Polymeric materials

• US 8,372,321 B2
• Filed: 12/19/2007
• Issued: 02/12/2013
• Est. Priority Date: 12/23/2006
• Status: Active Grant

• Current Assignee: ColorMatrix Holdings, Inc. (Avient Corp.)
• Original Assignee: ColorMatrix Holdings, Inc. (Avient Corp.)
• Inventors: Chisnall, David Andrew, Frost, Mark
• Primary Examiner(s): HEITBRINK, JILL LYNNE
• Application Number:
  US12/519,601
• Publication Number:
  US 20100044897A1
• Time in Patent Office: 1,882 Days
• Field of Search: 264/40.1, 356/402
• US Class Current: 264/40.1
• CPC Class Codes: B01F 33/84 Mixing plants with mixing receptacles receiving material dispensed from several component receptacles, e.g. paint tins
• CPC Class Codes: B01F 33/8442 using a computer for controlling information and converting it in a formula and a set of operation instructions, e.g. on the point of sale
• CPC Class Codes: B01F 33/846 using stored recipes for determining the composition of the mixture to be produced, i.e. for determining the amounts of the basic components to be dispensed from the component receptacles
• CPC Class Codes: B01F 35/20 Measuring; Control or regulation
• CPC Class Codes: B01F 35/2131 Colour or luminescence
• CPC Class Codes: B29B 7/002 Methods chemical aspects C08J3/00

Abstract

A part may be manufactured in a desired color from virgin or recycled polymeric material by selection of a color formulation to be used in a first location 4, 6, 8, 10, 12; relaying color information to a centralized match prediction system 16 as regards the desired color and other information concerning a polymeric material which is to be made in the desired color. The system 16 includes a database and associated software and is able to take the color information and predict how to reproduce the colors using an associated color dispense system. A device 30 controls dispense stations 32, 34, 36, 38 and 40 which may be conveniently situated at customer sites or the like. The dispense stations dispense colors for use.

Claims

1. A method of selecting and manufacturing a non-volatile colour formulation for manufacturing, in a selected desired colour, a part comprised of a polymeric material, the method comprising the steps of:

(i) at a first location, selecting the desired colour for the polymeric material;

(ii) communicating the colour selected in step (i) to a centralised colour match prediction system;

(iii) at the centralised colour match prediction system, determining, via a computer, one or more non-volatile colour formulations for delivery into a polymeric material to match or closely match the desired colour, wherein said one or more non-volatile colour formulations is selected with regard to one or more of the following variables;

(a) the identity of the polymer into which the non-volatile colour formulation is to be incorporated,

(b) the grade of polymer into which the non-volatile colour formulation is to be incorporated,

(c) the processing conditions to which the polymer into which the non-volatile colour formulation is to be incorporated will be subjected, and

(d) country of use;

(iv) delivering information through said computer relating to the non-volatile colour formulation(s) determined in step (iii) to an assessment location for assessment;

(v) optionally repeating step (iii) to determine one or more additional non-volatile colour formulations for delivery into the polymeric material to match or closely match the desired colour; and

(vi) selecting a colour formulation for use in the manufacture of the part;

(vii) wherein the centralised colour match prediction system communicates with a device which includes software arranged to operate a colour dispense system, wherein said colour dispense system includes more than ten base colour formulations which include liquid dispersions of pigments or dyes; and

(viii) wherein the non-volatile colour formulation is manufactured using one of said colour dispense system.

2. A method according to claim 1, wherein said polymeric material is a thermoplastic polymeric material.

3. A method according to claim 1, wherein said non-volatile colour formulation comprises a non-volatile carrier and one or more pigments or dyes.

4. A method according to claim 1, wherein the colour formulation is for use in manufacturing a coloured part comprising a polymeric material in a process that comprises heating a mixture of a said colour formulation and polymeric material to allow the mixture to be shaped to define the part.

