CN104015415A - 可重构的多层层压材料和方法 - Google Patents

可重构的多层层压材料和方法 Download PDF

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CN104015415A
CN104015415A CN201410203037.4A CN201410203037A CN104015415A CN 104015415 A CN104015415 A CN 104015415A CN 201410203037 A CN201410203037 A CN 201410203037A CN 104015415 A CN104015415 A CN 104015415A
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laminated material
reconstruct
rete
peel ply
adhesive
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CN104015415B (zh
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V·P·侯尔贝尔特
P·L·普尔德芙
R·A·内曼
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Avery Dennison Corp
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Abstract

本发明描述了多层层压材料，其包括衬底、膜和在衬底层和膜层之间的粘合剂层。层压材料包括在膜层和粘合剂层之间的第一剥离层，以及在衬底和粘合剂层之间的第二剥离层。控制两个剥离层的剥离特性，从而在接受印刷的图案和/或文本之后使膜层能够从层压材料的剩余部分去除、重新定向、然后重新施加到层压材料的剩余部分。还描述了与重构层压材料和施加到物品或其它接受表面相关的方法。

Description

可重构的多层层压材料和方法
本申请为分案申请，原申请的申请日是2011年3月1日、申请号是201180023307.8(PCT/US2011/026595)、发明名称为“可重构的多层层压材料和方法”。
相关申请的交叉引用
本申请要求2010年3月9日提交的美国临时申请序列号61/312,052的优先权。
发明领域
本发明涉及接受印刷图案和/或文本的多层层压材料，其可被黏附地施加到目标基底或物品。本发明还涉及包括层压材料和将层压材料施加到基底或物品的方法。
发明背景
通常，大量消费产品的标签通过将图案和/或文本印刷到多层层压材料上而形成。在印刷成特定标签形状之前或之后，层压材料可被冲切。一般而言，这样的层压材料包括纸或膜衬底层、纸或膜面层和布置在衬底层和面层之间的粘合剂层。剥离层通常被包括在粘合剂层和衬底之间。将衬底层从粘合剂层分离之后，即通过剥离层，暴露的粘着面使面层能够容易地施加和保持到基底或其它接受表面如消费产品或容器。
在将层压材料或由其冲切的标签施加到基底或接受表面之前，装饰图案、徽标和/或文本通常被印刷在层压材料面层的暴露表面上。取决于面材料、印刷墨的特性和其它因素，一个或多个外涂层可被施加到暴露的面表面，以促进印刷墨的保持和化学稳定性。
印刷之后，经常需要将一个或多个另外的层施加到印刷图案、徽标和/或文本上，以减少印刷组合物从面层非故意的转移或去除的可能性。这些一个或多个另外的层可包括外清漆(over-varnish)或基漆(lacquer)材料。
虽然这些实践被广泛使用和提供吸引人的、耐久的和耐磨的标签，但是将期望提供更经济的策略，导致相当高性能的标签。
发明概述
与先前已知的层压材料和技术有关的困难和缺点在本发明多层层压材料和相关方法中得以解决。
