CN105705316A - 用于产生超声波密封件的方法以及具有所述超声波密封件的膜结构和柔性容器 - Google Patents

用于产生超声波密封件的方法以及具有所述超声波密封件的膜结构和柔性容器 Download PDF

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Publication number
CN105705316A
CN105705316A CN201480020416.8A CN201480020416A CN105705316A CN 105705316 A CN105705316 A CN 105705316A CN 201480020416 A CN201480020416 A CN 201480020416A CN 105705316 A CN105705316 A CN 105705316A
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China
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sealing
multilayer film
sealant
ultrasonic
usop
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CN201480020416.8A
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CN105705316B (zh
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S·本萨松
J·J·范登
G·塞尼
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Dow Global Technologies LLC
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Dow Global Technologies LLC
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    • 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
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    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/82—Testing the joint
    • B29C65/8207—Testing the joint by mechanical methods
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/112—Single lapped joints
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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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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    • 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
    • B29C66/731—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 intensive physical properties of the material of the parts to be joined
    • B29C66/7311—Thermal properties
    • B29C66/73115—Melting point
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
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    • 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
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    • B29C66/73713—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 bi-axially or multi-axially
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Abstract

本发明是针对用于产生具有超声波密封件的超声波可密封的膜结构和柔性容器的方法。所述膜结构包括第一多层膜和第二多层膜。每一个多层膜包括背层和密封层。每一个密封层包括具有以下特性的超声波可密封的烯烃基聚合物(USOP)：(a)熔融热ΔHm小于130J/g；(b)峰值熔融温度Tm小于125℃；(c)剪切储能模量(G′)为50MPa到500MPa；以及(d)剪切损耗模量(G″)大于10MPa。所述多层膜被安排成使得所述第一多层膜的所述密封层与所述第二多层膜的所述密封层接触。当在4N/mm密封力下进行超声波密封时，所述密封层形成密封强度为30N/15mm到80N/15mm的超声波密封件。

Description

用于产生超声波密封件的方法以及具有所述超声波密封件的膜结构和柔性容器
技术领域
本发明是针对用于产生具有超声波密封件的超声波可密封的膜结构和柔性容器的方法。
背景技术
