Application US20190134872

METHOD FOR MANUFACTURING A CLOSURE FOR A PRODUCT-RETAINING CONTAINER
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US20190134872

1. A method for manufacturing a closure for a product-retaining container constructed for being inserted and securely retained in a portal-forming neck of said product-retaining container, said method comprising at least the following method steps: (1) (4)

i. intimately combining the following components, to form a composition: (a) 51 to 80 wt. % (dry weight) or 51 to 85 wt. % (dry weight) of a plurality of coated particles, said coated particles each comprising (1) a core comprising cork material and (2) at least one outer shell comprising a first plastic material, said first plastic material comprising one or more thermoplastic polymers;

(b) 12 to 49 wt. % of a second plastic material comprising one or more thermoplastic polymers;

(d) optionally, 0 to 15 wt. % of one or more lubricants;

(e) optionally, 0 to 2 wt. % of one or more pigments; and

(f) optionally, 0 to 10 wt. % of one or more additives and/or fillers;

ii. heating the composition obtained in step i. to form a melt;

iii. forming, by means of extrusion or molding, a closure precursor from the melt obtained in step ii; and

iv. optionally cutting and/or finishing the closure precursor to form the closure.

48. A closure produced by the method of claim 1. (6) (0)

49. The closure of claim 48, wherein the closure has an oxygen ingress rate measured according to ASTM F1307 of less than about 5 mg oxygen per container in the first 100 days after closing the product-retaining container. (0)

50. The closure of claim 48, wherein the closure has an oxygen ingress rate measured according to ASTM F1307 selected from the group consisting of less than about 1 mg oxygen, less than about 0.8 mg oxygen, less than about 0.5 mg oxygen, less than about 0.25 mg oxygen, less than about 0.2 mg oxygen and less than about 0.1 mg oxygen, per product-retaining container in the first 100 days after closing the product-retaining container. (0)

51. The closure of claim 48, wherein the closure has an oxygen transfer rate measured according to ASTM F1307 in 100% oxygen of less than 0.05 cc/day. (0)

52. The closure of claim 48, wherein the closure has a moisture rate as determined by ISO 9727-3 of less than 3%. (0)

55. The closure according to claim 48, having a surface roughness R_ameasured by contact profilometry in the range from 5 μm to 18 μm. (0)

58. A closure system comprising the product-retaining container and the closure of claim 48. (0)

2. A method for manufacturing a closure for a product-retaining container constructed for being inserted and securely retained in a portal-forming neck of said product-retaining container, said method comprising at least the following method steps: (39) (4)

i. intimately combining the following components, to form a composition: (a) 52 to 100 wt. % (dry weight) of a plurality of coated particles, said coated particles each comprising (1) a core comprising cork material and (2) at least one outer shell comprising a first plastic material, said first plastic material comprising one or more thermoplastic polymers;

(b) 0 to 48 wt. % of a second plastic material comprising one or more thermoplastic polymers;

(d) optionally, 0 to 15 wt. % of one or more lubricants;

(e) optionally, 0 to 2 wt. % of one or more pigments; and

(f) optionally, 0 to 10 wt. % of one or more additives and/or fillers;

ii. heating the composition obtained in step i. to form a melt;

iii. forming, by means of extrusion or molding, a closure precursor from the melt obtained in step ii; and

iv. optionally cutting and/or finishing the closure precursor to form the closure.

3. The method of claim 2, wherein the closure or closure precursor is substantially free of thermoset polymers (including polyurethane) and/or substantially free of adhesives (including reactive and non-reactive adhesives). (0)

4. The method of claim 2, wherein the closure or closure precursor has a content of releasable trichloroanisole measured according to the test method defined herein of less than 2 ng/L, preferably less than 1 ng/L, preferably less than 0.5 ng/L, preferably less than 0.3 ng/L. (0)

5. The method of claim 2, wherein steps i., ii., and iii. are carried out sequentially or simultaneously and/or wherein at least one of steps i., ii., and iii. is carried out in an extruder. (0)

6. The method of claim 2, wherein each one of steps i., ii., and iii. is carried out in an extruder. (0)

7. The method of claim 2, wherein the temperature in any of steps i., ii., and iii. does not exceed 200° C. (0)

8. The method of claim 2, wherein the pressure in any of steps i., ii. and iii. does not exceed 30 bar. (0)

9. The method of claim 2, wherein during the heating step ii., at least one of the first plastic material or the second plastic material is foamed. (0)

10. The method of claim 2, wherein the components (a), (b), and (c) are present in the following weight percent amounts, based on the total weight of the composition: (0) (3)

11. The method of claim 2, wherein the components (a), (b), and (c) are comprised in the following weight percent amounts, based on the total weight of the composition: (0) (3)

12. The method of claim 2, wherein coated particles of said plurality of coated particles have a substantially isotropic shape. (0)

13. The method of claim 2, wherein, for each coated particle, the core is a cork particle having a particle size distribution D₅₀measured by means of mechanical sieving according to ISO ICS 19.120 and in particular ISO 2591-1:1988, in the range of from 0.25 millimetres to 5 millimetres. (0)