5. A method according to claim 1, wherein in step (i) of the method, colour is determined by selecting an identifier of a colour in accordance with a defined colour system or a colour spectrum of the desired colour is determined.

6. A method according to claim 1, wherein in step (i), the desired colour is selected spectrophotometrically.

7. A method according to claim 1, wherein said variables further include:

(e) the use and/or requirements of the part for which the colour formulation is to be selected.

8. A method according to claim 7, wherein, in step (ii), information is communicated to the second location relating to the identity of the polymer into which the colour formulation is to be incorporated.

9. A method according to claim 1, wherein the polymeric material is a recycled polymeric material and the method includes determining colour information relating to the recycled polymeric material before step (iii).

10. A method according to claim 1, wherein the identity of the intended user of the selected colour is determined at the first location and information relating thereto is communicated to the second location.

11. A method according to claim 1, wherein the computer is arranged to receive information determined in step (i) and determine a match or close match of the desired colour, said computer including a database which comprises information relating to the spectra in the visible region of each of a plurality of base colour formulations.

12. A method according to claim 11, wherein said computer includes information relating to properties and/or effects of said base colour formulations when incorporated into different types of polymeric materials.

13. A method according to claim 12, wherein said computer is configured to determine the effect of adding a mixture of a plurality or multiplicity of base colour formulations at different concentrations into a polymeric material.

14. A method according to claim 8, wherein, in step (iii), a plurality of colour formulations for delivery into a polymeric material are determined.

15. A method according to claim 1, wherein in step (iv), information delivered includes information relating to the differences between the colour obtainable and the desired colour.

16. A method according to claim 1, wherein a display device is provided at said assessment location to enable a display of the actual colour obtainable in a part if manufactured using the colour formulation in relation to which information has been delivered.

17. A method according to claim 1, wherein in the assessment location, a person may assess information relating to the colour or colours obtainable with a view to selecting a colour formulation for use in manufacturing the part.

18. A method of manufacturing a part comprising a polymeric material in a predetermined colour, the method comprising incorporating a colour formulation selected and manufactured in a method according to claim 1 into a polymeric material and forming a mixture of colour formulation and polymeric material into said part in an extrusion or injection moulding process.

19. A method according to claim 1, wherein the more than ten base colour formulations are manufactured in accordance with a quality assurance system so that identical colour formulations can be prepared in each colour dispense system under the effective control of said computer.

20. A method according to claim 1, wherein at least three of said colour dispense systems are provided at separate locations, the method further comprising the step of arranging said computer to communicate information to said colour dispense systems on the amounts of base colour formulations to be dispensed so that identical colour formulations can be prepared in each colour dispense system under the effective control of said computer.

21. A method according to claim 1, wherein said computer of said colour match prediction system includes a database which comprises information in relation to the base colour formulations included in said colour dispense systems.

22. An arrangement for selecting and manufacturing a non-volatile colour formulation for manufacturing, in a selected colour, a part comprised of a polymeric material, the arrangement comprising:

(a) at a first location, a device configured to determine the desired colour for the polymeric material;

(b) a centralised colour match prediction system, at a second location, remote from said first location, said centralised colour match prediction system including a computer receiving information from said first location and an associated software determining one or more non-volatile colour formulations for delivery into a polymeric material to match or closely match the desired colour, wherein said one or more non-volatile colour formulations is selected having regard to one or more of the following variables;

(i) the identity of the polymer into which the non-volatile colour formulation is to be incorporated,

(ii) the grade of polymer into which the non-volatile colour formulation is to be incorporated,

(iii) the processing conditions to which the polymer into which the non-volatile colour formulation is to be incorporated will be subjected, and

(iv) country of use;

(c) at an assessment location, a display unit for assessing a colour obtainable as determined by said centralised colour match prediction system at said second location;

(d) a selection device arranged to allow selection of a non-volatile colour formulation for use in the manufacture of the part; and

(e) a colour dispense system which includes more than ten base colour formulations which include liquid dispersions of pigments or dyes;

(f) wherein the centralised colour match prediction system communicates with a device which includes software arranged to operate said colour dispense system and dispense predetermined amounts of said base colour formulations into a receptacle.

