CN116981722A - Method of processing coated flexible substrates for packaging applications - Google Patents
Method of processing coated flexible substrates for packaging applications Download PDFInfo
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- CN116981722A CN116981722A CN202080108170.5A CN202080108170A CN116981722A CN 116981722 A CN116981722 A CN 116981722A CN 202080108170 A CN202080108170 A CN 202080108170A CN 116981722 A CN116981722 A CN 116981722A
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- flexible substrate
- barrier layer
- charged particle
- coated flexible
- processing
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- 239000000758 substrate Substances 0.000 title claims abstract description 229
- 238000000034 method Methods 0.000 title claims abstract description 45
- 238000004806 packaging method and process Methods 0.000 title claims description 32
- 230000004888 barrier function Effects 0.000 claims abstract description 172
- 239000002245 particle Substances 0.000 claims abstract description 82
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical group [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 38
- 229910052760 oxygen Inorganic materials 0.000 claims description 38
- 239000001301 oxygen Substances 0.000 claims description 38
- 239000008199 coating composition Substances 0.000 claims description 27
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 claims description 14
- CERQOIWHTDAKMF-UHFFFAOYSA-M Methacrylate Chemical compound CC(=C)C([O-])=O CERQOIWHTDAKMF-UHFFFAOYSA-M 0.000 claims description 14
- 239000000178 monomer Substances 0.000 claims description 14
- 239000000463 material Substances 0.000 claims description 13
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 10
- 229910052782 aluminium Inorganic materials 0.000 claims description 8
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 8
- 239000011368 organic material Substances 0.000 claims description 8
- -1 polyethylene Polymers 0.000 claims description 8
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 7
- 239000004372 Polyvinyl alcohol Substances 0.000 claims description 6
- 230000035515 penetration Effects 0.000 claims description 6
- 229920002451 polyvinyl alcohol Polymers 0.000 claims description 6
- 235000012239 silicon dioxide Nutrition 0.000 claims description 5
- 239000000377 silicon dioxide Substances 0.000 claims description 5
- 229920001328 Polyvinylidene chloride Polymers 0.000 claims description 4
- 239000005033 polyvinylidene chloride Substances 0.000 claims description 4
- PMHQVHHXPFUNSP-UHFFFAOYSA-M copper(1+);methylsulfanylmethane;bromide Chemical compound Br[Cu].CSC PMHQVHHXPFUNSP-UHFFFAOYSA-M 0.000 claims description 3
- 238000006116 polymerization reaction Methods 0.000 claims description 3
- 239000004952 Polyamide Substances 0.000 claims description 2
- 239000004698 Polyethylene Substances 0.000 claims description 2
- 229920002367 Polyisobutene Polymers 0.000 claims description 2
- 239000004743 Polypropylene Substances 0.000 claims description 2
- 239000004793 Polystyrene Substances 0.000 claims description 2
- 229920001483 poly(ethyl methacrylate) polymer Polymers 0.000 claims description 2
- 229920002647 polyamide Polymers 0.000 claims description 2
- 229920000573 polyethylene Polymers 0.000 claims description 2
- 239000005020 polyethylene terephthalate Substances 0.000 claims description 2
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 2
- 229920001155 polypropylene Polymers 0.000 claims description 2
- 229920002223 polystyrene Polymers 0.000 claims description 2
- 239000004810 polytetrafluoroethylene Substances 0.000 claims description 2
- 229920001343 polytetrafluoroethylene Polymers 0.000 claims description 2
- 229920002689 polyvinyl acetate Polymers 0.000 claims description 2
- 239000011118 polyvinyl acetate Substances 0.000 claims description 2
- 238000000576 coating method Methods 0.000 description 12
- 239000011248 coating agent Substances 0.000 description 8
- 229920000642 polymer Polymers 0.000 description 8
- 230000005540 biological transmission Effects 0.000 description 6
- 238000004519 manufacturing process Methods 0.000 description 6
- 229920000877 Melamine resin Polymers 0.000 description 5
- 229940123973 Oxygen scavenger Drugs 0.000 description 5
- 229920000058 polyacrylate Polymers 0.000 description 5
- 229920000193 polymethacrylate Polymers 0.000 description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 5
- 230000009286 beneficial effect Effects 0.000 description 3
- 238000007766 curtain coating Methods 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 230000006870 function Effects 0.000 description 3
- 239000004640 Melamine resin Substances 0.000 description 2
- 238000007774 anilox coating Methods 0.000 description 2
