CA1115014A - Fusible composite binding strap - Google Patents
Fusible composite binding strapInfo
- Publication number
- CA1115014A CA1115014A CA301,258A CA301258A CA1115014A CA 1115014 A CA1115014 A CA 1115014A CA 301258 A CA301258 A CA 301258A CA 1115014 A CA1115014 A CA 1115014A
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Abstract
Abstract of the Disclosure A sheetform article such as a binding strap and the like which exhibits improved fusibility is a laminar composite made of a crystalline synthetic thermoplastic polymer. The composite has a major thickness portion or base layer of the polymer having a relatively lower average molecular weight and a minor thickness portion of the same polymer but having a relatively higher average molecular weight. The minor thick-ness portion defines a fusible face of the sheetform article, and all thickness portions of the article have substantially similar planar crystalline orientation.
Description
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Back~r_und of the Invention This invention relates to fusible sheetform articles, particularly to fusible plastic binding strap that can be joined by friction fusion, hot knife techniques, or the like manner.
Plastic strap is a convenient and relatively inexpen-; sive strapping material ~hat has been used ~or a wide variety of ~ tying and packaying operations. For many applications plastic ; strap is uniquely suited by virtue of the inherent elasticity thereof, e.g., or tying packages subject to dimensional change, ~ -or to handling situations whereby shock conditions may be imposed upon the strap loop that surrounds the package. Tying usually is accomplished by forming a strap loop about the package, shrinking or reducing the formed loop to a snug fit a~out the pack~ye, and thereafter joining o~erlapping ends of the strap loop by means of a wrap-around seal or a fused joint.
Wrap-around seals for plastic strap are generally formed in a manner analogous to steel strap, e.g~ by crimping a deform-able metal band around overlapping strap ends so as to form a mechanical interlock. Such wrap-around seals are not completely effective, however, because plastic strap has inhexen~ly low shear strength which xestricts the crimping and interlocking techniques normally utilized with wrap-around seals.
As an a}ternate strap sealing approach, strap joints have been formed by melting and fusing overlapping portions of thermoplastic strap so as to form a joint. For this purpose heated pressure jaws, high frequency dielectric heating means, ~
ultrasonic welders, and friction fusion devices have been used. ~;
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None of the foregoing joint-forming means are capable of produc-ing routinely and consistently, and in an economic manner, a seal that exhibits a joint strength that is greater than about 40 to 50 percent of the plastic strap tensile strength. It is very desirable, however, to have joint strengths that approach the tensile strength of the strap much more closely.
Summary of the Invention ; It has now been found that the usibility of plastic sheetform articles, such as binding strap and the like, can be improved by forming the articles from a crystalline synthetic thermoplastic polymer as a laminar composite in which the lamina or layers are constituted of the same polymer, i.eO, having the same repeating unit or units in the structural chain, but of a different average molecular weight. In the laminar composite, the polymer on at least one fusible face of the produced article has a relatively higher average molecular we~ght than the same polymer in the body of the article so that the ultimately formed joint is in a fused region which contains the relatively higher average molecular weight polymer. Stated in another way, the intrinsic viscosity and relative viscosity of the polymer consti-tuting the fusible face, or faces, is higher than the intrinsic viscosity and relative viscosity of the polymer in the body of the article. If melt index is used as the primary measurement of the molecular weight, then the melt index of the polymer con-stituting the fusible face is lower than the melt index of the polymer in the body of the article.
Accordingly, the present invention contemplates a sheetform, crystalline synthetic ~hermoplastic polymer article of substantially uniform cross-section and comprising a laminar - -composite which has a major thickness portion made up of the .. . . . . . . . . ~ .. ...... .. . ., .. .. ... . . . . , ., ., .. _ . . . . . .......... . ..
.. . .
polymer having a relatively lower average molecular weight and at least one minor thic~ness portion which is made up of the same polymer but having a relatively higher average molecular weight. Each minor thickness portion o~ the article has a thickness that is less than the thickness of the major thick-ness portion; however, the sum of the thicknesses of the indi-vidual minor thickness portions on opposite sides of the sheetform article may be greater than the thickness of the major thickness portion. The terms "sheetform" and "sheet"
as used herein and in the appended claims designate an article of manufacture having a thickness greater than about 10 mils.
The minor thickness portion of the sheetform article defines a fusible face of the article. Both the major thickness portion and the minor thickness portion of the article are con-stituted of the same polymer type, and both portions have sub-stantially similar planar crystalline orientation.
A fusible binding strap which embodies the present invention likewise is formed as a ribbon of an oriented crystal~
line synthetic thermoplastic polymer having a thickness greater than about 10 mils. The binding strap has a substantially rec-tangular and uniform cross-section which is defined by a pair of opposed major faces and a pair of opposed minor faces or sides.
The binding strap comprises a base layer of the polymer having a relativaly lower average molecular weight and a generally planar surface layer contiguous with the base layer, de~ining at least one major face of the strap, which is made up of a `
polymer of the same general type but having a relatively higher average molecular weight than the polymer in the base layer.
The axial crystalline orientation aIong the longitudinal dimen-sion of the strap is substantially similar throughout the strap cross-section.
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For the purposes of the present invention, suitable crystalline synthetic thermoplastic polymers are polyamides, polyesters, polyolefins, and the like. Preferred polymers for strapping are polyethylene terephthalate, polypropylene, poly-hexamethylene adipamide (Nylon 66), and polycaprolactam (Nylon 6).
Brief Description of the Drawing In the drawing, FIGURE 1 is a perspective view of a binding strap seg-ment embodying the present invention;
FIGURE 2 is a schematic representation of an extrusion assemhly suitable for fabricating the strap illustrated in FIGURE
1 and showing an enlarged portion of the extruded strap;
FIGURE 3 is a perspective view of another binding strap segment made in accordance with this invention;
FIGURE 4 is a schematic representation of an extrusion assembly suitable for fabricating the strap illustrated in FIGrJ~, 3 and showing an enlarged portion of the extruded strap; and FIGURES 5A and 5B are sectional elevations of fused strap joints formed utilizing a composite strap of the present ,, .
invention.
