
for a liquid container", etc.). Cork has a good grip on
glass, and requires an appropriate force of about
250-430 N to pull off the cork from a bottle. Stoppers
made of cork can be used for closing a half-used bottle
for a second time. Besides, swell of cork stoppers when
in contact with wine improves their grip. Also, cork is a
light material (density of about 0.22
Cork is hence a popular material in the production of stoppers.
However, stoppers made of cork may become infected by fungi and bacteria, and they may impart undesired flavour and colour to the contents of the vials and bottles wherein they are used. Moreover, good quality cork is becoming rare and hence expensive. Accordingly, synthetic bottle stoppers have been developed.
Obviously, these synthetic bottle stoppers need to
perform similar to cork as regards the elasticity of the
material, long term creep, good control during insertion
and manufacture, and possibility of reinsertion. Most
Synthetic stoppers for vials and bottles are known.
International application 99/01354 (Supreme Corq)
discloses a synthetic cork for removable insertion into
an opening of a bottle comprising a hard plastic top and
a shaft made of a thermoplastic elastomer (TPE) combined
with a blowing agent, wherein the TPE consists of one or
more styrenic block copolymers. Suitable styrenic block
copolymers are selected from the group corresponding to
the general formulae A-B or A-B-A, wherein"A"represents
a polystyrene block
International application 94/25513 is an earlier application by Supreme Corq, disclosing a synthetic cork (referred to as"molded closure for a liquid container") comprising the TPE and blowing agent mentioned above.
US patent No. 3,984,022 (assigned to Le Bouchage Mécanique) discloses a bottle stopper of biconical configuration, which is made from a foamed plastic with a dense outer layer enclosing a closed cellular or honeycomb structure around the centre. The stopper is produced by injection of a plastic material, which may be a polyolefin such as polyethylene or EVA (ethylene-vinyl acetate), with a pore-forming additive into a mould.
US patent No. 4,499,141 (assigned to the Coca Cola
Company) discloses a plastic closure for sealing liquid
product containers wherein a synthetic cork article is
US patent No. 4,188,457 (assigned to Metal Box
Limited.) discloses
These synthetic bottle stoppers, however, are either
too dense and/or too hard. As a result, these bottle
stoppers will be difficult to insert (problem of
leakage), and to remove (in one piece) with an ordinary
corkscrew. Moreover, it may be difficult to insert a
corkscrew if the stopper is too hard. Besides, these
synthetic stoppers (or at least those of Supreme Corq)
require the presence of a plasticiser in the form of an
oil. If no or too little oil is used, then the thermo-
plastic elastomer composition will be too viscous and the
cells therein will not be able to expand. The end-result
is a
Summary of the invention
The present invention provides a synthetic bottle
stopper made from a foamed thermoplastic elastomer
composition comprising
Detailed description of the invention The synthesis of foamed TPE compositions is known. In addition to the references cited herein before, such compositions are described in Japanese patent application No. 58173146 (Yokohama Rubber KK, Derwent abstract No. 83-822911/47). This reference describes a composition comprising a thermoplastic block copolymer and a thermoplastic resin and/or plasticizer or softener. The composition forms a non-adhesive foaming material and can be used as a packing or gasket material.
In US patent No. 4,764,535 (assigned to
Hot melt compositions from which foamed products can be obtained are disclosed in US patent No. 4,529,740 (assigned to W. R. Grace&Co.). The compositions include a thermoplastic elastomer, a small amount of a salt of a sulfonated styrene polymer, and a blowing agent. The composition may be used to produce foamed products suited for example as sealants in closures for containers.
Plastic foam products are also disclosed in US patent
No. 5, 585, 411 and International application No.
The use of a composition as described in claim 1 for the purpose of preparing a superior synthetic bottle stopper is neither disclosed nor hinted at in any of these references. The components of the composition are described in more detail herein after.
Component a) The expression"thermoplastic block copolymer"refers to a polymer having two or more distinguishable polymer blocks, of which at least one is glassy or crystalline at service temperature but fluid at higher temperatures, and at least one of which is elastomeric (rubbery) at service temperature. A comprehensive review on such polymers is provided by Messrs. Legge, Holden and Schroeder, in "Thermoplastic Elastomers", published by Hanser Publishers in 1987 (ISBN 3-446-14827-2). Such polymers include thermoplastic polyurethane elastomers and various other block copolymers.
