CN104768733A - 密封取向薄膜 - Google Patents

密封取向薄膜 Download PDF

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Publication number
CN104768733A
CN104768733A CN201380058407.3A CN201380058407A CN104768733A CN 104768733 A CN104768733 A CN 104768733A CN 201380058407 A CN201380058407 A CN 201380058407A CN 104768733 A CN104768733 A CN 104768733A
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CN
China
Prior art keywords
film
substrate
polypropylene
ultra
polyethylene
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN201380058407.3A
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English (en)
Inventor
贝尔特·博若德斯
曼佛瑞德·特里纳
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Borealis AG
Borealis AS
Original Assignee
Borealis AS
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Borealis AS filed Critical Borealis AS
Publication of CN104768733A publication Critical patent/CN104768733A/zh
Pending legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B51/00—Devices for, or methods of, sealing or securing package folds or closures; Devices for gathering or twisting wrappers, or necks of bags
    • B65B51/10—Applying or generating heat or pressure or combinations thereof
    • B65B51/22—Applying or generating heat or pressure or combinations thereof by friction or ultrasonic or high-frequency electrical means, i.e. by friction or ultrasonic or induction welding
    • B65B51/225—Applying or generating heat or pressure or combinations thereof by friction or ultrasonic or high-frequency electrical means, i.e. by friction or ultrasonic or induction welding by ultrasonic welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/431—Joining the articles to themselves
    • B29C66/4312—Joining the articles to themselves for making flat seams in tubular or hollow articles, e.g. transversal seams
    • B29C66/43121—Closing the ends of tubular or hollow single articles, e.g. closing the ends of bags
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
    • B29C66/7371—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined oriented or heat-shrinkable
    • B29C66/73711—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined oriented or heat-shrinkable oriented
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
    • B29C66/7371—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined oriented or heat-shrinkable
    • B29C66/73711—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined oriented or heat-shrinkable oriented