14. The method of claim 2, wherein, for each coated particle, the core is a cork particle, and the cork particles comprise a mixture of at least: (0) (4)

from 5 wt. % to 100 wt. %, based on the total weight of the cork particles of smaller cork particles having a particle size distribution D₅₀measured by means of mechanical sieving according to ISO ICS 19.120 and in particular ISO 2591-1:1988, in the range of from 0.1 millimetres to less than 1.0 millimetre; and

from 0 wt. % to 95 wt. %, based on the total weight of the cork particles of larger cork particles having a particle size distribution D₅₀measured by means of mechanical sieving according to ISO ICS 19.120 and in particular ISO 2591-1:1988, in the range of from 1.0 millimetre to 3.0 millimetres; or

from 5 wt. % to 100 wt. %, based on the total weight of the cork particles of larger cork particles having a particle size distribution D₅₀measured by means of mechanical sieving according to ISO ICS 19.120 and in particular ISO 2591-1:1988, in the range of from 1.0 millimetre to 3.0 millimetres; and

from 0 wt. % to 95 wt. %, based on the total weight of the cork particles of smaller cork particles having a particle size distribution D₅₀measured by means of mechanical sieving according to ISO ICS 19.120 and in particular ISO 2591-1:1988, in the range of from 0.1 millimetres to less than 1.0 millimetre.

15. The method of claim 2, wherein, for each coated particle, the core is a cork particle having a water content of less than 3 wt. %, in particular less than 2 wt. %, less than 1.5 wt. %., or less than 1 wt. %. (0)

16. The method of claim 2, wherein, for each coated particle, the core is a cork particle and wherein said cork particles have a content of releasable trichloroanisole measured according to the test method defined herein of less than 6 ng/L. (0)

17. The method of claim 2, wherein, for each coated particle, the core is a cork particle and wherein the density of said cork particles in the closure precursor or in the closure is in the range of 50 to 100 g/L. (0)

18. The method of claim 2, wherein, for each coated particle, the core is substantially encapsulated by said at least one outer shell comprising said first plastic material. (0)

19. The method of claim 2, wherein, for each coated particle, the at least one outer shell of said coated particles has a thickness of 5 to 100 microns. (0)

20. The method of claim 2, wherein said second plastic material comprising one or more thermoplastic polymers has an average particle size distribution D50 measured by means of mechanical sieving according to ISO ICS 19.120 and in particular ISO 2591-1:1988, of less than 1000 microns. (0)

21. The method of claim 2, wherein said second plastic material comprising one or more thermoplastic polymers is milled. (0)

22. The method of claim 2, wherein said second plastic material comprising one or more thermoplastic polymers is provided in the form of a polymer dispersion, a polymer emulsion and/or polymer gum. (0)

23. The method according to claim 2, wherein said second plastic material is provided in the form of a melt. (0)

24. The method of claim 2, wherein at least one of said first plastic material or said second plastic material is thermoplastically processable. (0)

25. The method of claim 2, wherein at least one of said first plastic material or said second plastic material comprises one or more polymers that are biodegradable according to ASTM D6400. (0)

26. The method of claim 2, wherein at least 90 wt. % of said first plastic material and/or said second plastic material is biodegradable according to ASTM D6400. (0)

27. The method of claim 2, wherein from 1% by weight to 49% by weight of the closure, based on the entire weight of the closure, is biodegradable according to ASTM D6400. (0)

28. The method of claim 2, wherein said first and/or second plastic material comprises one or more thermoplastic polymers independently selected from the group consisting of: polyethylenes; metallocene catalyst polyethylenes; polybutanes; polybutylenes; thermoplastic polyurethanes; silicones; vinyl-based resins; thermoplastic elastomers; polyesters; ethylenic acrylic copolymers; ethylene-vinyl-acetate copolymers; ethylene-methyl-acrylate copolymers; thermoplastic polyolefins; thermoplastic vulcanizates; flexible polyolefins; fluorelastomers; fluoropolymers; polytetrafluoroethylenes; ethylene-butyl-acrylate copolymers; ethylene-propylene-rubber; styrene butadiene rubber; styrene butadiene block copolymers; ethylene-ethyl-acrylic copolymers; ionomers; polypropylenes; copolymers of polypropylene and ethylenically unsaturated comonomers copolymerizable therewith; olefin copolymers; olefin block copolymers; cyclic olefin copolymers; styrene ethylene butadiene styrene block copolymers; styrene ethylene butylene styrene block copolymers; styrene ethylene butylene block copolymers; styrene butadiene styrene block copolymers; styrene butadiene block copolymers; styrene isoprene styrene block copolymers; styrene isobutylene block copolymers; styrene isoprene block copolymers; styrene ethylene propylene styrene block copolymers; styrene ethylene propylene block copolymers; polyvinylalcohol; polyvinylbutyral; polyhydroxyalkanoates; copolymers of hydroxyalkanoates and monomers of biodegradable polymers; polylactic acid; copolymers of lactic acid and monomers of biodegradable polymers; aliphatic copolyesters; polycaprolactone; polyglycolide; poly(3-hydroxybutyrate); poly(3-hydroxybutyrate-co-3-hydroxyvalerate); poly(3-hydroxybutyrate-co-3-hydroxyhexanoate); poly(butylenesuccinate); aliphatic-aromatic copolyesters, in particular aliphatic-aromatic copolyesters comprising units derived from renewable resources and/or units derived from fossil resources, in particular one or more aliphatic-aromatic copolyesters selected from poly(butylenesuccinate-co-adipate); poly(trimethyleneterephthalate); poly(butylenadipate-co-terephthalate); poly(butylenesuccinate-co-terephthalate); poly(butylenesebacate-co-terephthalate); polymers derived from lactic acid, copolymers of lactic acid and monomers of biodegradable polymers, in particular selected from polylactic acid, lactic acid caprolactone lactic acid copolymers; lactic acid ethylene oxide lactic acid copolymers; polymers formed from monomer units selected from vinylidene chloride, acrylonitrile and methyl methacrylate; copolymers formed from two or more monomer units selected from vinylidene chloride, acrylonitrile and methyl methacrylate; PEF, PTF, bio-based polyesters, and combinations of any two or more thereof. (0)