The preferred thermoplastic block copolymers in
accordance with the present invention, are styrenic block
copolymers, i. e., wherein the or each glassy polymer
block of the block copolymer is made of polymerized
vinylaromatic monomer, such as styrene, in an amount of
at least 80 mole
Preferred styrenic block copolymers are those wherein
the or each elastomeric polymer block of the block
copolymer is made of polymerized conjugated diene, such
as butadiene or isoprene, in an amount of at least
80 mole% on the total monomer content of the elastomeric
polymer block. Butadiene and isoprene are the preferred
dienes, but other suitable conjugated dienes include
dienes with from 4 to 8 carbon atoms per monomer, for
example,
The vinyl content of the elastomeric polymer block
(i. e. that part of the conjugated diene that is
polymerized in a"1, 2-fashion") is preferably at least
55% (mol/mol on total conjugated diene), more preferably
in the range of
Still more preferred, are styrenic block copolymers
that have at least one elastomeric polymer block made of
polymerized conjugated diene that is hydrogenated. In
Excellent synthetic bottle stoppers have been made
from styrenic block copolymers having an overall content
of vinylaromatic monomer in the range of 10 to
Block copolymers come in the form of linear diblocks,
triblocks and multiblocks (produced with sequential
polymerization techniques or difunctional coupling
agents), or branched block copolymers (using multi-
functional coupling agents
Suitable block copolymers include, amongst others,
those sold by Shell under the trademark"KRATON", and
those sold under the trademarks"DYNAFLEX" (CC&P),
"VECTOR"
Component b)
A branched polyolefin is a polymer having alkyl
groups containing 2 or more carbon atoms attached to the
backbone. Such polyolefins are known as high melt
strength polymers and hence impart high melt strength and
drawability to blends thereof with (styrenic) block
copolymers. Such branched polyolefins include e. g., high
melt strength propylene polymers, containing long-chain
branches inside the polypropylene, disclosed by
Dr. Ulf Panzer at the SPO'98; and
They may be produced by the polymerisation of an alpha-
or internal alkene having 3 or more carbon atoms using
the Daploy process disclosed by Dr. Pzanzer, or by
(Ziegler-Natta low pressure) polymerization of an alpha-
or internal alkene having 4 to 10 carbon atoms,
preferably a linear alkene such as 1-butene, 1-pentene,
2-pentene, 1-hexene, 1-heptene, l-octene, or the
copolymerization of these alkenes with e. g., up to
10 mole% ethene and/or propene (e. g., as described in
DE-A-1,570,353). Preferably the branched polyolefin
contains from 80%, more preferably from
Branched polyolefins that have been found to be very suitable are polymers of 1-butene, having a 1-butene content of at least 50 mole%, preferably at least 70 mole%. The most preferred branched polyolefin is poly- 1-butene.
The weight average molecular weight of the polyolefin
may range from 60,000 to 1,000,000
Component b) is preferably used in an amount of 10 to
100 parts per 100 parts of component
Component c) Plasticisers are well known to those skilled in the art. Typically, the hardness of polymer compound is decreased by adding a plasticiser. The plasticiser is typically substantially compatible with at least the elastomeric polymer blocks of the thermoplastic block copolymer used as component a).
Examples of plasticisers commonly used in respect of
the preferred elastomeric block copolymers include
hydrocarbon oil, preferably naphthenic or paraffinic oil,
more preferably paraffinic oil. Examples of alternative
plasticisers which may be used in the compound of the
invention are, oligomers of randomly or sequentially
polymerised styrene and conjugated diene, oligomers of
conjugated diene, such as butadiene or isoprene, liquid
polybutene-1, and ethylene-propylene-diene rubber, all
having a weight average molecular weight in the range
from 300 to 35,000, preferably
Whereas the presence of such plasticisers in the
prior art formulations is essential, as in mentioned
herein before with respect to the Supreme Corq bottle
stoppers, the presence thereof in the present formulation
is only optional, and in the preferred embodiment even
absent. If present, then such plasticisers may be used in
Blowing agent As noted above the foamed thermoplastic elastomer composition of the present invention also contains a blowing agent. Normally a blowing agent decomposes above a certain temperature thereby releasing gas, such as nitrogen, which causes a volume increase of the reaction mass. The temperature at which the blowing agent starts decomposing is further referred to as the activation temperature. In principle, any known blowing agent such as the ones mentioned above, and more particular as described in US patent No. 5,585,411 may be used.
Generally known blowing agents are for instance sodium
bicarbonate, azodicarbonamide-based compound and
diphenyloxide-4,4'-disulphohydrazide. The latter is
commercially available under the
Alternative blowing agents are heat expandable
thermoplastic particles encapsulating heat expandable gas
or liquified gas. Such heat expandable thermoplastic
particles are known in the art and available commercially
under the
Preferably, the blowing agent is azodicarbonamide or sodium bicarbonate or mixtures thereof. Especially good results may be obtained with sodium bicarbonate.
The blowing agent is preferably present in an amount
from 1 to 10
Other components
Optionally, the foamed thermoplastic elastomer
composition comprises further components. Such other
components include the"olefinic rubbers"mentioned in US
patent No.