一方面，本发明提供可重构的多层层压材料，其包括膜层、衬底层和布置在膜层和衬底层之间的粘合剂层。多层层压材料还包括布置在膜层和粘合剂层之间的第一剥离层。并且，多层层压材料包括布置在衬底层和粘合剂层之间的第二剥离层。第一剥离层的剥离力与第二剥离层的剥离力之比在约1:1.5至约1:100的范围内。
另一方面，本发明提供重构的多层层压材料，其包括限定第一面和相反朝向的第二面的膜层、衬底层和布置在膜层和衬底层之间的粘合剂层。粘合剂层接触膜层的第一面。层压材料还包括布置在膜层上并接触膜层第二面的第一剥离层。并且，层压材料还包括布置在膜层和粘合剂层之间的印刷区。
另一方面，本发明提供重构多层层压材料的方法。该方法包括提供可重构的多层层压材料，其包括具有外面的膜层、衬底层、布置在膜层和衬底层之间的粘合剂层，第一剥离层布置在膜层和粘合剂层之间，第二剥离层布置在衬底层和粘合剂层之间。第一剥离层的剥离力与第二剥离层的剥离力之比在约1:1.5至约1:100的范围内。该方法还包括将膜层和第一剥离层与粘合剂层分离，从而暴露粘合剂层的面。并且，该方法包括重新定向膜层和第一剥离层以及使膜层的外面与粘合剂层的暴露面接触以形成重构的层压材料，借此暴露第一剥离层。
另一方面，本发明提供形成标签的方法。该方法包括提供可重构的多层层压材料，其包括具有外面的膜层、衬底层、布置在膜层和衬底层之间的粘合剂层、布置在膜层和粘合剂层之间的第一剥离层和布置在衬底层和粘合剂层之间的第二剥离层。第一剥离层的剥离力与第二剥离层的剥离力之比在约1:1.5至约1:100的范围内。该方法进一步包括在膜层的外面上形成至少一个印刷区。该方法另外包括将膜层、印刷区(一个或多个)和第一剥离层与粘合剂层分离，从而暴露粘合剂层的面。并且，该方法还包括重新定向膜层、印刷区(一个或多个)和第一剥离层以及使印刷区(一个或多个)和膜层的外面中至少一个与粘合剂层的暴露面接触，从而形成标签，借此暴露第一剥离层。
另一方面，本发明提供产生重构的多层层压材料的系统。该系统包括可重构的多层层压材料，其包括具有外面的膜层、衬底层、布置在膜层和衬底层之间的粘合剂层、布置在膜层和粘合剂层之间的第一剥离层和布置在衬底层和粘合剂层之间的第二剥离层，其中第一剥离层的剥离力与第二剥离层的剥离力之比在约1:1.5至约1:100的范围内。该系统还包括用于如下的设备：(i)在膜的外面上形成至少一个印刷区，(ii)将膜层、印刷区(一个或多个)和第一剥离层与粘合剂层分离，从而暴露粘合剂层的面，和(iii)重新定向膜层、印刷区(一个或多个)和第一剥离层以及使印刷区(一个或多个)和膜层的外面中至少一个与粘合剂层的暴露面接触，形成标签，借此暴露第一剥离层。
如将被认识到的，本发明能够进行其它和不同实施方式，并且它的若干细节能在各个方面进行修改，所有这些都不背离本发明。因此，附图和说明书将被认为是说明性的而不是限制性的。
附图简述
图1是图解根据本发明优选实施方式的多层层压材料的各层的示意性横截面图。
图2是图解重构根据本发明优选实施方式的多层层压材料的优选方法的示意图。
图3是图解重构根据本发明优选实施方式的多层层压材料的系统的示意图。
实施方式的详细描述
本发明涉及如下的多层层压材料和包括层压材料的各种方法。新的多层层压材料包括(i)衬底、(ii)粘合剂层和(iii)膜层，其中(ii)粘合剂层布置在(i)衬底层和(iii)膜层之间。层压材料还包括(iii)膜层和(ii)粘合剂层之间的第一剥离层(a)，和(ii)粘合剂层和(i)衬底层之间的第二剥离层(b)。一个或多个外涂层或其它剂可被施加到(iii)膜层暴露的外表面。
