CN1166726C - 在聚烯烃制品上涂覆聚硅酸盐防渗涂层的方法以及由此得到的产品 - Google Patents

在聚烯烃制品上涂覆聚硅酸盐防渗涂层的方法以及由此得到的产品 Download PDF

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CN1166726C
CN1166726C CNB998083933A CN99808393A CN1166726C CN 1166726 C CN1166726 C CN 1166726C CN B998083933 A CNB998083933 A CN B998083933A CN 99808393 A CN99808393 A CN 99808393A CN 1166726 C CN1166726 C CN 1166726C
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R·普拉萨德
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Abstract

本发明公开了一种生产经涂覆的聚合产品的方法：将聚丙烯与马来酐改性的聚丙烯共挤塑，进行电晕处理，并涂覆聚硅酸盐防渗涂层。还提供了用该方法生产的薄膜和瓶子。

Description

在聚烯烃制品上涂覆聚硅酸盐防渗涂层 的方法以及由此得到的产品
发明领域
概括地讲，本发明涉及经涂覆的聚合产品的生产，尤其涉及带有防渗涂层的产品的生产。
发明背景
包括薄膜和瓶子在内的聚合产品广泛地被用来包装产品，尤其是食品。但是，未经改性的聚合产品不具备包装所需的阻气性和防潮性。
因此，已设计出具有改进的阻气性和防潮性的多层聚合薄膜。例如，在US 5,192,620(Chu等人)中，聚丙烯薄膜被涂覆了乙烯-丙烯酸共聚物与聚乙烯醇的混合物，然后再被金属化以制成具有防潮性的薄膜。US 5,491,023公开了向经过马来酐改性聚丙烯改性的聚烯烃基材表面上涂覆一层聚乙烯醇。
令人遗憾的是，某些为改进阻气性和防潮性而涂覆到聚合物薄膜上的涂层在对基材粘附性方面面临着问题。已经采用了各种手段来解决这些问题。但是，到目前为止，没有一种手段能有效地生产出具有足够防渗性的产品。
发明概述
一方面，本发明提供了一种制备经涂覆的聚合产品的方法。该方法包括将选定的聚烯烃与马来酐改性的聚烯烃共挤塑，由此制成一种具有经改性的马来酐表面的聚合基材。对聚合基材的马来酐表面进行表面处理，并向经过处理的聚合基材上涂覆聚硅酸盐防渗涂层。
另一方面，本发明方法进一步包括在涂覆防渗涂层之前将基材双轴取向。
又一方面，本发明提供了一种经涂覆的聚合产品，该产品包含由共挤塑的马来酐改性聚丙烯和选定的聚烯烃构成的基材以及涂覆在该共挤塑基材表面上的聚硅酸盐涂层。
本发明的其它方面将通过研究发明详述部分而变得明了。
发明详述
本发明提供了一种生产带有防渗涂层的聚合产品的方法。有益的是，本发明方法无需单独向基材上涂覆一层底涂层(例如溶剂涂层)就能使防渗涂层对基材具有良好的粘附性。因此，本发明方法在生产经涂覆的产品方面也具有优点。
一方面，本发明提供了一种通过将选定的聚烯烃与改性聚烯烃共挤塑来生产经涂覆的聚合产品的方法。该改性聚烯烃为亲水性较适宜。更适当的是，改性聚烯烃在被改性前与选定的未改性聚烯烃相同。在一个优选实施方案中，聚烯烃是聚丙烯的均聚物或共聚物。然而，其它合适的聚烯烃也可以容易地选用。其它合适聚烯烃的实例包括(但不限于)聚乙烯、聚酯、聚丁烯、聚碳酸酯、聚丙烯腈和烯烃共聚物，烯烃共聚物包括环烯共聚物(COC)，如乙烯与降冰片烯的共聚物[US5,087,677]。