23. An arrangement according to claim 22, wherein a spectrophotometer is provided at the first location for determining the desired colour.

24. An arrangement according to claim 22, wherein the more than ten base colour formulations are manufactured in accordance with a quality assurance system so that identical colour formulations can be prepared in each colour dispense system under the effective control of said computer.

25. An arrangement according to claim 22, wherein at least three of said colour dispense systems are provided at separate locations, and wherein the computer is arranged to communicate information to said colour dispense systems on the amounts of base colour formulations to be dispensed so that identical colour formulations can be prepared in each colour dispense system under the effective control of said computer.

26. An arrangement according to claim 22, wherein said computer of said colour match prediction system includes a database which comprises information in relation to the base colour formulations included in said colour dispense systems.

27. A method of manufacturing colour formulations in a plurality of separate locations, the method comprising providing respective colour dispense systems in said plurality of locations, wherein each said colour dispense system comprises more than ten base colour formulations arranged to be dispensed in predetermined amounts into a receptacle, said base colour formulations comprising liquid dispersions of pigments or dyes;

and

communicating information to said colour dispense systems in locations in which said colour formulations are to be manufactured relating to the amounts of base colour formulations to be dispensed, said information being communicated to said locations from a single computer, wherein said computer includes a centralized colour match prediction system for determining one or more non-volatile colour formulations for delivery into a polymeric material to match or closely match a desired colour.

28. A method according to claim 27, wherein the more than ten base colour formulations are manufactured in accordance with a quality assurance system so that identical colour formulations can be prepared in each colour dispense system under the effective control of said computer.

29. A method according to claim 27, wherein at least three of said colour dispense systems are provided at separate locations, the method further comprising the step of arranging said computer to communicate information to said colour dispense systems on the amounts of base colour formulations to be dispensed so that identical colour formulations can be prepared in each colour dispense system under the effective control of said computer.

30. A method according to claim 27, wherein said computer includes a database which comprises information in relation to the base colour formulations included in said colour dispense systems.

31. A method of selecting and manufacturing a non-volatile colour formulation for manufacturing a part comprising a polymeric material in a selected desired colour, the method comprising the following steps:

(i) at a first location, determining the desired colour for the polymeric material;

(ii) communicating the desired colour determined in step (i) to a centralized colour match prediction system;

(iii) at the centralised colour match prediction system, determining, via a computer, one or more non-volatile colour formulations for delivery into a polymeric material to match or closely match the desired colour;

(iv) delivering information through the computer relating to the non-volatile colour formulation(s) determined in step (iii) to an assessment location for assessment;

(v) optionally repeating step (iii) to determine one or more additional non-volatile colour formulations for delivery into the polymeric material to match or closely match the desired colour;

(vi) selecting a non-volatile colour formulation for use in the manufacture of the part; and

(vii) manufacturing said non-volatile colour formulation in a method comprising using a colour dispense system which includes more than ten base colour formulations to dispense predetermined amounts of said base colour formulations into a receptacle, wherein said computer communicates information to the colour dispense system relating to the amounts of said base colour formulations to be dispensed, and wherein said ten base colour formulations include liquid dispersions of pigments or dyes.

32. A method according to claim 31, wherein the more than ten base colour formulations are manufactured in accordance with a quality assurance system so that identical colour formulations can be prepared in each colour dispense system under the effective control of said computer.

33. A method according to claim 31, wherein at least three of said colour dispense systems are provided at separate locations, the method further comprising the step of arranging said computer to communicate information to said colour dispense systems on the amounts of base colour formulations to be dispensed so that identical colour formulations can be prepared in each colour dispense system under the effective control of said computer.

34. A method according to claim 31, wherein said computer of said colour match prediction system includes a database which comprises information in relation to the base colour formulations included in said colour dispense systems.

