CN113677527A - 高性能可回收盖 - Google Patents
高性能可回收盖 Download PDFInfo
- Publication number
- CN113677527A CN113677527A CN201980095061.1A CN201980095061A CN113677527A CN 113677527 A CN113677527 A CN 113677527A CN 201980095061 A CN201980095061 A CN 201980095061A CN 113677527 A CN113677527 A CN 113677527A
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- China
- Prior art keywords
- component
- high density
- density polyethylene
- lid
- lidding
- Prior art date
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Abstract
该膜结构具有：具有高密度聚乙烯和无机颗粒的第一外层，具有用于密封的基于聚乙烯的材料的第二外层，以及具有高密度聚乙烯、成核剂和烃树脂的内层。该膜可用作用于包装的可热封盖部件，并提供高湿气阻隔性、良好的耐热性、以及推入性和/或儿童安全性的性能，同时保持对于回收可接受的总组成。
Description
技术领域
本披露涉及膜结构，特别是适于包装的高性能可回收膜。本文所述的膜是基于可用于杯子或托盘上封盖的高密度聚乙烯材料。
背景技术
高性能包装膜用于包装许多产品，如食品、药物、消费品或工业物品。对环境敏感的产品使用专门设计的包装，以帮助保护产品并将保质期延长到消费者可以使用产品的时间点。通常，这些包装由各种类型的聚合物和添加剂制成，这些聚合物和添加剂提供实现“高性能”所需的特性。选择用于包装的材料可以增强尤其阻隔特性、物理特性或美观性。通常，包装的设计包括多种材料，以实现若干特征。
将多种材料组合成单个包装材料在确定使用后如何处置包装时会造成困难。通常，只有当包装中的材料是相同的聚合物类型时回收是最有效的或者才有可能进行回收。尝试使用可回收包装材料，尤其是使用单一聚合物类型的那些，导致较低的性能和/或显著更高的成本。举几个例子，遇到的较低性能特征可能是视觉缺陷、较差的阻隔和较短的保质期、较慢的包装设备速度。
一种特别适于回收的聚合物类型是高密度聚乙烯。这种材料已经用于牛奶罐和其他瓶很多年了。这些瓶是100％高密度聚乙烯，并在厚壁的情况下提供合适的阻隔特性。在许多国家，目前存在适当地收集、分类和回收这些包装的工艺。
然而，使用高密度聚乙烯作为主要组分并没有转化为最具柔性的包装形式，尤其是具有苛刻要求的那些包装形式。例如，高密度聚乙烯对于诸如谷物等干货具有足够好的湿气阻隔特性，但对于诸如药物等高度敏感的物品而言却不够好。高密度聚乙烯对于高速包装线也没有足够好的耐热性。由于这些原因以及其他原因，在许多高性能包装应用中不使用基于高密度的包装膜，使这些物品的可回收性受挫。
发明内容
为了若干优点，配置本文所述的盖包装部件的结构和材料组分，从而产生可回收的高性能盖。该盖提供湿气阻隔性、良好的耐热性以及推入式功能和/或儿童安全性。封盖进一步被设计成当热密封到高密度聚乙烯材料时提供良好的热密封强度，即使在相对低的密封温度和低的密封停留时间下也是如此。在可回收的基于高密度聚乙烯的膜结构中这些高性能包装特征的组合是独特且出乎意料的。
在各个实施例中，这些盖包装部件包括具有高密度聚乙烯和无机颗粒的第一外层、具有高密度聚乙烯和烃树脂的第一内层、以及第二外层。该无机颗粒可以包括碳酸钙，并且该无机颗粒可以以15重量％的量装载到该第一外层中。
该第一内层还可以包含成核剂，并且该第二外层可以具有基于聚乙烯的材料，如聚乙烯塑性体或乙烯乙酸乙烯酯共聚物。该第一内层的体积可以为该盖包装部件的总体积的50％至90％。该盖包装部件还可以具有与该第一外层相邻的印刷标记和含有乙烯乙烯醇共聚物的第二内层。
在一些实施例中，当该盖在0.5秒和30psi的条件下密封到高密度聚乙烯时，该盖包装部件具有小于130℃的热密封起始温度。当该盖包装部件在0.5秒和30psi的条件下被热密封到高密度聚乙烯时，该第二外层的基于聚乙烯的材料可具有在约3N/2.5cm和约29.4N/2.5cm之间的热密封强度。
