CN102498159A - 氧清除膜 - Google Patents
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Abstract
在聚合物基质中混合的充分分散的氧清除微粒。所述氧清除制剂由平均粒径在1-25μm内并且预涂有至少一种或多种活化和酸化粉末状化合物的铁粉组成,所述粉末状化合物通常为碱金属和碱土金属的固体有机盐和无机盐形式,比如氯化钠和硫酸氢钠。使用常规的熔体处理方法(比如双螺杆挤出)将预涂的铁微粒分散在聚合物树脂中。将所述氧清除化合物与聚合物粒料固态混合,然后熔融。所述聚合物树脂粒料和经涂布的铁粉优选在干燥状态下用表面活性剂处理,以帮助用树脂粒料分散铁/盐粉末。将熔体挤出的化合物造粒并保持在干燥状态下,以防止过早活化。
Description
发明背景
技术领域
本发明涉及可用于处理树脂粒料或经涂布的铁粉以使分散最大化的表面活性剂,所述表面活性剂包括润滑剂(比如矿物油)、脂肪酸(比如硬脂酸)和低分子量化合物(比如蜡)。
相关技术的描述
US 6,503,587 B2(属于Mitsubishi Gas Chemical Co.)描述了一种多层层叠物,氧清除颗粒(包括铁)夹在层之间。该方法可引起夹层粘合问题,这不可避免地影响包装的机械和消费者性质。
US 6,821,594 B2(属于Mitsubishi Gas Chemical Co.)描述了一种具有突出结构的氧吸收标记方法。
US 6,559,205 B2和7,056,565 B1(属于Chevron Phillips Co.)描述了用于多层容器的基于有机物的支化和侧链(pendant)环状烯烃氧清除剂。
US 7,494,605(属于Cryovac Corp.)描述了一种具有聚合氧清除剂的氧清除膜。
US 6,746,772 B2(属于Mitsubishi Gas Chemical Co.)描述了一种在膜中含有环氧-固化剂的多层膜,其可导致硬和脆的结构。
US 6,063,503(属于Mitsubishi Gas Chemical Co.)描述了具有层结构并且氧清除粒径不同于本发明的描述的氧吸收多层膜。
发明概述
在本发明中,发现了制备满足要求并且与现有技术不同的多层氧清除膜的方法。所述方法在聚合物基质中挤出细微氧清除颗粒(比如在美国专利6,899,822、美国专利申请2005/0205841和2007/020456中所描述的那些,均属于Multisorb Technologies Inc.,通过引用将它们整体结合到本文中)以形成多层膜。所述膜可形成为包装材料的一部分或用作标记或作为包装内的分隔物,或者作为盘的一部分或另一个刚性载体用于包装内的产品。所述膜可与包装材料一起直接挤出,或者通过后挤出处理步骤(比如层叠、胶合或胶带粘贴)与包装成为整体。本发明特别关注平均粒径为1-25um的基于铁的粉末,其中铁颗粒预涂有活化和氧化反应促进剂颗粒以形成均质粉末。与较大颗粒(透明度和反应性差)和较小纳米尺度颗粒(透明度差)相比,使用细微分散的这种氧清除颗粒生产的膜或片材有利地具有高透明度和高对氧反应性。
本发明的第一个目的是提供在聚合物基质中混合的充分分散的氧清除微粒。所述氧清除制剂由平均粒径在1-25um内并且预涂有至少一种或多种活化和酸化粉末状化合物的铁粉组成,所述活化和酸化粉末状化合物通常为碱金属和碱土金属的固体有机盐和无机盐形式,比如氯化钠和硫酸氢钠。使用常规的熔体处理方法(比如双螺杆挤出)将预涂的铁微粒在聚合物树脂中分散。将所述氧清除化合物与聚合物粒料固态混合,然后熔融。所述聚合物树脂粒料和经涂布的铁粉优选在干燥状态下用表面活性剂处理,以帮助用树脂粒料分散铁/盐粉末。将熔体挤出的化合物造粒并保持在干燥状态下,以防止过早活化。
本发明的第二个目的是使用与聚合物一起挤出的含铁化合物提供多层挤出的膜或片材。所述膜或片材由三层相同的基底树脂组成,层厚度比从5/90/5到25/50/25不同,并且中间(活化)层包含在树脂中分散的基于铁的氧清除剂。在处理期间或在处理之后,所述多层膜可未取向(未拉伸)、单轴或双轴拉伸。细微调节活化层厚度、在多层结构中的位置以及氧清除剂微粒在其中的分数,以提供期望的功能(比如氧吸收速率、活化阻挡保护的持续时间和暂时性阻挡改进或它们的组合)。
本发明的第三个目的是通过模具切割、袋制造、包制造、层叠、热成形或其它转化方法,由挤出的膜或片材提供产品形状的制品。所述制品可为粘合的或插入的标记形式或作为袋膜的一部分以满足产品要求。特别是,将所述氧清除膜层叠、胶带粘贴、粘合在袋的一个内表面上,或者简单地储存为袋中的插入物。任选将挤出的膜或片材进行图形装饰,使其与袋的图形设计相容。