Description of Preferred Embodiments - When sheetform thermoplastic polymer articles are joined to one another, overlapping face portions of the articles are fused together to define a joint. In the case of thermoplastic polymer binding strap, a strap segment forms a loop which encir-cles a package to be bound, and the end portions of the strap segment are overlapped and fused together at an interface region therebetween. As a result, a closure joint unitary with the '~ strap is produced having a relatively thin central or interface region or layer of fused, i.e., merged and resolidified, strap surface portions. The average overall thickness of the prod~ced central fused region generally is about 0.001 inch (0O025 mm) to about 0.004 inch (0.1 mm) using friction fusion techniques. The thickness of the fused region is somewhat greater if a hot knife technique is used.
It has now been discovered that the tensile stxength of the formed joint (joint strength) can be substantially in-creased, and in an economically advantageous manner, by intro-ducing into the central fused region, as a unitary part of the sheetform article, a polymer having a relatively higher average molecular weight while surrounding or adjacent unfused strap regions comprise a polymer having a relatively lower average molecular weight. This condition can be readily accomplished by providing the article, e.g., binding strap, on at least one face thereof, with a unitary facing layer of a polymer having a relatively higher average molecular weight than that of the polymer which constitutes the major portion of the article itself. In this manner the strap, or any other sheetform arti-cle that has to be joined by means of a fused joint, e.g., using 20 friction fusion, hot knife, or similar techniques, can be fabri- ;
cated primarily of a relatively lower cost, relatively lower molecular weight polymeric material and still provide improved joint strength by virtue of the presence of a relatively higher molecular weight polymeric material which provides a relatively ~;
high-strength joint interface.
To produce sheetform articles embodying the present invention, any crystallizable thermoplastic polymer the crystals of which can be oriented by mechanical working can be used, in-cluding polymers that are amorphous as extruded but which can be converted to a crystalline form by mechanical working, e.g., drawing. Crystalline polymers, of course, are those which exhibit cxystallographic reflections when examined with X-rays in a known manner. The polymers may or may not contain plasticizers that enhance the processability thereof into sheetform articles.
However, the thermoplastic polymers that constitute the sheet-form article embodying the present invention should have substan-tially the same crystallizability, i.e., nature and degree o~
crystallinity that is achieved upon mechanical working after extrusion should be substantially the same in the major and the minor thickness portions of the produced article. Thus, it is preferred that the composition of the extruded polymer mass forming the major and minoX thickness portions of the sheet-~orm article be substantially the same except that the molecular weight of the thermoplastic polymer itself is different in these portions as stated hereinabove.
Some thermoplastic polymers, such as polyesters, if solidified in a crystalline state immediately after extrusion, tend to be brittle and are more difficult to orient by subsequent mechanical working. Accordingly, in such instances it is preferable to select the extrusion conditions so that the extruded composite sheetform article initially solidifies in a substantially ; amorphous state from which it is then subsequently converted to a crystalline state and oriented during mechanical working~
Illustrative of the types of crystalline or crystal-lizable thermoplas~ic polymers that can be used in the practice of this invention are the polyesters such as polyethylene tere-phthalate, copolyesters of terephthalic acid and isophthalic acid with cyclohexanedimethanol, and the like, the polyolefins such as polyethylene, polypropylene, and the like, and the poly-amides such as polycaprolactam, polyhexamethylene adipamide,polyhexamethylene sebacamide, and the like.
The difference in the average molecular weights between the major and the minor thickness portion (or portions) varies depending on the type of polymer that is used and also on the in-crease in the joint strength that is desirea. Preferably, the average molecular weight of the polymer in the fusible minor thickness portion exceeds the average molecularweight in the core portion by at least about 20 percent, and more preferably by at least about 50 percent.
Inasmuch as commercially available polymer supplies are polydisperse, i.e., the polymer is present in a range of molecu-lar weights, the selection of the polymer for practicing the pre-sent invention is based on the average molecular weight for that ; polymer. The term "average molecular weight" as used herein re-fers to the weight average molecular weight of the crystallizable polymer in the supply used for practicing the present invention ~; ;
and can be determined according to various techniques known in the art, e.g., light scattering, ultracentrifugation, and the like. It is not necessary to make an absolute determination, rather reliance can be had on other well known expedients such as a determination of intrinsic viscosity, relative viscosity, or melt index of the polymer.
The intrinsic viscosity of a polymer is directly re-lated to the molecular weight of the polymer and is usually obtained from experimentally determined specific relative vis-cosity values for a polymer solution ~flow time of the polymer solution through a capillary viscometer divided by the flow time of the solvent) at several concentrations of the polymer.
The obtained values are plotted and the resulting curve is extrapolated to infinite dilution ~ero concentration) to obtain the value for the intrinsic viscosity. Inasmuch as the slopes of the viscosity-concentration curve for the commercially avail-able extrudable polymers in the usual solvents therefor are . .. .
known in the art, it is possible to ascertain ~he intrinsic vis-cosity of a polymer from a single value of relative viscosity.
Accordingly, it is the customary practice to measure only a single value of relative viscosity and from the measured value to ascertain the intrinsic viscosity by referring ~o the stan-dard plots thereof.
The melt index of a thermoplastic polymer is also related ~o its molecular weight and viscosity and is an indi-cation of the amount of the thermoplastic polymer that can be forced through a given orifice at a specific temperature and in a given time period using a constant force of known value.
The melt indices reported herein are determined according to ASTM Standard D1238-73 at 230C. and using a 2160-gram force.
In the case of polyesters, e.g., polyethylene tere-phthalate, for manufacturing composite binding strap embodying the present invention the intrinsic viscosity of the polyester forming the fusible, minor thickness portion of the strap pre-ferably is greater than about 0.7 and exceeds the intrinsic viscosity of the polymer forming the core portion of the strap .
preferably by at least about 20 percent, and more preferably by at least about 50 percent.
Binder strap or a similar sheetform article of manu-facture providing the foregoing advantages is illustrated in FIGURE 1. Binder strap segment 10 comprises major thickness portion 11 which is made up of a crystallizable thermoplastic polymer, e.g., polyethylene terephthalate, having a relatively lower molecular weight and a unitary minor thickness portion 12 wh1ch is made up of the same polymer but having a relativel~
higher molecular weight. Portions 11 and 12 are of substan-tially the s~me composition but for the molecular weight ofthe polymer. Minor thickness portion 12 provides a generally planar surface layer contiguous with and intimately bonded to _g_ ~ f~
major thickness portion 11, which forms the base layer of the strap, and defines a fusible face. Minor thickness portion 12 should be at least about one mil (0~001 inch; 0.025 mm) thick, and usually comprises about 1 up to about 25 percent of the ;
strap thickness, preferably about 3 to about 20 percent of the strap thickness.