29. The method of claim 2, wherein said first and/or second plastic material comprises one or more thermoplastic polymers independently selected from the group consisting of aliphatic (co)polyesters, aliphatic aromatic copolyesters, polylactic acid, EVA, olefinic polymers such as metallocene polyethylene, and styrenic block copolymers. (0)

30. The method of claim 2, wherein said first and/or second plastic material comprises one or more thermoplastic polymers having a melt flow index (MFI) as determined by ISO 1133-1 of greater 5, in particular greater 10 or greater 12. (0)

31. The method of claim 2, wherein said first and second plastic materials are identical. (0)

32. The method of claim 2, wherein said first and/or second plastic material is unfoamed and/or foamed plastic material. (0)

33. The method of claim 2, wherein the composition in step i. comprises 0.05 to 10 wt. % of the one or more blowing agents. (1) (0)

35. The method of claim 2, wherein said closure or closure precursor comprises a plurality of cells. (3) (0)

39. The method of claim 2, wherein the closure or the closure precursor has an overall density in the range of from 100 kg/m³to 500 kg/m³. (0)

40. The method of claim 2, wherein the first plastic material and/or the second plastic material in the closure or closure precursor has a foam density in the range of from 25 kg/m³to 800 kg/m³. (0)

41. The method of claim 2, wherein a distribution of the plurality of coated particles in the closure or the closure precursor is substantially uniform throughout at least one of a length or a diameter of the closure. (0)

42. The method of claim 2, wherein coated particles of the plurality of coated particles are distributed homogeneously throughout the closure. (0)

43. The method of claim 2, wherein the closure or the closure precursor does not comprise a binder; and/or wherein the closure does not comprise a crosslinking agent; and/or wherein the closure does not comprise a binder and does not comprise a crosslinking agent; and/or wherein the first plastic material and/or the second plastic material is not crosslinked by means of a crosslinking agent. (0)

44. The method of claim 2, wherein the closure precursor in step iii. is formed by means of monoextrusion or co-extrusion. (0)

45. The method of claim 2, wherein the closure precursor and/or the closure is further subjected to one or more surface treatments such as sanding, chamfering, bleaching, and/or coating. (0)

46. A composition for use in manufacturing a closure for a product-retaining container, comprising as components: (0) (6)

(a) 51 to 80 wt. % (dry weight) or 51 to 85 wt. % (dry weight) of a plurality of coated particles, said coated particles each comprising (1) a core comprising cork material and (2) at least one outer shell comprising a first plastic material, said first plastic material comprising one or more thermoplastic polymers;

(b) 12 to 49 wt. % of a second plastic material comprising one or more thermoplastic polymers;

(d) optionally, 0 to 15 wt. % of one or more lubricants;

(e) optionally, 0 to 2 wt. % of one or more pigments; and

(f) optionally, 0 to 10 wt. % of one or more additives and/or fillers.

47. A composition for use in manufacturing a closure for a product-retaining container, comprising as components: (0) (6)

(a) 52 to 100 wt. % (dry weight) of a plurality of coated particles, said coated particles each comprising (1) a core comprising cork material and (2) at least one outer shell comprising a first plastic material, said first plastic material comprising one or more thermoplastic polymers;

(b) 0 to 48 wt. % of a second plastic material comprising one or more thermoplastic polymers;

(d) optionally, 0 to 15 wt. % of one or more lubricants;

(e) optionally, 0 to 2 wt. % of one or more pigments; and

(f) optionally, 0 to 10 wt. % of one or more additives and/or fillers.

53. A closure for a product-retaining container constructed for being inserted and securely retained in a portal-forming neck of said product-retaining container, wherein the closure comprises: (1) (3)

56. (canceled) (0)

57. (canceled) (0)

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Application US20190134872

METHOD FOR MANUFACTURING A CLOSURE FOR A PRODUCT-RETAINING CONTAINER

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