For instance, the composition may further comprise
from 5 to 50 phr of a polyolefin other than the branched
polyolefin, e. g., selected from polyethylene,
polypropylene and copolymers thereof. Preferably, the
polyolefin is polypropylene or polyethylene, in
particular
The foamed thermoplastic elastomer composition may also comprise polymers that are compatible with the glassy polymer blocks of the thermoplastic block copolymers, such as polyphenylene ether and/or polystyrene. For instance, the composition may comprise from 5 to 50 phr of such polymers.
It will be appreciated that the compounds of the present invention may further contain additional compounds like stabilisers, fillers, slipping agents (compounds that are known to provide grip to the glass, such as stearates, eureamide and/or kenamide), waxes and colouring agents (pigments) and even bits of natural cork to give the stopper a cork-like appearance.
The compositions of the invention can be prepared
according to procedures well known to those skilled in
the art. For instance they may be made by extrusion and
melt blending. Examples of apparatus which may be used to
prepare the compositions of the present invention
include, but are not limited to, single or multiple screw
extruders, mixing rollers, internal mixers, Banbury
mills, and kneaders. For example, the compositions of the
present invention may be prepared by feeding ingredients
The composition ingredients are preferably pre- blended as follows. If a plasticiser is used, then first the block copolymer is blended with part or all of the plasticiser. The latter is preferred. The plasticiser and block copolymer may be blended by contacting the plasticiser and oil and rolling, tumbling or mixing in suitable apparatus. Alternatively, the block copolymer and plasticiser may be melt mixed using apparatus such as single or multiple screw extruders, mixing rollers, internal mixers, Banbury mills, and kneaders. If pre- blending block copolymer and plasticiser is conducted in an extruder, then the plasticiser is typically metered into the extruder such that the metering rate is matched to the proportion of oil and polymer desired in the final composition.
The pre-blending step is typically carried out in a
so-called turbo-mixer, such as
The block copolymer or blend of block copolymer and
plasticiser is then blended with the branched polyolefin
(e. g.,
Subsequently, blowing agent may be added, either in the same or a separate blending step. Alternatively, and most preferably, no blowing agent is added at this stage and first a composition without blowing agent is produced.
If a composition without blowing agent is produced,
then the composition may subsequently be pre-blended or
tumble-mixed with a blowing agent to prepare a
If a composition with blowing agent is produced, care should be taken that during the compounding process the temperature is kept below the blowing agent decomposition temperature unless (full or partial) foaming is desired during this first step.
The preparation of a foamed thermoplastic elastomer composition as described above comprises a second aspect of the present invention. In order to produce the"cork", the composition is injected into a mould, e. g. as described in US patents Nos. 3,984,022 and/or 4,499,141.
Alternatively, the present composition allows corks to be made via extrusion, which is much preferred over injection moulding since producing uniform corks in a continuous fashion at a higher rate. A third aspect of the present invention concerns foamed articles (including, but not limited to corks) obtainable by this preparation.
The invention is illustrated by the following
examples.
TPE Compositions
Compositions not containing blowing agent were
prepared as follows. 100 parts by weight of a KG1652 were
blended with a desired amount (0 or 30 parts by weight,
To the pre-blend thus obtained were added the desired
amount (0 or 25 phr) of KG1701, a desired amount (27 or
54 phr) of
The pre-blend thus obtained was fed into a co-
rotating twin-screw extruder (Werner-Pfeifferer) to
produce various compositions. The temperature in the
twin-screw extruder ranged from 140 to
Table 1
The masterbatches A and B thus obtained were fed into
a single screw lab extruder (Extrudex), using a
temperature profile of
Results are shown in Table 2.
Table 2
Example 2
Pellets of compositions A and B obtained in example 1
were dry-blend with 2.5 or
The masterbatches thus obtained were fed into an
injection moulding machine (Battenfeld), using a
temperature profile of
Table 3
Example 3
Pellets of compositions A, C and D were dry-blended
with 5% by weight of azodicarbonamide as blowing agent to
prepare masterbatches A, C and D. The masterbatch A and C
has been prepared with the blowing
The masterbatch D has been prepared with the blowing
The masterbatches A, C and D thus obtained were fed
into an injection moulding machine (Negri Bossi & C),
using a temperature profile of
Table 4
The foaming conditions have not been optimised in
examples 2 and 3. For instance, optimisation of foaming
conditions such as optimum temperature profile and die
It is known that
Example 4 Foamed stoppers C and D thus obtained in example 3 have been inserted in glass bottles filled with water, using a manual cork insertion machine. An ordinary corkscrew was then fixed into the stoppers. The bottles have been then fixed in a tensile machine (Zwick) while the corkscrew was fixed at the moving crosshead. The stoppers were pull-out of the bottle at a constant speed of 100 mm/min. The force needed to extract the stoppers was measured and the wall-stress was calculated with the stopper length and the bottle circumference. The stoppers C and D have been measured in comparison with natural cork of 3 and 5 years old and in comparison with competitor synthetic stoppers X and Y, having both a density of 0.60. The results are shown in Table 5.
Table 5