CN104884254A - 用于制造包装材料的方法 - Google Patents
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47G—HOUSEHOLD OR TABLE EQUIPMENT
- A47G19/00—Table service
- A47G19/22—Drinking vessels or saucers used for table service
- A47G19/2205—Drinking glasses or vessels
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- 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
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/15—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor incorporating preformed parts or layers, e.g. extrusion moulding around inserts
- B29C48/154—Coating solid articles, i.e. non-hollow articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
- B29C48/18—Articles comprising two or more components, e.g. co-extruded layers the components being layers
- B29C48/21—Articles comprising two or more components, e.g. co-extruded layers the components being layers the layers being joined at their surfaces
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- 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
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- 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
- B32B27/10—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 paper or cardboard
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
- B32B37/153—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state at least one layer is extruded and immediately laminated while in semi-molten state
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- A—HUMAN NECESSITIES
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/022—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the choice of material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
- B29K2023/04—Polymers of ethylene
- B29K2023/06—PE, i.e. polyethylene
- B29K2023/0608—PE, i.e. polyethylene characterised by its density
- B29K2023/0625—LLDPE, i.e. linear low density polyethylene
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- B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
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- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/0088—Blends of polymers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2711/00—Use of natural products or their composites, not provided for in groups B29K2601/00 - B29K2709/00, for preformed parts, e.g. for inserts
- B29K2711/12—Paper, e.g. cardboard
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
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- B32B2307/30—Properties of the layers or laminate having particular thermal properties
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- B32B2307/00—Properties of the layers or laminate
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- B32B2307/7246—Water vapor barrier
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
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- Engineering & Computer Science (AREA)
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Abstract
本发明涉及聚合物涂覆的包装材料、制造聚合物涂覆的包装材料的方法,和由所述材料制成的产品如一次性饮水杯。所述包装材料包含纸或者板的纤维基体(1)、最内部的聚合物层(2),和超过90wt-%HDPE的外层(3),所述最内部的聚合物层(2)含有如下的共混物:(i)10至25wt-%低密度聚乙烯(LDPE)和(ii)75至90wt-%具有较高熔体粘度的第二聚乙烯;所述第二聚乙烯选自线性低密度聚乙烯(LLDPE)和高密度聚乙烯(HDPE)。可提供与用于最内部的层(2)的聚合物共混物类似的聚合物共混物的最外部的层(4)用于热密封。可将所述层(2、3和4)通过共挤出引至并粘合至纤维基体(1)。为了最大化材料的再生能力,用于该结构体的HDPE和LLDPE是生物来源的。
Description
技术领域
本发明涉及制造包装材料的方法,其中将聚合物涂层挤出在纤维基体如纸、纸板或者卡纸上。此外,本发明涉及通过所述方法提供的聚合物涂覆的包装材料,以及由所述材料制成的一次性饮水杯和其它产品。
背景技术
用于容器和产品包装的基于纤维的包装材料如包装纸或者板通常设有聚合物涂层,所述聚合物涂层使得所述材料不透液和允许通过热密封形成容器或者包装。由聚合物涂覆的纸或者板制成的典型制品是液体包装和一次性餐具如饮水杯。LDPE(低密度聚乙烯)由于它的良好的热密封能力而广泛用于涂覆。
近来,在市场上对于这种完全或者至少主要由来自可再生来源的原料(即,生物来源的原料)制成的纸或者板产品具有增加的需求。传统上,聚乙烯由化石原料如石油生产。最近,开发了由甘蔗、糖用甜菜或者小麦谷物制成的聚乙烯,尤其是易于获得的生物LLDPE(线性低密度聚乙烯)和生物HDPE(高密度聚乙烯)。此外,生物LDPE(即,具有支化结构的普通低密度聚乙烯)是已知的,但是具有有限的供应并因此具有高价格。迄今为止,已经将所有这些新聚合物产品特制用于制造聚合物膜,已经发现它们对于挤出涂覆的适合性是差的。
HDPE通常相对于LDPE或者LLDPE在提供优异水蒸汽阻挡中具有优势,其在液体容器和包装中是非常理想的。另一方面,HDPE由于它与LDPE相比较的高熔融温度而具有差的热密封性,甚至,它在与纤维基体的直接接触中的粘合性是不足的。而且,纯HDPE由于它的窄的分子量分布(MWD)而不适合于单层挤出涂覆。当生产涂层重量为15至25g/m2的薄涂层时,纯HDPE在挤出涂覆中具有高内缩量(缩幅,neck-in)和差流动性(runnability)。
