CN115315350A - 具有覆膜层和可移除的表层的膜叠堆 - Google Patents

具有覆膜层和可移除的表层的膜叠堆 Download PDF

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Publication number
CN115315350A
CN115315350A CN202180023017.7A CN202180023017A CN115315350A CN 115315350 A CN115315350 A CN 115315350A CN 202180023017 A CN202180023017 A CN 202180023017A CN 115315350 A CN115315350 A CN 115315350A
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Prior art keywords
film
film stack
layer
base
skin layer
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CN202180023017.7A
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English (en)
Inventor
台会文
约翰·A·尼尔森
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3M Innovative Properties Co
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3M Innovative Properties Co
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Publication of CN115315350A publication Critical patent/CN115315350A/zh
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Abstract

本发明提供了膜叠堆。具体地，描述了包括基底覆膜层和设置在该基底覆膜层上的可移除的表层的膜叠堆。由于该可移除的表层在不可逆地损坏该基底覆膜层之前产生雾度，因此该膜叠堆可防止在该膜叠堆被一起拉伸时意外过度拉伸。

Description

具有覆膜层和可移除的表层的膜叠堆
背景技术
包括覆膜层的膜叠堆用于图形膜应用中，以保护印刷的或以其他方式成像的图形膜，尤其是油墨，并增加其耐久性。可移除的表层是可在施用之时或之后被使用者剥离的外层。
发明内容
在一个方面，本发明涉及一种膜叠堆。该膜叠堆包括：基底覆膜层，该基底覆膜层由第一材料形成并具有第一主表面和第二主表面；可移除的表层，该可移除的表层由第二材料形成且设置在基底覆膜层的第一主表面上；和粘合剂层，该粘合剂层设置在基底覆膜层的第二主表面上。基底覆膜层是透明的。可移除的表层比基底覆膜层的刚度更大。膜叠堆可拉伸至30％的伸长率，而不会对基底覆膜层造成不可逆的损坏。
在另一方面，本发明涉及一种膜叠堆。该膜叠堆包括基底覆膜层和设置在基底覆膜层的主表面上的可移除的表层。当拉伸该膜叠堆时，在达到对覆膜层造成不可逆的损坏之前，可移除的表层提供可见指示。
在另一方面，本发明涉及一种防止在拉伸膜叠堆时过度拉伸的方法。该方法包括提供膜叠堆，该膜叠堆包括基底覆膜层和设置在基底覆膜层上的可移除的表层，其中当拉伸膜时，在对基底覆膜层造成不可逆的损坏之前，可移除的表层变得模糊；以及将膜叠堆拉伸至小于或达到可移除的表层变得模糊的程度。
附图说明
图1是包括基底覆膜层和可移除的表层的膜叠堆的示意性侧正视图横截面。
图2是包括两个基底覆膜层和两个可移除的表层的另一膜叠堆的示意性侧正视图横截面。
图3A-图3C是未拉伸的膜叠堆、被拉伸使得可移除的表层产生雾度的膜叠堆以及其中模糊的可移除的表层与膜叠堆分层从而显露下面的基底覆膜层的膜叠堆的示意性俯视平面图。
图4是示出实施例3(及其组件)和比较例5的负荷力对比伸长率的曲线图。
具体实施方式
