CN102481753B - 充气交叉层合体及其制造方法和设备 - Google Patents

充气交叉层合体及其制造方法和设备 Download PDF

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CN102481753B
CN102481753B CN201080037864.0A CN201080037864A CN102481753B CN 102481753 B CN102481753 B CN 102481753B CN 201080037864 A CN201080037864 A CN 201080037864A CN 102481753 B CN102481753 B CN 102481753B
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奥利-本特·拉斯马森
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Abstract

本发明涉及热塑性薄膜的交叉层合体，薄膜中的至少一个形成为凹槽结构，两个薄膜相互层合，从而形成包括气体的袋部。袋部容许气体在至少两个相邻凹槽之间流通，由此该产品具有改进的手感，并且由该层合体构成的袋子在装满粗颗粒物时具有良好的堆叠特性。凹槽节距一般而言不超过3mm，而袋部长度小于50mm。粘接方法包括薄膜之间的点粘接，其是借助于低压过程下，在薄膜上的凸起的冠部部分之间将薄膜利用另一薄膜上的熔态材料粘接在一起而达成，例如借助供应空气压力经由制造设备例如模具部分的调适而达成。

Description

充气交叉层合体及其制造方法和设备
技术领域
本发明的主要目的是提供具改进的物质触感的低规格(lowgauge)交叉层合体。
背景技术
Rasmussen的WO02/102592中公开了一种交叉层合体，其包括具有波浪形状的薄膜(A)以及具有平坦形状的薄膜(B)，Rasmussen的WO04/054793中公开了一种交叉层合体，其包括两个薄膜(A)和(B)，这两个薄膜都具波浪形状，两组波浪的方向相互交叉。在这两个公开中解释了交叉层合体的一般的技术、该波浪(凹槽)的目的以及获得该结构的方法与设备。该凹槽形状的一个目的是为了在弯曲时获得改进的刚度，另一目的在于赋予该交叉层合体改进的物质触感。进一步的目的是改进热密封特性。已经发现该凹槽形状改进了抗撕裂蔓延性。
随着对于节省原料的需求增加，降低凹槽状交叉层合体及相关结构的交叉层合体的每平方米的重量的需要也与日俱增，同时与平坦的交叉层合体的刚度与触感比较，仍能获得与弯曲有关的良好刚度以及明确地改进的物质触感。这些目标为本发明的目的，并且在本发明的第一个方面中借助层合薄膜之间气体(通常为大气)的适合包装实现这些目标。
由以上提及的WO02/102592的权利要求17和25中所了解的是，该凹槽每隔一段距离变平并且横过每个凹槽的整个宽度进行粘接，以形成一列窄的闭合的长形袋部。该包装气体(例如，大气)有助于为该层合体提供增加的物质触感以及在一个方向上增加的刚度。
本发明之前的试验中，发明人已再三地进行WO02/102592的实例中所说明的凹槽/交叉层合步骤，然而该交叉层合体的两个薄膜中的每一个具有更低规格，也就是对非凹槽形状而言为20gm-2。该结果是非常“宽松(sloppy)”的层合体。接着凹槽借助简单的加热至105℃的成对的密封棒每隔一段距离变平并且粘接，以将空气包装在每个凹槽中。这显著地增加“物质”的触感以及在一个方向上的刚度。