相比于常规热密封，在柔性包装中采用超声波密封提供例如以下能力的性能优势：(i)防污染密封，(ii)形成更窄的密封区域，以及(iii)在更高的线速度下并且在更低的温度环境下形成密封件。适用于超声波焊接的包装系统包括垂直或水平成型填充密封。尽管存在这些益处，但是超声波密封具有显著的缺点。由于焊头与砧座之间的接触几何和振荡变形，所以超声波密封常常导致显著的材料流出并且聚合物被挤出远离密封区域。超声波密封的这种“挤出”现象会引起破坏，并且最终毁坏所形成的超声波密封件中的层状结构。当进行超声波密封时，层压步骤，即焊头与砧座(例如在角撑板和褶皱以及横截面鳍形密封件中)之间的材料的厚度改变的步骤，特别容易遭到破坏。在这些区域中的有缺陷的密封降低了密封强度(如通过剥离测试所测量)，会破坏密封区域中的层压结构，并且形成通道泄漏部，导致含铝或阻挡聚合物的薄层的包装层压结构的阻挡特性丢失，所述阻挡聚合物例如乙烯-乙烯醇共聚物(EvOH)。
所提出的用于缓解上述问题的方法包括(i)优化接触几何，尤其是能量导引器；和(ii)控制密封期间的焊头位移，这两者都受到了限制。
谨慎地选择多层结构的聚合物和优化提供了用于缓解以上问题的替代途径。因此需要鉴别可以进行超声波密封并且提供与通过常规热密封可达到的密封强度相当的密封强度的聚合物和结构。进一步存在对增加超声波密封强度的超声波密封方法的需要。还存在对克服了接触几何优化或密封力位移调整的缺点的加强型超声波密封件的需要。进一步存在对满足柔性容器的更多面使用的需求的经过改良的超声波可密封膜的需要。
发明内容
本发明是针对一种用于产生超声波密封件的方法，以及含有所述超声波密封件的膜结构和柔性容器。本发明方法包括基于除了接触几何优化和密封力调整之外影响超声波密封区域中的材料流动的四个因素，选择用于超声波密封的聚合物。另外，所述方法包括调整膜组成和结构，以便进一步改良超声波密封强度。
本发明提供一种用于产生超声波密封件的方法。所述超声波密封件形成于两个聚合物膜之间。所述方法包括制备多层膜，所述多层膜具有背层和密封层。密封层包括超声波可密封的烯烃基聚合物(USOP)。USOP基于以下特性加以选择：
(a)熔融热ΔHm小于130J/g，
(b)峰值熔融温度Tm小于125℃，
(c)剪切储能模量(G′)为50MPa到500MPa，以及
(d)剪切损耗模量(G″)大于10MPa。
所述方法包括使第一多层膜的密封层与第二多层膜的密封层接触，形成密封区域。所述方法包括使密封区域经历超声波能量。所述方法包括在两个密封层之间形成超声波密封件，所述超声波密封件具有30N/mm到80N/mm的密封强度。
本发明提供一种膜结构。所述膜结构包括第一多层膜和第二多层膜。每一个多层膜包括背层和密封层。每一个密封层包括具有以下特性的超声波可密封的烯烃基聚合物(USOP)：
(a)熔融热ΔHm小于130J/g，
(b)峰值熔融温度Tm小于125℃，
(c)剪切储能模量(G′)为50MPa到500MPa，以及
(d)剪切损耗模量(G″)大于10MPa。
所述多层膜被安排成使得第一多层膜的密封层与第二多层膜的密封层接触。当在4N/mm密封力下进行超声波密封时，所述密封层形成密封强度为30N/15mm到80N/15mm的超声波密封件。
本发明提供一种柔性容器。所述柔性容器包括第一多层膜和第二多层膜。每一个多层膜包括背层和密封层。密封层包括具有以下特性的超声波可密封的烯烃基聚合物(USOP)：
(a)熔融热ΔHm小于130J/g，
(b)峰值熔融温度Tm小于125℃，
(c)剪切储能模量(G′)为50MPa到500MPa，以及
(d)剪切损耗模量(G″)大于10MPa。
所述多层膜被安排成使得每一个多层膜的密封层彼此接触并且第二多层膜叠加在第一多层膜上，形成共同的外围边缘。所述柔性容器包括2折叠区域和4折叠区域。当在4N/mm密封力下对2折叠区域和4折叠区域进行超声波密封时，所述区域各自形成密封强度为30N/15mm到80N/15mm的超声波密封件。
附图说明
图1是示出了根据本发明实施例的G′对比G″的标绘图的图。
图2A是根据本发明实施例的具有平坦超声波密封几何的柔性容器的示意性图示。
图2B是根据本发明实施例的具有平坦密封几何的超声波密封的示意性图示。
图3A是根据本发明实施例的具有2折叠区域和4折叠区域的柔性容器的示意性图示。
图3B是根据本发明实施例的具有2折叠/4折叠密封几何的2折叠区域和4折叠区域的超声波密封的示意性图示。
图4示出了关于根据本发明实施例的超声波密封膜结构，超声波密封强度对比密封力的图。
图5示出了关于根据本发明实施例的超声波密封膜结构，超声波密封强度对比密封力的图。
图6示出了关于根据本发明实施例的超声波密封膜结构，超声波密封强度对比密封力的图。
图7示出了关于根据本发明实施例的超声波密封膜结构，超声波密封强度对比密封力的图。
图8示出了关于根据本发明实施例的超声波密封膜结构，超声波密封强度对比密封力的图。
具体实施方式
本发明提供一种用于产生超声波密封件的方法。所述超声波密封件形成于两个聚合物膜之间。所述方法包括制备多层膜，所述多层膜具有背层和密封层。密封层包括超声波可密封的烯烃基聚合物(USOP)。USOP基于以下特性加以选择：
(a)熔融热ΔHm小于130J/g，
(b)峰值熔融温度Tm小于125℃，
(c)剪切储能模量(G′)为50MPa到500MPa，以及
(d)剪切损耗模量(G″)大于10MPa。
所述方法包括使第一多层膜的密封层与第二多层膜的密封层接触，形成密封区域。所述方法包括使密封区域经历超声波能量。所述方法包括在两个密封层之间形成超声波密封件，所述超声波密封件具有30N/mm到80N/mm的密封强度。
本发明方法利用超声波密封装置，从而在两个聚合物膜之间产生超声波密封件。超声波密封装置包括以下组件。
(1)砧座，其中放置膜以在压力下接触。砧座允许将高频振动导引到密封区域中的膜。砧座包括接触所述膜中的一个的能量导引器。
(2)超声波堆叠包括(a)转换器(将电信号转换成机械振动)、(b)变幅杆(修改振动的振幅)以及(c)焊头(将机械振动施加到要焊接或密封的零件)。焊头也称为超声波发生器。将超声波堆叠的所有三个元件调整到在相同的超声波频率(通常是从15kHz、20kHz、30kHz、35kHz到40kHz或70kHz)下共振。