覆膜用于图形膜中以保护印刷的基底图形膜或增强其耐久性。覆膜可提供物理保护，诸如保护免受磨蚀或环境条件的影响。覆膜可帮助延长印刷的图形膜产品的可用或最佳使用寿命。通常，在印刷之时或之后将覆膜层压到印刷的基底图形膜。
覆膜的外表面可决定膜叠堆对于观察者的总体外观。例如，光泽的外表面(几乎没有表面结构)提供高百分比的镜面反射对比漫反射，并且通常提供低雾度和高清晰度。可能期望其他期望的外部表面结构；例如，某些覆膜可具有糙面结构或其他纹理化表面。出于此原因，重要的是保留和保护覆膜的表面特征。表面划痕和其他缺陷可能影响膜叠堆的最终外观，并且可能令客户或观察者讨厌。因此，通常在膜的表面上提供保护性表层，以在层压或最终应用之后移除，这可能需要刮刷或可能损坏暴露表面的其他物理接触。
另外，覆膜可能是薄的、高度可适形的，并因此难以处理。可移除的表层可赋予足够的刚度以便更容易处理。通常，一旦覆膜被层压到基底图形膜，或者在组合的膜叠堆粘附到期望的表面或基底之后，可移除可移除的表层。
在不同的步骤中形成的纸材衬垫或聚合物材料通常被层压到基底覆膜。这通常需要附加的粘合剂层和附接步骤，这可增加制造过程的复杂性。或者，在安装步骤期间，在正面上提供临时衬垫作为保护。纸材衬垫是不透明的，并且不允许安装者在安装期间观看图形。
本文所述的某些可移除的表层可通过吹胀薄膜挤塑或传统挤塑工艺形成，并且可与基底覆膜共形成，从而无需单独的粘合剂和/或热层压工艺。此类可移除的表层可能需要适度的剥离力以将该层从基底覆膜剥离，同时在装运、处理和安装过程中仍然保持牢固地附接。
图1是包括基底覆膜层和可移除的表层的膜叠堆的示意性侧正视图横截面。图1包括膜叠堆100，该膜叠堆包括基底覆膜层110、可移除的表层120、具有任选的剥离层132的衬垫130、压敏粘合剂140和任选的接合层150。
基底覆膜层110可以是任何合适的材料，并且可通过任何合适的工艺形成。在一些实施方案中，基底覆膜层包含聚氯乙烯或由聚氯乙烯制成。在一些实施方案中，基底覆膜层包含聚氨酯和乙酸丙酸纤维素或乙酸丁酸纤维素。在一些实施方案中，基底覆膜层包含聚酯或共聚酯，或者由其制成。在一些实施方案中，基底覆膜包含乙烯和甲基丙烯酸的共聚物的离聚物树脂，或者由其制成。在一些实施方案中，基底覆膜层包含乙烯-乙酸乙烯酯(EVA)，或者由其制成。在一些实施方案中，基底覆膜层包含聚碳酸酯、聚丙烯或聚苯乙烯，或者由其制成。在一些实施方案中，基底覆膜层包含或含有弹性体组分。包含聚酰胺的嵌段共聚物和聚酰胺可为合适的。可根据其物理、光学和/或流变特性选择特定材料或材料的组合。在一些实施方案中，基底覆膜层可包括多于一个层，所述多于一个层包含相同或不同的材料。
基底覆膜层110可具有任何合适的厚度，并且可通过挤塑(诸如熔融挤塑或吹胀薄膜挤塑)工艺形成。在一些实施方案中，基底覆膜层110的厚度为25微米-100微米。基底覆膜层110可具有平滑表面结构，或者可具有纹理化表面结构。
可移除的表层120可为任何合适的材料，并且可由任何合适的材料形成。在一些实施方案中，可移除的表层比基底覆膜层的刚度更大。在一些实施方案中，可移除的表层120可以是或包含聚丙烯。在一些实施方案中，可移除的表层120可以是或包含任何其他合适的聚合物、共聚物或它们的共混物。可移除的表层120可具有任何合适的厚度，包括10微米-150微米的厚度。可选择厚度和材料以赋予膜叠堆足够的刚度并保持适度的剥离力以进行分层。在一些实施方案中，进行分层的90度剥离力可在50克/英寸至100克/英寸(大约20克/厘米至40克/厘米)之间。可移除的表层可被挤塑(熔融挤塑或吹胀薄膜挤塑)、溶剂浇铸或涂覆。
可移除的表层120具有选定的材料和厚度的组合，使得当拉伸时，表层快速产生雾度。虽然许多材料可产生拉伸诱导的雾度，但是某些材料将表现出在某一伸长阈值下雾度的快速增加。例如，表层从0％伸长至30％可使雾度增加50个百分点或更多。在一些实施方案中，表层从0％伸长至30％可使雾度增加60个百分点或更多。在一些实施方案中，表层从0％伸长至30％可使雾度增加70个百分点或更多。在一些实施方案中，表层从0％伸长至30％可使雾度增加80个百分点或更多。在一些实施方案中，表层从0％伸长至30％可使雾度增加90个百分点或更多。