    • B29C66/73712—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined oriented or heat-shrinkable oriented mono-axially
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B32B27/327—Layered products comprising a layer of synthetic resin comprising polyolefins comprising polyolefins obtained by a metallocene or single-site catalyst
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/04—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the partial melting of at least one layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B5/00—Packaging individual articles in containers or receptacles, e.g. bags, sacks, boxes, cartons, cans, jars
    • B65B5/04—Packaging single articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D75/00—Packages comprising articles or materials partially or wholly enclosed in strips, sheets, blanks, tubes, or webs of flexible sheet material, e.g. in folded wrappers
    • B65D75/28—Articles or materials wholly enclosed in composite wrappers, i.e. wrappers formed by associating or interconnecting two or more sheets or blanks
    • B65D75/30—Articles or materials enclosed between two opposed sheets or blanks having their margins united, e.g. by pressure-sensitive adhesive, crimping, heat-sealing, or welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
    • B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
    • B29C55/04—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets uniaxial, e.g. oblique
    • B29C55/06—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets uniaxial, e.g. oblique parallel with the direction of feed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
    • B29C66/7234—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered comprising a barrier layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/94—Measuring or controlling the joining process by measuring or controlling the time
    • B29C66/949—Measuring or controlling the joining process by measuring or controlling the time characterised by specific time values or ranges
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Abstract

一种用于将纵向取向的聚丙烯或聚乙烯薄膜密封至基片的方法，包括使薄膜和基片接触，且将至少一部分接触区域经历超声，以在薄膜与基片之间形成封口。

Description

密封取向薄膜
技术领域
本发明涉及将聚烯烃取向薄膜密封至基片(例如聚烯烃基片)，特别是将纵向取向的聚烯烃薄膜密封至聚烯烃基片，尤其是超声焊接在与基片形成封口中的用途。在另一实施例中，基片也为纵向取向的聚烯烃薄膜。
背景技术
聚烯烃薄膜在包装中已使用许多年。许多这些薄膜为取向薄膜，该薄膜已被拉伸(典型地在纵向上被拉伸)以提供对于包装工业理想的薄膜。由于薄膜分子结构的形态变化，取向薄膜提供了大量有利性质，例如优异的机械性质、不透湿气、对油脂的高耐受性和耐刮性。这些薄膜经常具有低雾度和高光泽，且可以容易地在其上印刷。
然而，纵向取向(MDO)薄膜非常难以通过热密封而密封。将高度取向薄膜暴露于热导致薄膜的严重收缩和相当低的密封强度。工业通常通过设计复杂的多层薄膜结构和在多层薄膜的密封层中使用特定的材料而解决这个问题。