使聚合物膜经历超声波能量，由于振动能量的吸收而引起塑料的局部熔融。跨越要焊接的接合点引入振动。
超声波密封不同于并且不包括热密封。热密封程序包括从打开位置移动到闭合位置的热金属密封夹。在闭合位置时，在预定密封压力和预定密封温度下，热金属夹与膜的最外层直接接触一段时间(停留时间)。在停留时间期间，热量穿过膜的最外层传递以熔融并熔化相对的内部密封层，形成热密封件。一般来说，最外层的熔融温度高于密封层。因此，在密封层熔融形成密封件时，膜的最外层不熔融并且不会粘住或基本上不会粘住密封夹。可以对密封夹条施加表面处理以进一步降低对膜的粘性影响。密封夹再次打开后，将膜冷却到室温。
在热密封中，相对的膜经由界面处的材料相互扩散而接合在一起，所述相互扩散通过从密封条到密封界面的传导型热流得到促进，借此热密封条的温度和停留时间是关键的自变量。在如聚乙烯的半结晶聚合物密封剂的情况下，举例来说，热密封条温度需要设定成至少在对应于密封剂的完全熔融的温度下，以便形成强密封件。
反之，在超声波密封中，密封条(焊头和砧座对)通常是在环境温度下，并且超声波产生和流动是因变量，它们受到接触几何、振动振幅和频率、静载荷以及材料选择的控制。实现界面处的完全熔融所必需的超声波能量内部产生于聚合物内。关于指定频率和接触几何，影响超声波密封件形成的过程变量是振荡的振幅和通过焊头施加的叠加的密封力。用以促进超声波密封所需的高温通过变形能部分耗散成超声波而内部产生，如受到聚合物的粘弹性特征控制。所耗散的能量引起温度增加，增加的程度取决于系统的超声波能力。
在常规超声波焊接系统中，密封力将焊头振荡的振幅转化为材料内部的振荡变形并且无意中导致砧座逐步渗透到密封区域中。从砧座延伸到密封区域中的能量导引器的轮廓和半球形形状进一步放大了密封区域中的应力集中，进一步恶化了过量材料围绕砧座流动的问题。
关于线形粘弹性方案中的振荡变形，每单位体积(拉伸变形的每正弦周期)超声波产生的速率示出在方程式(I)中：
其中f是振荡频率，
ε是变形振幅，并且
E″是损耗模量。
方程式(I)显示，对于指定变形振幅和频率来说，超声波产生速率与损耗模量成线性比例，然而对于振动振幅的函数关系是二次幂。将方程式(I)直接用于超声波密封是有问题的，因为(i)变形是不均匀的，(ii)密封区域中的大量材料是非等温的，并且(iii)以上方程式中的振幅ε不是焊头的振幅，而是施加到材料的变形的振幅，它取决于在密封周期期间变化的密封力。
1.背层和密封层
所述方法包括制备多层膜。多层膜具有背层、密封层以及任选的胶粘剂层。适合背层的材料的非限制性实例包括聚(对苯二甲酸乙二酯)(PET)、聚酰胺、丙烯基聚合物(例如双向拉伸聚丙烯或BOPP)以及金属箔(例如铝箔)。
多层膜的密封层包括超声波可密封的烯烃基聚合物(USOP)。
鉴于以上方程式(I)，申请人已经求出了参数来确定聚合物是否适合于超声波密封。第一，基于超声波产生速率与损耗模量之间的比例关系，在焊头振荡开始展现高损耗模量的聚合物是快速超声波所要的。
第二，超声波产生速率与变形振幅的平方函数关系表明，具有更低刚性的聚合物是所要的，因为这将允许针对指定密封力在聚合物中实现更大的变形振幅。尽管增加对焊头的密封力可以增强振荡开始时聚合物中的变形振幅，但是为了避免在熔融后挤压聚合物，需要极小的密封力来产生超声波密封件。因为半结晶聚合物的模量在熔融后会下降超过两个数量级，所以使用大密封力将导致熔融物被过度挤离密封区域。为了确保极小密封力情况下的最大超声波产生，所希望的是选择具有低模量的聚合物，以便在密封周期早期产生最大的振荡振幅。具有较低模量的聚合物在环境条件下还具有固态模量与熔融状态模量之间的较小差异，所述较小差异是防止熔融物中的材料过度流动的额外因数。基于以上内容，在变形开始时，以高损耗模量以及低储能模量为特征的聚合物是所要。
第三，由于粘弹性耗散所产生的超声波升高了温度，从而使界面处的半结晶熔融，从而允许形成强密封件。对于快速超声波密封特征来说，具有较低的熔融超声波以及进行完全熔融的低温的聚合物是所要的。对于这些聚合物来说，用于将聚合物变换成熔融物所必需的振荡持续时间可以显著缩短，因此周期时间较短。
第四，为了防止可以被推出密封区域的受到高应力的熔融物凝固，具有快速弛豫时间的聚合物是所要的。快速弛豫时间可以通过以下因素中的一个或多个获得，所述因素包括较低分子量、窄分子量分布以及减少的或无长链支化。被挤出的聚合物材料的珠粒形成了呈剥离几何的初始应力区域，因此，这种珠粒对周围材料的强粘附以及没有大的应力冻结有利于高剥离强度。不良粘附或定向冻结区域可以在剥离测试期间提供对裂纹的开始和传播的抗性降低的路径。
第五，具有低分子量的聚烯烃对于改良填缝力是合乎需要的，所述填缝力即密封剂流入空隙和周围的污染物中的能力。超声波密封不受热粘着强度限制(热密封受热粘着强度限制)，因为超声波密封利用冷密封工具，这允许密封件在与工具接触的同时有效冷却。这些冷却区段可以在振荡停止之后并入到密封周期中，从而允许热粘着强度的快速积累和聚合物的凝固远快于常规超声波密封中可实现的。
因此，经由本发明超声波密封方法实现了具有填缝力和包装周期时间的组合的组合物。其它条件相同的情况下，在超声波密封中，较低分子量聚烯烃执行起来将比高分子量聚烯烃要好。
鉴于以上原理，本发明方法包括为密封层选择超声波可密封的烯烃基聚合物。如本文中所用的“超声波可密封的烯烃基聚合物”(或USOP)是当经历超声波能量时形成密封件并且具有以下特性中的每一个的烯烃基聚合物：
(a)熔融热ΔHm小于130J/g并且如本文中所述通过差示扫描量热法(DSC)测量；
(b)峰值熔融温度Tm小于125℃并且如本文中所述通过(DSC)方法测量；
(c)在10℃下的剪切储能模量(G′)为50MPa到500MPa，其中G′是通过本文中所述的动态机械热分析(DMTA)测量的模量的同相分量；以及
(d)在10℃下的剪切损耗模量(G″)大于10MPa，其中G″是通过本文中所述的动态机械热分析(DMTA)测量的模量的异相分量。
在一个实施例中，USOP是当经历超声波能量时形成密封件并且具有以下特性中的每一个的烯烃基聚合物：
(a)熔融热ΔHm是从50J/g到小于130J/g；