共挤出在纤维基体上的多层涂层广泛用于履行多个目标如水蒸汽阻挡、氧气和香味阻挡、粘合性、热密封性等。在现有技术中,参见例如US7,335,409,已经将内HDPE层和外LDPE层的组合描述为提供水蒸汽阻挡和热密封性。然而,这种组合与纤维基体的粘合性不足,并且从环境的角度考虑,生物级LDPE的目前差的可用性是另一个阻碍。
发明内容
因此需要这样的方法:其允许在技术上有效地和成本有效地将生物来源的聚乙烯(特别是,在现在的市场上容易获得的膜级聚乙烯)用于在纤维基体上的挤出涂覆。所述方案应使得生物HDPE的增加的使用变得可能,以通过简单的手段在纸或者板产品中实现改善的水蒸汽阻挡。同时,目标是尽可能低地降低涂层重量。
本发明的发明人解决所述问题的途径是将不同种类的聚乙烯产品共混。更具体地,优异聚合物涂层令人惊奇地通过以下方法实现:在纤维基体上共挤出内部聚合物层,和超过90wt-%HDPE的外层,所述内部聚合物层含有如下的共混物:(i)10至25wt-%低密度聚乙烯(LDPE)和(ii)75至90wt-%具有较高熔体粘度的第二聚乙烯,所述第二聚乙烯选自线性低密度聚乙烯(LLDPE)和高密度聚乙烯(HDPE)。
像这样共混不同种类聚乙烯是平常的,在文献中可发现很多这种配方。然而,那些教导主要目标在于制备聚合物膜,而非在纤维基体上的涂层,因此,未提及这样的共混物与纤维基体的粘合性(其为本发明的一个重要方面)。而且,通常将少量LLDPE或者HDPE描述为与主要份额的常用的支化LDPE共混,这与本发明的发明人的教导相反。
根据本发明的结构体克服了HDPE在挤出中的内缩量和流动性问题,并且作为双层结构体,允许与纤维基体的改善的粘合。将如上所述的聚合物共混物的层共挤出作为在超过90wt-%HDPE的外层和纤维基体之间的内层。
优选地,所述内部聚合物层含有如下的共混物:(i)10至25wt-%低密度聚乙烯(LDPE),熔体指数为至少7.5g/10分钟(190℃,2.16kg),或者甚至更优选地,熔体指数为至少15g/10分钟(190℃,2.16kg);和(ii)75至90wt-%第二聚乙烯,其是生物来源的且熔体指数为至多7.2g/10分钟(190℃,2.16kg),所述第二聚乙烯选自线性低密度聚乙烯(生物LLDPE)和高密度聚乙烯(生物HDPE)。
外蒸汽阻挡层可具有100%HDPE,不过如果希望的话,也可包含少于10wt-%的其它聚合物。
本发明因此提供所述聚合物共混物涂层,其可用作与纤维基体直接接触的粘合层。同时,当将所述包装材料成形为容器或者封闭的产品包装时,也可将类似的聚合物共混物层设置为最外部的热密封层。蒸汽阻挡HDPE层将夹在两个聚合物共混物层之间。主要份额的生物聚合物将产品转化为主要基于可再生材料,即使少量份额的LDPE是石油来源的。
根据本发明的有利实施方案,将LDPE和生物LLDPE的共混物或者LDPE和生物HDPE的共混物的最内部的粘合层、HDPE的中间层,和这样的共混物的最外部的热可密封层在单一步骤下共挤出至纤维基体上。优选地,将同样的共混物用于最内部的和最外部的聚合物层两者。该结构体可由在纤维基体上的最内部的,中间的和最外部的聚合物层组成,或者可存在其它聚合物层,例如夹在最内部的和最外部的聚合物共混物层之间的氧气阻挡层如EVOH或者聚酰胺的氧气阻挡层。
每当用在根据本发明的结构体中时,HDPE优选是生物来源的,即在中间的全-HDPE层中也是这样。
本发明的优选的实施方案提供:所述聚合物共混物含有80至90wt-%,或者80至85wt-%的生物来源的LLDPE或者HDPE和10至20wt-%,或者15至20wt-%的普通支化的LDPE。
本发明的其它实施方案提供:所述共混物的最内部的粘合层的重量为至多15g/m2,优选至多10g/m2,和最优选约5g/m2,所述共混物的最外部的热密封层的重量为至多15g/m2,优选至多10g/m2,和最优选约5g/m2,且中间HDPE层的重量为至多15g/m2,优选至多10g/m2,和最优选约5g/m2。优选地,在三层涂层中,聚合物层的总重量为至多25g/m2,优选至多20g/m2,和最优选约15g/m2。因此,非常薄的多个聚合物层结构体可通过本发明制成。
从经济和环境的视角考虑,甚至进一步降低涂层重量是理想的。在本发明的范围内,如果可通过现有共挤出技术制成,各涂层重量为4+4+4g/m2或者甚至4+2+4g/m2的三层是可预期的。
本发明还涵盖包装材料,其可通过根据权利要求所保护的本发明的方法得到。
优选地,根据本发明的包装材料包含:
-纸、纸板或者卡纸的纤维基体,