35. A method of selecting and manufacturing a non-volatile colour formulation for manufacturing, in a selected desired colour, a part comprising a polymeric material, the method comprising the steps of:

(i) at a first location, determining the desired colour for the polymeric material;

(ii) communicating the desired colour determined in step (i) to a centralised colour match prediction system;

(iii) at the centralised colour match prediction system, determining, via a computer, one or more non-volatile colour formulations for delivery into a polymeric material to match or closely match the desired colour;

(iv) delivering information through the computer relating to the non-volatile colour formulation(s) determined in step (iii) to an assessment location for assessment, wherein said information includes a series of costed options as regards to colour and/or colour tolerance;

(v) optionally repeating step (iii) to determine one or more additional non-volatile colour formulations for delivery into the polymeric material to match or closely match the desired colour; and

(vi) selecting the non-volatile colour formulation for use in the manufacture of the part;

(vii) wherein the centralised colour match prediction system communicates with a device which includes software arranged to operate a colour dispense system, wherein said colour dispense system includes more than ten base colour formulations which include liquid dispersions of pigments or dyes;

(viii) wherein the non-volatile colour formulation is manufactured using said colour dispense system.

36. A method according to claim 35, which includes manufacturing the part using the colour formulation, assessing the colour of the part manufactured and feeding information relating to its colour to the computer in order to allow the relationship between colours predicted by said computer and actual colours achieved to be compared and for adjustment to the computer to improve the relationship between its predicted colour and actual colour.

37. A method according to claim 35, wherein the more than ten base colour formulations are manufactured in accordance with a quality assurance system so that identical colour formulations can be prepared in each colour dispense system under the effective control of said computer.

38. A method according to claim 35, wherein at least three of said colour dispense systems are provided at separate locations, the method further comprising the step of arranging said computer to communicate information to said colour dispense systems on the amounts of base colour formulations to be dispensed so that identical colour formulations can be prepared in each colour dispense system under the effective control of said computer.

39. A method according to claim 35, wherein said computer of said colour match prediction system includes a database which comprises information in relation to the base colour formulations included in said colour dispense systems.

40. A method of selecting and manufacturing a non-volatile colour formulation for manufacturing, in a selected desired colour, a part comprised of a polymeric material, the method comprising the steps of:

(i) at a first location, selecting the desired colour for the polymeric material;

(ii) communicating the colour selected in step (i) to a centralised colour match prediction system;

(iii) at the centralised colour match prediction system, determining, via a computer, one or more non-volatile colour formulations for delivery into a polymeric material to match or closely match the desired colour, wherein said one or more non-volatile colour formulations is selected with regard to one or more of the following variables;

(a) the identity of the polymer into which the non-volatile colour formulation is to be incorporated,

(b) the grade of polymer into which the non-volatile colour formulation is to be incorporated,

(c) the processing conditions to which the polymer into which the non-volatile colour formulation is to be incorporated will be subjected, and

(d) country of use;

(iv) delivering information through said computer relating to the non-volatile colour formulation(s) determined in step (iii) to an assessment location for assessment;

(v) optionally repeating step (iii) to determine one or more additional non-volatile colour formulations for delivery into the polymeric material to match or closely match the desired colour; and

(vi) selecting the non-volatile colour formulation for use in the manufacture of the part;

(vii) wherein the centralised colour match prediction system communicates with a device which includes software arranged to operate a colour dispense system, wherein said colour dispense system includes more than ten base colour formulations which include liquid dispersions of pigments or dyes;

(viii) wherein the centralised colour match prediction system communicates the colour formulation selected in step (vi) after the assessment in step (iv) to a device which includes software arranged to receive the colour formulation without human intervention and to operate a computer controlled colour dispense system with information determined by the centralised match prediction system, wherein said colour dispense system includes more than ten base colour formulations as fluid in receptacles to be accurately dispensed according to the colour formulation selected in step (vi);

(ix) wherein the non-volatile colour formulation is manufactured using said colour dispense system.