然而，这种空气的包装过程也证实会导致例如试图在该交叉层合体上完成快干印刷(flexographicprinting)效果不良的问题。此外，转为相互垂直(如同堆栈袋)的两片交叉层合体之间的摩擦测量就摩擦系数而言显示极低值。
发明内容
本发明的第一个方面背后的基本概念在于该气体(空气)不应包装在“一维的”袋部中，即仅仅包括一个凹槽的袋部，而应包装在包括多个凹槽的“二维的”袋部中，从而在每个袋部内具有用于气体从每个凹槽至相邻凹槽中的一个或两个凹槽的通道。
为尝试该方式，波浪状薄膜(A)与平坦薄膜(B)之间的粘接并未如已知步骤中那样形成为线粘接，而是点粘接，并且该气体的包装并未单独借助横向焊接线而完成，而是借助横向和纵向焊接线的结合。这样，在借助两个焊接线系统所形成的每个袋部内，气体能够在凹槽之间自由地移动。
因为将气体自发生压力不足的位置去除，所以极为显著地改进了印刷质量。当释放印刷压力时，该气体返回并重新成形该凹槽。另外发现改进了该产品的手感。此外，据信例如当内容物是由粗粒谷物组成时以该薄膜制成的袋子将显现较佳的堆叠特性。该效果与上述印刷的效果相似。
根据这些显著的结果，本发明的第一个方面是如权利要求1中所陈述，以及如权利要求23中所陈述的制造方法。
就此而论，特定袋部中气体的体积能够借助切割该袋部并测量其在水中的浮力而确定，该水中可任选地包括低水平的表面活性剂以将附着在产品表面的气泡减至最少，同时聚合物材料的对应体积是由袋部的重量除以聚合物材料的密度而确定。
在这种结构中，如权利要求4至6中进一步记载的，薄膜(A)可具有凹槽形状，另外可任选的是薄膜(B)可具有凹槽形状。然而，具有选择可能性的是，一个薄膜(A)具有杯状或槽状凸起，由此将该点粘接局部化到凸起的所有或一些的冠部部分或基底部分，如以下进一步地说明。在该层合体中可包括具有相似凸起的第三薄膜(C)。权利要求6至9和15中记载了这种可能性。借助“杯状或槽状凸起”指的是薄膜的两个表面突出至相同侧的位置。该位置在一个方向上可以是长形的。凸起的实例见于或参考WO9112125、US5205650的图1、2a、2b和3，以及WO2009090208中所示的微照片。
词语“凸起”也偶尔用来表示实质上比相邻薄膜材料为厚的点或线，从而突出到薄膜的两侧，但此并非为本说明书的意图。
由凸起薄膜及未凸起薄膜构成的交叉层合体能够经特性化为“蜂窝状(cellular)交叉层合体”。在上述说明中，薄膜(B)能够粘接至(A)上的凸起的冠部部分或基底部分。以上所提及的US5205650中的附图示出了在一侧上的凸起的基底部分与另一侧上的冠部部分之间清楚的区别，并容易地想象薄膜(B)层合至该凸起薄膜的一侧或另一侧。(这些附图示出了凸起，该凸起限定在薄膜的限制部分，但该专利的说明书教导该凸起可包括整个薄膜)。与这些附图相比，WO2009090208中的微照片示出了波浪式的凸起，在薄膜的两侧上具有冠部部分而凸起没有基底部分，并且容易想象薄膜(B)层合至凸起薄膜一侧或另一侧上的冠部部分。
层合至该凸起薄膜(A)的薄膜(B)在层合之前为平坦薄膜，但由于层合力以及接下来收缩的趋势，薄膜(B)在最终层合体中可能已经失去其平坦性。
应注意的是该低重量交叉层合体结构自身被视为具有创造性而与形成袋部以封装该气体无关，该交叉层合体结构包括具有杯状或槽状凸起的薄膜(A)，以及未凸起薄膜(B)，该未凸起薄膜已借助挤压涂覆而构成，从而恰好“轻触”薄膜(A)并构成点粘接。权利要求15中要求保护本发明的该第二个方面。本发明的第二个方面的目的在于提供低重量交叉层合体，其具有改进的刚度、物质触感以及织物状手感。权利要求24中要求保护一种制造该交叉层合体的方法。