(b)峰值熔融温度Tm大于90℃到小于125℃；
(c)在10℃下的剪切储能模量(G′)为50MPa到350MPa，以及
(d)剪切损耗模量(G″)为大于10MPa到40MPa。
在一个实施例中，超声波可密封的烯烃基聚合物是丙烯基塑性体或弹性体(“PBPE”)。“丙烯基塑性体或弹性体”(或“PBPE”)包含至少一种如下共聚物，所述聚合物具有至少50重量％衍生自丙烯的单元和至少约5重量％衍生自除丙烯以外的共聚单体的单元。此类PBPE型聚合物进一步描述于USP6,960,635和6,525，157中，所述专利以引用的方式并入本文中。此类PBPE可以商标名VERSIFY购自陶氏化学公司(TheDowChemicalCompany)或以商标名VISTAMAXX购自埃克森美孚化学公司(ExxonMobilChemicalCompany)。
在一个实施例中，PBPE的另一特征为包含(A)介于60wt％与小于100wt％之间、介于80wt％与99wt％之间或介于85wt％与99wt％之间的衍生自丙烯的单元和(B)介于大于零与40wt％之间或介于1wt％与20wt％之间、介于4wt％与16wt％之间或介于4wt％与15wt％之间的衍生自乙烯的单元以及任选地一种或多种C4-10□-烯烃；并且每1000个总碳平均含有至少0.001、至少0.005或至少0.01个长支链，其中术语长支链是指比短支链多至少一(1)个碳的链长，并且其中短支链是指比共聚单体中的碳数少两(2)个碳的链长。举例来说，丙烯/1-辛烯互聚物的主链具有长度是至少七(7)个碳的长支链，但这些主链还具有长度仅六(6)个碳的短支链。丙烯/乙烯共聚物互聚物中长支链的最大数量不超过每1000个总碳3个长支链。
在一个实施例中，PBPE共聚物的熔融温度(Tm)为55℃到小于125℃。
适合USOP的PBPE的非限制性实例包括可获自陶氏化学公司的VERSIFY2000和VERSIFY2200。
在一个实施例中，超声波可密封的烯烃基聚合物是线性低密度聚乙烯。线性低密度聚乙烯(“LLDPE”)包含以LLDPE的总重量计大多数重量百分比的呈聚合形式的衍生自乙烯的单元。在一个实施例中，LLDPE是乙烯与至少一种烯系不饱和共聚单体的互聚物。在一个实施例中，所述共聚单体是C3-C20α-烯烃。在另一个实施例中，所述共聚单体是C3-C8α-烯烃。在另一个实施例中，C3-C8α-烯烃选自丙烯、1-丁烯、1-己烯或1-辛烯。在一个实施例中，LLDPE选自以下共聚物：乙烯/丙烯共聚物、乙烯/丁烯共聚物、乙烯/己烯共聚物以及乙烯/辛烯共聚物。在另一个实施例中，LLDPE是乙烯/辛烯共聚物。
在一个实施例中，LLDPE的密度在0.865g/cc至0.940g/cc或0.90g/cc到0.94g/cc的范围内。LLDPE的熔融指数(MI)是0.1g/10min到10g/10min或0.5g/10min到5g/10min。
LLDPE可以用齐格勒-纳塔催化剂(Ziegler-Nattacatalyst)或单活性中心催化剂(例如钒催化剂)、限制几何构型催化剂以及茂金属催化剂产生。在一个实施例中，LLDPE用齐格勒-纳塔型催化剂产生。LLDPE为线性的，并且不含长链支化，并且不同于低密度聚乙烯(“LDPE”)，所述低密度聚乙烯是支化或非均匀支化的聚乙烯。LDPE具有相对较大数量的从主聚合物主链延伸的长支链。LDPE可以在高压力下使用自由基引发剂制备，并且密度通常是0.915g/cc到0.940g/cc。
在一个实施例中，LLDPE是齐格勒-纳塔催化的乙烯与辛烯的共聚物，并且密度为0.90g/cc到0.93g/cc或0.92g/cc。适合的齐格勒-纳塔催化的LLDPE的非限制性实例是以商标名DOWLEX出售的聚合物，其可购自密歇根州米德兰市的陶氏化学公司(TheDowChemicalCompany，Midland，Michigan)。
适合USOP的LLDPE的非限制性实例包括可获自陶氏化学公司的DOWLEX5056G。
在一个实施例中，超声波可密封的烯烃基聚合物是超低密度聚乙烯。超低密度聚乙烯(“ULDPE”)包含以ULDPE的总重量计大多数重量百分比的呈聚合形式的衍生自乙烯的单元。在一个实施例中，ULDPE是乙烯与至少一种烯系不饱和共聚单体的互聚物。在一个实施例中，所述共聚单体是C3-C20α-烯烃。在另一个实施例中，所述共聚单体是C3-C8α-烯烃。在另一个实施例中，C3-C8α-烯烃选自丙烯、1-丁烯、1-己烯或1-辛烯。在一个实施例中，ULDPE选自以下共聚物：乙烯/丙烯共聚物、乙烯/丁烯共聚物、乙烯/己烯共聚物以及乙烯/辛烯共聚物。在另一个实施例中，ULDPE是乙烯/辛烯共聚物。
在一个实施例中，ULDPE的密度在0.900g/cc到0.915g/cc的范围内。ULDPE的熔融指数(MI)是0.1g/10min到10g/10min或0.5g/10min到5g/10min。
适合USOP的ULDPE的非限制性实例包括可获自陶氏化学公司的ATTANE4100和ATTANESL4102。
在一个实施例中，超声波可密封的烯烃基聚合物是聚烯烃塑性体(或POP)。适合POP的非限制性实例包括乙烯/辛烯塑性体，例如可获自陶氏化学公司的AFFINITYPL1881G。
在一个实施例中，超声波可密封的烯烃基聚合物是乙烯/丙烯酸共聚物(或EAA)。合适的乙烯/丙烯酸共聚物的非限制性实例是可获自陶氏化学公司的PRIMACOR1410。
在一个实施例中，USPO是聚丁烯。
在一个实施例中，USOP是丙烯基三元共聚物，例如丙烯/丁烯/乙烯三元共聚物。
所述方法包括使第一多层膜的密封层与第二多层膜的密封层接触，形成密封区域。第二多层膜可以是与第一多层膜相同或不同的多层膜的部分。第二多层膜的密封层的组成可以与第一多层膜的密封层的组成相同或不同。
在一个实施例中，第二多层膜具有与第一多层膜相同的材料组成和结构。
所述方法进一步包括使密封区域经历(i)超声波能量和(ii)从2N/mm或3N/mm或4N/mm到5N/mm或6N/mm的密封力，并且在密封层之间形成超声波密封件，所述超声波密封件的密封强度是从30N/15mm或31N/15mm或32N/15mm或33N/15mm或34N/15mm或35N/15mm或36N/15mm或37N/15mm或38N/15mm或39N/15mm或40N/15mm或45N/15mm或50N/15mm或55N/15mm或60N/15mm或65N/15mm到70N/15mm或75N/15mm或80N/15mm。