衬垫130可作为膜叠堆100的一部分提供，以保护压敏粘合剂140免于暴露于元素、降解和无意粘附。衬垫130也允许膜叠堆100以卷的形式被配置、储存和输送，而无需自粘附。衬垫130可为任何合适的材料，通常包括纸材或聚合物(诸如聚乙烯)。在一些实施方案中，衬垫130被任选的剥离层132涂覆或覆盖，该剥离层可增强衬垫与压敏粘合剂之间的平滑性和/或易于分离性。任选的剥离层132可以是有机硅、蜡、嵌段共聚物或任何其他合适的材料。在一些实施方案中，可以省略任选的剥离层132，或其不是提供期望的剥离特征所必需的。
压敏粘合剂140设置在衬垫130与基底覆膜层120之间。压敏粘合剂140可以是任何合适的粘合剂，包括丙烯酸粘合剂、环氧化物或光学透明粘合剂。特别是对于透明或半透明的基底覆膜，粘合剂的光学特征(通常是高透射率、低雾度和高清晰度)对于维持膜在使用中的总体外观可能是重要的。压敏粘合剂可被挤塑(熔融挤塑或吹胀薄膜挤塑)、溶剂浇铸或涂覆。
在一些实施方案中，压敏粘合剂140可具有足够的结构以在暴露温度和湿度范围内维持其形状(即，不流动)。在一些实施方案中，粘合剂可为完全或部分交联的。粘合剂可包含颜料、染料或其他着色剂。在一些实施方案中，粘合剂的厚度可介于10微米至100微米之间。在一些实施方案中，粘合剂可包括由诸如玻璃、陶瓷或聚合物树脂的材料制成的部分嵌入的微珠或它们的用合适的粘结剂材料保持在一起的附聚体。在一些实施方案中，微珠可与结构化粘合剂折射率匹配并且/或者为透明的。
因为基底覆膜层可能不会内在牢固地粘结到压敏粘合剂，所以一些实施方案可包括任选的接合层150。接合层(也通常称为底漆或底漆层)可以是具有任何合适厚度的任何合适的物质或组合物。对接合层的选择是确保基底覆膜层与压敏粘合剂之间具有足够粘附性(以防止层间粘结失效)。在一些实施方案中，接合层可包含聚酰胺或共聚酰胺。某些材料可另选地或除此之外用作阻隔层，以防止增塑剂、水、溶剂或其他污染物从膜叠堆的前侧迁移到粘合剂中。接合层可以是极薄的：小于10微米厚、小于6微米厚、小于5微米厚、小于4微米厚、小于3微米厚、小于2微米厚或甚至小于1微米厚。接合层可被溶剂浇铸、涂覆或甚至挤塑或(与其他层中的一者或多者)共挤塑。
膜叠堆100总体上可一起拉伸至一定程度，而不会对基底覆膜层造成不可逆的损坏。在一些实施方案中，膜叠堆100可拉伸至30％的伸长率，而不会对基底覆膜层造成不可逆的损坏。在一些实施方案中，膜叠堆100可拉伸至50％的伸长率，而不会对基底覆膜层造成不可逆的损坏。在一些实施方案中，膜叠堆100可拉伸至100％的伸长率、200％的伸长率或更大的伸长率，而不会对基底覆膜层造成不可逆的损坏。可拉伸有助于在最小程度提起的情况下将此类膜施加到复杂、弯曲或有通道的表面。然而，每个可拉伸膜均具有发生不可逆的塑性变形并最终破裂或撕裂的限值。在一些情况下，过度拉伸的膜的应力将导致膜从所粘附的表面抬起。在一些情况下，膜可产生光学伪影，诸如混浊。
在使用和安装期间重要的是避免过度拉伸。在本文所述的实施方案中，当拉伸膜叠堆时，在基底覆膜层受到不可逆的光学或物理损坏之时或之前，可移除的表层产生雾度。在一些实施方案中，在这些层中的任何层受到不可逆的损坏之时或之前，可移除的表层产生雾度。
因此，可以使用本文所述的构造和叠堆，因为它们向安装者或使用者提供基底覆膜正接近其推荐伸长率的物理限值的视觉指示。因为可移除的表层可在施加之后剥离，所以使用者可在观察到雾度之时或前后停止拉伸，在就接近于不可逆损坏提出警告之后继续安装膜，并且在确信下面的基底覆膜层已保留其光学和物理质量的前提下移除表层。
在一些实施方案中，将本文所述的膜叠堆层压到基底图形膜(即，彩色或数字印刷的装饰性膜)，并且整个叠堆仍然可一起拉伸。正如其他地方所述，整体膜叠堆可具有推荐或安全的伸长率限值。在一些实施方案中，此限值可以是30％。在一些实施方案中，此限值可以是150％。在一些实施方案中，此限值可以是100％、200％或更大。类似地，在基底覆膜层和/或基底图形膜被过度拉伸至失效之时或之前，可移除的表层产生雾度。
图2是包括两个基底覆膜层和两个可移除的表层的另一膜叠堆的示意性侧正视图横截面。膜叠堆200类似于图1中的膜叠堆100；然而，图2示出了另选的构造，其中形成两个基底覆膜层并且这两个基底覆膜层储存在单个衬垫层上。膜叠堆200包括两个可移除的表层220、两个基底覆膜层210、两个任选的接合层250、两个压敏粘合剂层240和单个衬垫230，它们可在一个或两个表面上包括或不包括剥离涂层。