例如，已知的是，均聚物的特征是低密封强度，因此避免均聚物在密封层中的使用。均聚物经常具有比共聚物高的熔点，使均聚物更难例如热密封。因此，典型包括三聚物、丙烯无规共聚物或丙烯嵌段共聚物的多层薄膜结构经常在取向薄膜中使用。双轴取向薄膜常规上使用例如聚丙烯共聚物制备。
密封也是更复杂的薄膜操作(例如成型、充填和密封技术)中的严重问题。在典型的成型、充填和密封薄膜密封操作中，制造商必须密封薄膜的不同区域。这些区域可以包括2、3或4个薄膜层，尤其是在存在三角片的情况下。热密封满足2至4个薄膜厚度的区域是困难的，因为施加的热经常如此大，以致薄膜可能被损坏。如果不施加足够的热，不会形成封口，且包装完整性有危险或密封强度较差。
因此，对于取向聚烯烃薄膜，存在需要克服的热密封问题。能够密封均聚物密封层或成功地密封多个薄膜层而不害怕损坏是有用的。
发明人已经认识到该问题的可能解决方案是超声焊接。超声焊接是基于高频声学振动的可选密封技术。超声焊接通过产生非常高的电压且通过转换器(压电元件)将电压转换为高频振动而进行。
将待密封的薄膜表面暴露于高频振动，这导致薄膜表面与薄膜密封至其上的基片之间的薄膜间和分子间摩擦力。通过密封区域中的摩擦力产生热，且薄膜的密封层和基片密封在一起。
超声焊接传统上用于非聚烯烃环境。超声焊接已经用于典型由纸、铝或高熔点聚合物薄膜(例如聚对苯二甲酸乙二醇酯)制成的层压板。超声焊接在尿布技术中的使用也是已知的。
已经建议在聚烯烃薄膜中使用超声焊接，但是几乎没有出版物公开。在EP-A-1837162中，使用超声焊接密封复杂多层薄膜。
在EP-A-0332341中，描述了HDPE婴儿奶瓶衬垫，该衬垫在横向上拉伸且在一端超声焊接。US2007/0215610也提到了在用于微波应用的复杂共挤出薄膜中使用超声焊接作为一种密封选择。
发明人已经认识到超声焊接提供了针对纵向取向(MDO)的聚烯烃薄膜中的热密封问题的理想解决方案。以前没有人考虑在纵向取向的聚烯烃薄膜中使用超声焊接。发明人证明这种形式的焊接也适用于MDO聚烯烃薄膜，提供了优异的密封强度，尤其是在横向上。
在MDO聚烯烃薄膜中使用超声焊接允许形成非常高的密封强度，在多数情况下比使用常规热密封技术所达到的密封强度高。这尤其对于横向密封来说是真实的。
而且，由于技术的性质(即不接触热密封杆)，几乎不存在任何薄膜收缩。超声焊接的使用可以允许更精确的焊接过程发生，且可以允许形成光滑的焊接线。这使封口不易破裂，且避免难看的皱纹或裂缝。薄膜密封还可以在密封表面上存在污染物的情况下进行。
使用超声焊接的另一主要益处涉及节约原料成本。在使用常规热密封在表面之间形成分封口时，层可以重叠多达10mm。因此，该重叠大多数是浪费的薄膜。使用超声焊接，该重叠可以减少至6mm。在每小时2000个包装的情况下，这意味着损耗的显著降低。因此，本发明的方法对于制造成批生产的包装(例如重型航运袋)是理想的。
因此，超声焊接的使用对于MDO聚烯烃薄膜生产商来说是显著飞跃。
发明内容
因此，从一个方面看，本发明提供了一种用于将纵向取向的聚丙烯或聚乙烯薄膜密封至基片(优选聚丙烯或聚乙烯基片)的方法，该方法包括使所述薄膜和所述基片接触，且将至少一部分所述接触区域经历超声，以在所述薄膜与所述基片之间形成封口。
从另一方面看，本发明提供了超声在将纵向取向的聚丙烯或聚乙烯薄膜密封至基片(优选聚丙烯或聚乙烯基片)中的用途。
从另一方面看，本发明提供了一种用于包装产品(特别是热敏产品)的方法，该方法包括：
提供容器，所述容器具有敞开端且包括纵向取向的聚丙烯或聚乙烯薄膜；
通过将所述产品穿过所述容器的所述敞开端分配而使用所述产品充填所述容器；且
通过超声焊接所述敞开端而密封所述容器。
从另一方面看，本发明提供了一种用于包装产品(特别是热敏产品)的方法，该方法包括：
由纵向取向的聚丙烯或聚乙烯薄膜形成容器，所述容器具有敞开端；
通过将所述产品穿过所述容器的所述敞开端分配而使用所述产品充填所述容器；且
通过将所述敞开端超声焊接至自身而密封所述容器。
从另一方面看，本发明提供了一种通过前面限定的方法可得到的产品。
具体实施方式
定义
术语纵向取向薄膜是指在纵向上已经拉伸了其长度的至少3倍的薄膜。
聚丙烯是指含有至少70重量％丙烯残基，优选至少80重量％丙烯残基的聚合物。本发明的聚丙烯中存在的任何共聚单体是另一种α烯烃。
聚乙烯是指含有至少70重量％乙烯残基，优选至少80重量％乙烯残基的聚合物。本发明的聚丙烯中存在的任何共聚单体是另一种α烯烃。
本发明涉及将聚乙烯或聚丙烯纵向取向薄膜超声焊接至基片，优选该基片也为聚乙烯或聚丙烯薄膜。
基片可以与纵向取向薄膜相同或不同，但是薄膜和基片优选基于聚乙烯或聚丙烯聚合物。因此，这意味着纵向取向薄膜包括聚乙烯或聚丙烯组分，且基片包括聚乙烯或聚丙烯组分。
在本发明的薄膜中，MDO聚乙烯或聚丙烯薄膜可以是单层或多层的。如果薄膜为多层薄膜，则聚乙烯或聚丙烯聚合物必须至少在密封至基片的层中。然而，当然，薄膜的其他层也可以含有聚乙烯或聚丙烯化合物。
本发明中使用的薄膜本身不是新的，且MDO薄膜在自由市场上可得到。在这种情况下，这些聚烯烃薄膜通常是合适的。
本发明的MDO薄膜焊接至其上的基片也是优选含有聚乙烯或聚丙烯的基片。再次，基片可以是单层或多层的，且如果基片是多层的，则聚乙烯或聚丙烯化合物优选存在于密封至MDO薄膜的层中。
在优选实施例中，基片是如本文对于取向薄膜所限定的纵向取向聚乙烯或聚丙烯薄膜。还要更优选地，基片和取向薄膜为同一薄膜，即薄膜超声焊接至自身。
除了基于聚乙烯或聚丙烯烯烃聚合物的层之外，本发明的基片还可以包括阻挡层，例如基于聚酰胺类、乙烯-乙烯醇、镀铝层、乙烯-丙烯酸酯聚合物等的层。基片还可以是层压板。
通常观察到的是，已经证明具有优异超声焊接性能的聚合物不是在常规热密封中表现良好的聚合物。例如，丙烯均聚物可以成功地超声焊接，但是在热密封时表现较差。
如以下更详细地说明的，本发明的MDO薄膜中特别感兴趣的聚合物是其中薄膜的密封曾包括线型低密度聚乙烯，特别是金属茂LLDPE的聚合物。
聚丙烯