为增加该层合体的抗撕裂蔓延性及剥离强度，薄膜可进一步借助弯曲或直的线性粘接剂粘接在一起，针对该目的不需构成气密袋部。
用以生产杯或槽状凸起的大部分过程，将使得这些凸起中的薄膜比周围薄膜薄。然而，在以下说明的结构中，凸起中大多数的薄膜部分比相邻的薄膜部分厚，这对于结构的稳定性而言是有利的。
如已论述的，本发明的两个方面的主要目的在于减少交叉层合体的平方米重量，同时仍能获得与粘接相关的良好刚度，特别是获得良好的物质触感。因此，权利要求1和15针对薄膜在该交叉层合体中所具有的形式的薄膜(A)和(B)中的每个薄膜的规格设定30gm-2的限制。然而，该规格有利地最高为20gm-2或甚至不超过15gm-2。
用于制造显现凹槽形状的交叉层合体的过程步骤，如权利要求4和5中所限定的交叉层合体，出现在上述提及公开案Rasmussen的WO02/102592及Rasmussen的WO04/54793中，但在本发明的第一个方面中，对于这些众所周知的步骤必须增加以下步骤：以直线或曲线(1)的图案进一步将薄膜密封在一起，其经结合以形成气体封装袋部，每个袋部周围具有借助已知步骤形成的至少5个点粘接部分。在任何方向上每个袋部的最长延伸部分最高为50mm，优选地最高为30mm并且优选地为至少6mm。
在WO2009090208中公开了一种凸起薄膜，基于以上陈述的理由其特别适于制造权利要求6至10和15中所述的产品。该申请在本申请的优先权专利申请提出申请时并未公开。该薄膜由热塑性聚合物材料形成，并且包括平行带状阵列、线性延伸区域(a)和与之区别的线性延伸织物(b)，该织物一体地连接所述区域。每个织物(b)都位于比该区域(a)的相邻部分薄的其线性延伸部分的相应位置处。
在该薄膜中，(a)和(b)被定向为在每个位置处具有支配性取向方向。该薄膜的特征在于在该区域(a)中该支配性取向方向与(a)延伸的方向形成大于零度但不大于80度的角度(v)，并且所述织物(b)包括为颈部收缩(necking-down)区域的线性沟(c)阵列，所述沟相对于(a)延伸的方向形成的角度(u)比(v)大。本发明中所使用的薄膜进一步的特征在于该区域为波浪状，每个波浪部分延伸跨过该区域的宽度并且织物比该区域(a)的相邻部分短，以强制(a)成波浪状。这种波浪状部分形成杯或槽状凸起部分。
制造该薄膜的方法是以具有支配性取向方向的薄膜开始。该薄膜借助一对相互啮合的第一沟槽滚轮加以伸展，伸展方向与薄膜中支配性原始的取向方向不同，但最高与其相差80度。该方法的特征在于该对沟槽滚轮中的至少一个的顶点的边缘足够尖锐以在薄膜材料的平行、线性延伸的织物(b)之间形成相异的区域，该织物在两个第一沟槽滚轮的顶点与介入的线性延伸带状区域(a)之间已被冷伸展，该带状区域已铺放在尖锐边缘的顶点上且未伸展或是已在所述沟槽滚轮之间伸展至较小程度。产生(a)的波浪状且由此产生凸起的这种收缩如无反作用就固有地产生。
在本发明的第一个方面中，用以包装空气的图案粘接线由两个阵列以其最简单的形式构成，每个阵列具有平行的直线，阵列相互十字交叉。这可以借助两对密封滚轮实现，一对滚轮接续另一对进行工作，并且每一对滚轮是由热轧钢滚轮靠着热硅树脂涂覆的滚轮所构成。钢质滚轮之一可设置有例如为0.5mm宽的圆形顶点的图案，另一个钢质滚轮设置有例如也为0.5mm宽的轴向齿部分。或者，它们都可以设置有螺旋状顶点的图案，其中一个为右旋而另一个为左旋。