超声波能量和密封力参数的非限制性实例提供在以下表A中。经历步骤可以包括以下表A中所示出的参数的任何组合。
表A
申请人发现，满足USOP的要求(特性(a)到(d))的聚合物材料出乎意料地能够使用极小密封力(2-6N/mm)形成强超声波密封件(30-80N/mm)。不受特定理论限制，我们相信，选择具有上述特性(a)到(d)的USOP以协同方式使产生适合超声波密封件所需的密封力降到最低。极小密封力(2-6N/mm)有利地(i)减少对膜聚合物的应力，(ii)减少或消除对其它膜层(例如阻挡层)的破坏，(iii)减少或消除聚合物被“挤出”密封区域，并且(iv)能够在密封区域中存在污染物时形成密封件。调整特性(a)到(d)以匹配特定的超声波密封件应用，本发明方法通过使用较少能量(使负载强度降到最低)和使密封件缺陷降到最低而有利地提高了生产效率，所述使用较少能量(使负载强度降到最低)和使密封件缺陷降到最低中的每一个在商业规模的柔性袋的生产期间，例如在FFS生产中均是有利的。
在一个实施例中，第一多层膜的密封层和第二多层膜的密封层是相同材料。
在一个实施例中，使多层膜进行自身折叠，使得相对的密封层面朝彼此并且形成密封区域。在这个实施例中，第一多层膜是折叠膜的第一部分并且第二多层膜是进行自身折叠的折叠膜的第二部分。换句话说，第二多层膜是经折叠并且放置成与密封层成相对关系的多层膜的一部分。对单一多层膜的将相同密封层的部分放置成彼此成相对关系以便形成密封件的操控发生于例如成型、填充和密封包装系统中。
在一个实施例中，使密封区域的膜部分与超声波密封装置的焊头和砧座接触。所述方法包括在形成步骤期间，将焊头从0微米或大于0微米或2微米或5微米的距离处移动到10微米或15微米或20微米。在密封工艺期间的焊头位移可以用例如激光传感器测量。以此方式，本发明方法有利地减少或消除了超声波密封工艺期间进入密封区域中的焊头位移。
在一个实施例中，背层是聚(对苯二甲酸乙二酯)(或PET)并且密封层是单层并且包括USOP。密封层中所存在的USOP选自ULDPE和POP。所述方法包括使密封区域经历超声波能量和4N/mm到6N/mm或4N/mm的密封力，并且形成密封强度为37N/mm到55N/mm的超声波密封件。
在一个实施例中，背层是BOPP，并且密封层是单层并且包括USOP，所述USOP选自ULDPE、PBPE和POP。所述方法包括使密封区域经历超声波能量和3N/mm到6N/mm或4N/mm的密封力；并且形成密封强度为55N/15mm到80N/15mm的超声波密封件。
在一个实施例中，密封层包括共挤出结构。共挤出结构包括面层、核心层和内层。背层被层压到共挤出结构。这形成了具有以下层结构的多层膜：背层/胶粘剂层/内层/核心层/面层。面层是接触层。内层位于背层与核心层之间。核心层包括选自ULDPE、PBPE和POP的USOP。所述方法包括使密封区域经历超声波能量和4N/mm密封力并且形成密封强度为35N/mm到55N/mm的超声波密封件。
在一个实施例中，密封件包括共挤出结构。共挤出结构包括面层、核心层和内层。核心层和任选地内层包括USOP。面层不含USOP。所述方法包括形成密封强度为35N/mm到50N/mm的超声波密封件。凭借恰当选择USOP，本发明方法有利地实现了将USOP放置在共挤出层中不是面层的一个层中。申请人出乎意料地发现，选择具有特性(a)到(d)的USOP不需要USOP存在于面层中来产生强超声波密封件(30-80N/mm)。
2.掺合物
第一多层膜和第二多层膜中的任何层都可以是两种或更多种组分的掺合物。
在一个实施例中，多层膜包括共挤出结构，所述共挤出结构是密封层。核心层和任选地内层包括低密度聚乙烯和USOP的掺合物。面层不含LDPE。术语“低密度聚乙烯”或“LDPE”是在高压釜中或在高压聚合工艺中，例如管状高压聚合工艺中制成的聚乙烯。在另一个实施例中，LDPE不包括线性低密度聚乙烯和高密度聚乙烯。LDPE的熔融指数(MI)是0.2g/10min或0.5g/10min到10g/10min或20g/10min或50g/10min。
LDPE的密度是0.915g/cc到0.925g/cc或0.930g/cc、0.935g/cc或0.940g/cc。
在一个实施例中，多层膜包括阻挡层。阻挡层是位于背层与密封层之间的内层。阻挡层的适合聚合物包括HDPE、LLDPE、LDPE、乙烯乙烯醇共聚物(EVOH)、经顺丁烯二酸酐改性的聚乙烯、聚酰胺(PA)、环烯烃共聚物(COC)、乙烯乙酸乙烯酯(EVA)、丙烯均聚物(PP)以及偏二氯乙烯聚合物以及其组合。
在许多商业应用中，一起使用两个超声波可密封的柔性膜，使得第二多层膜叠加在第一多层膜上，以便第一多层膜的密封层与第二多层膜的密封层接触。在其它应用中，可以折叠单一多层膜或单一薄片，使得同一密封层的两个表面彼此接触。
本发明方法可以包含两个或更多个本文中所披露的实施例。
3.膜结构
本发明方法产生经密封的膜结构。在一个实施例中，所述方法产生膜结构。所述膜结构包括第一多层膜和第二多层膜。每一个多层膜包括背层和密封层。每一个密封层包括具有以下特性的超声波可密封的烯烃基聚合物(USOP)：
(a)熔融热ΔHm小于130J/g，
(b)峰值熔融温度Tm小于125℃，
(c)剪切储能模量(G′)为50MPa到500MPa，以及
(d)剪切损耗模量(G″)大于10MPa。
所述多层膜被安排成使得第一多层膜的密封层与第二多层膜的密封层接触。当在4N/mm密封力下进行超声波密封时，所述密封层形成密封强度为30N/15mm到80N/15mm的超声波密封件。
在一个实施例中，当在4N/mm下进行超声波密封时，所述密封层形成超声波密封件，所述超声波密封件的密封强度是从30N/15mm或31N/15mm或32N/15mm或33N/15mm或34N/15mm或35N/15mm或36N/15mm或37N/15mm或38N/15mm或39N/15mm或40N/15mm或45N/15mm或50N/15mm或55N/15mm或60N/15mm或65N/15mm到70N/15mm或75N/15mm或80N/15mm。