该盖包装部件可用于推入式泡罩包装配置。当根据ASTM F1306使用1/8英寸ASTM探针抵靠盖的第二外层侧测试时，盖包装部件的各个实施例具有小于约12牛顿或小于约7牛顿的穿刺阻力。
有利地，该盖包装部件的一些实施例具有适于回收的总组成。该盖可以基本上不含聚酯、乙烯乙烯醇共聚物和聚酰胺。
本文披露的经包装产品的各个实施例包括盖包装部件、产品和热成型基座，该热成型基座具有至少一个腔和围绕这些腔中每个的凸缘。该盖被气密地密封到该热成型基座的凸缘，从而将该产品封闭在该热成型基座的腔内。一些实施例包括可剥离地密封到该基座的盖。经包装产品的一些实施例包括允许分配产品的盖。当手动压下该底座的腔时，该盖可以被产品刺穿。
该经包装产品可以包括含有高密度聚乙烯的热成型基座。在一些实施例中，该盖和该底座可在同一回收工艺中回收。在一些实施例中，该热成型基座具有：具有高密度聚乙烯和成核剂的第一层、具有高密度聚乙烯和任选地烃树脂和/或成核剂的第二层、以及具有高密度聚乙烯和成核剂的第三层，第二层位于第一层和第三层之间。
附图说明
考虑以下结合附图对本披露的各个实施例的详细说明，可以更完全地理解本披露，在附图中：
图1是具有第一外层、第一内层和第二外层的盖包装部件的实施例的截面的示意图；
图2是具有第一外层、第一内层、第二内层和第二外层的盖包装部件的实施例的截面的示意图；
图3是包括印刷标记的盖包装部件的实施例的截面的示意图；
图4是包括盖包装部件和热成型基座部件的经包装产品的实施例的截面的示意图；以及
图5是包括三层的可热成型基膜的实施例的示意图。
附图示出了一些但不是全部的实施例。附图中描绘的元件是说明性的，并且不必须按比例绘制，并且在整个附图中，相同(或相似)的附图标记表示相同(或相似)的特征。
具体实施方式
本文描述了一种基于高密度聚乙烯的膜，其适于包装可能对氧和/或湿气敏感的产品。该膜可以用作盖包装部件，并且可以热密封到热成型基座包装部件，从而建立在高密度聚乙烯回收工艺中可接受的包装。高性能包装可适于产品，例如但不限于药物、营养食品、医疗产品、新鲜食品、冷藏食品、耐贮存食品、消费品、化妆品和化学品。
盖包装部件的结构和材料组分被独特地配置为提供湿气阻隔性、耐热性、优异的高速密封特征、推入式功能和可回收性选择。令人惊讶的是，本文所述的膜是基于聚乙烯的，但具有使它们用于药物泡罩包装中封盖的性能特性。可以针对儿童安全性和/或推入式性能设计盖包装部件膜。
本文所述的盖包装部件对于需要推入式功能的泡罩包装特别有用。典型的推入式封盖掺入了箔材料，以实现正确的穿刺阻力。出乎意料的是，本文所述的盖包装部件具有优异的推入式功能，其可以针对特定应用而变化，同时保持容易回收的全聚乙烯结构。
本文所述的包装并入至少两个包装部件。首先是由基于高密度聚乙烯的膜制成的热成型基座部件。热成型腔可以是深的或浅的，并且通常成型为将预期产品保持在其中。其次是盖包装部件。盖包装部件被配置成气密高速热密封到热成型基座部件，从而生产用于产品的保护性包装。
在包装的一些实施例中，高性能盖部件和热成型基座部件两者均具有大量高密度聚乙烯的组成。热成型基座部件和盖包装部件的组合提供了优异的包装特征，同时保持了高度均匀的聚合物组成(基本上包括聚乙烯，主要是高密度聚乙烯)，以提供在单个流(例如高密度聚乙烯瓶流)中回收整个包装的机会。
本文所述的包装部件是独特的，因为它们是使用高水平的高密度聚乙烯生产的，又保留了要求苛刻的包装应用所需的高性能特征。气密密封包装提供卓越的产品保护(即湿气阻隔)、良好的外观、良好的耐热性和良好的密封强度。以前尚未使用可以容易回收的材料交付具有这些性能水平的包装。
盖包装部件
盖包装部件10是多层膜，其至少具有第一外层20、第二外层30和第一内层40，如图1所示。在盖包装部件中也可以有额外的层。
如本文所用，术语“层”是指膜的结构单元，其是单一材料类型或材料的均匀共混物的结构。膜包含一个或多个彼此连接的层。层可含有单一聚合物、单一聚合物类型(即聚乙烯)内的材料的共混物或各种聚合物类型的共混物，可含有金属材料或其他非聚合物材料，并且可以具有添加剂。膜的层可以是连续的或可以是不连续的或相对于膜图案化。多层膜在膜的每个主表面上具有两个彼此相对的外层。外层是位于膜的表面的层，且没有在该表面处连接到该膜的另一层。多层膜可以具有一个或多个内层。内层是不位于膜的表面的层且在其每一侧都必具有另一层。