层压材料的独特特性允许当事方(party)如转变者(converter)将期望的标记或文本印刷到(iii)膜层暴露的外表面上。印刷的标记或文本的取向与其意图的最终取向是颠倒的。印刷之后，然后将层压材料沿着第一剥离层(a)的界面分离(或分层)。沿着第一剥离层(a)使层压材料分离之后，该剥离层携带有(iii)膜层，从而暴露(ii)粘合剂层的面。然后将层压材料的分离部分——即印刷的膜层(iii)和携带其的第一剥离层(a)——优选通过转动杆组件(turnbar assembly)"翻转"。然后将重新定向的层压材料部分再施加到其它层压材料部分，即(i)衬底、第二剥离层(b)和(ii)粘合剂层，以便(iii)膜层的印刷面与(ii)粘合剂层的暴露面接触，由此将印刷物"夹"或包封在(iii)膜层和(ii)粘合剂层之间。在得到的重构的层压材料中，第一剥离层(a)现在被暴露。当通过第一剥离层(a)和(iii)膜层观察时，印刷标记或文本现在以它们意图的取向呈现并且不是反向的(backwards)。
然后通过沿着第二剥离层(b)将(i)衬底与(ii)粘合剂分离，可以将得到的层压材料施加到基底或物品。在分离这些层之后，第二剥离层(b)携带有(i)衬底，从而暴露(ii)粘合剂层的面。然后(ii)粘合剂层的暴露面使层压材料的剩余部分(包括印刷物)粘着地附于目标基底或物品。如本文更详细说明，通常，在将层压材料施加到目标基底或物品之前，将层压材料进行一些类型的切割处理，由此形成一个或多个成形的标签。本领域技术人员已知的许多种方法可以用于完成这些。
层压材料的显著特性是第一和第二剥离层(a)和(b)分别具有特定的剥离性质。具体而言，第一剥离层(a)较第二剥离层(b)更容易剥离或分离。理想地，分离第一剥离层与分离第二剥离层(b)所需要的力量之间的比是约1:3。这些方面都在本文中被更详细地描述。
图1示意性地显示优选实施方式的层压材料100。层压材料100包括衬底层10，其可以是包括一个或多个结构层如层12和14的多层衬底。应当理解，可以使用单个结构层。层压材料还包括粘合剂层20。并且，层压材料100另外包括膜层40。粘合剂层20布置在衬底10和膜层40之间。层压材料100还包括布置在膜层40和粘合剂层20之间的第一剥离层30。并且，层压材料100另外包括布置在粘合剂层20和衬底层(一个或多个)12或14之间的第二剥离层16。多层层压材料100可任选地进一步包括布置在膜层40上的一个或多个外涂层50。这些层中的每一个和其适合的材料如下被更详细地描述。
如所指出的，衬底层10可以是单层形式或作为多层组件。多种材料可用于衬底层，包括纸、箔或膜材料。合适材料的代表性实例包括但不限于超压光牛皮纸(SCK)、涂布牛皮纸(CK)、机制纸(MF)、BG、聚对苯二甲酸乙酯(PET)、PK和其组合。应当理解，其它材料和/或材料的组合可用于衬底。
粘合剂层20通常包括一种或多种压敏粘合剂。具体实例包括但不限于，基于溶剂、乳液和/或热熔丙烯酸或橡胶的压敏粘合剂。可使用其它类型的粘合剂，如基于乙烯基的粘合剂、UV热熔丙烯酸粘合剂、聚氨酯粘合剂、环氧粘合剂等等。再次，应当理解，本发明不限于这些特定粘合剂的使用。
在某些实施方式中，一种或多种着色粘合剂(pigmented adhesives)可用于多层层压材料。着色粘合剂可掺入到层压材料中以改善制成的层压材料的不透明度。当生产某些标签时，增加的不透明度是重要特性。通常的颜料加载水平的范围是约5％至约60％或更多，优选约10％至约25％。这些百分比是重量百分比并且基于施用之前粘合剂的重量。增加粘合剂的不透明度一般通过在粘合剂中掺入一种或多种颜料来实现。可以使用几乎任何类型的乳浊剂(opacifying agent)，如二氧化钛、碳酸钙、乳浊剂微球和多种有机颜料。除了或代替这些乳浊剂中任何一种，还考虑可以利用一种或多种金属颜料如但不限于铝、银和/或其它金属。
膜层40还可利用多种材料，例如包括但不限于，各种聚烯烃膜，如聚乙烯(PE)和聚丙烯(PP)、各种基于乙烯基的聚合物、聚酯如聚对苯二甲酸乙酯(PET)和聚碳酸酯(PC)。一般，任何热塑性膜材料可用于膜层。