优选地，改性聚烯烃是马来酐改性的聚丙烯。马来酐改性的聚丙烯可以通过任何方法来制备，例如US 3,433,777、US 4,198,327或US5,153,074中阐述的方法。市售的马来酐改性的聚丙烯或丙烯共聚物具有以下物理性能：密度为0.90(ASTM D1505)，维卡软化点为143℃(ASTM D1525)，肖氏硬度为67℃(ASTM 2240)，以及熔点为160℃(ASTM D2117)。或者，这些改性聚烯烃可以用其它方法生产或是市售的(例如从Uniroyal购买(Polybond牌)，从Mitsui购买(Attmar牌)，或从Dow购买(Primacor牌))。
用常规方法将聚烯烃与经亲水化改性的聚烯烃共挤塑。例如，合适的挤出温度在180-240℃范围内，所得共挤塑基材的厚度在508-1270微米(20-50密耳)厚的范围内。合适的方法包括采用选择模塞或多模腔模头。
所得的聚合基材具有一个改性聚烯烃层和一个未改性聚烯烃层。在涂覆防渗涂层之前对该改性聚烯烃层进行预处理。优选地，该预处理包括进行表面处理以允许防渗涂层粘附。适当的表面处理是本技术领域中公知的，包括电晕处理、火焰处理、等离子处理、化学处理或电晕放电处理。更理想的是，处理该表面，从而使表面能提高到按ASTMD2578-84标准为约45-约60达因/cm。
非必需地，聚合基材可以在被处理和被涂覆防渗涂层之前进行取向。理想的是，基材通过顺序拉伸而被双轴取向。例如，基材可以在纵向被拉伸至多5倍，而在横向被拉伸至多10倍，从而使厚度处在约12.7-约50.8微米(约0.5-约2密耳)的范围内，在一个理想的实施方案中，厚度达到19.05微米(0.75密耳)。
合适的是，防渗涂层是无机涂层，优选是聚硅酸盐涂层。合适的聚硅酸盐涂层可以容易地从本技术领域所公知的那些中选择出来。
合适涂层的一个实例公开在WO 97/47694(1997.12.18)中，它公开了一种包含有分散在无机粘合剂中的层状无机矿物填料的阻气性涂覆液。优选地，该填料是层状无机矿物质，而粘合剂是碱金属硅酸盐。层状无机填料在干涂层的无机成分中的重量分数为0-99％。合适的无机矿物质选自叶硅酸盐、伊利石矿物质和层状双氢氧化物。更优选地，层状材料是蛭石。合适的粘合剂包括选自聚硅酸锂、聚硅酸钠、聚硅酸钾和它们的共-聚硅酸盐混合物的金属聚硅酸盐。
另一种合适的聚硅酸盐涂层公开在WO 97/44379(1997.11.27)中，它公开了化学式为(Li2O)x(K2O)1-x(SiOx)y的锂-钾共-聚硅酸盐，其中Li2O的摩尔分数是x，SiO2与M2O的摩尔比是y，M2O是(Li2O)x(K2O)1-x。在该共-聚硅酸盐中，y在1-10之间，x小于约1。理想地，x的范围为约0.5至小于1，y的范围为1至约10。更优选地，x的范围为0.5至小于1，y大于4.6且其值至多约为10。这些涂层一般含有至多约25wt％的固体。然而，该百分数可以根据需要来调整。
再一种合适的无机涂层公开在WO 97/47695(1997.12.18)中。该公开文本公开了一种含有金属聚硅酸盐和透明的非结晶二氧化钛(TiO2)的阻气性涂覆液，该涂覆液特别适合于涂覆聚(对苯二甲酸乙二醇酯)型聚合产品。金属聚硅酸盐基本上按照WO 97/44379中的定义来定义。合适地，非结晶二氧化钛的存在量至多占涂覆液中全部固体的约25wt％。优选地，二氧化钛占全部固体的约2wt％-约9wt％。合适地，非结晶二氧化钛的平均粒径小于约100nm，优选小于约50nm。可以采用市售的两种结晶形式(锐钛型和金红石型)的二氧化钛中的任何一种。