图2中的每个组件如结合图1所述，不同的是特定膜叠堆的制造可有利地适合于挤塑工艺。具有单个衬垫的两个可用膜侧面的形成可提供更加经济的制造、储存和装运，并且浪费更少。另外，当膜叠堆200以卷的形式储存或配置时，可移除的表层220充当保护性衬垫，以最大程度减少基底覆膜上的表面压痕或划痕。
图3A-图3C是未拉伸的膜叠堆(诸如结合图1所述和所示的膜叠堆)、被拉伸使得可移除的表层产生雾度的膜叠堆以及其中模糊的可移除的表层与膜叠堆分层从而显露下面的基底覆膜层的膜叠堆的示意性俯视平面图。
在第一步骤中，图3A示出了其中可移除的表层320可见的膜叠堆的俯视图。在一些实施方案中，可移除的表层320是基本上透明的或透明的，并且下面的基底覆膜的表面透过顶表面可以看见。
在第二步骤中，图3B示出了其中可移除的表层320和任何下面层(诸如基底覆膜310)均被拉伸的膜叠堆的俯视图。在一些实施方案中，这可以是130％或甚至150％的伸长率。可移除的表层因拉伸而产生雾度。在一些实施方案中，产生雾度意指从未拉伸到拉伸时雾度变化超过50个百分点。在一些实施方案中，产生雾度意指从未拉伸到拉伸时雾度变化超过60个百分点。在一些实施方案中，产生雾度意指从未拉伸到拉伸时雾度变化超过70个百分点。在一些实施方案中，产生雾度意指从未拉伸到拉伸时雾度变化超过80个百分点。在一些实施方案中，产生雾度意指从未拉伸到拉伸时雾度变化超过90个百分点。下面的基底覆膜未产生雾度，并且为了物理和光学完整性保持在其推荐的拉伸范围内。
在第三步骤中，图3C示出了其中可移除的表层与基底覆膜层分层的膜叠堆的俯视图。可移除的表层320保持其雾度，但是可容易且干净地移除，以显露下面受保护的基底覆膜310。可在最终安装在期望的基底上之前、期间或之后移除表层。
实施例
材料
Figure BDA0003856258210000071
实施例的制备
实施例1至3和比较例1至5在3层吹塑膜生产线上制备。该生产线具有客户设置3层模头，该模头具有2英寸开口并连接至3个独立的3/4"Brabender单螺杆挤出机(德国杜伊斯堡
Figure BDA0003856258210000072
49-55 47051的布拉本德公司(Brabender GmbH&Co.KG,
Figure BDA0003856258210000073
49-55 47051Duisburg))。实施例4、5和6以及比较例6在七层饼状叠堆模头(LF-400 Coex 7层型，来自莱伯泰科工程公司(Labtech Engineering))上制备。手动控制到模头的气流以实现大约2:1的吹胀比。随后气泡在模头上方大约十英尺处塌缩，横穿辊，然后缠绕到3英寸芯上并卷起。喂料由7个独立的20mm直径的挤出机(Labtech Scientific LE20-30/C HA型单螺杆挤出机)供应。
实施例和比较例的组成列于下表中。
3层吹塑膜
Figure BDA0003856258210000081
7层吹塑膜
Figure BDA0003856258210000082
测试方法
90°剥离力测量
在由美国特拉华州纽卡斯尔19720的测试仪器公司(Testing Machines,Inc.,NewCastle,DE 19720USA)制造的剥离测试仪(80-91LAB MASTER剥离和粘附测试仪)上进行90度剥离测试。将样品在CTH(恒定温度73F和湿度50％)室中调理至少24小时。将调理的样品切成2.5cm(TD，横向)乘大约30.5cm(纵向)条带。使用3M光学透明粘合剂8171将样品层压到金属板，其中离聚物膜侧面向粘合剂，并测量用于剥离可剥离表皮的剥离力。以120英寸/分钟的速度测量90度剥离力(以克为单位)。
表3：90°剥离力
样品 剥离力，克
实施例4 86
实施例5 92
光学雾度测量
用Haze-Gard Plus雾度计测量样品的光学雾度，该雾度计可从美国马里兰州哥伦比亚21046-2729的毕克化学仪器部门(Columbia,Maryland21046-2729,USA)商购获得。将样品切成38mm×127mm(1.5"×5.0")。测量未拉伸样品的光学雾度并将样品拉伸至30％。在测量之前，使用3M光学透明粘合剂8171将这些样品层压到透明的3mm厚60mm×240mm通用丙烯酸面板。表皮侧位于空气侧上。雾度结果列于下表。