盖包装部件的第一外层含有高密度聚乙烯和无机颗粒。高密度聚乙烯应以大于80重量％的量、大于85重量％的量或者约90重量％或更多的量存在于第一外层中。在第一外层中可以使用两种或更多种不同的高密度聚乙烯材料。如贯穿本申请使用的，术语“高密度聚乙烯”或“HDPE”是指(a)密度为约0.960g/cm3至约0.970g/cm3的乙烯均聚物和(b)密度为约0.940g/cm3至约0.958g/cm3的乙烯和α-烯烃(通常为1-丁烯或1-己烯)的共聚物。高密度聚乙烯包括用Ziegler或Phillips型催化剂制成的聚合物和用单位点茂金属催化剂制成的聚合物。高密度聚乙烯可以是双峰的，并且可以是预成核的。
可能适于盖包装部件的预成核高密度聚乙烯材料的实例是可从伊奎斯塔公司(Equistar)获得的等级M6020SB和可从诺瓦化学公司(Nova Chemicals)获得的HPS167AB。可能适于盖包装部件的未成核高密度聚乙烯材料的实例是均可从伊奎斯塔公司获得的等级M6020或等级L5885。
掺入到第一外层的高密度聚乙烯中的是无机颗粒，其存在的量为相对于第一外层的总重量的10％和50％之间(按重量计)。在盖包装部件的一些实施例中，第一外层中的无机颗粒的量为约15％。所需的无机颗粒的量部分取决于无机颗粒的类型。例如，诸如滑石等的板形颗粒提供了优异的耐热特性，并且可以帮助降低所需的无机颗粒的负载。通过多于一种类型的无机颗粒的共混物，可以最有效地增加第一外层的耐热性。如果使用无机颗粒的共混物，则各种无机颗粒的总重量应为第一外层的10重量％和50重量％之间的量。如本文所用，提及“该无机颗粒”或“无机颗粒”包括多于一种类型的无机颗粒的共混物。
包含无机颗粒是盖包装部件的一个重要方面，使得所得到的膜具有足够的耐热性以承受密封到另一包装部件而不会起皱、收缩或另外在视觉上变得不完美。第一外层应具有足够的耐热性，使其不会粘到加热的密封条(或辊、板等)上。无机颗粒为选自由滑石、氧化钛、炭黑、碳酸钙、粉末状玻璃、石膏、叶蜡石硅酸盐、碳酸镁、高岭土、粘土、亚硫酸钙、氢氧化铝、硫酸钡和氧化镁组成的组的至少一种材料。在一个优选的实施例中，无机颗粒是碳酸钙、二氧化硅、滑石、二氧化钛或这些中两种或更多种的共混物。在一个示例性实施例中，无机颗粒是碳酸钙。
除了高密度聚乙烯和无机颗粒之外，第一外层还可以具有其他组分。例如，第一外层可以包含另一种类型的聚乙烯。如果通过母料将无机颗粒添加到第一外层，则载体聚合物(典型地为低密度聚乙烯或线性低密度聚乙烯)也是该层的组分。第一外层的任何额外的组分应与预期的回收工艺相容。
移到盖部件的第一内层，该层还含有高密度聚乙烯。在一些实施例中，第一内层含有高密度聚乙烯、烃树脂和成核剂。在一些实施例中，盖包装部件膜的第一内层含有高密度聚乙烯和烃树脂或成核剂。
高密度聚乙烯应以约50重量％至约90重量％的量存在于第一内层中。高密度聚乙烯可以以大于80％的量或大于85％的量存在于第一内层中。两种或更多种不同的高密度聚乙烯材料可以存在于第一内层中。成核剂可以以层的约0.2重量％至约3.5重量％的水平存在于盖包装部件的第一内层中。烃树脂可以以0％和50％之间的量存在于第二层中。使用的烃树脂的上限可以由加工问题(即，在挤出过程中熔体强度不足)或膜特性决定。例如，高水平的烃树脂可能会导致层间粘附问题或膜脆性。在第一内层中使用的烃的量还将取决于所使用的烃树脂的类型和第一内层的厚度。例如，较薄的第一内层可能能够在遇到问题之前用较高水平的烃树脂进行加工。
在盖包装部件的一些实施例中，烃树脂可以以高达30重量％的水平存在。烃树脂可以以2.5％和30％之间的水平装载到第一内层中。盖包装部件的一些实施例将在第一内层中具有5重量％和20重量％之间的烃树脂水平。在示例性实施例中，烃树脂以约15％或约7.5％的量存在。可以调节烃树脂的水平以控制膜的湿气阻隔特性和穿刺阻力(推入式功能)。增加烃树脂水平增加了膜的湿气阻隔特性。增加烃树脂水平增加了可刺穿膜的难易程度，这对于推入式封盖应用可能是希望的。此外，实现各种水平的这些性能特征所需的烃树脂的量也受第一内层的厚度的影响。