Binder strap of the type illustrated in FIGURE 1 can be fabricated using the coextrusion assembly schema~ically depicted in FIGURE 2. Extrusion assembly 15 includes die 16, single-side feed block 17 and extruder adapter 18. The poly-meric material which ultimately forms major thickness portion 11 of the extruded strap is fed to die 16 from a first extruder ~not shown) via feed conduit 19, and the polymeric material which ultimately forms minor chickness portion 12 is fed to die 16 from a second extruder (not shown) via feed conduit 20.
The3e two melt layers o~ the same polymer but of different aver-age molecular weight merge within die cavity 21 and exit from the die orifice, without commingling, as a single melt stream constituted by distinct melt layers. The melt stream is then solidified, intimately bonding the coextruded layers to one another. Preferably the polymer in each thickness portion is ; maintained in an amorphous state upon solidification. There-ater the produced laminar sheet of predetermined configuration can be hot drawn or otherwise worked to impart the desired crystallinity, crystalline orientation, and physical charac- ~- ?
teristics to the finally produced product.
To produce binder strap of the type illustrated in FIGURE 3, i.e., having base layer or core 22 flanked on each side by generally planar, contiguous surface or facing layers 30 23 and 24, an extrusion assembly 25 shown in ~IGURE 4 can be ;
utilized. More specifically, die 26 is provided with double-sided feed block 27 and extruder adapter 28 which together form a ~nitary assembly. Feed conduit 29 is defined by apertures in :
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adapter 28, feed block 27 and die 26, and serves to convey to die cavity 31 the molten polymeric material which, upon extrusion and solidification, forms the aforesaid base layer or core 22 of the extruded strap segment. Feed conduits 30 and 32 are provided in feed block 27 or supplying the relatively higher molecular weight polymeric material which ultimately forms surface layers 23 and 24. Streams of molten, relatively higher molecular weight polymeric material exiting into die cavity 31 from feed conduits 30 and 32 merge without commingling, with the molten polymeric material exiting from feed conduit 29 so as to produce a single, three-layer melt stream which is extruded from die cavity 31 and solidified. The coextruded, multi-layer ribbon of polymeric material can be hot-drawn, rolled, or otherwise worked to impart thereto the desired degree of crystallinity and crystalline orientation.
For binding strap having the polymer of relative~y higher molecular weight on both major faces thereof, the thick-ness of the facing layers can be relatively small because when the strap portions to be sealed are overlapped, the total thick-ness of the desired polymer of relatively higher molecular weightthat is available for fusion is doubled.
Plso, binding strap can be coextruded as a ribbon which is reduced to the desired thickness and width dimensions of the ultimate strap product upon mechanical working; however, it is usually more expeditious to coextrude a sheet of substantial width that is mechanically worked to achieve the desired thick-ness and subsequently cut to produce binding strap having the desired width.
A weld or joint produced in a loop formed ~y thermo-plastic strap similar to the strap produced in FIGURE 4 isshown in FIGURES 5A and 5B. The strap is provided on both faces thereof with respective minor thickness portions 23 and 24 of a polymer having a molecular weight at least about20 percent higher than the molecular weight of the polymer which constitutes major thickness portion 22. The strap loop is formed so that for over-lapping strap ends 34 and 35 the minor thickness portions 23 and 24 are contiguous with one another. Vpon joining o~ strap ends 34 and 35 by insertion of a hot sealing blade between the con-tiguous minor thickness portions 23 and 24, or by rubbing the thickness portions against one another as in friction fusion joint-forming techniques, the contiguous regions thereof in the joint area are softened or molten and, upon cooling while under pressure, fuse together to form c~ntral, fused interfacial region 36 which is primarily, and in some cases exclusively, constituted by the polymer of relatively higher molecular weight and which region is substantially surrounded by the polymer of relatively lower molecular weight in unfused major thickness portions 22.
In FIGURE 5A the inLG-facial region includes also some of the po-ymer of relatively lower molecular weight and in FIGURE 5B
the interfacial region is made up only of the polymer having rela-tively higher molecular weight. The thickness of the central fused region can be about 1 to about 20 percent of the thickness of the overlapping strap ends 34 and 35.
For optimum joint strength it is desirable that the binder strap welding conditions, as well as the thicknesses of the contiguous minor thickness portions are selected so that the central fused region is maintained solely within the minor thickness portions.
During joint formation r the original crystalline orientation of the polymers present in what ultima~ely becomes the central fused region of the joint is modified or obviated, thus the crystalline orientation of thecentral fused region is '. ' usually different than the crystalline orientation of the strap portions adjacent thereto.
The present invention i5 further illustrated by the following examples. -ExAMæLE I: Composite Polyethylene Terephthalate Strap One half-inch wide and 0.020 inch thick polyethylene terephthalate strap is produced by coextrusion and subsequent crystallization and orientation of polyethylene terephthalate having intrinsic viscosity of about 0.6 with the same polymer having intrinsic viscosity of about l.1. Coextrusion is carried out so that the polymer ha~ing the relatively higher intrinsic viscosity forms a surface layer about 0.0015 inch thick on one major face of the extruded strap. A11 layers of the extruded strap are crystalline and have substantially similar planar cry-stalline orientation.
Segments of the pl-~d~ced strap are joined utilizing conventional hot knife techniques to produce joint strengths in excess of about 80 percent of strap strength. Consistently high joint strengths are obtained by fusing the layer of rela-tively higher intrinsic viscosity, i.e., molecular weight, tothe layer of relatively lower intrinsic viscosity, i.e., molecular weight, as well as by fusing together both layers of relatively higher intrinsic viscosit~.
