CN111770833B - 生产多层基材的方法 - Google Patents

生产多层基材的方法 Download PDF

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CN111770833B
CN111770833B CN201980013409.8A CN201980013409A CN111770833B CN 111770833 B CN111770833 B CN 111770833B CN 201980013409 A CN201980013409 A CN 201980013409A CN 111770833 B CN111770833 B CN 111770833B
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coating material
multilayer substrate
package
heat treatment
substrate
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CN111770833A (zh
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R·博赫尼亚
S·施特伦格
R·邦格尔斯
M·埃克斯
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Henkel AG and Co KGaA
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Abstract

本发明涉及一种生产多层基材的方法以及通过该方法所生产的基材的用途，其中所述基材包含多功能涂层。

Description

生产多层基材的方法
本发明涉及一种生产多层基材的方法以及通过这种方法所生产的基材的用途，其中所述基材包含多功能涂层。
近年来，互联网作为各种类型的商品的分销渠道已变得日益重要。虽然服装、电子设备、电脑和鞋类占了互联网上所销售的商品的最大份额，但越来越多的人正通过互联网购买家庭用品、家具和内部装饰以及日用品，例如食品、药店物品(drugstore item)和宠物用品。为了使商品到达消费者手中，不仅需要复杂的物流系统，还需要安全的运输，从而使敏感易碎的商品完好无损地抵达消费者手中。
例如，借助于适合的包装材料，可以实现商品的安全包装；所述包装材料通常具有一种衬垫，通过所述衬垫对待运输的商品进行保护。这种包装材料的典型实例是气垫膜，也就是塑料膜，其具有空气填充的气袋，藉此可以缓冲机械振动。然而，这些气泡缠绕膜的缺点在于它们通常由基于石油的塑料制成且其生产和废弃处理涉及严重的生态干预。鉴于对可持续性的日益增长的需要和日益增长的期望，这一问题更加严重。因此需要具有相同性能但显示出更好的环境相容性的替代性包装材料。
WO 2014/051876描述了一种用于生产包装材料的粘合剂组合物，该粘合剂组合物含有具有绝缘效果的微球体。
DE 20 2011109 020描述了一种复合体，其由用天然纤维制成的承载基材(carrier substrate)和至少一个用柔性膜状基材制成的结合基材层组成，这两者完全结合到经干燥的粘合剂层上，其中所述粘合剂层由含水的发泡粘合剂制成。
WO 2010/129493公开了一种可充气的邮件袋，其具有可充气的衬里和可以通过其给所述衬里充气的连接器(connector)。
现有技术中所描述的材料通常只能通过复杂的生产工艺获得，因此，产量有限。此外，常规材料的缺点在于由于引入的衬垫层而具有庞大的体积，从而导致很高的成本，尤其是在运输和储存所述材料时。
因此，本发明的目标是提供一种允许生产既可以吸收机械冲击又易于储存和运输的包装材料的方法。
令人惊讶地发现，通过生产具有多功能涂层的多层基材的方法实现了这一目标。
因此本发明的第一主题是生产多层基材的方法，其包括以下步骤：
a)提供第一材料，所述第一材料具有第一表面，所述第一表面具有至少一个边缘区域和被所述边缘区域围绕的至少一个内部区域；
b)向所述第一表面的内部区域施用涂布材料，所述涂布材料包含可膨胀的微粒；
c)干燥所述涂布材料；
d)将所述第一材料的第一表面与第二材料的表面接触以形成所述多层基材，从而使得所述涂布材料位于所述第一材料与所述第二材料之间。
令人惊讶地发现，以此方式可以获得体积较小的基材。根据本发明的方法的进一步特征在于，其允许大量生产基材，且所述生产可在不需要对所用设备进行复杂改造的情况下实现。
在优选实施方案中，第一材料具有一个以上的内部区域。
涂布材料优选施用于整个表面上。出于本发明的目的，这应理解为意指用涂布材料覆盖整个内部区域的方式施用。为了节省成本和材料，有利的是，间歇地或仅部分施用涂布材料，从而不完全覆盖内部区域。因此，优选其中将涂布材料部分施用到内部区域的替代性实施方案。