如本文所用，短语“烃树脂”是指由煤焦油、石油和松节油原料聚合生产的低分子量产物(分子量小于约10,000道尔顿)。烃树脂可包括2002年8月13日公布的美国专利号6,432,496或2008年11月20日公布的美国专利申请2008/0286547中披露的任何烃树脂，这两者都通过引用以其整体并入本申请。更具体地，作为非限制性实例，烃树脂可包括石油树脂、萜烯树脂、苯乙烯树脂、环戊二烯树脂、饱和脂环族树脂或这类树脂的混合物。另外，作为非限制性实例，烃树脂可包括源自于富含二环戊二烯(DCPD)的烯烃进料的聚合、源自于石油裂化过程中产生的烯烃进料(例如粗C9进料流)的聚合的烃树脂、源自于纯单体(如苯乙烯、α-甲基苯乙烯、4-甲基苯乙烯、乙烯基甲苯或者这些或类似的纯单体原料的任何组合)的聚合、源自于萜烯烯烃(如α-蒎烯、β-蒎烯或d-柠檬烯)的聚合或源自于这类的组合。烃树脂可以完全或部分氢化。烃树脂的具体实例包括但不限于可从伊士曼化学公司(Eastman Chemical Company)(金斯波特，田纳西州)获得的
R1140烃树脂、可从阿康伊士曼化学公司(金斯波特，田纳西州)获得的
T1140、可从荒川化学工业有限公司(Arakawa Chemical Industries,Limited)(日本大阪)的
P-140和可从大力神公司(Hercules Incorporated)(威尔明顿，特拉华州)获得的
S135聚萜烯树脂。
如贯穿本申请使用的，术语“成核剂”是指在聚合物熔体中形成核以控制晶体生长的添加剂。成核剂可以是能够使高密度聚乙烯成核的任何类型，并且可以在高密度聚乙烯(预成核高密度聚乙烯)的聚合点或在稍后的时间点通过添加和熔融共混含有成核剂的母料的方式添加。成核添加剂的实例包括矿物质，如白垩、滑石、粘土、高岭土、硅酸盐等，以及有机试剂，如脂肪族或芳族羧酸的盐、芳族磷化合物的金属盐、喹吖啶酮和芳族酰胺。成核剂的其他实例包括甘油锌、甘油钙、六氢邻苯二甲酸钙、六氢邻苯二甲酸锌盐等及其混合物。成核剂可以以层的约0.2重量％至约3.5重量％的水平存在于盖包装部件的第一内层中。
适于盖包装部件的成核剂母料材料的实例是可从美利肯公司(Milliken)获得的
HPN成核剂。
盖包装部件的第一内层提供对膜重要的关键特性。第一内层的体积(即厚度)应为盖包装部件的总体积的约50％至约90％。
在盖包装部件的一些实施例中，膜被设计用于在使用“推入式”功能进行产品(例如，药物或口香糖包装)分配的包装应用中使用。在这种情况下，第一内层可具有允许希望的容易推动通过的烃树脂含量。
本文披露的盖包装部件的一个优点是，它们在相对低的密封温度和低的停留时间下热密封到其他包装部件(包括其自身)。盖包装部件的第二外层被设计用于低温密封并且含有基于聚乙烯的材料。即使第一外层针对高耐热性而设计，当与高速包装设备上的典型密封条件相比时，可以热密封材料而没有明显变形的温度仍然相当低。在一些实施例中，第二外层必须在130℃或更低的密封温度下密封到另一包装部件。在一些实施例中，第二外层必须在110℃或更低的密封温度下密封到另一包装部件。在一些实施例中，第二外层必须在约100℃的密封温度下密封到另一包装部件。当在0.5秒和30psi的条件下热密封到高密度聚乙烯时，盖包装部件应具有130℃或更低的热密封起始温度。在一些实施例中，当在0.5秒和30psi的条件下热密封到高密度聚乙烯时，盖包装部件应具有110℃或更低的热密封起始温度。如本文所用，“热密封起始温度”是指定的热密封实现1,000g/in的密封强度的最低温度。
如本文所用，“基于聚乙烯的材料”是包括乙烯键的均聚物或共聚物。可用于盖包装部件的第二外层的基于聚乙烯的材料的实例包括乙烯乙酸乙烯酯共聚物或聚乙烯塑性体，如乙烯-α-烯烃共聚物。第二外层可用的基于聚乙烯的材料可具有80℃或更低的熔融温度。第二外层可用的基于聚乙烯的材料可具有约50℃或更低的软化点。
在一些实施例中，第二外层含有乙烯乙酸乙烯酯共聚物。如贯穿本申请使用的，术语“乙烯乙酸乙烯酯共聚物”是指由乙烯和乙酸乙烯酯的重复单元组成的共聚物。乙烯乙酸乙烯酯共聚物可以用如下通式表示：[(CH2-CH2)n-((CH2-CH(COO)(CH3))m]。乙酸乙烯酯含量可以从小于2重量％至大于95重量％(基于总乙烯乙酸乙烯酯共聚物组成)变化。用于包装应用的乙烯乙酸乙烯酯共聚物的乙酸乙烯酯含量可以从2重量％至40重量％变化。典型地，用于包装应用的乙烯乙酸乙烯酯共聚物的乙酸乙烯酯含量可以从约2重量％至28重量％变化。可商购的乙烯乙酸乙烯酯共聚物的实例包括可从埃克森美孚公司(ExxonMobil)获得的EscoreneTM共聚物。
在一些实施例中，第二外层含有聚乙烯塑性体。如贯穿本申请使用的，术语“聚乙烯塑性体”是指具有弹性体和塑料两者的特性的乙烯α-烯烃共聚物。聚乙烯塑性体的实例包括可从陶氏化学公司(The Dow Chemical Company)获得的AffinityTM聚烯烃塑性体等级板岩中可用的那些。