在更为进步的形式中，此图案为蜂巢图案。这提供较佳的刚度，但需更为昂贵的密封滚轮。一个滚轮可为热轧钢滚轮，靠着热硅树脂涂覆滚轮进行工作。
这两个图案仅为袋部的形状的实例。应注意的是，形成用于封装空气的袋部的粘接线(4)的图案附加地具有的功能在于增加层合体的抗撕裂蔓延性以及剥离强度。
在形成袋部并封装气体(通常为空气)的密封过程期间，可将周围压力保持为稍高于正常的大气压力，以在最终层合体中获得适合的内部张力。
优选地通过一个或更多个共同挤压的层合层来构建薄膜(A)、(B)与可任择的(C)之间的每个粘接。
更合宜地，每个薄膜(A)和(B)的50％以上是由高密度聚乙烯(HDPE)、线性低密度聚乙烯(LLDPE)、结晶聚丙烯(PP)或以聚乙烯或是聚丙烯为基底的混合物或共聚合物构成。
尽管本发明的第一个和第二个方面主要地构想为用于水不能透过的包装薄膜，但是其也能够应用于可吸入薄膜，例如用于卫生目的。为此，可以具有聚集在个别区域中的穿孔，这些区域散布有空气封装袋部。
在常规的两个固态薄膜的挤压层合中或在挤压涂覆中(其中将直接挤压成形的薄膜层合至预先成形的固态薄膜上)，在滚轮之间进行层合，并施以较高的层合压力，否则可能会残留空气。然而，本发明的目标在于捕获大体积的空气，从而构成蜂窝型的产品。为达此目的，权利要求28限定的方法和权利要求29所述的设备及其从属权利要求是特别优选的。加压空气薄膜的配制，通常使用气流通过其被加压的模具中的多微孔壁，针对多个不同的目的通常用作“空气润滑”。在本发明中，其也用作用以建立可容易地调节且低的层合压力的设备，其中至少在一侧上是无接触的，并强化空气的捕获。就此而论，有利的但非所有状况下皆为必需的是，该固态薄膜在层合之前已经具有凸起。
如以上所说明，通常通过将空气加压通过由多微孔材料构成的模具壁来生产加压空气薄膜。这通常借助烧结方式形成。或者，该模具壁可设置有例如借助激光处理所形成的大量精细孔洞。在本发明中，该加压空气薄膜亦也可借助单个狭槽构成，该狭槽横过薄膜组件的整个宽度，例如借助激光处理或火花腐蚀所形成的0.1-0.2mm间隙。
可借助调节空气薄膜的间隔和/或调节气流而调节层合压力。
附图说明
在附图中图解说明本发明。
图1示出了均具有凹槽的两个定向薄膜(A)和(B)的交叉层合体。在每个薄膜中，主要的取向方向与其凹槽的延伸方向相一致。
图2示出了凸起薄膜(A)和大致平坦的薄膜(B)的交叉层合体，凸起薄膜(A)与加工方向成锐角进行定向，薄膜(B)通过挤压涂覆形成，通过挤压涂覆其已经形成沿加工方向的融合定向。在涂覆期间，两个薄膜已相互“轻触”以形成点粘接，使得超过50％的薄膜区域仍未粘接。
图3示出了该特别实施的挤压涂覆，涉及本发明的第二个方面。
具体实施方式
在图1中，线(1)示出了薄膜(A)上的凹槽的纵向延伸的外侧顶点的中间部分。
同样地，线(2)示出了薄膜(B)上的凹槽的横向延伸的外侧顶点的中间部分。点(3)示出了点粘接，其是建立在内侧顶点的两个阵列部分之间。该结构能够借助在Rasmussen的WO04/54796的实例中所说明的步骤而制成，除了薄膜(A)和(B)的规格必须较低之外。同一专利说明书的图1中示出了该结构的透视图。
新的特征是相互交叉的密封线(4)的两个阵列。优选地，该密封作用是构成为绝对的紧密密封以包装空气。
如上述实例中所述，在整个共同挤压的层合层上进行薄膜之间的粘接。