第一和第二剥离层30和16分别可由本领域已知的多种剥离材料形成，如例如硅氧烷和基于硅氧烷的材料。用于剥离层的主要材料是硅氧烷制剂。已知基于聚硅氧烷的很多硅氧烷剥离涂层材料。在层压材料和贴标签系统中配制、设计和应用这些材料在本专利权人的很多专利中有描述，包括：美国专利5,728,469；5,543,231；5,562,992；5,494,945；5,654,093；6,423,406；5,084,317；6,235,363和5,843,549。考虑剥离层(一个或多个)可以不含硅氧烷和/或聚硅氧烷。本发明包括几乎任何剥离材料的使用。
剥离层——即第一和第二剥离层中的任何一个或两者——展示特定的剥离力。剥离力是将剥离层与紧密邻近的层分离所必需的力量。该力根据许多种因素而变化，包括剥离材料、邻近层的材料、这些层的表面特性、层的厚度、剥离层的均匀性以及剥离材料与邻近层材料之间的物理和化学相互作用。
如本领域技术人员已知的，实现两个面或层之间的剥离所必需的力——即剥离力——通常通过TLMI剥离测试仪来测量。可商业获得多种用于测量TLMI剥离性质的仪器，如可从意大利的Ichemco S.R.L.获得的AR-1000粘合/剥离测试仪。
如所指出的，优选第一剥离层30的剥离力与第二剥离层16的剥离力之比优选是约1:3。然而，本发明包括低至1:1.5的比。据信，该比没有上限，只要衬底层10仍可与粘合剂层20分离。为了定量该比的合适范围的目的，考虑1:100的上限。因此，本发明包括约1:1.5至约1:100的第一剥离层的剥离力与第二剥离层的剥离力之比。
外涂层材料在本领域是众所周知的。多种这样的材料可从诸如本专利权人；BASFResins和Trebnick of Springboro,OH商业获得。本发明包括使用几乎任何外涂层材料或材料的组合。
图2示意地显示根据本发明的进行优选重构处理的优选实施方式多层层压材料200。优选实施方式层压材料200包括衬底210、粘合剂层220、膜层240、布置在膜层240和粘合剂层220之间的第一剥离层230以及布置在衬底210和粘合剂层220之间的第二剥离层216。优选的重构处理包括提供或另外获得层压材料如多层层压材料200。这在图2中显示为操作(I)。本发明不限于特定的层压材料200。相反，可使用其它层压材料，如结合图1描述的多层层压材料100。
虽然不是与层压材料200的重构有关的必需操作，但是通常进行印刷操作，如操作(II)中显示的。可进行通常的印刷操作，由此将一个或多个图案、徽标和/或文本——示意地描述为印刷区255——施加到膜240暴露的外面242上。印刷组合物如墨或其它印刷组合物的使用可通过一个或多个本领域已知的印刷辊250来进行。可使用其它印刷或标记技术如喷涂或类似技术。例如，印刷区(一个或多个)255可通过多种印刷技术来施加。可使用利用胶印液体调色剂技术的数字印刷机，如可从HewlettPackard获得的Indigo Printing。可使用的其它印刷技术的实例包括但不限于，热转移、苯胺印刷、丝网印刷、胶印、喷墨印刷和这些技术的组合。而且，应当理解，在将印刷组合物印刷或另外沉积到膜240的面242上之前，可将一个或多个外涂层施加到面242上。
重构处理包括从层压材料的剩余部分，即粘合剂层220、第二剥离层216和衬底210，分离和去除膜层240和第一剥离层230的操作。该操作在图2中被示意地描述为操作(III)。在该操作中，膜层240沿着第一剥离层230和粘合剂层220之间的界面被分离。膜层240和第一剥离层230的去除暴露粘合剂层220的面222。当膜层240被从层压材料的剩余层移去——通常是以图2中箭头A的方向时，第一剥离层230和印刷区(一个或多个)255携带有膜层240。
重构处理继续并然后重新定向或"翻动"膜层240并将该层重新附于粘合剂层220的暴露面222。在该操作——示意地描述为图2中的(IV)——中，将重新定向的膜层240与粘合剂层220的暴露面222接触，并且通常以箭头B的方向。由于膜层240的重新定向，印刷区(一个或多个)255也与粘合剂层220的面222接触。并且，进一步由于膜层240被重新定向，如图2的操作(IV)所示，第一剥离层230现在暴露。