在优选实施方案中，第一材料与第二材料的接触通过使用粘合剂而进行。粘合剂优选在第一材料与第二材料的接触之前施用于第一表面的边缘区域上。尤其优选将粘合剂均匀或连续地施用于第一表面的边缘区域上，从而使所述边缘区域被所述粘合剂完全覆盖。令人惊讶地发现，以此方式可以在不损害涂布材料的性能的情况下改善基材中材料的复合粘附性。当确保内部区域没有粘上粘合剂时，根据本发明的方法的优点得到充分发挥。
在根据本发明的方法的优选实施方案中，第一材料和第二材料以连续幅材(continuous web)的形式提供。在替代性的优选实施方案中，在施用涂布材料之前或之后，将第一材料划分成单个的单元，各个单元具有边缘区域和被所述边缘区域围绕的内部区域。在替代性的优选实施方案中，第一材料的划分与将涂布材料施用到内部区域上同时进行。在工艺技术方面，将切割与施用涂布材料组合，且优选在合并的步骤中进行。
在优选实施方案中，第一材料选自基于纤维素、塑料和金属的材料。例如，第一材料可具有合成纤维以提高材料的稳定性。
第一材料尤其优选基于纤维素的材料。特别是，第一材料选自纸、卡纸板和涂布纸。
在优选实施方案中，第二材料选自基于纤维素、塑料和金属的材料。例如，第二材料可具有合成纤维以提高材料的稳定性。
第二材料尤其优选基于纤维素的材料。特别是，第二材料选自纸、卡纸板和涂布纸。
在优选实施方案中，第一材料和第二材料为纸。第二材料尤其优选以连续幅材的形式存在。
根据本发明的方法的特征在于其快速过程控制，从而允许短时间内生产出大量的多层基材。这尤其通过仔细协调所用材料的特性来实现。因此，其中在80℃或更低的温度下、优选在40℃至75℃的温度下干燥涂布材料的本发明的实施方案是优选的。令人惊讶地发现，在这些温度下实现了快速干燥而不会损害涂布材料的性能，因此提高了工艺产量。
当使用基于聚合物的涂布材料时，在工艺产量方面实现了最佳结果。因此，在每种情况下基于涂布材料的总重量，其中涂布材料为具有10至40重量％、优选15至35重量％的可膨胀的微粒的基于聚合物的涂布材料的实施方案是优选的。令人惊奇地发现，这样的涂布材料可以高速施用，但同时具有足够的稳定性，从而使得其在施用后不会流动。
根据本发明的方法中所用的涂布材料具有可膨胀的微粒。微粒优选在未膨胀状态下具有5至18μm、优选10至17μm的以D50值表示的粒径。
可膨胀的微粒优选是可热膨胀的微粒，其优选具有球体形状。
在根据本发明的方法的优选实施方案中，在另一步骤中将多层基材转变成包装。这可以例如通过切割和折叠多层基材进行。包装优选是信封、邮件袋、袋子、购物袋、小袋(pouch)或纸箱，其样式和大小可变。在特别优选的实施方案中，包装是邮件袋。
在优选实施方案中，根据本发明的方法包括又一步骤，其中对多层基材进行处理以使可膨胀的微粒膨胀。
在优选实施方案中，在根据本发明的方法的步骤d)之后，进行热处理步骤。
根据本发明的方法允许生产其体积可随热处理增加的基材，其中该热处理可独立于生产方法进行。在优选实施方案中，热处理可以在时间和/或位置方面与其它方法步骤分开进行。以此方式，可以在体积较小的状态下运输和储存基材。基材由于热处理而达到其最终体积，其中所述热处理使得涂布材料的微粒发生膨胀。根据本发明的方法使得可以仅在使用基材前短时间内进行热处理，用现有技术中所描述的常规方法这是不可能的。例如，可以将基材进一步加工成邮件袋，其因为很小的体积和很小的厚度而仅占用很小的空间。在使用邮件袋之前，可对其进行热处理，从而使微粒膨胀，邮件袋呈现出其期望的缓冲效果。以此方式，可以通过根据本发明的方法节约有价值的储存和运输容量。
热处理优选在85℃至150℃的温度下进行，优选在90至140℃的温度下进行。这确保了微粒完全膨胀而不会受损且不会丧失其冲击吸收效果。
为了实现最佳的机械吸收效果，已经证明有利的是，微粒在膨胀状态下具有20μm至200μm的粒径。因此，其中微粒在膨胀状态下具有20μm至200μm、优选20至150μm的以D50值表示的粒径的实施方案是优选的。
热处理优选使用常规热源进行。热处理尤其优选使用红外辐射和/或热空气进行。
通过根据本发明的方法生产的多层基材的特征在于其具有灵活的体积。因此，本发明的另一主题是通过根据本发明的方法可获得的多层基材。根据本发明的基材优选为连续幅材的形式。在替代性的优选实施方案中，根据本发明的基材为包装形式，优选为信封、邮件袋、袋子、购物袋、小袋或纸箱的形式，其样式和大小可变。
可以将根据本发明的基材容易地加工成包装。因此，另一主题是使用已通过根据本发明的方法生产的多层基材生产包装的方法，其中所述多层基材通过切割和折叠形成所述包装。
本申请的另一主题是根据本发明的方法可获得的包装。包装优选是信封、邮件袋、袋子、购物袋、小袋或纸箱，其样式和大小可变。
将结合以下实例更详细地阐释本发明，但所述实例绝不应理解为对本发明构思的限制。
适合的涂布材料可包含30至70重量％的VAE共聚物分散体(3928)、5至15重量％的石蜡分散体(/>743 PE)、15至30重量％的微粒(/>031WUF 40)、5至10重量％的丙三醇和任选存在的至多1重量％的羟乙基纤维素(MEHC，250LR)，其中重量百分比是指基于涂布材料的总重量的且总和为100重量％。
图1示意性示出了连续幅材形式的第一材料，其中(1)表示边缘区域，(2)表示内部区域。
图2示意性示出了单个单元形式的第一材料，其中(1)表示边缘区域，(2)表示内部区域。

