US 6,475,579 B1 · Multi-layer plastic container having a carbon-treated internal surface and method for making the same

Abstract

A blow molded multi-layer container is provided having an upper wall portion, including an opening; an intermediate sidewall portion positioned beneath the upper wall portion; and a base portion positioned beneath the intermediate sidewall portion, the base portion being adapted to dependently or independently support the container. The container includes (i) a molded inner layer formed from a plastic material, the inner layer having a vertical length and a carbon-treated inner surface; and (ii) a molded outer layer formed from recycled plastic that is substantially coextensive with the inner layer. The recycled outer layer comprises at least 40% by weight of the overall weight of the container, but can comprise more than 90% by weight, depending upon the needs of the application. In a preferred embodiment, the thickness of the inner and/or outer layers is controllably adjusted along their respective vertical lengths. If functionally desirable, the inner layer and/or outer layer may also include additional barrier materials and/or oxygen scavenging/reacting materials.

Claims23

Dependent claims

A blow molded multi-layer container including an upper wall portion having an opening;

a sidewall portion positioned beneath the upper wall portion;
and a base portion positioned beneath the sidewall portion which supports the container, the container comprising:
a molded inner layer formed from a plastic material having a vertical length and an inner surface, said inner layer having a wall thickness along its vertical length that is within the range of about 0.5 mil to 5 mil;
a molded outer layer formed from recycled plastic having a vertical length and an inner surface that is coextensive with the inner layer, the outer layer having a wall thickness along its vertical length that is within the range of about 6.0 mils to 23.0 mils;
and
an innermost amorphous carbon coating formed on the inner surface of the inner layer, said carbon coating having a thickness that is less than 10 μm and controllably along the vertical length of the container, and is independently controllably varied with respect to the outer layer;
and
wherein the outer layer comprises at least 0.40 by weight of the overall weight of the container, and wherein said outer layer is in contacting relationship with the inner layer along the entire inner surface of the outer layer.

5 more elements

A method of manufacturing a multi-layer container coated with a carbon coating, which comprises:

providing a multi-layered container including an upper wall portion having an opening;
a sidewall portion positioned beneath the upper wall portion;
and a base portion positioned beneath sidewall portion which supports the container, said container further comprising:
a molded inner layer formed from a plastic material having a vertical length and an inner surface, the inner layer having a wall thickness along its vertical length that is within the range of 0.5 mil to 5 mil;
a molded outer layer formed from recycled plastic having a vertical length and an inner surface coextensive with said inner layer, said outer layer having a wall thickness along its vertical length that is within the range of 6.0 mils to 23.0 mils;
wherein the outer layer comprises at least 0.40 by weight of the overall weight of the container;
enclosing the multi-layered container within a hollow space provided to accommodate the container;
discharging the air within the container creating a vacuum;
charging the internal volume of the container with raw gas;
and
inducing the formation of a carbon coating on the inner surface of the container, wherein the carbon coating has a thickness that is less than 10 μm which controllably varies along the vertical length of the container, and is independently controllably varied with respect to the outer layer of the container.

8 more elements

Dependencies are inferred from the claim text.

Multi-layer plastic container having a carbon-treated internal surface and method for making the same

Life of this patent

Multi-layer plastic container having a carbon-treated internal surface and method for making the same

Life of this patent

Abstract

Claims23