本发明的取向薄膜可以含有聚丙烯聚合物。聚丙烯可以是均聚物或共聚物。均聚物包括基本上包括100％的丙烯残基。出人意料地已经发现丙烯均聚物可以成功地超声焊接，且这形成本发明的一个方面。
丙烯共聚物包括至少一种α烯烃共聚单体，至少一种α烯烃共聚单体优选选自乙烯或C4-10α烯烃，例如1-丁烯、1-己烯或1-辛烯。可能存在一种共聚单体或多于一种的共聚单体，例如两种共聚单体(由此形成三聚物)。优选地，仅仅存在一种共聚单体。更优选地，共聚单体为乙烯。特别优选的是，乙烯是丙烯共聚物中存在的唯一共聚单体。
任何共聚物可以是无规共聚物或嵌段共聚物，优选为嵌段共聚物。
丙烯聚合物可以是单峰的或多峰的。单峰聚合物在GPC曲线中具有单个峰，且在单个步骤中形成。术语单峰的是指就分子量分布而言是单峰的。
丙烯聚合物可以是单峰无规聚丙烯共聚物或多峰无规聚丙烯共聚物，例如无规异相聚丙烯共聚物。
本发明的多峰聚丙烯聚合物在至少两个阶段(理想地仅仅两个阶段)中制备，因此含有至少两种级分，优选仅仅含有两种级分。
术语“多峰的”在本文中是指，除非另外声明，就分子量分布而言是多峰的，因此包括双峰聚合物。通常，包括至少两种聚烯烃级分的聚合物组合物被称为“多峰的”，至少两种聚烯烃级分在不同聚合条件下制备，导致级分的不同(重均)分子量和分子量分布。前缀“multi”涉及聚合物中存在的不同聚合物级分的数量。因此，例如，多峰聚合物包括所谓的“双峰”聚合物，“双峰”聚合物由两种级分组成。多峰聚合物的分子量分布曲线的形式，即聚合物重量份数作为其分子量的函数的曲线图的外观，显示出两个或更多个最大值，或者与单独级分的曲线相比典型地明显变宽。例如，如果聚合物以序列多阶段方法使用串联连接的反应器且在每个反应器中使用不同的条件制备，在不同反应器中制备的聚合物级分中的每一种具有其自己的分子量分布和重均分子量。在记录该聚合物的分子量分布曲线时，这些级分的单独曲线典型地一起形成整个得到的聚合物产物的变宽的分子量分布曲线。
优选的是，本发明的聚丙烯聚合物是多峰的，尤其是双峰的。组成多峰聚丙烯的组分优选为共聚物，或者均聚物和共聚物，且优选组分是不同的，例如就它们的共聚单体含量而言。
聚丙烯共聚物中的共聚单体含量优选在1至15重量％范围内，例如在2至12重量％范围内，优选在3至10重量％范围内，例如在3.5至9重量％范围内。
聚丙烯聚合物的MFR2优选为12.0g/10min以下，例如10.0以下，例如8.0g/10min以下，尤其是5g/10min以下。最小值可以是0.01g/10min，例如0.1g/10min。本发明的聚丙烯还可以使用已知成核剂成核，成核剂为例如山梨糖醇或环状乙烯基化合物的聚合物，例如乙烯基环己烷。
通常已经观察到的是，长分子量链的存在提高聚丙烯在超声焊接条件下的性能。
无规共聚物优选为无规异相共聚物。在无规异相共聚物中，其一种组分典型地是具有高共聚单体含量的橡胶，且第二组分含有较低的共聚单体含量。
合适的聚丙烯可从供应商(例如Borealis、Dow、Exxon等)商购。
聚丙烯聚合物可以使用本领域已知的齐格勒-纳塔催化剂或金属茂催化剂制备。如本领域已知的，聚丙烯可以是被减粘裂化的。
聚乙烯
本发明的薄膜还可以包括聚乙烯。聚乙烯可以是以低压或高压工艺(LDPE)制备的均聚物，或者聚乙烯可以是共聚物。
聚乙烯的密度为890至980kg/m3，或者聚乙烯可以是HDPE、MDPE或LLDPE。HDPE的密度为至少940kg/m3且HDPE在薄膜中是最不优选的。
用于制备取向薄膜的优选聚乙烯为LLDPE。LLDPE的MFR2优选在0.01至20g/10min范围内，例如在0.05至10g/10min范围内，优选在0.1至6.0g/10min范围内。非常优选地，MFR2在0.10至5g/10min范围内。
取向薄膜的LLDPE的密度可以在905至935kg/m3范围内，优选在910至930kg/m3范围内，优选例如在912至925kg/m3范围内。
LLDPE的重均分子量Mw优选不大于100,000，优选不大于75000，例如为50,000以下。
LLDPE的Mw/Mn可以变化。优选的Mw/Mn值为3以上，例如6以上，甚至10以上。可以设想3.5至30的范围。
LLDPE含有至少一种共聚单体，优选仅仅含有一种共聚单体。该共聚单体优选为C3-10α烯烃共聚单体。因此，三聚物的使用是可能的，但是不是有利的。优选地，共聚单体为1-丁烯、1-己烯或1-辛烯。优选的是，使用的共聚单体是1-丁烯或1-己烯。
LLDPE中存在的共聚单体的量可以在0.5至10重量％范围内，例如在0.5至5重量％范围内，例如在1至4重量％范围内。
LLDPE可以是单峰的或多峰的，优选为多峰的。单峰LLDPE在其GPC光谱中具有单个峰，因为多峰LLDPE以单阶段方法制备。这些术语在前面关于聚丙烯层讨论过。最优选的是，LLDPE是由均聚物组分和共聚物组分形成的多峰LLDPE。这些聚合物是本领域已知的，且从Borealis等(例如Borstar型商标名)可得到。
本发明的LLDPE可以使用齐格勒-纳塔催化或单中心催化(mLLDPE)制备，优选使用齐格勒-纳塔催化剂制备。这些催化剂是本领域已知的。
聚乙烯还可以是以本领域熟知的高压工艺制备的低密度聚乙烯(LDPE)。LDPE的密度可以为905至935kg/m3。LDPE的MFR2小于2g/10min。
本发明的MDO薄膜当然可以含有多层或单层薄膜中的薄膜层中的不同组分的共混物。例如，薄膜层中的LDPE和LLDPE的组合是优选选择。单峰和双峰LLDPE聚合物的组合也是优选的，等等。
聚乙烯/聚丙烯的制备
为了制备本发明的聚合物，可以使用本领域技术人员熟知的聚合方法。可以使用任何常规的立体有择齐格勒-纳塔催化剂作为催化剂。这些催化剂中的必要组分是固体催化剂组分，固体催化剂组分包括具有至少一个钛-卤素键的钛化合物、内电子给体化合物和作为钛化合物和给体化合物的载体的活性形式的卤化镁。作为内电子给体，催化剂可以含有选自醚类、酮类、内酯类、含有N、P和/或S原子的化合物以及一元羧酸和二元羧酸的酯类的化合物。