EXAMPLE II: Composite Polyethylene Terephthalate Strap Polyethylene terephthalate having an intrinsic viscos-ity of about 0.8 is coextruded with polyethylene terephthalate having an intrinsic viscosity of about 1.2 to produce, after drawing, strap about 5/8-inch wide and about 0.020 inch thick and so that the polyethylene terephthalate having the relatively higher intrinsic viscosity forms a surface layer about 0.001 inch thick on one major face of the extruded strap. After coex-trusion, the extruded article is crystallized and oriented to provide substantially similar planar crystalline orientation in Rll layers thereof.
Segments of the produced strap are formed into loops, ~
and the ends thereof are overlapped and joined by friction fusion.
Joint strengths in excess of about 85 percent of strap strength are obtained.
EXAMPLE III: Composite Polypropylene Bindin~LStrap Oriented polypropylene binding strap having a thickness of about 0.030 inch is produced by coextrusion and subsequent drawing of polypropylene having an average melt index of about 0.2 and polypropylene having an average melt index of about 6 into a sheetform article that is subsequently cut into ribbons about one half-inch wide and suitable as binding strap. Coextru-sion is effected so that the polypropylene having the relatively ~oweX melt index forms a surface layer about 0.003 inch thick on each side of the sheetform article produced after drawing.
All la~ers of the produced strap are crystalline and have substan-~ially similar planar crystalline orientation.
EXAMPLE IV: Composite Polyethylene Terephthalate Binding Strap Polyethylene terephthalate having intrinsic viscosities of about 0.6 and about 1 is coextruded and subsequently crystal-lized and oriented by drawing under tension so as to produce one half-inch wide strap having a thickness of about 0.020 inch, and having minor thickness portion which is a layer of the polymer having intrinsic viscosity of about 1 on each major face of the strap. Each of the minor thickness portions in the produced strap is about 0.092 inch thick, and all strap portions have 30 substantially the same planar crystalline orientation. `~
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Control strap of substantially the same overall dimen-sions is produced in a similar manner and with similar planar crystalline orientation, but using only polyethylene terephthal-ate having an intrinsic viscosity of about 0.6.
Strap segments of each type of produced strap are superposed so that a face of one segment is contiguous with a face of the other segment, and are then welded together using a torsion bar type laboratory friction fusion welder at a welding time of about 0.004 second and welding pressure of about 10,000 1~ to about 13,000 pounds per square inch (p.s.i.). The produced welds are contained within the layers of the relatively higher intrinsic viscosity material.
Upon testing for joint strength, the fol'~owing is observed:
Control Strap Composite Strap joint strength, % 55 80 EXAMPLE V: Composite Nylon Binding Strap Polyhexamethylene adipamide (Nylon 66) binding strap having a thickness of about 0.020 inch is produced by coextrusion and subsequent crystallization and orientation of Nylon 66 having a relative viscosity of about 225 and Nylon 66 having a relative viscosity of about 50. The coexlrusion is performed so that a surface layer about 0.004 inch thick and constituted by the Nylon 66 of the relatively higher relative viscosity is provided on each major face of the produced strap. All layers of the pro-duced strap are crystalline and have substantially similar planar crystalline orientation.
Segments of the produced strap are formed into loops and joined by ~riction fusion so as to produce a weld within contiguous layers of the Nylon 66 having the relatively higher relative viscosity. The welds, when tested for joint strength exhibit a joint strength of about 60 percent of strap strength.
This compares favorably with a joint strength of only about 40~ that is attained under same conditions using Nylon 66 strap having a relative viscosity of about 50.
EXAMPLE VI: Composite Polyethylene Terephthalate Binding Strap In a manner similar to Example IV, oriented crystalline binder strap is produced with each face of the strap defined by a 0.0036 inch thick layer of the polyethylene terephthalate hav-ing the relatively higher intrinsic viscosity.
Control strap having substantially the same overall dimensions and crystalline orientation is produced from poly-ethylene terephthalate having the relatively lower intrinsic viscosity (i.e., I.V. = 0.6).
Upon testing for joint strength, welds produced in the same manner and on the same equipment as in Example IV, the fol-lowing is observed.
Control Strap Composite Strap joint strength, % 57 92 The foregoing specification is intended as illustrative and is not to be taken as limiting. Other variations within the spirit and scope of this invention are possible and will readily present themselves to one skilled in the art.
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Back~r_und of the Invention This invention relates to fusible sheetform articles, particularly to fusible plastic binding strap that can be joined by friction fusion, hot knife techniques, or the like manner.
Plastic strap is a convenient and relatively inexpen-; sive strapping material ~hat has been used ~or a wide variety of ~ tying and packaying operations. For many applications plastic ; strap is uniquely suited by virtue of the inherent elasticity thereof, e.g., or tying packages subject to dimensional change, ~ -or to handling situations whereby shock conditions may be imposed upon the strap loop that surrounds the package. Tying usually is accomplished by forming a strap loop about the package, shrinking or reducing the formed loop to a snug fit a~out the pack~ye, and thereafter joining o~erlapping ends of the strap loop by means of a wrap-around seal or a fused joint.
Wrap-around seals for plastic strap are generally formed in a manner analogous to steel strap, e.g~ by crimping a deform-able metal band around overlapping strap ends so as to form a mechanical interlock. Such wrap-around seals are not completely effective, however, because plastic strap has inhexen~ly low shear strength which xestricts the crimping and interlocking techniques normally utilized with wrap-around seals.
As an a}ternate strap sealing approach, strap joints have been formed by melting and fusing overlapping portions of thermoplastic strap so as to form a joint. For this purpose heated pressure jaws, high frequency dielectric heating means, ~
ultrasonic welders, and friction fusion devices have been used. ~;
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None of the foregoing joint-forming means are capable of produc-ing routinely and consistently, and in an economic manner, a seal that exhibits a joint strength that is greater than about 40 to 50 percent of the plastic strap tensile strength. It is very desirable, however, to have joint strengths that approach the tensile strength of the strap much more closely.
Summary of the Invention ; It has now been found that the usibility of plastic sheetform articles, such as binding strap and the like, can be improved by forming the articles from a crystalline synthetic thermoplastic polymer as a laminar composite in which the lamina or layers are constituted of the same polymer, i.eO, having the same repeating unit or units in the structural chain, but of a different average molecular weight. In the laminar composite, the polymer on at least one fusible face of the produced article has a relatively higher average molecular we~ght than the same polymer in the body of the article so that the ultimately formed joint is in a fused region which contains the relatively higher average molecular weight polymer. Stated in another way, the intrinsic viscosity and relative viscosity of the polymer consti-tuting the fusible face, or faces, is higher than the intrinsic viscosity and relative viscosity of the polymer in the body of the article. If melt index is used as the primary measurement of the molecular weight, then the melt index of the polymer con-stituting the fusible face is lower than the melt index of the polymer in the body of the article.