-如下共混物的最内部的粘合层:(i)10至25wt-%低密度聚乙烯(LDPE),熔体指数为至少7.5g/10分钟(190℃,2.16kg),或者更优选至少15g/10分钟(190℃,2.16kg);和(ii)75至90wt-%第二聚乙烯,其是生物来源的且熔体指数为至多7.2g/10分钟(190℃,2.16kg),所述第二聚乙烯选自线性低密度聚乙烯(LLDPE)和高密度聚乙烯(HDPE),
-生物来源的HDPE的中间层,和
-如下共混物的最外部的热可密封层:(i)10至25wt-%低密度聚乙烯(LDPE),熔体指数为至少7.5g/10分钟(190℃,2.16kg)或者更优选为至少15g/10分钟(190℃,2.16kg);和(ii)75至90wt-%第二聚乙烯,其是生物来源的且熔体指数为至多7.2g/10分钟(190℃,2.16kg),所述第二聚乙烯选自线性低密度聚乙烯(LLDPE)和高密度聚乙烯(HDPE),
所述层已经通过共挤出引至所述纤维基体上。
优选地,根据本发明的包装材料在两侧上类似地涂有聚合物层。
包含在本发明范围内的最终产品包括通过由上述包装材料热密封制成的饮水杯。本发明涵盖的其它制品为一次性盘、碟和其它餐具,以及密封的液体包装如乳制品和汁液纸盒,其中其它氧和光阻挡层可为期望的。
在本发明的背景下,高密度聚乙烯是指密度超过0.940g/cm3的聚乙烯。
本发明尤其适合于生产用于包装食物,尤其是冷冻食物的材料,但是不限于这种应用。
附图说明
图1显示了根据本发明的包装材料的多层结构,
图2显示了根据本发明的第二包装材料的多层结构,
图3显示了根据本发明的第三包装材料的多层结构,和
图4显示了根据本发明的第四包装材料的多层结构。
具体实施方式
图1中所示的包装材料包含纤维基体1、与纤维基体1直接接触的内部粘合层2和HDPE的外层3,所述粘合层2包含如下的共混物:(i)10至25wt-%具有较低熔体粘度的低密度聚乙烯(LDPE)和(ii)75至90wt-%具有较高熔体粘度的第二聚乙烯。在形成所述内部粘合层2的共混物中,所述低密度聚乙烯(LDPE)的熔体指数优选为至少7.5g/10分钟(190℃,2.16kg),或者更优选为至少15g/10分钟(190℃,2.16kg),第二聚乙烯的熔体指数优选为至多7.2g/10分钟(190℃,2.16kg)。第二聚乙烯可为线性低密度聚乙烯(LLDPE)或者高密度聚乙烯(HDPE)。在本发明的结构体中使用的HDPE和LLDPE是可再生生物来源。纤维基体1可为重量为40至500g/m2的纸、纸板或者卡纸,优选为重量为170至350g/m2的板。将所述内部粘合层2和外HDPE层3通过共挤出引至纤维基体1上。共挤出的聚合物层2、3中的每个层的重量可为例如3至15g/m2,优选5至10g/m2。
根据图2的包装材料与图1中所示的材料的区别在于它甚至包含最外部的聚合物共混物的层4,其与用于最内部的粘合层2的共混物相似,优选相同。例如,当所述材料转变成容器如一次性饮水杯时,最外部的层4用作热密封层。三个层2、3、4已经通过共挤出引至纤维基体1上。共挤出的聚合物层2、3、4中的每个层的重量可为例如3至12g/m2,优选5至10g/m2。
根据图3的包装材料与图2中所示的材料的区别在于它甚至包含在纤维基体1的相对侧上的热密封层4′。优选地,该热密封层4′具有聚合物共混物,其与用于纤维基体的相反侧上的最内部的和最外部的层2、4的共混物相同,当材料转变成饮水杯时,所述最外部的层4形成内侧。
根据图4的包装材料包含在纤维基体1的两侧上的共挤出的多层结构2、3、4;2′、3′、4′。这些多层结构可对应于上面关于图2所述的那些结构。图4的材料适合于阻挡水蒸汽渗透的热密封产品包装,所述水蒸汽渗透来自包装的内侧,即,来自潮湿产品,和来自包装的外侧,即,来自湿润的环境。
实施例
将20wt-%石油来源的挤出级LDPE与甘蔗来源的膜级生物HDPE干混,以形成聚合物共混物。将这种聚合物共混物与100wt-%生物HDPE一起共挤出在纸板表面上,使得聚合物共混物在纸板表面和HDPE层的中间形成粘合层。粘合层的克重为8g/m2和HDPE层的克重为7g/m2。所以,在全部涂层中,存在1.6g/m2LDPE和13.4g/m2HDPE。实现15g/m2的涂层重量,具有良好的流动性、可接受的内缩量和与纸板的良好粘合性。
一系列试验通过以下方法进行:在纸板基体上挤出根据本发明的两层或者三层涂层,以及挤出单层涂层作为对比例。将挤出级基于油的LDPE、膜级生物HDPE,和膜级生物LLDPE(生物HDPE和生物LLDPE由Braskem,Brazil自甘蔗制成)用于试验。测量在挤出中的内缩量和完成的材料的热密封温度,并基于等级1(不粘合)至5(完美粘合)评价与板基体的粘合性。结果呈现在下表1中。
表1.