其它合适的聚硅酸盐涂层可以由本领域的熟练技术人员容易地选择出来。
因此，本发明所用的聚硅酸盐涂层理想地是选自含水的聚硅酸锂、聚硅酸钠或聚硅酸钾以及这些材料的共-聚硅酸盐混合物的碱金属聚硅酸盐。一种商标为InobondLi 2043(van Baerle & Cie)的典型市售产品是一种聚硅酸锂的含水胶态悬浮体，它含有约24.5wt％的氧化硅和约3wt％的氧化锂。其它可用的产品可以从van Baerle & Cie以商标K-4009购得，它是一种聚硅酸钾的含水胶态悬浮体，它含有约26.8wt％的氧化硅和约13wt％的氧化钾。将这种成分与水混合以达到可用于本发明的理想的涂覆液固含量。在搅拌了一段时间后，该防渗涂料混合物就准备好被涂覆到按照本文所述方法制备的聚合基材上。
可以用任何合适的方法将防渗涂料直接涂覆到经处理的聚合基材上。这些方法包括(但不限于)辊涂法、喷涂法和浸涂法。常规的辊涂法包括(但不限于)采用棒、辊、逆向辊、正向辊、气刀、辊衬刮刀、刮板、凹版和缝口模头的涂覆方法。有关涂覆方法种类的一般性说明可以在下述教科书中找到，如“现代涂覆和干燥技术(ModernCoating and Drying Techniques)”(E.Cohen和E.Gutoff编辑，VCH出版公司)纽约(1992)，以及“丝网方法和变换技术及设备(WebProcessing and Converting Technology and Equipment)”(D.Satas编辑，Van Nostrand Reinhold)纽约(1984)。立体产品可以用喷涂法或浸涂法涂覆。涂覆方法不是对本发明的限制，而是可以从这些及其它本领域熟练技术人员公知的方法中选择。
涂覆后，将经涂覆的产品在室温或高于室温的选定温度下干燥。对干燥温度的选择取决于所需的干燥时间；这样，加快干燥时间可以通过升高温度来实现，如果可以允许较长的干燥时间，则无需升高温度。本领域的熟练技术人员可以容易地根据需要来调整烘箱温度和干燥时间。干燥的阻气性涂层的性能在25-200℃的干燥温度范围内不受影响。
本发明方法允许将厚度范围为约200-约500nm的聚硅酸盐涂层涂覆到聚合基材上。但是，可以预料本发明的方法将允许厚度超过500nm的涂层。因此，所得的经涂覆产品比用其它方法生产的产品具备更好的氧气和湿气阻隔性。
非必需地，可以将保护性面涂层胶粘层压到或用其它合适的方法涂覆到上述氧气阻隔性涂层上。这些面涂层可以提供额外的氧气阻隔性或其它所需的性能，如提高的防潮性。该面涂层可以是薄(一般为，但不是必须为1-10nm厚)涂层或是一种层合膜。薄的面涂层可以用各种涂覆方法来涂覆：辊涂、喷涂、浸涂。通常，当采用辊涂法时，优选采用低于800英尺/分钟的生产线速度，更理想的是低于约500英尺/分钟。层合膜可以通过将层合层熔融-挤出在防渗涂层上或通过胶粘层压一种第二薄膜来制备。层合膜提供了弯曲保护，当表面被层合时性能不会因此而降低。面涂层另外还提供了改进的弯曲性能(即弯曲后阻气性的保持力)以及改进的防潮性(即在高的相对湿度下阻气性的保持力)。
合适地，这些面涂层可以是水溶性的。更合适地，这些面涂层适合于用在食物包装方面使用的柔性基材上的涂层之上。参见，例如21 CFR(美国联邦法)§175.210 et seq.中阐述的材料，该文献结合入本文供引用。合适的面涂层可以由本领域的熟练技术人员容易地选择出来。目前，优选的面涂层材料选自聚甲基丙烯酸酯、乙酸纤维素和硝酸纤维素。然而其它合适的层压材料的实例包括取向的聚丙烯(OPP)，其中包括金属化的OPP。市售的取向OPP可以从Mobil Chemical、FilmsDivision Bicor 70MB-HB购买。