还可以使用能够催化烯烃聚合物的形成的任何金属茂催化剂。合适的金属茂催化剂包括以最大内部孔体积浸入多孔载体中的金属茂/活化剂反应产物。催化剂络合物包括典型地桥联的配体、第IVa至VIa族的过渡金属和有机铝化合物。催化剂金属化合物典型地为金属卤化物。
多峰(例如双峰)聚合物通过以本领域已知的方式在其聚合工艺(所谓的原位工艺)过程中原位共混每个组分而制备。
本发明中有用的多峰聚合物优选通过在包括溶液过程、浆料过程和气相过程(按任何顺序)的多阶段(即两个或更多个阶段)聚合工艺过程中原位共混而得到。虽然可能在工艺的每个阶段使用不同单中心催化剂，优选的是使用的催化剂在两个阶段中是相同的。
因此，理想地，本发明的多峰聚合物以使用相同催化剂的至少两阶段聚合工艺制备。因此，例如，可以使用两个浆料反应器或两个气相反应器、或其任何组合(按任何顺序)。然而，优选地，聚乙烯使用环流式反应器中的浆料聚合和接着气相反应器中的气相聚合来制备。
环流式反应器-气相反应器系统熟知为Borealis技术，即BORSTARTM反应器系统。该多阶段工艺公开于例如EP517868中。
该工艺中使用的条件是熟知的。对于浆料反应器，反应温度通常在60℃至110℃范围内，例如在85℃至110℃范围内，反应器压力通常在5至80巴范围内，例如在50至65巴范围内，且停留时间通常在0.3至5小时范围内，例如在0.5至2小时范围内。使用的稀释剂通常为沸点在-70℃至+100℃范围内的脂肪烃，例如丙烷。在这些反应器中，如果需要，聚合反应可以在超临界条件下进行。浆料聚合反应也可以以本体形式进行，其中反应介质由被聚合的单体形成。
对于气相反应器，使用的反应温度通常在60℃至115℃范围内，例如在70℃至110℃范围内，反应器压力通常在10至25巴范围内，且停留时间通常在1至8小时范围内。使用的气体通常为非反应性气体(例如氮气)或低沸点烃类(例如丙烷)以及单体。
根据需要，可以将链转移剂(优选氢气)加入反应器。预聚合步骤可以先于实际的聚合工艺。
在使用单峰聚合物的情况下，该聚合物可以是在以上描述的工艺的一个阶段中形成的聚合物，例如环流式反应器中形成的聚合物。
本发明的聚合物本身不是新的，且用于制备该聚合物的方法是已知的。该聚合物也是可商购的。
可以理解的是，本发明的薄膜的聚丙烯和聚乙烯组分可以含有标准聚合物添加剂。这些聚合物添加剂形成小于5重量％，例如小于2重量％的聚合物材料。添加剂(例如抗氧化剂、亚磷酸酯类、粘附添加剂、颜料、着色剂、填充剂、抗静电剂、加工助剂、澄清剂等)也可以被包括在本发明的聚合物中，因此被包括在由聚合物形成的薄膜中。薄膜可以含有标准添加剂，例如防结块剂、滑爽剂、脱模剂等。这些添加剂在工业上是熟知的，其它们的使用是本领域技术人员熟悉的。
聚合物性质在不存在添加剂的条件下测量。薄膜性质在已形成的薄膜上测量，因此它们易于包含来自聚合物的添加剂。
MDO薄膜制备
本发明的薄膜为通过本领域熟知的(共)挤出和吹塑/铸造制备的吹塑或流延薄膜。取向前，本发明的薄膜的厚度优选为100至600微米，优选100至400微米。取向后，本发明的薄膜的厚度典型为15至200μm，更优选为20至150μm。特别优选的是，取向后，薄膜的厚度为20至120μm，例如25至90微米。
优选的是，本发明的薄膜是多层的。多层薄膜优选由至少三个层，例如3个层、5个层或6个层形成。因此，薄膜优选至少包括层A、B和C。
优选的是，本发明的薄膜中的两个或更多个层包括上面限定的多峰LLDPE。尤其优选的是，薄膜的至少两个层包括多峰LLDPE。
薄膜的层(A)优选为外层。它优选涉及薄膜的密封(理想地密封至自身)。层(A)优选至少包括多峰LLDPE，特别是多峰齐格勒-纳塔LLDPE。理想地，该层是该多峰LLDPE与单峰LLDPE(特别是金属茂LLDPE)的共混物。这些单中心LLDPE给予薄膜优异的密封性能。层(A)还可以是多峰LLDPE组分合本文描述的极低密度聚乙烯的共混物。
层(B)优选包括多峰LLDPE，例如由多峰LLDPE组成。
层(C)优选包括与层(A)相同的结构。因此，本发明的优选薄膜是ABA型薄膜。
薄膜层
下面关于薄膜层材料使用的术语“基本上由……组成”是指仅仅排除其他聚烯烃组分(优选其他聚合物)的存在。因此，该术语不排除添加剂(例如常规薄膜添加剂)的存在，即每个层可以独立地含有常规的薄膜添加剂，例如抗氧化剂、紫外线稳定剂、酸清除剂、成核剂、抗结块剂、滑爽剂等以及聚合物加工助剂(PPA)等。
本发明的薄膜优选包括下面的层(A)和层(B)，尤其是包括下面的层(A)、层(B)和层(C)。
层(A)
因此，在本发明的第一优选实施例(i)中，层(A)包括多峰LLDPE和单峰LLDPE或极低密度聚乙烯的混合物。在该实施例(i)中，层(A)优选包括40至75重量％的多峰LLDPE，更优选40至70重量％的多峰LLDPE。该实施例(i)中的层(A)优选包括25至60重量％的单峰LLDPE或极低密度聚乙烯，更优选30至60重量％的单峰LLDPE或极低密度聚乙烯。此处，多峰LLDPE和单峰LLDPE或极低密度聚乙烯的50/50重量％的分裂(split)的使用是尤其优选的。层(A)优选基本上由这些组分组成。
层(B)
层(B)优选包括至少50重量％，优选至少60重量％，更优选至少70重量％的多峰LLDPE。在一些实施例中，甚至约80重量％以上的多峰LLDPE是优选的。多峰LLDPE优选为多峰znLLDPE。优选地，层(B)由多峰LLDPE聚合物组成。因此，层(B)可以包括两种多峰LLDPE的共混物或单个多峰LLDPE。
层(C)
层(C)可以具有如上面关于层(A)描述的聚合物组成。优选地，在ABA型薄膜结构中，层(A)和层(C)可以相同。
ABC层薄膜的薄膜厚度分布(％)优选为总薄膜厚度(100％)的20％-40％/20％-60％/20％-40％。
在另一优选实施例中，本发明的薄膜包括至少五个/六个层，优选按以下顺序：