*对比
尽管具有最大层厚度,但是对比HDPE单层涂层具有最差的内缩量和粘合性。更薄的HDPE单层在挤出中全部失败。添加LLDPE或者HDPE与20wt-%LDPE的共混物的内层改善了粘合性和减少了内缩量,即使总涂层重量和厚度是降低的,并且在LLDPE+LDPE的情况中通过添加相同共混物的最外部的层显著改善了热密封性。
Claims (16)
1.制造包装材料的方法,所述方法包括在纤维基体上共挤出内部聚合物层,和超过90wt-%HDPE的外层,所述内部聚合物层含有如下的共混物:(i)10至25wt-%低密度聚乙烯(LDPE)和(ii)75至90wt-%具有较高熔体粘度的第二聚乙烯;所述第二聚乙烯选自线性低密度聚乙烯(LLDPE)和高密度聚乙烯(HDPE)。
2.权利要求1的方法,其特征在于,用于该结构体的HDPE和/或LLDPE是生物来源的。
3.权利要求1或者2的方法,其特征在于,在所述共混物中,所述低密度聚乙烯(LDPE)的熔体指数为至少7.5g/10分钟(190℃,2.16kg)和所述第二聚乙烯的熔体指数为至多7.2g/10分钟(190℃,2.16kg)。
4.前述权利要求中的任一项的方法,其特征在于,所述共混物的内部聚合物层为与所述纤维基体直接接触的粘合层。
5.前述权利要求中的任一项的方法,其特征在于,存在作为最外部的热可密封层共挤出的所述共混物的层。
6.权利要求4和5的方法,其特征在于,将相同共混物用于内部粘合层和最外部的热密封层。
7.前述权利要求中的任一项的方法,其特征在于,所述聚合物共混物含有至少80wt-%,优选80至85wt-%的生物来源的LLDPE或者HDPE和10至20wt-%,优选15至20wt-%LDPE。
8.前述权利要求中的任一项的方法,其特征在于,内部粘合层的重量为至多15g/m2,优选至多10g/m2,和最优选约5g/m2。
9.前述权利要求中的任一项的方法,其特征在于,最外部的热密封层的重量为至多15g/m2,优选至多10g/m2,和最优选约5g/m2。
10.前述权利要求中的任一项的方法,其特征在于,所述HDPE外层的重量为至多15g/m2,优选至多10g/m2,和最优选约5g/m2。
11.通过权利要求1-10中的任一项的方法制得的包装材料。
12.权利要求11的包装材料,其特征在于,它包含
(i)纸或者板的纤维基体,
(ii)如下共混物的最内部的粘合层:(i)10至25wt-%低密度聚乙烯(LDPE)和(ii)75至90wt-%具有较高熔体粘度的第二聚乙烯,所述第二聚乙烯是生物来源的且选自线性低密度聚乙烯(LLDPE)和高密度聚乙烯(HDPE),
(iii)超过90wt-%的生物来源的HDPE的中间层,和
(iv)如下共混物的最外部的热可密封层:(i)10至25wt-%低密度聚乙烯(LDPE)和(ii)75至90wt-%具有较高熔体粘度的第二聚乙烯,所述第二聚乙烯是生物来源的并选自线性低密度聚乙烯(LLDPE)和高密度聚乙烯(HDPE),
所述层已经通过共挤出引至所述纤维基体上。
13.权利要求12的包装材料,其特征在于,在所述最内部的和最外部的聚合物层中含有相同共混物。
14.权利要求12或者13的包装材料,其特征在于,最内部的、中间的和最外部的聚合物层中的每一个的重量为至多15g/m2,优选至多10g/m2,和最优选约5g/m2,和聚合物层的总重量为至多25g/m2,优选至多20g/m2,和最优选约15g/m2。
15.权利要求11-14中的任一项的包装材料,其特征在于,所述纤维基体在两侧上类似地涂有聚合物层。
16.饮水杯,其通过由通过权利要求1-10中的任一项的方法制成的包装材料或者由权利要求11-15中的任一项的包装材料热密封制得。
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CN116018375A (zh) * | 2020-08-31 | 2023-04-25 | 三菱化学株式会社 | 树脂组合物 |
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EP2925524A4 (en) | 2016-06-29 |
ES2718305T3 (es) | 2019-07-01 |
SE1300276A1 (sv) | 2014-05-31 |
AR093667A1 (es) | 2015-06-17 |
SE538048C2 (sv) | 2016-02-23 |
WO2014083466A1 (en) | 2014-06-05 |
US10011096B2 (en) | 2018-07-03 |
AU2013350853B2 (en) | 2017-08-24 |
EP2925524B1 (en) | 2019-01-09 |
CN104884254B (zh) | 2018-10-12 |
EP2925524A1 (en) | 2015-10-07 |
BR112015012433A2 (pt) | 2018-05-08 |
KR20150092174A (ko) | 2015-08-12 |
US20150298438A1 (en) | 2015-10-22 |
AU2013350853A1 (en) | 2015-05-14 |
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