第二外层的厚度应为相对于盖包装部件的总厚度的至少10％。在一些实施例中，第二外层为盖包装部件的大致20％。第二外层的厚度可以为盖包装部件的厚度的10％和30％之间。
已经成功地用于盖包装部件的第二外层中的材料共混物的一些实例(按重量计)在下文中作为密封共混物1和密封共混物2给出。可接受的热密封强度可能因应用而异，并且可以通过ASTM F88(测试速度12in/min，无支撑尾部)进行测量。第二外层应配制成实现至少300g/in(3N/2.5cm)、至少800g/in(7.9N/2.5cm)或至少900g/in(8.8N/2.5cm)的热密封强度。在盖包装部件的一些实施例中，盖包装部件和另一包装部件之间的热密封强度在300g/in(3N/2.5cm)和3,000g/in(29.4N/2.5cm)之间。热密封强度可以在500g/in(4.9N/2.5cm)和2,500g/in(24.5N/2.5cm)之间。在该范围内，热密封是可手动剥离的，并且该两个部件可剥离地彼此密封。在一些实施例中，热密封强度足够高，使得在热密封强度测试期间失败是由于材料断裂，并且因此没有记录的密封强度。
密封共混物1：86％乙烯乙酸乙烯酯共聚物[26％VA]、10％爽滑剂母料、3％防结块剂母料和1％加工助剂母料(各母料都有聚乙烯载体)
密封共混物2：94％塑性体(乙烯-辛烯共聚物)、5％防结块剂母料、1％加工助剂母料(各母料都有聚乙烯载体)
盖包装部件的第一外层、第二外层或第一内层中存在的或者盖包装部件的其他层中存在的任何额外的材料对于高密度回收工艺而言应是可接受的。额外的材料可以以较低的水平存在，使得它们不会破坏或以其他方式阻碍回收工艺。额外的材料可以是回收工艺可接受的类型，如其他类型的基于聚乙烯的材料。额外的非基于聚乙烯的材料可以与增容剂系统一起存在。
盖包装部件可以包括其他层。例如，盖包装部件可以具有如图2所示的第二内层。这里，盖包装部件10包括第一外层20、第二外层30、第一内层40和第二内层50。在一些实施例中，第二内层50含有乙烯乙烯醇共聚物以提供额外的氧阻隔。在这种情况下，第二内层50可以非常薄，使得乙烯乙烯醇共聚物不以破坏回收工艺的水平的存在，或者盖包装部件还含有允许乙烯乙烯醇共聚物在回收单元中被加工而不引起缺陷的增容剂。氧传输水平可为约0.2cc/100in2/天或更少。
盖包装部件中可以存在其他层，只要这些层不损害该膜的特性(即材料必须是高密度回收工艺可接受的)。其他层可以存在于盖包装部件的任何位置。
其他层可以存在于盖包装部件中，配置(位置和附接)为它们可以从含有第一外层、第二外层和第一内层的部分移除。例如，该盖包装部件可包括与该第一外部相邻的纸基层。该纸基层可以通过粘合剂来附接，允许消费者剥离纸基层。以这种方式，纸基层可以与包装的剩余部分分开丢弃或回收。
另外，盖包装部件可包括印刷标记。盖包装部件的一些实施例包括在第一外层20的外表面上的印刷标记60(即，印刷标记与第一外层相邻)，如图3所示。印刷标记可以从盖包装部件的一侧或两侧可见，并且标记可以位于盖包装部件的表面上或者盖包装部件中存在的任何层之间。
盖包装部件可以完全共挤出，或者可以通过其他工艺(如层压或涂覆)或工艺组合来生产。优选地，盖包装部件膜未定向。
总的来说，盖包装部件可具有约1密耳(25.4微米)至约10密耳(254微米)的厚度。一些包装应用将受益于具有约2密耳(50.8微米)至约8密耳(203.2微米)厚度的盖包装部件。在一些实施例中，盖包装部件具有约2密耳(50.8微米)至约6密耳(约152.4微米)的厚度。在一些实施例中，盖包装部件具有约2密耳(50.8微米)的厚度。在一些实施例中，需要更高的儿童安全性，并且盖包装部件具有约4密耳(101.6微米)的厚度。
盖包装部件应具有适于回收的总组成。盖包装部件应具有在典型地接受基于聚乙烯的材料的工艺中适于回收的总组成。总组成可适于在接受高密度聚乙烯材料的工艺中回收。
本文所述的盖包装部件可以在它们的初次使用完成之后回收。通常，术语可回收意指该产品适于再利用。可回收的一个具体上下文的一个实例是第二次再利用塑料杂货袋来容纳一些其他物品。塑料袋已经被再利用和回收。在稍微不同的上下文中，可回收意指产品在被转化成新产品之后适于再利用。如本文所用，术语“适于回收”意指表示通过在聚烯烃回收流(即基于聚乙烯的回收流)中再加工，膜可以被转化为新的有用物品。除了许多其他步骤之外，再加工可能需要洗涤、分离、熔化和成型。典型地，当通过再加工而回收塑料包装时，材料被机械地切成小块，熔化，混合并且重新形成新产品。如果多种不相容的材料存在于包装中，则在再加工期间发生相互作用，导致凝胶、脆性材料、差的外观和通常不能使用的或差品质的产品。使用术语“可回收”表示这些缺点通常不存在。作为可回收材料的资格不受任何特定机构的管制，而是可以从特定组如塑料回收协会(Association ofPlastic Recyclers)(APR)和How2RecycleTM获得。本文披露的可回收膜可适用于基于高密度聚乙烯的回收流。将可回收膜引入这些通过再加工进行回收的途径中的任一种中不应需要额外的相容剂。