Accordingly, the present invention contemplates a sheetform, crystalline synthetic ~hermoplastic polymer article of substantially uniform cross-section and comprising a laminar - -composite which has a major thickness portion made up of the .. . . . . . . . . ~ .. ...... .. . ., .. .. ... . . . . , ., ., .. _ . . . . . .......... . ..
.. . .
polymer having a relatively lower average molecular weight and at least one minor thic~ness portion which is made up of the same polymer but having a relatively higher average molecular weight. Each minor thickness portion o~ the article has a thickness that is less than the thickness of the major thick-ness portion; however, the sum of the thicknesses of the indi-vidual minor thickness portions on opposite sides of the sheetform article may be greater than the thickness of the major thickness portion. The terms "sheetform" and "sheet"
as used herein and in the appended claims designate an article of manufacture having a thickness greater than about 10 mils.
The minor thickness portion of the sheetform article defines a fusible face of the article. Both the major thickness portion and the minor thickness portion of the article are con-stituted of the same polymer type, and both portions have sub-stantially similar planar crystalline orientation.
A fusible binding strap which embodies the present invention likewise is formed as a ribbon of an oriented crystal~
line synthetic thermoplastic polymer having a thickness greater than about 10 mils. The binding strap has a substantially rec-tangular and uniform cross-section which is defined by a pair of opposed major faces and a pair of opposed minor faces or sides.
The binding strap comprises a base layer of the polymer having a relativaly lower average molecular weight and a generally planar surface layer contiguous with the base layer, de~ining at least one major face of the strap, which is made up of a `
polymer of the same general type but having a relatively higher average molecular weight than the polymer in the base layer.
The axial crystalline orientation aIong the longitudinal dimen-sion of the strap is substantially similar throughout the strap cross-section.
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For the purposes of the present invention, suitable crystalline synthetic thermoplastic polymers are polyamides, polyesters, polyolefins, and the like. Preferred polymers for strapping are polyethylene terephthalate, polypropylene, poly-hexamethylene adipamide (Nylon 66), and polycaprolactam (Nylon 6).
Brief Description of the Drawing In the drawing, FIGURE 1 is a perspective view of a binding strap seg-ment embodying the present invention;
FIGURE 2 is a schematic representation of an extrusion assemhly suitable for fabricating the strap illustrated in FIGURE
1 and showing an enlarged portion of the extruded strap;
FIGURE 3 is a perspective view of another binding strap segment made in accordance with this invention;
FIGURE 4 is a schematic representation of an extrusion assembly suitable for fabricating the strap illustrated in FIGrJ~, 3 and showing an enlarged portion of the extruded strap; and FIGURES 5A and 5B are sectional elevations of fused strap joints formed utilizing a composite strap of the present ,, .
invention.
Description of Preferred Embodiments - When sheetform thermoplastic polymer articles are joined to one another, overlapping face portions of the articles are fused together to define a joint. In the case of thermoplastic polymer binding strap, a strap segment forms a loop which encir-cles a package to be bound, and the end portions of the strap segment are overlapped and fused together at an interface region therebetween. As a result, a closure joint unitary with the '~ strap is produced having a relatively thin central or interface region or layer of fused, i.e., merged and resolidified, strap surface portions. The average overall thickness of the prod~ced central fused region generally is about 0.001 inch (0O025 mm) to about 0.004 inch (0.1 mm) using friction fusion techniques. The thickness of the fused region is somewhat greater if a hot knife technique is used.
It has now been discovered that the tensile stxength of the formed joint (joint strength) can be substantially in-creased, and in an economically advantageous manner, by intro-ducing into the central fused region, as a unitary part of the sheetform article, a polymer having a relatively higher average molecular weight while surrounding or adjacent unfused strap regions comprise a polymer having a relatively lower average molecular weight. This condition can be readily accomplished by providing the article, e.g., binding strap, on at least one face thereof, with a unitary facing layer of a polymer having a relatively higher average molecular weight than that of the polymer which constitutes the major portion of the article itself. In this manner the strap, or any other sheetform arti-cle that has to be joined by means of a fused joint, e.g., using 20 friction fusion, hot knife, or similar techniques, can be fabri- ;
cated primarily of a relatively lower cost, relatively lower molecular weight polymeric material and still provide improved joint strength by virtue of the presence of a relatively higher molecular weight polymeric material which provides a relatively ~;
high-strength joint interface.
To produce sheetform articles embodying the present invention, any crystallizable thermoplastic polymer the crystals of which can be oriented by mechanical working can be used, in-cluding polymers that are amorphous as extruded but which can be converted to a crystalline form by mechanical working, e.g., drawing. Crystalline polymers, of course, are those which exhibit cxystallographic reflections when examined with X-rays in a known manner. The polymers may or may not contain plasticizers that enhance the processability thereof into sheetform articles.
However, the thermoplastic polymers that constitute the sheet-form article embodying the present invention should have substan-tially the same crystallizability, i.e., nature and degree o~
crystallinity that is achieved upon mechanical working after extrusion should be substantially the same in the major and the minor thickness portions of the produced article. Thus, it is preferred that the composition of the extruded polymer mass forming the major and minoX thickness portions of the sheet-~orm article be substantially the same except that the molecular weight of the thermoplastic polymer itself is different in these portions as stated hereinabove.
Some thermoplastic polymers, such as polyesters, if solidified in a crystalline state immediately after extrusion, tend to be brittle and are more difficult to orient by subsequent mechanical working. Accordingly, in such instances it is preferable to select the extrusion conditions so that the extruded composite sheetform article initially solidifies in a substantially ; amorphous state from which it is then subsequently converted to a crystalline state and oriented during mechanical working~
Illustrative of the types of crystalline or crystal-lizable thermoplas~ic polymers that can be used in the practice of this invention are the polyesters such as polyethylene tere-phthalate, copolyesters of terephthalic acid and isophthalic acid with cyclohexanedimethanol, and the like, the polyolefins such as polyethylene, polypropylene, and the like, and the poly-amides such as polycaprolactam, polyhexamethylene adipamide,polyhexamethylene sebacamide, and the like.