(i)第一外层(A)，
(ii)第二外层(B)，
(iii)第一内层(C)，
(iv)第二内层(C)，
(v)第三外层(B)和
(vi)第四外层(A)。
该薄膜优选由两个相同的ABC型薄膜形成，且可以争辩中心C层合并成为一体(因此为5层结构)。对于ABCCBA薄膜结构，各层的厚度可以符合7.5-27.5％/15-35％/5-25％/15-35％/7.5-27.5％，其中总薄膜厚度为100％，且核心层的量为两个层(C)的和。
在ABCCBA结构中，优选的是层(C)不与层(A)相同。特别地，层(C)可以包括上面限定的极低密度聚乙烯。
每个A、B或C层可以独立地具有上面限定的组成。理想地，ABCCBA薄膜由通过它们的层(C)层压在一起的两个相同的ABC薄膜形成。
优选的是，密封层形成薄膜的总厚度的至少18％，优选薄膜的总厚度的至少20％，尤其是薄膜的厚度的至少25％。如果密封层太薄，薄膜的密封性能较差。
本发明的薄膜可以具有很有用的机械性能，例如高冲击强度、刚度、耐热性和拉伸性能。
更重要地，使用超声焊接实现的最大密封力与使用常规热密封可以实现的密封力一样好，或者比使用常规热密封可以实现的密封力更好，特别是在横向上。可以实现至少20Nmm2，例如至少30Nmm2的横向密封力。优选的是，通过超声焊接形成的密封强度为通过热密封形成的密封强度的至少两倍。
为了制备根据本发明的待密封的薄膜，通常至少两种聚合物熔体流通过多通道管形、环形或圆形模头同时挤出(即共挤出)，以形成使用空气(或气体组合)吹出、膨胀和/或冷却的管，以形成薄膜。吹塑薄膜的制备是熟知的工艺。
本发明的薄膜典型地通过穿过环形模头挤出，通过形成在固化之后在轧辊之间破裂的气泡而吹制成管形薄膜而制备。在这一点上可以使用常规的薄膜制备技术。典型地，层在160℃至240℃范围内的温度下挤出，且鼓吹10℃至50℃范围内的温度的气体(通常为空气)而冷却以提供为模头直径的2至8倍的霜白线高度而挤出。吹胀比应该通常在2至5范围内，优选在2.5至4范围内。合适的模头直径在100至250mm范围内。
然后在纵向上拉伸薄膜，以形成取向薄膜。拉伸进行至为初始薄膜长度的至少3倍。拉伸在纵向上进行，尽管理论上一些横向拉伸也可能发生。因此，薄膜可以是双轴取向的。此处可以设想BOPP薄膜的使用。
双轴取向薄膜可以通过两种不同的工艺-管架(气泡)工艺或拉幅机工艺制备。两种工艺早在商业制备双轴取向聚丙烯薄膜时就已使用，而且现在仍然使用(Edward P.Moore，Jr.，Polypropylene Handbook，Hanser Publishers，1996，374至375)。管架工艺有利于制备非常薄的薄膜。
拉幅机工艺是更常见的，由于与管架工艺相比，由技术的非常高的输出和较宽的可用性产生的较低的可变成本。
在拉幅机工艺中，薄膜的双轴取向常规地通过纵长(“纵向”(MD))地拉伸薄膜且然后使用拉幅机在垂直于纵向的方向(“横向”(TD))上拉伸薄膜而实现。
在横向取向(MDO)过程中，薄膜在加热了的一组滚筒上运转。这些滚筒的温度通常在120℃至130℃范围内，但是偶尔一些生产线使用较高的温度，例如快速运转生产线。
快速运转生产线需要较高的温度，以便允许拉伸，特别是如果使用丙烯均聚物组合物，用于制备双轴取向薄膜(BOPP薄膜)。
取向薄膜在纵向上的拉伸比可以多达10，优选为4至8，尤其为4至6。在横向(TDO)上，拉伸比典型地在7与10之间。
取向聚乙烯和聚丙烯薄膜的制备是熟知的。这些薄膜是本领域技术人员熟悉的可商购的产品。
基片
本发明的薄膜超声焊接至基片上。该基片优选为聚烯烃薄膜，由聚乙烯或聚丙烯，优选取向聚烯烃形成。更优选地，基片为与薄膜层相同的取向聚烯烃薄膜，即薄膜密封至自身。
超声焊接
一旦已经制备了取向薄膜和基片，在它们之间需要形成封口。这通过超声焊接实现。在超声焊接过程中，通过机械振动在薄膜与基片之间的焊接区域中产生热，产生引起被密封的材料塑化的摩擦力，在部件之间锻造不可溶的连接。
超声焊接使用焊接工具(超声焊极)，焊接工具典型地被取向，以水平地或竖直地施加振动。密封质量是非常均匀的，因为能量传递和释放的内部热保持恒定且限于密封区域。
因为超声焊接具有非常低的能量需要，不使用消耗品，不需要冷却水，且具有不大的空间需要，超声焊接提供了针对聚合物密封问题的经济有效的环境友好的解决方案。
首先使待焊接的部件接触，且夹在固定形座(砧)与连接至传感器的超声焊极之间。可以调节超声频率，以在被密封的材料中实施密封。因此，薄膜与基片之间的接触区域的至少一部分经历超声。可以理解的是，仅仅由于工艺的性质，薄膜和基片可以在比实际密封的区域大的区域上彼此接触。
需要的超声振动可能根据被密封的薄膜的性质等而变化。典型地，可以使用在15kHz至70kHz范围内的超声频率。
密封表面暴露于超声的时间可以非常短，例如50至200ms。
超声能量使薄膜与薄膜被密封至其上的基片之间的点接触熔化，在超声停止(或薄膜远离超声源移动)时产生封口。超声焊接导致塑料由于吸收振动能量而局部熔化。
超声焊接的使用是非常有利的，因为薄膜不接触热密封杆。超声焊极在整个工艺中保持为冷的。因此，这防止熔融聚合物在密封杆上的累积，因此防止密封后该杆的彻底清洁。因此，与热密封相反，通过使用超声焊接停工期显著减小。
即使存在污染物，也可以实现优异的密封。常见的是，一个密封表面可能与污染密封表面的被包装的材料接触。不管该污染，仍然可以使用超声焊接形成坚固的封口。似乎是超声的应用机械地将污染物从密封区域移除。在被包装的产品是在加热时产生气味的产品时，这是重要的。例如，如果密封区域上具有污染物的宠物食品被热密封时，结果是烧焦的宠物食品气味。超声焊接的使用避免了该问题。
超声焊接的另一个最重要的益处是避免薄膜收缩。在取向薄膜中，收缩是巨大问题，因为这些薄膜非常趋向于收缩。通过避免高温密封，使收缩最小化。此外，我们避免将包装的内容物暴露于高温。如果产品是受热时容易降解的产品，这是重要的。