本发明的第四个目的是提供含有在聚合物基质中混合的充分分散的氧清除剂的经印刷或经涂布的物品。所述物品可为将氧清除化合物印刷或涂布于其上的聚合物或金属基材。特别是,可将在聚合物基质中的基于铁的氧清除剂在聚合物膜上挤出涂布或溶液印刷,然后形成用于食品包装的袋、包或柔性外壳,特别地,经印刷或经涂布的图案是包装的图形设计的一部分。
附图简述
图1-FreschBlend尼龙膜的氧吸收性质。
发明详述
本发明涉及挤出氧清除聚合物膜的方法,所述氧清除聚合物膜含有细微分散的氧清除微粒。所述氧清除膜具有高透明度和可调节的氧吸收速率。本发明还涉及使用这种氧清除膜来构成塑料袋、包、柔性外壳和容器的方法,以通过吸收顶部空间氧和/或提供对氧渗透的活性阻挡,保持封装在包装中的食品和其它消费品的新鲜度。
柔性食品包装材料(比如在塑料袋中使用的)通常需要良好的氧阻挡性质,以防止微生物生长和保持食品的新鲜度。该需求可举例为,比如用于牛肉干、香肠、加工过的肉类等的包装。含有氧清除剂的小袋包装常用于食品袋,以吸收顶部空间氧和吸收通过包装壁进入的氧。在即用型食品包装中使用小袋已有数年了。然而,存在与使用小袋相关的潜在的缺点和限制。这包括以下:
(a)小袋有时被错误地看成是食品内含物的一部分而被消费者吃掉。
(b)当封闭或固定于食品袋或包装时,小袋有时被意外地割开,引起其内含物溢出并污染产品。
(c)小袋有时被看成是令人讨厌的东西,因为它们妨碍食品包装的美观和外观。
(d)小袋不能用于包装需要氧清除的液体产品。
根据本发明,发现如果在树脂中并入的氧清除颗粒的尺寸在1-25um内,最优选尺寸在2-5um内,则有利地改进聚合膜或片材基材的光学性质(比如接触透明度和可见光透过率)。这种颗粒足够小,使得人肉眼看不见,同时又足够大,使得尺寸与可见光波长(0.4-0.8um)可比的颗粒的光散射最小。结果是并入这种颗粒的塑料制品的雾度降低。
此外,发现包含用于有效氧化的所有必要组分的较小尺寸的复合氧清除颗粒(受在膜中产生显著的光散射和雾度的小粒径限制),产生对于渗透氧具有较高有效反应性的氧清除膜并且可较有效地设计阻挡结构。通过多层结构设计可进一步有利地改进阻挡膜反应性,其中氧清除层形成3层结构的中间层,该3层结构由相同的基质树脂制成。具体的最佳的层厚度比取决于整个膜厚度和活化的清除剂的氧化动力学。
可用于处理树脂粒料或经涂布的铁粉以使分散最大化的表面活性剂包括润滑剂(比如矿物油)、脂肪酸(比如硬脂酸)和低分子量化合物(比如蜡)。
优选缩小的铁粉的平均粒径为1-25um,更优选平均1-10um,最优选平均2-5um。根据美国专利6,899,822、美国专利申请2005/0205841和2007/020456的教导,选择在铁颗粒上涂布的活化和酸化组分的组合和相对分数,这些专利通过引用结合到本文中。涂布技术优选为在以上参考文献中所述的干涂布。
膜结构优选为3层或更多层,层比率在25/50/25和1/98/1范围,最佳比率取决于设计目标(比如顶部空间氧的吸收速率),一个实例比率为15/70/15。优选经涂布的铁位于三层的中间。
待用作袋的标记、层叠物或插入物的膜可由单层或多层结构组成,经涂布的铁在膜或所选的层中均匀分布。对于多层结构,经涂布的铁优选位于该结构的中间。它还可位于与外层相邻,以促进吸收。
为了在基材上印刷或涂布经涂布的铁制剂,可在一般的挤出涂布聚合物(比如LDPE、EVA、EAA、PP、PS、蜡、乳液等)中配制经涂布的铁。
以下实施例用于说明本发明的一些部分。
实施例1 含有FreshBlend氧清除剂的挤出的尼龙膜
如下制备氧清除剂包装:用硫酸氢钠和氯化钠涂布平均粒径4-5um的铁微粒,以形成均质涂布的复合粉末。使用该复合粉末(简写为“FreshBlend”氧清除剂)与尼龙6树脂(Custom Resins Nylene 3411)挤出。使用Coperion双螺杆挤出机混合设备将FreshBlend与树脂混合。使用计量加料器精确加料FreshBlend粉末和聚合物树脂,然后熔融。将树脂粒料与0.2%重量矿物油(零售药店级别)混合,然后加料至挤出机。对于所有加热区将挤出机设定为250C,模具温度设定为260C。FreshBlend的加料速率与挤出速率相当,导致重量比在5/95至20/80范围。将挤出的线材空气冷却或任选水冷却,然后造粒。
实施例2 氧清除膜的挤出
