Plastic Container Globe-Like Particles Inner Metal Layer
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Solution Overview
Problem
Conventional plastic containers with inner metal coatings face challenges in maintaining mechanical stability, scratch resistance, and adhesion to the plastic composition, especially when requiring elastic flexibility and resistance to abrasion, which complicates their production and increases material costs.
Innovation Solution
A method involving a plastic composition with globe-like particles added as an additive, which increases the hardness and surface area of the inner surface, followed by applying a metal layer using physical vapour deposition, enhances adhesion and mechanical stability of the inner coating, allowing for improved scratch resistance and flexibility without compromising the container's elastic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thin metal layer is applied to the inner surface of a plastic container, then the diffusion barrier and electromagnetic shielding properties are improved, but the scratch resistance and mechanical stability deteriorate
Solution Approach 1:
The invention applies a composite inner coating consisting of multiple layers: a primer layer for adhesion, a metal layer (such as aluminum or titanium) for diffusion barrier and electromagnetic shielding properties, and a protective top layer for scratch resistance. This multi-layer composite structure allows each layer to perform its specific function, resolving the contradiction between achieving reliable barrier properties with thin metal layers while maintaining scratch resistance.
2Strength
If the metal layer thickness is increased to improve scratch resistance, then the mechanical stability improves, but the flexibility and elastic properties of the container deteriorate
Solution Approach 1:
The invention uses a multi-layer coating structure where each layer has locally optimized properties: the primer layer provides adhesion to the plastic substrate, the metal layer provides barrier properties and partial mechanical strength, and the protective top layer provides scratch resistance. This local differentiation of functions allows the thin metal layer to maintain flexibility while the composite structure as a whole achieves the required mechanical stability and scratch resistance.
3Strength
If a multi-layer inner coating is applied to improve adhesion and mechanical stability, then the scratch resistance improves, but the manufacturing complexity increases
Solution Approach 1:
The invention combines multiple coating functions into an integrated multi-layer system that can be applied in a streamlined manufacturing process. The primer layer ensures adhesion, the metal layer provides barrier properties, and the protective layer provides scratch resistance. By merging these functions into a coordinated multi-layer structure applied sequentially, the invention achieves high adhesion and mechanical stability while managing manufacturing complexity through process integration.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method results in a container with increased mechanical stability, enhanced adhesion, and improved scratch resistance, enabling the container to withstand higher stresses and maintain flexibility, while also reducing production costs through efficient use of materials.
Implementation Method 1
The technique of physical vapour deposition is often used in containers
Data Source
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AI summary
The invention relates to a method for producing a container made of a plastic composition having an inner coating on an inner surface of the container, the inner coating having a maximum thickness of 1000 nm and comprising at least one metal layer. In order to produce a container with a higher mechanical stability of the inner coating and/or a better adhesion between inner coating and the inner surface of the container it is provided according the invention that the method comprises following steps: - preparing the plastic composition comprising at least one base polymer material (9) and at least a first additive comprising globe-like particles (8) having a hardness on the Mohs scale of at least 4; - extrusion blow moulding of a container, wherein globe-like particles (9) of the first additive which located on the inner surface (6) of the container increase the surface area and the hardness of the inner surface (6) of the container; - applying the at least one metal layer (7a) of the inner coating (7) onto the inner surface (6) of the container, wherein the applied metal layer (7a) bonds to the globe-like particles (8) of the first additive located on the inner surface (6) of the container.