重构层压材料之后——通常被称为重构的层压材料200'，印刷区255现在布置在膜层240和粘合剂层220之间。该安排用于包封和保护印刷组合物和印刷区(或多个)255的完整性。
虽然不是层压材料重构的必需操作，但是图2示意地描述了操作(V)，其中衬底210和第二剥离层216被去除，由此暴露粘合剂层220的另一面224。这样的暴露之后，重构的层压材料可容易地附于基底260如容器等的接受表面262。
图3示意地显示利用如本文所描述的优选实施方式层压材料进行印刷和重构处理的优选实施方式系统300。通常，如本文所描述的优选层压材料以卷的形式提供，表示为310。通常，可利用任何多层层压材料如例如层压材料100和200。将一段层压材料310带到一个或多个印刷辊320，将印刷区325沉积到层压材料的膜层315上。应当理解，膜层315可含有一个或多个施加在其上的外涂层。还应当理解，进行印刷，以便沉积区325相对于它们最终的意图取向反向沉积，在图3中显示为325'。该操作通常对应于先前描述的图2中的操作(II)。将层压材料从卷310移去，通常以图3中显示的箭头C的方向。然后将层压材料引导到转动杆组件——通常被表示为多个辊330、340、350、360、370、380，其优选如图3示意地显示的那样安排。
具体而言，层压材料到达辊330之后，将膜层和对应的剥离层与层压材料的剩余部分分离，如在图2描述的操作(III)中的那样。
将膜层、剥离层和在膜层上携带的印刷区325带到另一个辊340，然后连续地带到辊350、360、370和380，它们共同地重新定向或"翻动"这部分层压材料并将该层压材料部分返回到剩余的层压材料部分，如结合图2中的操作(IV)所描述的那样。
重新定向或翻动层压材料部分的设备和系统在本领域是众所周知的。转动杆组件通常结合压力用于将材料层翻转，以进行两面印刷。如所指出的，可使用常规的转动杆组件。转动杆设备和系统可以，诸如从Belmark Industries of India；DMS Inc.of LakeZurich,IL和AAA Press Int.,Inc.of Arlington Heights,IL商业获得。
将膜层在辊380重新附于其对应的层压材料部分之后，印刷区325'以其最终意图的状态被定向。然后重构的层压材料可进行施加操作，如结合图2所描述的操作(V)，或以适合储存或运输的形式如卷390放置。
当卷动或缠绕如本文所描述的各种优选的多层层压材料时，可期望粗糙化、适当地纹理化和/或涂布衬底暴露的外面。当形成具有外衬底面——其相对光滑和/或显示低的摩擦特性——的层压材料的卷时，缠绕的卷开卷或"伸缩(telescope)"的趋势可能发生。为了避免这样，可处理衬底的外表面或为此选择适当的材料以在缠绕时赋予邻近层更大的摩擦并由此最小化开卷。可选地或除了使衬底暴露的外面纹理化之外，考虑在衬底暴露的外面上进行表面处理工艺。该工艺将在"翻动"或重构层压材料之后进行。这样的表面处理工艺的实例包括但不限于电晕处理、火焰处理、等离子体处理或类似处理，以从翻动后的层压材料暴露的外面去除大部分至基本上全部剥离材料，例如硅氧烷。
应当理解，膜层印刷、翻动和层压材料的翻动部分重新附着之后，本文描述的层压材料然后通常进行一个或多个冲切操作。重构的层压材料一般是片或卷材的形式。具有特定大小和/或形状的标签可以容易地通过冲切该片或卷材而形成。冲切技术和设备在本领域是众所周知的并在本专利权人的许多专利中有描述：例如美国专利5,520,760；4,130,042；4,372,681；4,150,183；5,585,193；6,099,927和6,689,238。
本发明的使用提供许多优势。例如，可重构的层压材料的使用导致显著的材料节省，因为不需要一个或多个另外的层材料。如将想起的，这些材料通常被施加到印刷图案或文本上或之上。
一个或多个另外的层材料的消除导致更环境友好的工艺。另外，消除这些材料的储存和回收提供进一步的成本节省。