优选的是，在超声焊接操作过程中，薄膜在任何方向上的收缩不超过5％。
超声焊接的使用可以允许用于包装的薄膜设计更灵活。对于超声焊接，热粘附性不是问题，因为密封后热流动至相邻(较冷)薄膜层。在热密封的情况下，相邻层比封口热，这限制了热粘附性。因此，这限制了可以用于热密封环境的薄膜的性质。
这使本发明对于包装热敏产品来说是理想的。
超声焊接的使用还允许包装过程中顶部空间的减小。典型地，大顶部空间用于防止来自密封操作的热损坏被包装的商品。使用超声焊接，可以克服该问题，且每克包装材料可能需要较少的薄膜。
应用
本发明的薄膜可以用于多种多样的最终应用，然而，薄膜在制造包装(尤其是食品、饮料或医疗包装或中型或重型航运袋中商品的包装)中是特别感兴趣的。
特别地，薄膜可以在成型、充填和密封包装技术中或在形成竖立小袋过程中使用。本发明的特定特征是本文描述的材料可以经历超声焊接以及常规的热密封。特别地，超声焊接可以用于在横向上密封，而热密封可以用于在纵向上密封。
优选地，薄膜在立式成型充填密封(FFS)包装生产线中密封，其中取向薄膜最初从平的薄膜焊接(优选通过超声焊接)。然后，薄膜可以与第一横向焊缝超声焊接，包装被充填且通过热密封或超声焊接闭合。
在典型的FFS机器中，该机器装载有连续的平的取向薄膜卷。取向薄膜接近长的中空圆锥形管的后部，在塑料的中心接近管时，薄膜的外边缘形成卷绕圆锥形管的翼部。将该薄膜绕管的外侧向下拉，且竖直热密封杆夹持在薄膜的边缘上，通过将焊缝边缘熔化在一起而焊接薄膜。
为了开始装袋工艺，水平密封杆夹持穿过管的底部边缘，将薄膜焊接在一起，且切割下面的任何薄膜。然后，将密封的管端部降低到精密称量台上，且待装袋的产品通过袋中心的长圆锥形管分配。在达到充填产品的袋的毛重时，充填停止，且水平密封杆密封袋的顶部，同时形成上面的下一个袋的底部。然后，将该袋从该管切开，且现在成为密封的包装。在FFS工艺过程中，存在大量密封操作，因此可以使用超声焊接代替这些热密封操作中的一个或多个。特别地，超声焊接代替任何横向热密封设备。
双系统也可用于四面密封包装、以及每个面需要不同材料的包装。双系统使用两卷起始薄膜而不是一卷起始薄膜，两卷起始薄膜从机器的相对侧进给。底层和顶层热密封在一起，以形成小袋，且产品从顶部装载。具有装载产品的小袋然后向下行进，且顶部被密封，小袋被切开。小袋的顶部的密封形成下一个小袋的底部。
再次，超声焊接可以用于实施这些热密封操作中的一个或多个。
薄膜在重型航运袋或中型航运袋中是尤其有用的。为了提供强度，重型航运袋经常设有三角片。在存在三角片的情况下，薄膜厚度尤其高，因为存在大量薄膜折叠以密封在一起。在该环境中热密封的使用是困难的，因为密封所有的层需要的热如此高。超声焊接的使用可以在不依赖存在的层的数量的情况下产生高质量的封口。
竖立小袋经常通过热密封制备。充填后小袋的实际闭合可以通过超声焊接实现。因此，本发明的另一方面是本发明的取向薄膜可以热密封和超声焊接至基片上。在包装中需要多于一个封口时，包装形成过程中可以使用两种技术。
本发明在形成热敏产品(包括所有类型的人食品/饮料、宠物食品、热敏非易耗产品等)过程中是特别有用的。
本发明的特定特征在图2中示出。此处，示出成型充填和密封工艺，其中a为FFS袋的长度，b为袋内的顶部空间，c为焊接伸出量(welding overhang)。使用超声焊接，可以设想b和c的值可以减小，可能减小多达10％的组合量。这可能允许70g的重型航运袋减小至69g的重型航运袋。在每年400公吨袋的情况下，这意味着额外的80,000+个袋。
现在参考下面的非限制性示例和附图描述本发明。图1是示出示例1中的聚合物在热和超声下的密封强度的图。
熔体流动速率
熔体流动速率(MFR)根据ISO 1133测定，且以g/10min表示。MFR指示聚合物的熔体粘度。对于聚乙烯，MFR在190℃下测定，对于聚丙烯，MFR在230℃下测定。熔体流动速率在其下测定的负荷通常以下标表示，例如MFR2是在2.16kg负荷(条件D)下测量的，MFR5是在5kg负荷(条件T)下测量的，或者MFR21是在21.6kg负荷(条件G)下测量的。
共聚单体含量(NMR)：
共聚单体含量通过使用13C–NMR测定。13C–NMR光谱在Bruker 400MHz光谱仪上在130℃下从溶于1,2,4-三氯苯/苯-d6(90/10重量/重量)的样品记录。
分子量
Mw、Mn和MWD通过凝胶渗透色谱法(GPC)根据以下方法测量：
重均分子量Mw和分子量分布(MWD＝Mw/Mn，其中Mn为数均分子量，Mw为重均分子量)根据ISO 16014-4:2003和ASTM D 6474-99测量。使用装备有折射率检测器和在线粘度计的Waters GPCV2000仪器以及来自Tosoh Bioscience的2x GMHXL-HT和1xG7000HXL-HT TSK凝胶柱，以1,2,4-三氯苯(TCB，使用250mg/L 2,6-二叔丁基-4-甲基-苯酚稳定的)作为溶剂，在140℃下，在1mL/min的恒定流速下。每次分析注射209.5μL样品溶液。使用具有在1kg/mol至12000kg/mol范围内的至少15个窄MWD聚苯乙烯(PS)标准的普适标定(根据ISO 16014-2:2003)校准柱组。使用ASTM D 6474-99中给出的MarkHouwink常数。所有样品通过将0.5–4.0mg聚合物溶于4mL(140℃)稳定的TCB(与流动相相同)中且在取样至GPC仪器中之前在连续轻轻摇动的条件下在最高温度160℃下保持最长3小时。
如本领域已知的，如果共混物的组分的分子量是已知的，共混物的重均分子量可以根据下式计算：
Mw b = Σ i w i · M w i
其中Mwb为共混物的重均分子量，
wi为共混物中组分“i”的重量分数，且
Mwi为组分“i”的重均分子量。
数均分子量可以使用熟知的混合规则计算：
1 Mn b = Σ i w i Mn i
其中Mnb为共混物的重均分子量，
wi为共混物中组分“i”的重量分数，且