除了包装空气的主要功能外，这种图案的密封线也用以改进抗撕裂蔓延性。为此，该密封作用不需紧密，而“半包装”图案的直线或弯曲线将会是令人满意的。
图1示出了两个薄膜(A)和(B)中为1mm的波长，该包装为正方形，该正方形形成有10mm的边缘，并且线性密封的宽度为0.5mm。这些测量一般而言是便利的，但也能够有大的变化。
在图2中，这里点(3)示出为沿加工方向是长形的，再次图示了薄膜(A)和(B)之间的点粘接。在突出杯状或槽状凸起之间借助大体在图3中示出的挤压涂覆过程建立该粘接。偏斜地分子取向的凸起薄膜(A)优选地具有在WO2009090208中公开的于上述发明内容中简要地加以说明的结构，并且可以合宜地由HDPE构成。该涂层例如可由LLDPE、LDPE或低熔融乙烯共聚合物构成。
由于图式的简化，图2以极为规则的图案示出了该点粘接，但实际上其是更为随机化。
在图3中，具有偏斜取向的凸起薄膜(A)如箭头(5)所示被进给到涂覆设备中。其可取自于卷筒或可直接地来自于凸起站。融合薄膜(B)来自于平坦挤压模具(6)并借助抽拉(draw-down)例如自退出狭槽间隙0.25-0.5mm至5-20微米之间的最终厚度而成为沿加工方向定向的熔体。
该涂覆作业是在两个极为概略地示出的空气薄膜形成模具(7)和(8)之间进行。薄膜(A)于其上弯曲的模具(7)的边缘(9)为倒圆的，例如其半径约为1cm。这两个模具的面向两个薄膜的表面由多微孔材料构成以形成加压的空气薄膜，并且因而为倒圆的边缘(9)。由模具(7)所形成并在薄膜(A)上吹放的加压空气薄膜具有环境温度，而由模具(8)所形成并朝向薄膜(B)吹放的加压空气薄膜具有的温度实质上低于挤压模具(7)的出口温度，但足够高而足以产生粘接作用。
涂覆的薄膜为凸起薄膜(A)以及涂层的交叉层合体，该凸起薄膜是偏斜地取向，该涂层为沿着加工方向定向的熔体。其借助冷却滚轮(11)及橡胶滚轮(12)改变方向。这两个滚轮以相同的圆周速度被驱动。这两个滚轮彼此极为接近，但为避免毁坏凸起结构，它们没有互相压靠。
该交叉层合体(10)继续进行卷绕作业(未示出)。在该示出制程的整个过程中，将张力保持得足够低，以避免毁坏凸起部分。此作业所用的设备并未于图式中示出。
留有超过25％的薄膜面积未粘接的适合粘接是借助调节以下因素而产生的：1)薄膜(B)离开挤压模具处的温度；2)模具(7)及(8)的位置；3)借助模具(8)产生的空气薄膜的温度；以及4)两个空气流的空气速度。
该调节是使得两个薄膜仅相互“轻触”。
在滚轮(12)与缠绕作业之间可具有密封滚轮，以形成在图2中所示的线(4)。这些滚轮可包括热轧钢滚轮，其靠着热硅树脂涂覆滚轮进行工作。
实例1
在这个实例和以下两个实例中，该过程及设备基本上如参考图3所述。平坦挤压模具(6)被构造为用于两个部件的共同挤压。出口孔的间隙为0.5mm。在本实例中，8-0％的挤压薄膜由d＝0.95密度0.95gml-1的高分子量高密度聚乙烯(HMWHDPE)：以及20％的在约90℃熔融以及m.f.i.＝1.0的乙烯共聚合物(“Attane”)所组成。该较低熔融层设置在将面向固态薄膜的侧边上。挤压温度为270℃。滚轮(11)和(12)的挤压生产量和速度被调节以产生经计算为10微米的薄膜厚度。借助比例50比1的纵向抽拉，挤压薄膜达到牢固的熔体取向。
固态薄膜(A)为根据WO2009/090208中实例3构成的单个薄膜。强烈地以由每一侧边突出的凸起部分的顶点凸起。在不同的窄区域内其是双轴向不同地取向，但以接近45度的方向为主。尽管朝向模具(7)前进，供给周围环境温度的加压空气薄膜，但是借助从动的“香蕉滚轮(bananaroller)”而使产生褶皱的所有趋势消失。调节当与空气模具(7)接触时薄膜(A)中的张力为接近零，以维持最大的凸起程度。将其转动使其低熔融侧将面向挤压薄膜(B)。