在一个实施例中，膜结构的背层是选自PET、聚酰胺、BOPP、金属箔以及其组合的材料。
在一个实施例中，膜结构的USOP是选自PBPE、LLDPE、ULDPE、POP以及其组合的材料。
在一个实施例中，多层膜包括阻挡层。
在一个实施例中，第一多层膜和第二多层膜是单一柔性薄片的部分。单一柔性薄片经折叠以将第二多层膜叠加在第一多层膜上。
在一个实施例中，膜结构包括多层膜，其中背层包括BOPP并且密封层是单层，包含选自ULDPE、POP和PBPE的USOP。当在4N/mm密封力下进行超声波密封时，所述密封层形成密封强度为55N/15mm到80N/15mm的超声波密封件。
在一个实施例中，膜结构包括多层膜，其中背层是PET并且密封层是单层，包含选自ULDPE、POP和PBPE的USOP。当在4N/mm密封力下进行超声波密封时，所述密封层形成密封强度为37N/15mm到55N/15mm的超声波密封件。
在一个实施例中，膜结构包括多层膜，其中密封层是共挤出结构，包括面层、核心层和内层。面层包括选自ULDPE、POP和PBPE的USOP。当在4N/mm密封力下进行超声波密封时，所述密封层形成密封强度为35N/15mm到55N/15mm的超声波密封件。
在一个实施例中，膜结构包括多层膜，其中密封层是共挤出结构，包括面层、核心层和内层。核心层和内层中的至少一个包括选自ULDPE、POP和PBPE的USOP。面层不含USOP。当在4N/mm密封力下进行超声波密封时，所述密封层形成密封强度为35N/15mm到50N/15mm的超声波密封件。
在一个实施例中，膜结构包括多层膜，其中第二多层膜叠加在第一多层膜上，形成共同的外围边缘。所述超声波密封件沿着共同的外围边缘定位。
在一个实施例中，超声波密封件是硬密封件。
在一个实施例中，超声波密封件是脆密封件。
在一个实施例中，本发明包括包含本发明膜结构的柔性容器。合适柔性容器的非限制性实例包括袋、小袋、自立袋以及成型-填充和密封袋。
本发明膜结构可以包含两个或更多个本文中所披露的实施例。
4.柔性容器
本发明方法产生柔性容器。在一个实施例中，柔性容器包括第一多层膜和第二多层膜。每一个多层膜包括背层和密封层。密封层包括具有以下特性的超声波可密封的烯烃基聚合物(USOP)：
(a)熔融热ΔHm小于130J/g，
(b)峰值熔融温度Tm小于125℃，
(c)剪切储能模量(G′)为50MPa到500MPa，以及
(d)剪切损耗模量(G″)大于10MPa。
所述多层膜被安排成使得每一个多层膜的密封层彼此接触并且第二多层膜叠加在第一多层膜上，形成共同的外围边缘。所述柔性容器包括2折叠区域和4折叠区域。当在4N/mm密封力下对2折叠区域和4折叠区域进行超声波密封时，所述区域各自形成密封强度为30N/15mm到80N/15mm的超声波密封件。
在一个实施例中，2折叠区域和4折叠区域在4N/mm下进行超声波密封并且形成超声波密封件，所述超声波密封件的密封强度是从30N/15mm或31N/15mm或32N/15mm或33N/15mm或34N/15mm或35N/15mm或36N/15mm或37N/15mm或38N/15mm或39N/15mm或40N/15mm或45N/15mm或50N/15mm或55N/15mm或60N/15mm或65N/15mm到70N/15mm或75N/15mm或80N/15mm。
在一个实施例中，2折叠区域包括共同的外围边缘的至少一部分。
在一个实施例中，4折叠区域包括纵向密封件的至少一部分。
在一个实施例中，柔性容器的多层膜包括背层，所述背层选自PET和BOPP。
在一个实施例中，柔性容器包括多层膜，其中密封层是单层并且包括USOP，所述USOP选自由ULDPE、POP、PBPE以及其组合组成的群组。
在一个实施例中，2折叠区域是角撑板密封件。
在一个实施例中，4折叠区域是横截面鳍形密封件。
合适柔性容器的非限制性实例包括袋、小袋、自立袋以及成型-填充和密封袋。
适用于由柔性容器容纳的内含物的非限制性实例包括食物(饮料、汤、乳酪、谷物、点心、饼干、薯片)、液体、洗发精、油、蜡、润肤剂、洗剂、保湿霜、药剂、糊剂、表面活性剂、凝胶、胶粘剂、悬浮液、溶液、酶、皂、化妆品、擦剂、可流动微粒以及其组合。
本发明柔性容器可以包含两个或更多个本文中所披露的实施例。
定义
除非相反地陈述、从上下文暗示或本领域惯用的，否则所有份数和百分比都以重量计，并且所有测试方法都是到本发明的申请日为止的现行方法。
如本文中所用的术语“组合物”包括构成组合物的材料的混合物以及由组合物的材料形成的反应产物和分解产物。
术语“包含”和其派生词并不意图排除任何其它组分、步骤或程序的存在，无论其是否在本文中披露。为了避免任何疑问，除非相反地陈述，否则在本文中通过使用术语“包含”所要求的的所有组合物可以包括无论聚合或呈其它形式的任何其它添加剂、佐剂或化合物。相比之下，术语“基本上由......组成”从任何随后列举的范围中排除除外对可操作性来说不是必不可少的那些之外的任何其它组分、步骤或程序。术语“由......组成”排除未专门叙述或列举的任何组分、步骤或程序。除非另外说明，否则术语“或”是指单独以及以任何组合形式列举的成员。
如本文中所用的术语“乙烯基聚合物”是指如下聚合物，所述聚合物包含多数量的呈聚合形式的乙烯单体(以聚合物的重量计)并且任选地可以包含一种或多种共聚单体。
如本文中所用的术语“烯烃基聚合物”是指如下聚合物，所述聚合物包含多数量的呈聚合形式的烯烃单体，例如乙烯或丙烯(以聚合物的重量计)。
如本文中所用的术语“丙烯基聚合物”是指如下聚合物，所述聚合物包含多数量的呈聚合形式的丙烯单体(以聚合物的重量计)并且任选地可以包含一种或多种共聚单体。
如本文中所用的术语“丙烯/乙烯共聚物”是指如下聚合物，所述聚合物包含多数量的呈聚合形式的丙烯单体(以聚合物的重量计)和少数量的乙烯共聚单体，并且任选地可以包含一种或多种其它共聚单体。
测试方法
根据ASTMD792测量密度。