The difference in the average molecular weights between the major and the minor thickness portion (or portions) varies depending on the type of polymer that is used and also on the in-crease in the joint strength that is desirea. Preferably, the average molecular weight of the polymer in the fusible minor thickness portion exceeds the average molecularweight in the core portion by at least about 20 percent, and more preferably by at least about 50 percent.
Inasmuch as commercially available polymer supplies are polydisperse, i.e., the polymer is present in a range of molecu-lar weights, the selection of the polymer for practicing the pre-sent invention is based on the average molecular weight for that ; polymer. The term "average molecular weight" as used herein re-fers to the weight average molecular weight of the crystallizable polymer in the supply used for practicing the present invention ~; ;
and can be determined according to various techniques known in the art, e.g., light scattering, ultracentrifugation, and the like. It is not necessary to make an absolute determination, rather reliance can be had on other well known expedients such as a determination of intrinsic viscosity, relative viscosity, or melt index of the polymer.
The intrinsic viscosity of a polymer is directly re-lated to the molecular weight of the polymer and is usually obtained from experimentally determined specific relative vis-cosity values for a polymer solution ~flow time of the polymer solution through a capillary viscometer divided by the flow time of the solvent) at several concentrations of the polymer.
The obtained values are plotted and the resulting curve is extrapolated to infinite dilution ~ero concentration) to obtain the value for the intrinsic viscosity. Inasmuch as the slopes of the viscosity-concentration curve for the commercially avail-able extrudable polymers in the usual solvents therefor are . .. .
known in the art, it is possible to ascertain ~he intrinsic vis-cosity of a polymer from a single value of relative viscosity.
Accordingly, it is the customary practice to measure only a single value of relative viscosity and from the measured value to ascertain the intrinsic viscosity by referring ~o the stan-dard plots thereof.
The melt index of a thermoplastic polymer is also related ~o its molecular weight and viscosity and is an indi-cation of the amount of the thermoplastic polymer that can be forced through a given orifice at a specific temperature and in a given time period using a constant force of known value.
The melt indices reported herein are determined according to ASTM Standard D1238-73 at 230C. and using a 2160-gram force.
In the case of polyesters, e.g., polyethylene tere-phthalate, for manufacturing composite binding strap embodying the present invention the intrinsic viscosity of the polyester forming the fusible, minor thickness portion of the strap pre-ferably is greater than about 0.7 and exceeds the intrinsic viscosity of the polymer forming the core portion of the strap .
preferably by at least about 20 percent, and more preferably by at least about 50 percent.
Binder strap or a similar sheetform article of manu-facture providing the foregoing advantages is illustrated in FIGURE 1. Binder strap segment 10 comprises major thickness portion 11 which is made up of a crystallizable thermoplastic polymer, e.g., polyethylene terephthalate, having a relatively lower molecular weight and a unitary minor thickness portion 12 wh1ch is made up of the same polymer but having a relativel~
higher molecular weight. Portions 11 and 12 are of substan-tially the s~me composition but for the molecular weight ofthe polymer. Minor thickness portion 12 provides a generally planar surface layer contiguous with and intimately bonded to _g_ ~ f~
major thickness portion 11, which forms the base layer of the strap, and defines a fusible face. Minor thickness portion 12 should be at least about one mil (0~001 inch; 0.025 mm) thick, and usually comprises about 1 up to about 25 percent of the ;
strap thickness, preferably about 3 to about 20 percent of the strap thickness.
Binder strap of the type illustrated in FIGURE 1 can be fabricated using the coextrusion assembly schema~ically depicted in FIGURE 2. Extrusion assembly 15 includes die 16, single-side feed block 17 and extruder adapter 18. The poly-meric material which ultimately forms major thickness portion 11 of the extruded strap is fed to die 16 from a first extruder ~not shown) via feed conduit 19, and the polymeric material which ultimately forms minor chickness portion 12 is fed to die 16 from a second extruder (not shown) via feed conduit 20.
The3e two melt layers o~ the same polymer but of different aver-age molecular weight merge within die cavity 21 and exit from the die orifice, without commingling, as a single melt stream constituted by distinct melt layers. The melt stream is then solidified, intimately bonding the coextruded layers to one another. Preferably the polymer in each thickness portion is ; maintained in an amorphous state upon solidification. There-ater the produced laminar sheet of predetermined configuration can be hot drawn or otherwise worked to impart the desired crystallinity, crystalline orientation, and physical charac- ~- ?
teristics to the finally produced product.
To produce binder strap of the type illustrated in FIGURE 3, i.e., having base layer or core 22 flanked on each side by generally planar, contiguous surface or facing layers 30 23 and 24, an extrusion assembly 25 shown in ~IGURE 4 can be ;
utilized. More specifically, die 26 is provided with double-sided feed block 27 and extruder adapter 28 which together form a ~nitary assembly. Feed conduit 29 is defined by apertures in :
~i5~
adapter 28, feed block 27 and die 26, and serves to convey to die cavity 31 the molten polymeric material which, upon extrusion and solidification, forms the aforesaid base layer or core 22 of the extruded strap segment. Feed conduits 30 and 32 are provided in feed block 27 or supplying the relatively higher molecular weight polymeric material which ultimately forms surface layers 23 and 24. Streams of molten, relatively higher molecular weight polymeric material exiting into die cavity 31 from feed conduits 30 and 32 merge without commingling, with the molten polymeric material exiting from feed conduit 29 so as to produce a single, three-layer melt stream which is extruded from die cavity 31 and solidified. The coextruded, multi-layer ribbon of polymeric material can be hot-drawn, rolled, or otherwise worked to impart thereto the desired degree of crystallinity and crystalline orientation.
For binding strap having the polymer of relative~y higher molecular weight on both major faces thereof, the thick-ness of the facing layers can be relatively small because when the strap portions to be sealed are overlapped, the total thick-ness of the desired polymer of relatively higher molecular weightthat is available for fusion is doubled.