通过将盖包装部件的总组成中的高密度聚乙烯的总量保持在高水平，可以获得适于回收的总组成。使用的任何添加剂都应保持在最低限度。存在的任何非基于聚乙烯的聚合物可以伴随有增容剂，以实现适于回收的组成。对于理想的可回收性选择，盖包装部件的组成是由高密度聚乙烯、无机颗粒、烃树脂、成核剂、其他加工添加剂(如爽滑剂或防结块剂)和其他基于聚乙烯的聚合物组成。盖包装部件可以不含非基于聚乙烯的聚合物。盖包装部件可以不含金属。
为了进一步努力实现适于回收的总组成，盖包装部件的一些实施例可不含聚酯材料。归因于持久性、刚度和透明性，典型地在膜中使用聚酯材料。但是，聚酯的存在可能会极大地阻碍膜的可回收性。
为了进一步努力实现适于回收的总组成，盖包装部件的一些实施例可不含EVOH材料。EVOH因为是高效且可挤出的氧阻隔材料而典型地在膜中使用。但是，EVOH的存在可能会极大地阻碍膜的可回收性。
为了进一步努力实现适于回收的总组成，盖包装部件的一些实施例可不含聚酰胺材料。归因于持久性和刚度，典型地使用聚酰胺材料。但是，聚酰胺的存在可能会极大地阻碍膜的可回收性。
盖包装部件可以不含聚酯、EVOH和聚酰胺。
已经发现，如本文所述的具有至少第一外层、第二外层和第一内层的盖包装部件可用作具有优异结果的高性能包装。这是令人惊讶的，因为盖包装部件含有大量的高密度聚乙烯，先前已显示不具有对于高性能包装应用而言可接受的特性组合。本文所述的盖包装部件提供了以下的关键的和先前未实现的组合：1)推入式功能，2)高耐热性，3)对高密度聚乙烯的高速密封性，4)可回收性以及任选地5)高湿气阻隔性。
最令人惊讶的是本文所述的盖包装部件的湿气阻隔和推入式特征的组合。这些特征是在保持适于在高密度回收工艺中回收的结构的同时实现的。以前，这种类型的性能组合只能通过使用将不可回收的含箔结构来实现。
有利地，盖包装部件具有优异的湿气阻隔性。湿气阻隔特性取决于层组成。增加湿气阻隔性的一种方法是增加第一内层中的烃树脂或成核剂的量。增加湿气阻隔性的另一种方法是使用双峰高密度聚乙烯。盖包装部件的湿气阻隔性能很重要，因为它允许这种材料代替可能不容易回收的其他用于包装对湿气敏感的产品的标准包装膜(如PVC)。
有利地，盖包装部件具有可调整至所需穿刺强度的推入式功能。
经包装产品
盖包装部件可以与其他包装部件(如热成型托盘)结合使用，以生产用于多种产品的包装。盖包装部件可以用作托盘上的盖，或用于另一种包装形式，如袋。
盖包装部件可以通过密封件、优选地气密密封件的方式附接到另一个包装部件或其自身。以这种方式，包装内部的产品被完全封闭在腔中，并通过盖包装部件和其他包装部件受到保护。气体、液体、微生物或其他材料的交换仅限于能够穿过包装部件的那些，因为气密密封不允许在部件之间的空间中穿过。
在经包装产品的一个实施例中，盖包装部件与热成型基座组合以形成包装。热成型基座具有一个或多个用于保持产品的腔，每个腔都由凸缘围绕。凸缘是基座的未成型部分，其用作将热成型基座与盖包装部件连接的位置。连接可以是在盖包装部件的第二外层与热成型基座部件的凸缘的表面之间的气密密封。在一些实施例中，盖部件被气密地密封到围绕热成型基座的每个腔的区域中的凸缘，使得每个腔被单独地气密密封(即，在腔之间没有气体连通的通道)。可替代地，封盖可以在包括围绕所有腔(并且不在各腔之间)的整个周边的区域中的凸缘处连接到热成型基座。
在热成型基座的腔中含有的产品不受限制。产品可能对环境敏感，如药物或食品。产品可能需要物理保护，如精巧的医疗设备。为了保护消费者，可能需要含有的产品如药品或清洁剂应在儿童防护包装中。产品可适于容易的单一单位分配，如复合包装中的口香糖或糖果。
在图4的横截面示意图中显示了使用盖包装部件10和热成型基座100的经包装产品1000的一个实例。在该实施例中，热成型基座100具有多个(示出6个)腔110，每个腔都含有被凸缘120围绕的产品1100。通常，热成型基座的腔的尺寸可以专门设计为保持单个药物片剂或胶囊。可替代地，热成型基座的腔可以较大，并保持多个产品件。本申请预期所有数量、尺寸和形状的空腔。