DMTA(动态机械热分析)
在185℃下将样品从颗粒压缩模制，并且在10±5℃/min的平均冷却速率下固化。从模制薄片中切出矩形样品用于测量。在TA仪器(TAInstruments)的旋转流变仪ARES中，在从-100℃到接近样品的完全熔融温度的温度范围内，执行扭转动态机械测量。在每步长浸泡时间为120秒的情况下，以5℃的步长升高温度。在10rad/s的频率下向30mm长度、12.7mm宽度和2.8mm厚度的矩形样品施加0.1％的动态振荡变形。所测量的转矩用于计算随温度而变的储能剪切模量G′和损耗剪切模量G″。
差示扫描量热法(DSC)
差示扫描量热法(DSC)用于测量聚合物(例如，乙烯基(PE)聚合物)的熔融和结晶行为。首先在约175℃下将样品熔融按压成薄膜并且然后冷却到室温。用模用冲头切割出约5到8mg聚合物膜样品并且对其进行称重并且将其放置到DSC盘中。将盖子在盘上旋紧以确保封闭的气氛。将样品盘放置到用氮气净化的经校准的DSC单元中，并且然后以约10℃/min的速率加热，对于PE来说，加热到180℃的温度。使样品在此温度下保持三分钟。然后，以10℃/min的速率将样品冷却到-40℃以记录结晶轨迹，并且在所述温度下等温保持三分钟。接着以10℃/min的速率对样品进行再加热，直到完全熔融为止，并且所得第二熔融轨迹用于计算熔融热和熔融温度。结晶度百分比是通过将从第二加热曲线测定的熔融热(Hm)除以PE的理论熔融热292J/g(PP为165J/g)并且将此数量乘以100来计算(例如结晶度％＝(Hm/292J/g)×100(对于PE来说))。
除非另外说明，否则峰值熔点(Tm)从第二加热曲线测定并且对应于最高吸热峰的温度。结晶温度(Tc)从冷却曲线(峰值Tc)测定。
熔体流动速率或MFR根据ASTMD1238，条件230℃/2.16kg来测量。
熔融指数或MI根据ASTMD1238，条件190℃/2.16kg来测量。
密封强度
通过沿着组成性吹塑膜的横向对齐密封条，对100mm宽的样品执行密封。切割出三份宽度为15mm的样品用于测量密封强度。所述程序重复三次以得到总共九份样本用于密封强度测试。根据DIN55529测量密封强度。对于以T形剥离几何加载的50mm长的臂来说，牵拉速率是100mm/min。从力-伸长曲线的最大值确定密封强度。所报告的值是九份样本的密封强度的平均值和标准偏差。
现将在以下实例中详细描述本发明的一些实施例。
实例
1.材料
下表1中提供本发明实例和比较样品的材料。
表1
Dowlex、Attane、Affinity、Primacor、Versify是由陶氏化学公司制造的商用产品家族。
Surlyn1601是由杜邦(DuPont)供应的钠离聚物。
PB0300M是来自莱昂德巴塞尔聚合物(LyondellBasellPolymers)的聚丁烯-1树脂。
CosmopleneFL7641L是来自聚烯烃公司(新加坡)私人公司(PolyolefinCompany(Singapore)PteLtd.)的聚丙烯三元共聚物。
GreenflexFD20是来自欧洲聚合体公司(PolimeriEurope)的含5％VA含量的乙烯乙酸乙烯酯共聚物(EVA)。
TNS20是来自意大利塔格乐菲工业有限公司(TaghleefIndustriesS.p.A.，Italy)的BOPP。
HostaphonRN是来自德国皮茨薄膜有限公司(PuetzGmbH+CoFolienKGGermany)的PET。
图1示出了若干USOP的G′对比G″的标绘图，所述USOP包括表1的USOP。
实例1
密封层可以是通过吹塑膜挤出形成的单层结构或共挤出结构。
1.单层吹塑膜在Covex吹塑膜线上用45mm(28L/D)挤出机和150mm直径模具制备。对于LLDPE和乙烯共聚物来说，模隙是1.5mm；对于LDPE来说，模隙是1.0mm；并且对于丙烯共聚物来说，模隙是2.0mm。使用2.5的吹胀比以22.5kg/h产生规格为50微米的膜。熔融温度是220℃。为了44达因表面张力，对膜进行电晕处理。
2.共挤出的多层吹塑膜在具有两个50mm外皮挤出机(30L/D)和65mm核心层挤出机(30L/D)的阿尔派线(Alpineline)上以及配备有内部气泡冷却的直径200mm的模具来制备。模隙是2.5mm。对于三层结构，使用1∶3∶1的标称厚度比，在115kg/h的总输出速率下产生规格为50微米的膜。吹胀比是2.5并且熔融温度是约230℃。为了44达因表面张力，在密封剂的侧面上对膜进行电晕处理。
多层膜是通过将背层(12微米PET层或20微米BOPP层)层压到50微米密封层(单层结构或共挤出结构)上产生的。使用胶粘剂层将背层层压到密封层。层压结构经烘箱固化以完全固化胶粘剂并且形成超声波可密封的柔性膜结构。当密封层是共挤出结构时，多层膜具有以下层配置：背层(12或20)/胶粘剂层/内层(10)/核心层(30)/面层(10)，其中厚度以微米计示出在圆括号中。
在下表2中所提供的条件下，对多层膜进行超声波密封。
表2提供用于评估多层膜的超声波密封件条件。
表2-超声波密封件条件
将相对多层膜的密封层放置成彼此接触并且使其经历上表2中的超声波密封件条件。
图2A是在如图2B中示意性地展现的平坦密封几何的情况下产生的超声波密封件的示意性图示。
图3A是在如图3B中示意性地展现的2折叠/4折叠密封几何的情况下产生的2折叠区域和4折叠区域的超声波密封件的示意性图示。
下表3提供本发明超声波热密封件和比较样品的特性。
表3
表3(续)
对于共挤出结构的解释：
实例16、17、18的[*]：面层示出在树脂列F中，核心层和内层是：Dowlex5056G+20％LDPE310E
实例29的[+]：所有层都是Dowlex5056G
实例30的[#]：面层是Versify2000；核心层和其它表层是Dowlex5056G
实例31的[$]：面层和内层是Dowlex5056G，核心层是Versify2000
[&]为了获得15N/15mm的密封强度所需的USS密封力
**比较样品
PHSS-根据DIN55529测定的平稳段热密封强度(N/15mm)
USS-根据DIN55529测定的超声波密封强度(N/15mm)