Plso, binding strap can be coextruded as a ribbon which is reduced to the desired thickness and width dimensions of the ultimate strap product upon mechanical working; however, it is usually more expeditious to coextrude a sheet of substantial width that is mechanically worked to achieve the desired thick-ness and subsequently cut to produce binding strap having the desired width.
A weld or joint produced in a loop formed ~y thermo-plastic strap similar to the strap produced in FIGURE 4 isshown in FIGURES 5A and 5B. The strap is provided on both faces thereof with respective minor thickness portions 23 and 24 of a polymer having a molecular weight at least about20 percent higher than the molecular weight of the polymer which constitutes major thickness portion 22. The strap loop is formed so that for over-lapping strap ends 34 and 35 the minor thickness portions 23 and 24 are contiguous with one another. Vpon joining o~ strap ends 34 and 35 by insertion of a hot sealing blade between the con-tiguous minor thickness portions 23 and 24, or by rubbing the thickness portions against one another as in friction fusion joint-forming techniques, the contiguous regions thereof in the joint area are softened or molten and, upon cooling while under pressure, fuse together to form c~ntral, fused interfacial region 36 which is primarily, and in some cases exclusively, constituted by the polymer of relatively higher molecular weight and which region is substantially surrounded by the polymer of relatively lower molecular weight in unfused major thickness portions 22.
In FIGURE 5A the inLG-facial region includes also some of the po-ymer of relatively lower molecular weight and in FIGURE 5B
the interfacial region is made up only of the polymer having rela-tively higher molecular weight. The thickness of the central fused region can be about 1 to about 20 percent of the thickness of the overlapping strap ends 34 and 35.
For optimum joint strength it is desirable that the binder strap welding conditions, as well as the thicknesses of the contiguous minor thickness portions are selected so that the central fused region is maintained solely within the minor thickness portions.
During joint formation r the original crystalline orientation of the polymers present in what ultima~ely becomes the central fused region of the joint is modified or obviated, thus the crystalline orientation of thecentral fused region is '. ' usually different than the crystalline orientation of the strap portions adjacent thereto.
The present invention i5 further illustrated by the following examples. -ExAMæLE I: Composite Polyethylene Terephthalate Strap One half-inch wide and 0.020 inch thick polyethylene terephthalate strap is produced by coextrusion and subsequent crystallization and orientation of polyethylene terephthalate having intrinsic viscosity of about 0.6 with the same polymer having intrinsic viscosity of about l.1. Coextrusion is carried out so that the polymer ha~ing the relatively higher intrinsic viscosity forms a surface layer about 0.0015 inch thick on one major face of the extruded strap. A11 layers of the extruded strap are crystalline and have substantially similar planar cry-stalline orientation.
Segments of the pl-~d~ced strap are joined utilizing conventional hot knife techniques to produce joint strengths in excess of about 80 percent of strap strength. Consistently high joint strengths are obtained by fusing the layer of rela-tively higher intrinsic viscosity, i.e., molecular weight, tothe layer of relatively lower intrinsic viscosity, i.e., molecular weight, as well as by fusing together both layers of relatively higher intrinsic viscosit~.
EXAMPLE II: Composite Polyethylene Terephthalate Strap Polyethylene terephthalate having an intrinsic viscos-ity of about 0.8 is coextruded with polyethylene terephthalate having an intrinsic viscosity of about 1.2 to produce, after drawing, strap about 5/8-inch wide and about 0.020 inch thick and so that the polyethylene terephthalate having the relatively higher intrinsic viscosity forms a surface layer about 0.001 inch thick on one major face of the extruded strap. After coex-trusion, the extruded article is crystallized and oriented to provide substantially similar planar crystalline orientation in Rll layers thereof.
Segments of the produced strap are formed into loops, ~
and the ends thereof are overlapped and joined by friction fusion.
Joint strengths in excess of about 85 percent of strap strength are obtained.
EXAMPLE III: Composite Polypropylene Bindin~LStrap Oriented polypropylene binding strap having a thickness of about 0.030 inch is produced by coextrusion and subsequent drawing of polypropylene having an average melt index of about 0.2 and polypropylene having an average melt index of about 6 into a sheetform article that is subsequently cut into ribbons about one half-inch wide and suitable as binding strap. Coextru-sion is effected so that the polypropylene having the relatively ~oweX melt index forms a surface layer about 0.003 inch thick on each side of the sheetform article produced after drawing.
All la~ers of the produced strap are crystalline and have substan-~ially similar planar crystalline orientation.
EXAMPLE IV: Composite Polyethylene Terephthalate Binding Strap Polyethylene terephthalate having intrinsic viscosities of about 0.6 and about 1 is coextruded and subsequently crystal-lized and oriented by drawing under tension so as to produce one half-inch wide strap having a thickness of about 0.020 inch, and having minor thickness portion which is a layer of the polymer having intrinsic viscosity of about 1 on each major face of the strap. Each of the minor thickness portions in the produced strap is about 0.092 inch thick, and all strap portions have 30 substantially the same planar crystalline orientation. `~
~14~
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S
Control strap of substantially the same overall dimen-sions is produced in a similar manner and with similar planar crystalline orientation, but using only polyethylene terephthal-ate having an intrinsic viscosity of about 0.6.
Strap segments of each type of produced strap are superposed so that a face of one segment is contiguous with a face of the other segment, and are then welded together using a torsion bar type laboratory friction fusion welder at a welding time of about 0.004 second and welding pressure of about 10,000 1~ to about 13,000 pounds per square inch (p.s.i.). The produced welds are contained within the layers of the relatively higher intrinsic viscosity material.
Upon testing for joint strength, the fol'~owing is observed:
Control Strap Composite Strap joint strength, % 55 80 EXAMPLE V: Composite Nylon Binding Strap Polyhexamethylene adipamide (Nylon 66) binding strap having a thickness of about 0.020 inch is produced by coextrusion and subsequent crystallization and orientation of Nylon 66 having a relative viscosity of about 225 and Nylon 66 having a relative viscosity of about 50. The coexlrusion is performed so that a surface layer about 0.004 inch thick and constituted by the Nylon 66 of the relatively higher relative viscosity is provided on each major face of the produced strap. All layers of the pro-duced strap are crystalline and have substantially similar planar crystalline orientation.
Segments of the produced strap are formed into loops and joined by ~riction fusion so as to produce a weld within contiguous layers of the Nylon 66 having the relatively higher relative viscosity. The welds, when tested for joint strength exhibit a joint strength of about 60 percent of strap strength.