雾度结果
未拉伸样品的雾度 30％拉伸样品的雾度 雾度水平增加
比较例1 9.41 8.93 -0.48
比较例2 5.95 7.82 1.87
比较例3 19.3 15.6 -3.7
比较例4 21.3 21.8 0.5
实施例1 3.52 90.8 87.28
实施例2 3.33 98.4 95.07
实施例3 2.48 98.8 96.32
比较例5 6.33 5.3 -1.03
实施例4 31.5 93 61.5
实施例5 30.1 98.3 68.2
比较例6 3.84 3.64 -0.2
膜拉伸特性
在将膜在CTH(恒定温度和湿度，23℃室温和50％)室中调理24小时之后，将样品在纵向上切成38mm×127mm(1.0"×5.0")。使用来自马萨诸塞州诺伍德02062的英斯特朗公司(Instron,Norwood,MA 02062)的拉伸机(型号：EMSYSU 4242)以12"/min(304.8mm/分钟)的夹头速度用2英寸(50.8mm)间隙进行测试。实施例中的每个实施例都能够拉伸高至150％。
图4示出了选定的实施例和实施例的组件的负荷力(磅/英寸)对比伸长率(％)。在用于处理和层压的伸长率范围内(低水平)，表层420的刚度大于基底覆膜层410的刚度。同样，实施例3 440的全构造(包括刚性表层)比比较例5 430的刚性更大。

Claims (20)

1.一种膜叠堆，包括：
基底覆膜层，所述基底覆膜层由第一材料形成并具有第一主表面和第二主表面；
可移除的表层，所述可移除的表层由第二材料形成且设置在所述基底覆膜层的所述第一主表面上；和
粘合剂层，所述粘合剂层设置在所述基底覆膜层的所述第二主表面上；
其中所述基底覆膜层是透明的；
其中所述可移除的表层比所述基底覆膜层的刚性更大；
其中所述膜叠堆能够拉伸至30％的伸长率，而不会对所述基底覆膜层造成不可逆的损坏。
2.根据权利要求1所述的膜叠堆，其中当所述膜叠堆被一起拉伸时，所述可移除的表层产生雾度，而所述基底覆膜层保持透明。
3.根据权利要求1所述的膜叠堆，其中所述可移除的表层具有介于10微米和150微米之间的厚度。
4.根据权利要求1所述的膜叠堆，其中所述膜叠堆包括位于所述粘合剂层和所述基底覆膜层之间的接合层。
5.一种卷膜，包括根据权利要求1所述的膜叠堆，其中所述膜叠堆设置在衬垫上。
6.根据权利要求1所述的膜叠堆，其中所述第一材料和所述第二材料是可挤塑的。
7.根据权利要求1所述的膜叠堆，其中所述第一材料包括聚氯乙烯。
8.根据权利要求1所述的膜叠堆，其中所述第一材料包括聚氨酯。
9.根据权利要求1所述的膜叠堆，其中所述第二材料包括聚丙烯。
10.根据权利要求1所述的膜叠堆，其中所述基底覆膜层包含离聚物。
11.一种膜叠堆，包括：
基底覆膜层；和
可移除的表层，所述可移除的表层设置在所述基底覆膜层的主表面上；
其中，当拉伸所述膜叠堆时，在对所述基底覆膜层造成不可逆的损坏之前，所述可移除的表层提供可见指示。
12.根据权利要求11所述的膜叠堆，其中所述可见指示是雾度的突然增加。
13.根据权利要求12所述的膜叠堆，其中所述雾度的突然增加是增加至少50百分点。
14.一种防止在拉伸膜叠堆时过度拉伸的方法，所述方法包括：
提供膜叠堆，所述膜叠堆包括基底覆膜层和设置在所述基底覆膜层上的可移除的表层，其中当拉伸所述膜叠堆时，在对所述基底覆膜层造成不可逆的损坏之前，所述可移除的表层变得模糊；
将所述膜叠堆拉伸至小于或达到所述可移除的表层变得模糊的程度。
15.根据权利要求14所述的方法，其中拉伸所述膜叠堆意味着拉伸至30％的伸长率。
16.根据权利要求11所述的方法，其中拉伸所述膜叠堆意味着拉伸至50％的伸长率。
17.根据权利要求11所述的方法，其中拉伸所述膜叠堆包括将所述膜叠堆拉伸至所述可移除的表层的雾度增加50百分点的程度。
18.根据权利要求14所述的方法，还包括移除所述表层的步骤。
19.根据权利要求14所述的方法，包括进一步拉伸所述膜的步骤。
20.根据权利要求19所述的方法，包括向所述膜施加热量的步骤。
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