另外，印刷、分层、重新定向(翻动)和重新层压以及可能还将重构的层压材料施加到基底或物品的操作都可以在一个连续的工艺中进行。
另外，本发明减少库存单位(shelf-keeping units)(SKUs)并且为当事方如印刷标签或层压材料的转换者简化工艺复杂性。
另一个优势涉及重新定向(或翻动)之后的重构的层压材料。这样的操作之后，通常，层压材料的外面将由剥离层提供。因此，取决于剥离层的材料，层压材料是外表面将展示一个或多个特定性质或特性。例如，如果剥离层包括硅氧烷材料，那么硅氧烷层沿着层压材料外表面的配置可以提供一个或多个独特或有益的性质。例如，提供硅氧烷外表面可以为层压材料提供耐蚀性的性质。还考虑可以使用无硅氧烷的剥离层。而且，剂和其它添加剂可掺入到剥离层以对重新定位的(或翻动的)层压材料的外面赋予或提供期望的功能性。
本发明和各个优选实施方式特别适合与数字技术如数字印刷机设备结合使用。优选实施方式在标签或层压材料组件中能够结合静电印刷和可变印刷。
从该技术的未来应用和发展看，许多其它益处将无疑变得明显。
本文提到的所有专利、公开的申请和文章通过引用以其全部被并入本文中。
应当理解，本文描述的一个实施方式的任何一个或多个部件或组件可以与另一个实施方式的一个或多个其它部件或组件组合。因此，本发明包括本文描述的实施方式的部件或组件的任何和所有组合。
如上文所描述的，本发明解决了与先前类型的层压材料和工艺有关的许多问题。然而，应当理解，本领域技术人员可以进行各种细节、材料以及组件或操作安排——其已在本文中被描述和图解以说明本发明的性质——的改变，而不背离所附权利要求表示的本发明的原理和范围。

Claims (18)

1.重构的多层层压材料，包括：
限定第一面和相反朝向的第二面的膜层；
衬底层；
布置在所述膜层和所述衬底层之间的粘合剂层，所述粘合剂层接触所述膜层的所述第一面；
布置在所述膜层上并接触所述膜层的所述第二面的第一剥离层；和
布置在所述膜层和所述粘合剂层之间的印刷区。
2.权利要求1所述的重构的层压材料，其中所述所述印刷区接触所述粘合剂层。
3.权利要求1-2所述的重构的层压材料，其中所述印刷区被包封在所述层压材料内。
4.权利要求1-3所述的重构的层压材料，其中所述膜层包括选自聚烯烃、基于乙烯基的聚合物、聚酯、聚碳酸酯和其组合的材料。
5.权利要求1-4所述的重构的层压材料，其中所述膜层是聚对苯二甲酸乙酯(PET)。
6.权利要求1-5所述的重构的层压材料，其中所述衬底层包括选自纸、箔、膜和其组合的材料。
7.权利要求1-6所述的重构的层压材料，其中所述粘合剂层包括选自下述的材料：基于溶剂的压敏粘合剂、基于乳液的压敏粘合剂、基于热熔橡胶的压敏粘合剂、基于乙烯基的粘合剂、聚氨酯粘合剂、UV热熔丙烯酸粘合剂、环氧粘合剂、和其组合。
8.权利要求1-7所述的重构的层压材料，其中所述粘合剂层是压敏粘合剂。
9.权利要求1-8所述的重构的层压材料，其中所述粘合剂包括至少一个乳浊剂。
10.权利要求1-8所述的重构的层压材料，其中所述粘合剂包括至少一种颜料。
11.权利要求10所述的重构的层压材料，其中所述粘合剂包括按重量计约5％至约60％的所述至少一种颜料。
12.权利要求1-11所述的重构的层压材料，其中所述第一剥离层包括聚硅氧烷。
13.权利要求1-11所述的重构的层压材料，其中所述第一剥离层包括硅氧烷。
14.权利要求1-11所述的重构的层压材料，其中所述第一剥离层不含硅氧烷。
15.权利要求1-14所述的重构的层压材料，进一步包括：
布置在所述衬底层和所述粘合剂层之间的第二剥离层。
16.权利要求15所述的重构的层压材料，其中所述第二剥离层包括聚硅氧烷。
17.权利要求15-16所述的重构的层压材料，其中所述第一剥离层的剥离力与所述第二剥离层的剥离力之比在约1:1.5至约1:100的范围内。
18.权利要求15-17所述的重构的层压材料，其中所述比是约1:3。
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