Compression over-molding container preforms

Abstract

A method of making a preform for blow molding a plastic container. In one embodiment, a tubular shell of plastic construction is provided, wherein the shell has a closed end and an open end. A plastic mold charge is then placed within the shell, and a preform body is compression molded within the shell such that the shell is secured to an outer surface of the preform body. In another embodiment, a tubular shell of plastic construction is provided wherein the shell is open at opposed ends, and a preform body is then compression molded externally around the shell. A preform for blow molding a plastic container includes a plastic shell and a plastic body that is compression over-molded to the plastic shell.

1 . A method of making a preform for blow molding a plastic container, which includes the steps of: 
 (a) providing a tubular shell of plastic construction, said shell having a closed end and an open end,    (b) placing a plastic mold charge within said shell, and    (c) compression molding a preform body within said shell such that said shell is secured to an outer surface of said preform body.    
     
     
         2 . The method set forth in  claim 1  wherein said step (b) includes placing said mold charge within said closed end of said shell.  
     
     
         3 . The method set forth in  claim 1  wherein said tubular shell is of multilayer plastic construction.  
     
     
         4 . The method of  claim 3  wherein said tubular shell is composed of about 10% high IV material and about 90% low IV material.  
     
     
         5 . The method of  claim 1  wherein said tubular shell is of single layer plastic construction.  
     
     
         6 . The method of  claim 5  wherein said tubular shell is composed of at least one of a regrind polymer, post consumer resin and a low IV material.  
     
     
         7 . The method of  claim 1  wherein said preform is composed of about 90% low cost material such as a regrind polymer, post consumer resin, lower IV material and the like, and is further composed of about 10% virgin material.  
     
     
         8 . The method of  claim 7  wherein said 10% virgin material is composed of about 10% polycarbonate, polycarbonate blends, PEN or PEN blends, and about 90% PET.  
     
     
         9 . The method of  claim 1  wherein said step (c) includes molding a preform finish integrally with said body and adjacent to but outside of said open end of said shell.  
     
     
         10 . A preform for blow molding a plastic container wherein said preform is produced by the method of  claim 1 .  
     
     
         11 . A method of making a preform for blow molding a plastic container, which includes: 
 (a) providing a tubular shell of plastic construction, said shell being open at opposed ends, and    (b) compression molding a preform body externally around said shell.    
     
     
         12 . The method of  claim 11  wherein said tubular shell is composed of a virgin polymer composed of about 10% polycarbonate, polycarbonate blends, PEN or PEN blends, and about 90% PET.  
     
     
         13 . The method of  claim 11  wherein said tubular shell includes a flange portion at one of said opposed ends.  
     
     
         14 . The method of claim II wherein said tubular shell is composed of a multi-layer material including at least one layer of virgin polymer and at least one layer of a low cost material such as a regrind polymer, post consumer resin, lower IV material, and the like.  
     
     
         15 . The method of  claim 11  wherein said preform body is composed of a multi-layer material including at least one layer of virgin polymer and at least one layer of a low cost material such as a regrind polymer, post consumer resin, lower IV material, and the like.  
     
     
         16 . The method of  claim 11  wherein said preform is composed of about 90% low cost material such as a regrind polymer, post consumer resin, lower IV material, and the like and is further composed of about 10% virgin material.  
     
     
         17 . The method of  claim 11  further comprising loading said tubular shell to a core pin prior to said compression molding step.  
     
     
         18 . The method of  claim 11  wherein said step (b) includes molding a preform finish integrally with said preform body and adjacent to but outside of said open end of said shell.  
     
     
         19 . A preform for blow molding a plastic container wherein said preform is produced by the method of  claim 11 .  
     
     
         20 . A method of making a preform for blow molding a plastic container, said method includes: 
 providing a shell,    loading said shell to one of a compression mold cavity and a compression core pin,    introducing a softened polymer into said compression mold cavity, and    compression molding said softened polymer to said shell.    
     
     
         21 . The method of  claim 20  wherein said loading step includes loading said shell to said compression mold cavity and said introducing step includes introducing said softened polymer at least partially within said shell and said compression molding step includes compression molding said softened polymer at least partially within said shell.  
     
     
         22 . The method of  claim 21  wherein said shell is a substantially open-ended tubular-shaped component.  
     
     
         23 . The method of  claim 20  wherein said loading step includes loading said shell to said compression core pin and said compression molding step includes compression molding said softened polymer at least partially around said shell.  
     
     
         24 . The method of  claim 20  wherein said shell is a tubular-shaped component having a flange portion at one end thereof.  
     
     
         25 . A preform for blow molding a plastic container wherein said preform is produced by the method of  claim 20 .  
     
     
         26 . A preform for blow molding a plastic container, said preform including: 
 a plastic shell; and    a plastic body compression over-molded to said plastic shell.    
     
     
         27 . The preform of  claim 26  wherein said plastic body is compression over-molded at least partially around said plastic shell.  
     
     
         28 . The preform of  claim 26  wherein said plastic body is compression over-molded at least partially within said plastic shell.