在一些实施例中，该经包装产品由产品、盖包装部件和热成型基座组成，该盖和该基座熔合密封。盖包装部件可按照本文所述配制，使得产品可被推动穿过盖以进行分配。典型地，具有高水平高密度聚乙烯的膜展现出响应于“推入”力的拉伸。然而，本文所述的包括具有烃树脂的第一内层的盖包装部件展现出“爆裂(pop)”型穿刺阻力，适于推入式分配。特别地，对于包含药物片剂、胶块等的经包装产品的应用，热成型基座的腔可具有足够柔性，使得消费者可以手动压下该腔，迫使产品通过盖部件来分配。
热成型基座应具有性能与盖包装部件相似的湿气和/或氧阻隔性。经包装产品的一些实施例包括各自具有适于回收的总组成的盖包装部件和热成型基座。盖包装部件和热成型基座可具有适于在相同回收流中回收的总组成。盖包装部件和热成型基座均可适于在高密度聚乙烯流中回收。
在图5中显示了可被成型为热成型基座的可热成型膜的一个实例，该热成型基座可被密封到盖包装部件以提供经包装产品。可热成型膜可以具有含有高密度聚乙烯和成核剂的第一层210。可热成型膜可具有第二层230，该第二层具有高密度聚乙烯、任选地烃树脂和任选地成核剂。可热成型膜可具有第三层220，该第三层具有高密度聚乙烯和成核剂。如图5所示的可热成型基膜的一个优点是，与本文所述的盖包装部件相比，其具有类似的可回收性，使得整个包装可以一起回收而不分离。
实例和数据
使用缓慢穿刺试验(ASTM 1306，1/8英寸直径ASTM探针接触密封剂侧)测试盖包装部件的两个“推入式”样式实施例，以与标准推入式封盖进行比较。表1中概述了测试的盖包装部件结构。实例1具有含有约15％烃树脂的第一内层，并导致小于7牛顿的穿刺阻力。实例2具有含有约7.5％烃的第一内层，并导致小于约12牛顿的穿刺阻力。相比之下，具有25微米软回火箔与12微米基于聚乙烯的密封剂的标准推入式箔盖展现出小于6牛顿的穿刺阻力。另一种具有20微米硬回火箔与12微米基于聚乙烯的密封剂的标准推入式盖展现出小于4牛顿的穿刺阻力。本文所述的盖包装部件具有类似于含箔结构的推入力。
表1：盖包装部件结构
CaCO3 MB＝具有大于30％无机含量的聚乙烯
HC MB＝含有40％烃和60％高密度聚乙烯的烃母料
实施例
盖包装部件实施例：
A.一种盖包装部件，其包括：
包含高密度聚乙烯和无机颗粒的第一外层，
包含高密度聚乙烯、成核剂和烃树脂的第一内层，以及
包含基于聚乙烯的材料的第二外层。
B.根据任何其他实施例所述的盖包装部件，其中该无机颗粒包括碳酸钙，并且该第一外层中的无机颗粒的量在10重量％和50重量％之间。
C.根据任何其他实施例所述的盖包装部件，其中该第二外层包含聚乙烯塑性体或乙烯乙酸乙烯酯共聚物中的至少一种。
D.根据任何其他实施例所述的盖包装部件，其中当该盖包装部件在0.5秒和30psi的条件下密封到高密度聚乙烯时，该盖包装部件具有小于130℃的热密封起始温度。
E.根据任何其他实施例所述的盖包装部件，其中当该盖包装部件在0.5秒和30psi的条件下热密封到高密度聚乙烯时，该基于聚乙烯的材料具有在3N/2.5cm和29.4N/2.5cm之间的热密封强度。
F.根据任何其他实施例所述的盖包装部件，该盖包装部件进一步包括与该第一外层相邻的印刷标记。
G.根据任何其他实施例所述的盖包装部件，该盖包装部件进一步包括包含乙烯乙烯醇共聚物的第二内层。
H.根据任何其他实施例所述的盖包装部件，其中该盖包装部件具有小于7牛顿的穿刺阻力(ASTM F1306)。
I.根据任何其他实施例所述的盖包装部件，其中该盖包装部件具有小于12牛顿的穿刺阻力(ASTM F1306)。
J.一种盖包装部件，其包括：
包含高密度聚乙烯和无机颗粒的第一外层，
包含高密度聚乙烯和烃树脂的第一内层，以及
第二外层，并且
其中该第一内层的体积为该盖包装部件的总体积的50％至90％，并且其中当在0.5秒和30psi的条件下热密封到高密度聚乙烯时，该盖包装部件具有小于130℃的热密封起始温度。
K.根据任何其他实施例所述的盖包装部件，其中该盖包装部件具有适于回收的总组成。
L.根据任何其他实施例所述的盖包装部件，其中该盖包装部件基本上不含聚酯、乙烯乙烯醇共聚物和聚酰胺。
M.一种经包装产品，其包括：
包括至少一个腔和围绕这些腔中每个的凸缘的热成型基座，根据实施例A-L中任一项所述的盖包装部件，以及
产品，
其中该盖包装部件被气密地密封到该热成型基座的该凸缘，并且该产品被封闭在该热成型基座的该至少一个腔中。