另一方面，本发明提供了用本发明方法生产的经涂覆的产品。这些产品优选是薄膜，更优选地是经双轴取向的聚丙烯薄膜。但是，包括瓶子、塑料容器、罐、泡罩包装和盖在内的其它经涂覆的产品也可以容易地用本发明方法生产出来。在一个优选的实施方案中，该产品是用于储存食物的薄膜或瓶子。
因此，本发明提供了一种经涂覆的聚合产品，该产品由基材和在该共挤塑基材表面上的聚硅酸盐涂层构成，所述的基材由共挤塑的马来酐改性聚丙烯和选定的聚烯烃组成。本发明的经涂覆的聚合产品比以前制备的带有聚硅酸盐涂层的产品具有更好的氧气阻隔性。
提供以下实施例是为了举例说明本发明而不是为了限制其范围。本领域的熟练技术人员会意识到尽管以下实施例中界定了具体的范围和条件，但进行改进是可以的，并认为这种改进包含在本发明的精神和范围以内。
实施例1：对照薄膜
通过将聚丙烯均聚物与聚丙烯-聚乙烯共聚物一起单面共挤塑来制备聚丙烯薄膜。在120℃将该薄膜纵向拉伸约4-5倍，随后在174℃横向拉伸约9-10倍。
用常规约定方法制备锂-钾共-聚硅酸盐(Li2O)x(K2O)1-x(SiO2)y防渗涂料。该共-聚硅酸盐溶液中，总固含量为12wt％，Li2O的摩尔分数x为0.5，SiO2与全部碱金属氧化物的摩尔比y为3.64。聚硅酸锂采用的是具有3.0％w/w Li2O和24.5％w/w SiO2的InobondLi 2043聚硅酸锂溶液(van Baerle)。聚硅酸钾采用的是具有13.0％w/w K2O和26.85％w/w SiO2的K-4009硅酸钾溶液(van Baerle)。在连续搅拌下，用108.1g蒸馏水稀释53.1g InobondLi 2043溶液，随后加入38.8gK-4009聚硅酸盐。
电晕处理该薄膜的均聚物一侧，并用辊涂法(凹版)涂覆上锂-钾共-聚硅酸盐防渗材料，从而给该薄膜涂覆上干膜厚度为0.5μ的涂层。
在1bar、23℃和50％相对湿度条件下，测得该经涂覆薄膜的氧气透过率(OTR)为900-1000cc/m2/天。
实施例2：
通过将聚丙烯均聚物在一面与聚丙烯-聚乙烯共聚物以及对均聚物层的另一面以接枝上丙烯酸官能团改性的聚丙烯(POLYBOND1002，Uniroyal)一起共挤塑来制备聚丙烯薄膜。在120℃将该薄膜纵向拉伸约4-5倍，随后在174℃横向拉伸约9-10倍。电晕处理该薄膜的改性聚丙烯一侧，并涂覆上以上实施例1所述的锂-钾共-聚硅酸盐防渗材料。在1bar、23℃和50％相对湿度条件下，测得该薄膜的OTR为700-850cc/m2/天。
实施例3：
通过将聚丙烯均聚物、在一面与聚丙烯-聚乙烯共聚物以及在聚丙烯均聚物层的另一侧与乙烯-乙烯醇(SOARNAL)一起共挤塑来制备聚丙烯薄膜。在120℃将该薄膜纵向拉伸约4-5倍，随后在174℃横向拉伸约9-10倍。SOARNOL层不能被拉伸，并表现为一个均聚物层上的撕碎层。该薄膜不能被涂覆。本发明人认为观察到这种结果是因为试图将乙烯醇组分拉伸约5-6倍以上。这种涂层适用于需要较少取向步骤的薄膜以及不需要取向的薄膜和其它基材。
实施例4：
通过将聚丙烯均聚物、聚丙烯-聚乙烯共聚物(在聚丙烯均聚物层的一侧)以及经马来酐基团接枝改性的聚丙烯(POLYBOND EXP97-60-35，Uniroyal)(在聚丙烯均聚物层的另一侧)一起共挤塑来制备聚丙烯薄膜。在120℃将该薄膜纵向拉伸约4-5倍，随后在174℃横向拉伸约9-10倍。电晕处理该薄膜的改性聚丙烯一侧，并涂覆上实施例1所述的锂-钾共-聚硅酸盐防渗材料。
在1bar、23℃和50％相对湿度条件下，测得该薄膜的OTR为3-15cc/m2/天。