使用如实施例1中所制备的FreshBlend化合物来制备氧清除膜。由共挤出吹膜生产线(line)挤出三层膜,该生产线由三个挤出机、共挤出进料区(feedblock)和2英寸环形模具和0.060英寸模具间隙组成。以吹胀率为2和多种拉缩比制备膜,导致膜厚度在1.5-4密耳范围。该膜澄清且透明,几乎没有或没有可见的附聚物。对于各个层的尼龙/FreshBlend尼龙共混物/尼龙材料,该膜的层比率为约15/70/15。经过氧清除化合物的调稀(let-down),净氧清除剂含量在1-3%重量范围。
实施例3 袋中的氧清除膜性能
为了评价用作袋中的标记膜或插入膜的FreshBlend尼龙膜的氧吸收性能,将挤出的膜切成条,并储存于塑料袋中用于氧吸收性质测试。将具有所选的重量的挤出的样品膜切割,并储存于6英寸×6英寸尺寸的袋中。将提供92%相对湿度的加湿剂也储存于袋中,以活化氧清除剂的氧吸收能力。随后将袋密封,随后向袋中注射300cc的O2/N2=20/80的气体混合物。使用Mocon 450型顶部空间分析仪周期性地测量氧浓度。氧吸收性质显示于图1。可以看到,氧浓度随着时间逐步下降,2%重量膜的下降速率高于1%重量膜。该实施例证明氧清除膜在外壳(比如袋)中的效用。
虽然本文参考具体实施方案说明和描述了本发明,但是本发明不旨在局限于显示的细节,而是,在权利要求的等价的范围内且不脱离本发明,可对细节进行多种修改。因此,旨在使所附权利要求将所有这些变化覆盖为落入本发明的精神和范围之内。
Claims (8)
1.一种生产在聚合物基质中细微分散的铁/盐颗粒的方法,所述方法包括:用至少一种或多种活化和酸化粉末状组分预涂1-25um平均粒径铁,和将该氧清除剂与聚合物固态混合,然后熔体挤出为混合物;在混合前,用表面活性剂处理粒料或铁/盐粉末。
2.一种氧清除膜,所述氧清除膜由三层或更多层组成,根据权利要求1制备的氧清除微粒位于其它层之间,所述氧清除膜具有高透明度,没有可见的附聚物。
3.袋、包、柔性外壳或容器,其包括权利要求1的氧清除膜,所述氧清除膜作为标记、插入物、层叠物或作为多层结构的一部分,其中所述氧清除膜在外壳中提供氧吸收性能。
4.袋、包或柔性外壳,其包括权利要求1的氧清除剂,所述氧清除剂在包装中作为包装或图形设计的一部分。
5.在聚合物基质中的细微分散的铁/盐颗粒,所述细微分散的铁/盐颗粒包含1-25um平均粒径铁,所述铁预涂有至少一种或多种活化和酸化粉末状组分,用表面活性剂处理所述铁,然后与聚合物固态混合,然后熔体挤出为化合物。
6.具有最少可见附聚物的高透明度,包含三个或更多个塑料层,权利要求5的氧清除微粒位于其它层之间。
7.袋、包、柔性外壳或容器,其包含权利要求5的氧清除膜,所述膜为插入物、层叠物或作为多层结构的一部分的形式,其中所述氧清除膜在外壳中提供氧吸收性能。
8.袋、包或柔性外壳,其包括权利要求5的氧清除剂,所述氧清除剂在包装中作为包装或图形设计的一部分。
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AU2010236927A1 (en) | 2011-11-03 |
WO2010120435A3 (en) | 2011-01-13 |
MA33247B1 (fr) | 2012-05-02 |
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CA2757360A1 (en) | 2010-10-21 |
RU2011144021A (ru) | 2013-05-10 |
US20100255231A1 (en) | 2010-10-07 |
WO2010120435A2 (en) | 2010-10-21 |
RU2494120C2 (ru) | 2013-09-27 |
TN2011000497A1 (en) | 2013-05-24 |
EP2414436A2 (en) | 2012-02-08 |
KR20110136882A (ko) | 2011-12-21 |
BRPI1016129A2 (pt) | 2016-04-19 |
JP2012522869A (ja) | 2012-09-27 |
KR20160067191A (ko) | 2016-06-13 |
IL215469A0 (en) | 2011-12-29 |
ZA201107250B (en) | 2012-12-27 |
EP2414436A4 (en) | 2016-01-13 |
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CL2011002447A1 (es) | 2012-04-20 |
MX2011010421A (es) | 2011-12-06 |
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