N.根据任何其他实施例所述的经包装产品，其中该热成型基座包含高密度聚乙烯。
O.根据任何其他实施例所述的经包装产品，其中该盖包装部件可剥离地密封到该热成型基座部件的凸缘。
P.根据任何其他实施例所述的经包装产品，其中该热成型基座和该盖包装部件两者都可在同一回收工艺中回收。
Q.根据任何其他实施例所述的经包装产品，其中该热成型基座的腔可以被手动压下，并且该产品可以被推动穿过该盖包装部件以进行产品分配。
R.根据任何其他实施例所述的经包装产品，其中该热成型基座部件包括热成型基膜，该热成型基膜包括
包含高密度聚乙烯和成核剂的第一层，
包含高密度聚乙烯、任选地烃树脂和任选地成核剂的第二层，以及
包含高密度聚乙烯和成核剂的第三层，
其中该第二层位于该第一层和该第三层之间。
Claims (18)
1.一种盖包装部件，其包括：
包含高密度聚乙烯和无机颗粒的第一外层，
包含高密度聚乙烯、成核剂和烃树脂的第一内层，以及
包含基于聚乙烯的材料的第二外层。
2.根据权利要求1所述的盖包装部件，其中该无机颗粒包括碳酸钙，并且该第一外层中的无机颗粒的量在10重量％和50重量％之间。
3.根据权利要求1所述的盖包装部件，其中该第二外层包括聚乙烯塑性体或乙烯乙酸乙烯酯共聚物中的至少一种。
4.根据权利要求1所述的盖包装部件，其中当该盖包装部件在0.5秒和30psi的条件下密封到高密度聚乙烯时，该盖包装部件具有小于130℃的热密封起始温度。
5.根据权利要求1所述的盖包装部件，其中当该盖包装部件在0.5秒和30psi的条件下热密封到高密度聚乙烯时，该基于聚乙烯的材料具有在3N/2.5cm和29.4N/2.5cm之间的热密封强度。
6.根据权利要求1所述的盖包装部件，其进一步包括与该第一外层相邻的印刷标记。
7.根据权利要求1所述的盖包装部件，其进一步包括包含乙烯乙烯醇共聚物的第二内层。
8.根据权利要求1所述的盖包装部件，其中该盖包装部件具有小于7牛顿的穿刺阻力(ASTM F1306)。
9.根据权利要求1所述的盖包装部件，其中该盖包装部件具有小于12牛顿的穿刺阻力(ASTM F1306)。
10.一种盖包装部件，其包括：
包含高密度聚乙烯和无机颗粒的第一外层，
包含高密度聚乙烯和烃树脂的第一内层，以及
第二外层，并且
其中该第一内层的体积为该盖包装部件的总体积的50％至90％，并且
其中当在0.5秒和30psi的条件下热密封到高密度聚乙烯时，该盖包装部件具有小于130℃的热密封起始温度。
11.根据权利要求10所述的盖包装部件，其中该盖包装部件具有适于回收的总组成。
12.根据权利要求10所述的盖包装部件，其中该盖包装部件基本上不含聚酯、乙烯乙烯醇共聚物和聚酰胺。
13.一种经包装产品，其包括：
包括至少一个腔和围绕这些腔中每个的凸缘的热成型基座，
根据权利要求1所述的盖包装部件，以及
产品，
其中该盖包装部件被气密地密封到该热成型基座的该凸缘，并且该产品被封闭在该热成型基座的该至少一个腔中。
14.根据权利要求13所述的经包装产品，其中该热成型基座包含高密度聚乙烯。
15.根据权利要求13所述的经包装产品，其中该盖包装部件可剥离地密封到该热成型基座部件的该凸缘。
16.根据权利要求13所述的经包装产品，其中该热成型基座和该盖包装部件两者都可在同一回收工艺中回收。
17.根据权利要求13所述的经包装产品，其中该热成型基座的该腔可以被手动压下，并且该产品可以被推动穿过该盖包装部件以进行产品分配。
18.根据权利要求13所述的经包装产品，其中该热成型基座部件包括可热成型基膜，该可热成型基膜包括
包含高密度聚乙烯和成核剂的第一层，
包含高密度聚乙烯、任选地烃树脂和任选地成核剂的第二层，以及
包含高密度聚乙烯和成核剂的第三层，
其中该第二层位于该第一层和该第三层之间。
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| CN201980095061.1A Pending CN113677527A (zh) | 2019-04-04 | 2019-08-21 | 高性能可回收盖 |
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| CN116852830A (zh) | 2019-04-04 | 2023-10-10 | 阿姆科挠性物品北美公司 | 用于热成型的可回收膜 |
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