本说明书中列举的所有出版物均结合入本文供引用。尽管本发明是参考特定的优选实施方案进行说明的，但应当认识到，可以作出不背离本发明精神的改进。并认为这种改进属于附加权利要求的范围之内。

Claims (21)

1、一种制备经涂覆的聚合产品的方法，包括以下步骤：
(a)将选定的聚烯烃与马来酐改性的聚烯烃共挤塑，由此制成一种具有一个经改性的马来酐表面和一个聚烯烃表面的聚合基材；
(b)处理聚合基材的马来酐表面，使其能够接受聚硅酸盐防渗涂层；和
(c)向经过表面处理的聚合基材上涂覆聚硅酸盐防渗涂层。
2、权利要求1的方法，进一步包括在表面处理之前对聚合基材进行双轴取向的步骤。
3、权利要求2的方法，其中，取向步骤进一步包括将基材纵向拉伸至多5倍和在横向拉伸至多10倍的步骤。
4、权利要求1的方法，其中，聚烯烃是聚丙烯的均聚物或共聚物。
5、权利要求1的方法，其中，聚硅酸盐防渗涂层被直接涂覆在聚合基材的表面上。
6、权利要求1的方法，其中，所述聚硅酸盐防渗涂层包含聚硅酸锂。
7、权利要求1的方法，其中，所述聚硅酸盐防渗涂层包含锂-钾共-聚硅酸盐。
8、权利要求1的方法，进一步包括在聚硅酸盐防渗涂层上形成面涂层的步骤。
9、权利要求8的方法，其中，面涂层选自聚甲基丙烯酸酯、乙酸纤维素和硝酸纤维素。
10、一种经涂覆的聚合产品，包含：
(a)由共挤塑的马来酐改性聚烯烃层和选定聚烯烃层组成的聚合基材；和
(b)在该马来酐改性层上的聚硅酸盐涂层。
11、权利要求10的经涂覆的产品，其中，所述产品进一步包含一层面涂层。
12、权利要求11的经涂覆的产品，其中，面涂层选自聚甲基丙烯酸酯、乙酸纤维素和硝酸纤维素。
13、权利要求10的产品，其中，基材的特征在于厚度范围为508-1270微米。
14、权利要求10的产品，其中，该产品是一种薄膜。
15、权利要求14的产品，其中，该产品经过双轴取向。
16、权利要求14的产品，其中，在被涂覆前，基材的厚度为12.7-50.8微米。
17、权利要求10的产品，其中，该产品是一种瓶子。
18、权利要求10的产品，其中，选定聚烯烃是聚丙烯。
19、权利要求10的产品，其中，所述聚硅酸盐涂层的厚度范围为200-500nm。
20、权利要求10的产品，其中，所述聚硅酸盐涂层包含聚硅酸锂。
21、权利要求10的产品，其中，所述聚硅酸盐涂层包含锂-钾共-聚硅酸盐。
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US7118790B2 (en) 2006-10-10
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EP1105435B1 (en) 2004-02-04
CA2340759C (en) 2008-07-22
MXPA01001795A (es) 2002-04-08
DE69914610T2 (de) 2005-01-05
US20040043173A1 (en) 2004-03-04
CA2340759A1 (en) 2000-02-24
ATE258953T1 (de) 2004-02-15
DE69914610D1 (de) 2004-03-11
CN1320139A (zh) 2001-10-31
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ES2219053T3 (es) 2004-11-16
AU5516099A (en) 2000-03-06

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