Mni为组分“i”的重均分子量。
密度
聚合物的密度根据ISO 1183/1872-2B测量。
示例1-PE薄膜
具有单层结构的薄膜在7层Alpine共挤出生产线上共挤出，模头直径为300mm，吹胀比(BUR)为1:2,5，霜白线高度为3D，模头间隙为1.4mm。所有7个层由相同材料制成且具有相等的层分布。所有挤出机上的温度设置为210℃，且挤出机模头上的温度设置为210℃。
拉伸使用Augsburg/Germany的Hosokawa Alpine AG制造的单向拉伸机进行。从吹塑薄膜挤出得到的薄膜拉入取向机中，然后在两组轧辊之间拉伸，其中第二对在比第一对高的速度下运转，导致所需的拉伸比。离开拉伸机之后，薄膜进给至常规薄膜卷绕器，在薄膜卷绕器中薄膜分裂至其所需的宽度且被卷绕，以形成卷。
说明书中限定的用于确定PE薄膜性质的PE薄膜样品如以上描述的制备，且在拉伸之前具有150μm的起始薄膜厚度，拉伸比为1:6，在拉伸之后具有25μm的最终薄膜厚度。
该薄膜使用超声焊接或热密封在横向上密封至自身。被测试的聚合物FB2230(MFR2为0.2g/10min且密度为923kg/m3的双峰齐格勒-纳塔LLDPE聚合物)在超声焊接时显示出提高很多的密封强度，特别是在横向上(图1和表1)。
示例2–PP薄膜制备
具有单层结构的薄膜在单层流延薄膜生产线上制备，平模头宽度为800mm，牵引速度：8m/min，熔体温度：对于BC918CF为250℃，对于RD208CF为240℃。冷却辊温度(对于两种材料都是相同的)：分别为20℃和30℃；模头间隙为0,8mm。
BC918CF：说明书中限定的用于确定薄膜性质的单层PP薄膜样品如以上描述的制备，且在拉伸之前具有250μm的起始薄膜厚度，拉伸比为1:5，在拉伸之后具有50μm的最终薄膜厚度。该薄膜使用超声焊接在纵向和横向上密封至自身。
RD208CF：说明书中限定的用于确定薄膜性质的单层PP薄膜样品如以上描述的制备，且在拉伸之前具有240μm的起始薄膜厚度，拉伸比为1:6，在拉伸之后具有40μm的最终薄膜厚度。该薄膜使用超声焊接在横向上密封至自身。
BC918CF为MFR2＝3g/10min的异相聚丙烯。RD208CF为丙烯-乙烯无规共聚物。
示例3–重型航运袋
具有ABA结构的薄膜在3层Varex共挤出生产线上共挤出，模头直径为200mm，吹胀比(BUR)为1:3，霜白线高度为600mm，模头间隙为1.2mm。三个挤出机上的温度设置为A＝210℃/B＝210℃/C＝210℃，且挤出机模头上的温度设置为200℃。
拉伸使用Augsburg/Germany的Hosokawa Alpine AG制造的单向拉伸机进行。从吹塑薄膜挤出得到的薄膜拉入取向机中，然后在两组轧辊之间拉伸，其中第二对在比第一对高的速度下运转，导致所需的拉伸比。
说明书中限定的用于确定PE薄膜性质的PE薄膜样品如以上描述的制备，且在拉伸之前具有480μm的起始薄膜厚度，拉伸比为1:6，在拉伸之后具有80μm的最终薄膜厚度。该薄膜使用超声焊接在纵向和横向上密封至自身。
该薄膜具有与EP-A-1941998的示例1相同的结构(85％mLLDPE 1，15％LDPE 1(层A)和(层B)80％znLLDPE 3，20％mLLDPE 1)。
表1–MDO薄膜上的超声密封试验结果
基于PP的MDO薄膜
基于PE的MDO薄膜
用于密封的试验样本：宽度：25,4mm，长度：300mm。
可以清楚地看出，相对于纵向密封，横向热密封显著提高。

Claims (17)

1.一种用于将纵向取向的聚丙烯或聚乙烯薄膜密封至基片的方法，包括使所述薄膜和所述基片接触，且将至少一部分所述接触区域经历超声，以在所述薄膜与所述基片之间形成封口。
2.根据前述权利要求中任一项所述的方法，其中所述基片由纵向取向的聚丙烯或聚乙烯薄膜形成。
3.根据前述权利要求中任一项所述的方法，其中所述薄膜为聚乙烯薄膜，优选为LLDPE薄膜。
4.根据前述权利要求中任一项所述的方法，其中所述薄膜为聚丙烯无规共聚物薄膜，优选为多峰无规异相共聚物薄膜。
5.根据前述权利要求中任一项所述的方法，其中将所述薄膜密封至自身。
6.根据权利要求1所述的方法，其中所述MDO薄膜包括丙烯均聚物、聚丙烯嵌段共聚物或LLDPE。
7.根据前述权利要求中任一项所述的方法，其中所述封口在横向上形成。
8.根据前述权利要求中任一项所述的方法，其中所述MDO薄膜被拉伸了其初始长度的4至8倍。
9.根据前述权利要求中任一项所述的方法，其中UW频率为15至79kHz。
10.根据前述权利要求中任一项所述的方法，其中所述MDO薄膜为BOPP薄膜。
11.根据前述权利要求中任一项所述的方法，其中所述薄膜为多层薄膜。
12.根据前述权利要求中任一项所述的方法，其中超声焊接进行50至200ms。
13.根据前述权利要求中任一项所述的方法，其中在密封过程中，所述薄膜在任何方向上不收缩超出其长度的5％。
14.超声在将纵向取向的聚丙烯或聚乙烯薄膜密封至基片，优选聚丙烯或聚乙烯基片中的用途。
15.一种用于包装产品，特别是热敏产品的方法，包括：
提供容器，所述容器具有敞开端且包括纵向取向的聚丙烯或聚乙烯薄膜；
通过将所述产品穿过所述容器的所述敞开端分配而使用所述产品充填所述容器；且
通过超声焊接所述敞开端而密封所述容器。
16.一种用于包装产品，特别是热敏产品的方法，包括：
由纵向取向的聚丙烯或聚乙烯薄膜形成容器，所述容器具有敞开端；
通过将所述产品穿过所述容器的所述敞开端分配而使用所述产品充填所述容器；且
通过将所述敞开端超声焊接至自身而密封所述容器。
17.一种通过权利要求1至16中任一项所述的方法可得到的产品。
CN201380058407.3A 2012-11-07 2013-11-07 密封取向薄膜 Pending CN104768733A (zh)

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