This compares favorably with a joint strength of only about 40~ that is attained under same conditions using Nylon 66 strap having a relative viscosity of about 50.
EXAMPLE VI: Composite Polyethylene Terephthalate Binding Strap In a manner similar to Example IV, oriented crystalline binder strap is produced with each face of the strap defined by a 0.0036 inch thick layer of the polyethylene terephthalate hav-ing the relatively higher intrinsic viscosity.
Control strap having substantially the same overall dimensions and crystalline orientation is produced from poly-ethylene terephthalate having the relatively lower intrinsic viscosity (i.e., I.V. = 0.6).
Upon testing for joint strength, welds produced in the same manner and on the same equipment as in Example IV, the fol-lowing is observed.
Control Strap Composite Strap joint strength, % 57 92 The foregoing specification is intended as illustrative and is not to be taken as limiting. Other variations within the spirit and scope of this invention are possible and will readily present themselves to one skilled in the art.
': '~' .
`' . , .
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' ; ;'
Claims (27)
OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A sheetform, crystalline thermoplastic polymer article of substantially uniform cross section and having improved heat-weldability consisting essentially of a laminar composite in which a major thickness portion is constituted by said polymer having a predetermined average molecular weight and a minor thickness portion is constituted by the same polymer having a substantially higher average molecular weight than the polymer in said major thickness portion; said minor thickness portion being unitary with said major portion and defining a heat-weldable face of said article, said thickness portions having similar planar crystalline orientation and the average molecular weight of the polymer constituting said minor thickness portion being at least about 20 percent higher than the average molecular weight of the polymer constituting said major thickness portion.
2. The article in accordance with claim 1 wherein the average molecular weight of the polymer constituting said minor thickness portion is at least about 50 percent higher than the average molecular weight of the polymer constituting said major thickness portion.
3. The article in accordance with claim 1 wherein the polymer is a polyester.
4. The article in accordance with claim 3 wherein said polyester is polyethylene terephthalate.
5. The article in accordance with claim 1 wherein the polymer is a polyolefin.
6. The article in accordance with claim 5 wherein said polyolefin is polypropylene.
7. The article in accordance with claim 1 wherein the polymer is 2 polyamide.
8. The article in accordance with claim 7 wherein said polyamide is polyhexamethylene adipamide.
9. The article in accordance with claim 7 wherein the polyamide is a polycaprolactam.
10. The article in accordance with claim 1 wherein said minor thickness portion is at least about 1 mil thick.
11. Fusible binding strap of substantially rectangular and uniform cross section formed of layers of same oriented crystalline synthetic thermoplastic polymer which comprises a base layer comprising said polymer having a predetermined average molecular weight and a planar surface layer unitary and contiguous with said base layer; said strap having similar axial crystalline orientation along the longitudinal dimension of said strap throughout the cross section thereof; and the average molecular weight of the polymer constituting said planar surface layer being at least about 20 percent higher than the average molecular weight of the polymer constituting said base layer.
12. The fusible binding strap in accordance with claim 11 wherein said planar surface layer is present on each side of the base layer.
13. The fusible binding strap in accordance with claim 11 wherein the polymer is a polyester.
14. The fusible binding strap in accordance with claim 13 wherein said polyester is polyethylene terephthalate.
15. The fusible binding strap in accordance with claim 11 wherein the polymer is a polyolefin.
16. The fusible binding strap in accordance with claim 15 wherein said polyolefine is polypropylene.
17. The fusible binding strap in accordance with claim 12 wherein the polymer is a polyamide.
18. The fusible binding strap in accordance with claim 17 wherein said polyamide is polyhexamethylene adipamide.
19. The fusible binding strap in accordance with claim 17 wherein said polyamide is polycaprolactam.
20. The fusible binding strap in accordance with claim 11 wherein the polymer is a polyester and the average molecular weight of the polyester in said planar surface layer exceeds the average molecular weight of the polyester in the base layer by at least about 50 percent.
21. The fusible binding strap in accordance with claim 11 wherein the thickness of said planar surface layer is at least about 1 mil.
22. The fusible binding strap in accordance with claim 21 wherein the thickness of said planar surface layer is about 1 to about 25 percent of the thickness of said strap.
23. The fusible binding strap in accordance with claim 21 wherein the thickness of said planar surface layer is about 3 to about 20 percent of the thickness of said strap.
24. The fusible binding strap in accordance with claim 12 wherein each said planar surface layer is at least about 1 mil thick.
25. A binding strap segment constituted by layers of same oriented crystalline synthetic thermoplastic polymer but the average molecular weight of the polymer in a surface layer of the strap being at least about 20 percent higher than the average molecular weight of the polymer in a sub-surface layer of the strap; said segment having overlapping opposite end portions fused together so as to define a joint and said joint comprising a central fused region which contains said polymer of higher average molecular weight.
26. The binding strap segment of claim 25 wherein the thickness of said central fused region is about 1 to about 20 percent of the thickness of the overlapping end portions of said strap.
27. The binding strap segment of claim 25 wherein the polymer is oriented polyethylene terephthalate and said central fused region contains polyethylene terephthalate having an intrinsic viscosity of at least about 0.7.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US78819977A | 1977-04-18 | 1977-04-18 | |
| US788,199 | 1977-04-18 | ||
| US05/889,513 US4247591A (en) | 1978-03-27 | 1978-03-27 | Fusible composite binding strap |
| US889,513 | 1978-03-27 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1115014A true CA1115014A (en) | 1981-12-29 |
Family
ID=27120765
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA301,258A Expired CA1115014A (en) | 1977-04-18 | 1978-04-17 | Fusible composite binding strap |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1115014A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5288531A (en) * | 1991-08-09 | 1994-02-22 | The Dow Chemical Company | Pouch for packaging flowable materials |
-
1978
- 1978-04-17 CA CA301,258A patent/CA1115014A/en not_active Expired
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5288531A (en) * | 1991-08-09 | 1994-02-22 | The Dow Chemical Company | Pouch for packaging flowable materials |
| US5364486A (en) * | 1991-08-09 | 1994-11-15 | The Dow Chemical Company | Pouch for packaging flowable materials |
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