Claims (17)

1.生产多层基材的方法，包括以下步骤：
a)提供第一材料，所述第一材料具有第一表面，所述第一表面具有至少一个边缘区域和被所述边缘区域围绕的至少一个内部区域；
b)向所述第一表面的所述内部区域施用涂布材料，基于所述涂布材料的总重量，所述涂布材料包含10至40重量％的可膨胀的微粒，其中所述涂布材料为基于聚合物的涂布材料；
c)干燥所述涂布材料；以及
d)将所述第一材料的所述第一表面与第二材料的表面接触以形成多层基材，从而使得所述涂布材料在所述第一材料与所述第二材料之间，其中使用粘合剂实施步骤d)中的所述接触，所述粘合剂连续施用于所述第一材料的所述边缘区域；而且
其中所述方法包括又一步骤，其中对所述多层基材进行处理以使所述可膨胀的微粒膨胀，所述处理为热处理，所述热处理使用常规热源进行，而且所述热处理步骤在步骤d)之后进行。
2.根据权利要求1的方法，其特征在于将所述涂布材料在80℃或更低的温度下干燥。
3.根据权利要求2的方法，其特征在于将所述涂布材料在40℃至75℃的温度下干燥。
4.根据权利要求1至3中的任一项的方法，其特征在于基于所述涂布材料的总重量，所述涂布材料具有15至35重量％的可膨胀的微粒。
5.根据权利要求1至3中的任一项的方法，其特征在于所述可膨胀的微粒为可热膨胀的微粒。
6.根据权利要求1至3中的任一项的方法，其特征在于在另一步骤中将所述多层基材转变成包装。
7.根据权利要求6所述的方法，其特征在于所述包装为封套、袋子或者纸箱。
8.根据权利要求6所述的方法，其特征在于所述包装为小袋。
9.根据权利要求6所述的方法，其特征在于所述包装为邮件袋或购物袋。
10.根据权利要求1所述的方法，其特征在于所述热处理在85℃至150℃的温度下进行。
11.根据权利要求10所述的方法，其特征在于所述热处理在90℃至140℃的温度下进行。
12.根据权利要求1、10或11的方法，其特征在于，所述热处理在时间和/或位置方面与其它方法步骤分开进行。
13.根据权利要求1、10或11的方法，其特征在于所述热处理使用红外辐射和/或热空气进行。
14.通过根据权利要求1至13中的任一项的方法可获得的多层基材。
15.根据权利要求14所述的多层基材，其特征在于所述基材为连续幅材或包装的形式。
16.使用通过根据权利要求1至13中的任一项的方法生产的多层基材生产包装的方法，其中所述多层基材通过切割和折叠形成所述包装。
17.通过根据权利要求16的方法可获得的包装。
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