讨论
图4到6示出了含单层密封层和PET背层或BOPP背层的多层膜的超声波密封强度(USS)对比密封力曲线。
图7示出了单层密封层和共挤出密封层的USS对比密封力。实例6中的单层密封件与实例16中的面层相同(AFFINITY1881G)。实例5中的单层密封件与实例17中的面层相同(ATTANE4102)。实例8中的单层与实例18中的面层相同(VERSIFY2200)。
图8示出了用2折叠/4折叠密封几何制成的超声波密封件的USS对比密封力曲线。
A.申请人发现，在(i)单层密封层、(ii)共挤出密封层的面层或(iii)共挤出密封层的核心层和/或内层中存在USOP并且不含面层，并且密封力产生密封强度为35-55N/mm的超声波密封件。换句话说，USOP不一定要在面层中来帮助产生强超声波密封件。
B.申请人发现，当密封层中的USOP被调整到背层时，背层以协同方式促成增强的USS。当背层是BOPP时，4-6N/mm或4N/mm的密封力产生密封强度为55N/mm到80N/mm的超声波密封件。凭借恰当选择背层和USOP，所述层有助于改良密封强度。
C.申请人发现，在具有2折叠区域和4折叠区域的柔性膜容器中使用USOP并且用4N/mm密封力进行超声波密封的USS大于已经进行热密封的相同2折叠/4折叠密封件的0.8(USS∶PHSS比大于0.8)。
尤其期望的是，本发明不限于本文中所含有的实施例和说明，而是包括那些实施例的修改形式，所述修改形式包括在以下权利要求书范围内出现的实施例的部分和不同实施例的要素的组合。

Claims (15)

1.一种用于产生超声波聚合物密封件的方法，包含：
制备包含背层和密封层的多层膜，所述密封层包含具有以下特性的超声波可密封的烯烃基聚合物(USOP)：
(a)熔融热ΔHm小于130J/g，
(b)峰值熔融温度Tm小于125℃，
(c)剪切储能模量(G′)为50MPa到500MPa，以及
(d)剪切损耗模量(G″)大于10MPa；
使所述多层膜的所述密封层与第二多层膜的密封层接触，形成密封区域；
使所述密封区域经历超声波能量；以及
形成密封强度为30N/15mm到80N/15mm的超声波密封件。
2.根据权利要求1所述的方法，包含使所述密封区域经历(i)超声波能量和(ii)2N/mm到6N/mm的密封力。
3.根据权利要求1所述的方法，包含将所述密封区域放置在超声波密封装置的焊头与砧座之间；以及使所述密封区域经历(i)超声波能量和(ii)4N/mm的密封力。
4.一种膜结构，包含：
第一多层膜和第二多层膜，每一个多层膜包含背层和密封层，每一个密封层包含具有以下特性的超声波可密封的烯烃基聚合物(USOP)：
(a)熔融热ΔHm小于130J/g，
(b)峰值熔融温度Tm小于125℃，
(c)剪切储能模量(G′)为50MPa到500MPa，以及
(d)剪切损耗模量(G″)大于10MPa；
所述多层膜被安排成使得所述第一多层膜的所述密封层与所述第二多层膜的所述密封层接触；以及
当在4N/mm密封力下进行超声波密封时，所述密封层形成密封强度为30N/15mm到80N/15mm的超声波密封件。
5.根据权利要求4所述的膜结构，其中所述背层是选自由PET、聚酰胺、BOPP和金属箔组成的群组的材料。
6.根据权利要求4到5中任一项所述的膜结构，其中所述USOP是选自由PBPE、LLDPE、ULDPE、POP以及其组合组成的群组的材料。
7.根据权利要求4到6中任一项所述的膜结构，其中所述第一多层膜和所述第二多层膜是单一柔性薄片的部分，所述单一柔性薄片经折叠以将所述第二多层膜叠加在所述第一多层膜上。
8.根据权利要求4到7中任一项所述的膜结构，其中所述背层包含BOPP，并且所述密封层是单层，包含选自由ULDPE、POP和PBPE组成的群组的USOP，并且当在4N/mm密封力下进行超声波密封时，所述密封层形成密封强度为55N/15mm到80N/15mm的超声波密封件。
9.根据权利要求4到7中任一项所述的膜结构，其中所述背层是PET，并且所述密封层是单层，包含选自由ULDPE、POP和PBPE组成的群组的USOP，并且当在4N/mm密封力下进行超声波密封时，所述密封层形成密封强度为37N/15mm到55N/15mm的超声波密封件。
10.根据权利要求4到7中任一项所述的膜结构，其中所述密封层是共挤出结构，包含面层、核心层和内层；
所述面层包含选自由ULDPE、POP和PBPE组成的群组的USOP；以及
当在4N/mm密封力下进行超声波密封时，所述密封层形成密封强度为35N/15mm到55N/15mm的超声波密封件。
11.根据权利要求4到7中任一项所述的膜结构，其中所述密封层是共挤出结构，包含面层、核心层和内层；
所述核心层和所述内层中的至少一个包含选自由ULDPE、POP和PBPE组成的群组的USOP；
所述面层不含USOP；以及
当在4N/mm密封力下进行超声波密封时，所述密封层形成密封强度为35N/15mm到50N/15mm的超声波密封件。
12.根据权利要求4到11中任一项所述的膜结构，其中所述第二多层膜叠加在所述第一多层膜上，形成共同的外围边缘；并且所述超声波密封件沿着所述共同的外围边缘定位。
13.一种柔性容器，包含：
根据权利要求4所述的膜结构；
其中所述多层膜被安排成使得每一个多层膜的所述密封层彼此接触并且所述第二多层膜叠加在所述第一多层膜上，形成共同的外围边缘；
2折叠区域和4折叠区域；并且当在4N/mm密封力下对所述2折叠区域和所述4折叠区域进行超声波密封时，所述区域各自形成密封强度为30N/15mm到80N/15mm的超声波密封件。
14.根据权利要求13所述的柔性容器，其中所述2折叠区域包含所述共同的外围边缘的至少一部分。
15.根据权利要求13到14中任一项所述的柔性容器，其中所述4折叠区域包含纵向密封件的至少一部分。
CN201480020416.8A 2013-04-09 2014-04-09 用于产生超声波密封件的方法以及具有所述超声波密封件的膜结构和柔性容器 Active CN105705316B (zh)

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