吹送热空气遍及为热绝缘的空气模具(8)。空气退出此模具时的温度被调节至100℃。介于模具(7)与(8)之间的空间约为5mm，两个薄膜处于空气压力下的该区域的长度高于20mm。从挤压模具(6)的出口孔至两个空气模具(7)和(8)的距离也为约20mm。
用于两个模具(7)和(8)的空气取自于相同的贮气槽，其压力是可调节的，在这两个模具中气流通过多微孔壁的阻力实际上是相等的，因而两侧的进气实际上具有相同的压力。模具(8)所用的空气在与模具(8)接触的前被加热。
在模具(7)及(8)与第一转向滚轮(17)之间，将周围温度的空气吹送到层合薄膜组件(10)上。这未在图中示出。
借助试误法，将贮气槽中的压力调节至产生所需层合度的值，即所需的粘接面积的百分比。合宜地，这可为高于25-30％。借助显微镜样本进行确定。
实例2
此实例与实例1不同之处在于，挤压薄膜为一层薄膜，其由在实例1的挤压薄膜上形成层合层的共聚合物(Attane)构成。其它所有方面是依循实例1。
在这个程序中，挤压模具能够为单一挤压模具，并且这是简化的。当使用该单一挤压时，可以预期的是未掺杂的LLDPE或HDPE可适用，虽然熔点较高，但如此将使冷却状况的调节更为复杂。
实例3
在这个实例中，本发明用于以相互交叉的取向方向对两个固态薄膜进行挤压层合。这两个薄膜与实例1及2中所使用的固态薄膜(B)相同。如实例2中，挤压薄膜(B)为熔点约为90℃的(Attane)共聚合物，并且在该层合体中其厚度约为10微米。
挤压薄膜(B)施加在两个固态薄膜之间，因而图3中所示的线借助用以将附加固态薄膜进给覆盖空气模具(8)的设备而进行补偿，并且该空气模具具有位于模具(7)上的倒圆边缘(9)。
在这种情况下，处于周围温度的空气用于借助模具(7)及(8)形成的加压空气薄膜，并且施以经调节的冷却空气流至介于挤压模具(6)的出口孔与两个空气模具(7)及(8)之间的挤压薄膜。

Claims (5)

1.一种将固态薄膜与熔态直接挤压的平坦薄膜层合同时在两个薄膜之间引入气体空间的方法，其特征在于，层合压力以加压空气薄膜的形式形成在薄膜组件的一侧上，并且通过滚轮表面或通过加压空气薄膜形成在另一侧上。
2.一种用于挤压涂覆固态薄膜或挤压层合两个固态薄膜的设备，其包括用于薄膜的单一挤压或共同挤压的平坦模具，以及用于使固态薄膜和挤压薄膜以面对面关系形成为组件并且在挤压薄膜的至少每个表面处于熔融或半熔融状态的同时施加层合压力的构件，其特征在于，用于施加层合压力的构件在该组件的一侧上包括第一构件，以形成第一加压空气薄膜，并且在另一侧上包括滚轮表面或第二构件，以形成第二加压空气薄膜，进一步包括用于调节在该组件上施加的空气压力的构件。
3.根据权利要求2所述的设备，其特征在于，用于形成第一空气薄膜或第二空气薄膜或者第一空气薄膜和第二空气薄膜的模具包括多微孔模具壁。
4.根据权利要求2或3所述的设备，其特征在于，包括用于至少加热加压空气薄膜中的空气的装置，该装置与挤压薄膜直接地接触。
5.根据权利要求2-4中任一项所述的设备，其特征在于，包括用于在所述层合步骤之前使固态薄膜或者两个固态薄膜形成凸起的构件。
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