- 238000009792 diffusion process Methods 0.000 description 2
- 238000003618 dip coating Methods 0.000 description 2
- 238000001704 evaporation Methods 0.000 description 2
- 230000008020 evaporation Effects 0.000 description 2
- 235000013305 food Nutrition 0.000 description 2
- 238000007756 gravure coating Methods 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 230000035699 permeability Effects 0.000 description 2
- 238000005240 physical vapour deposition Methods 0.000 description 2
- 230000000379 polymerizing effect Effects 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 229920000219 Ethylene vinyl alcohol Polymers 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- 229910001423 beryllium ion Inorganic materials 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000005229 chemical vapour deposition Methods 0.000 description 1
- 230000000593 degrading effect Effects 0.000 description 1
- 238000000151 deposition Methods 0.000 description 1
- 238000005328 electron beam physical vapour deposition Methods 0.000 description 1
- 238000001017 electron-beam sputter deposition Methods 0.000 description 1
- UFRKOOWSQGXVKV-UHFFFAOYSA-N ethene;ethenol Chemical compound C=C.OC=C UFRKOOWSQGXVKV-UHFFFAOYSA-N 0.000 description 1
- 239000004715 ethylene vinyl alcohol Substances 0.000 description 1
- 239000011888 foil Substances 0.000 description 1
- 235000013882 gravy Nutrition 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229960003903 oxygen Drugs 0.000 description 1
- 239000000825 pharmaceutical preparation Substances 0.000 description 1
- 229940127557 pharmaceutical product Drugs 0.000 description 1
- 238000004544 sputter deposition Methods 0.000 description 1
Classifications
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
- C08J7/04—Coating
- C08J7/048—Forming gas barrier coatings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/04—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to gases
- B05D3/0486—Operating the coating or treatment in a controlled atmosphere
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/06—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation
- B05D3/068—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation using ionising radiations (gamma, X, electrons)
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/02—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to macromolecular substances, e.g. rubber
- B05D7/04—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to macromolecular substances, e.g. rubber to surfaces of films or sheets
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
- C08J7/04—Coating
- C08J7/042—Coating with two or more layers, where at least one layer of a composition contains a polymer binder
- C08J7/0423—Coating with two or more layers, where at least one layer of a composition contains a polymer binder with at least one layer of inorganic material and at least one layer of a composition containing a polymer binder
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
- C08J7/04—Coating
- C08J7/06—Coating with compositions not containing macromolecular substances
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
- C08J7/12—Chemical modification
- C08J7/123—Treatment by wave energy or particle radiation
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
- C08J7/12—Chemical modification
- C08J7/16—Chemical modification with polymerisable compounds
- C08J7/18—Chemical modification with polymerisable compounds using wave energy or particle radiation
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/26—Processes for applying liquids or other fluent materials performed by applying the liquid or other fluent material from an outlet device in contact with, or almost in contact with, the surface
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/28—Processes for applying liquids or other fluent materials performed by transfer from the surfaces of elements carrying the liquid or other fluent material, e.g. brushes, pads, rollers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D2201/00—Polymeric substrate or laminate
- B05D2201/02—Polymeric substrate
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B05D2502/00—Acrylic polymers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/50—Multilayers
- B05D7/52—Two layers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/50—Multilayers
- B05D7/56—Three layers or more
Abstract
A method of processing a coated flexible substrate is described. The method of processing a coated flexible substrate includes: providing the coated flexible substrate, the coated flexible substrate comprising: a flexible substrate comprising a first surface and a second surface opposite the first surface, and at least one barrier layer on the first surface of the flexible substrate; and simultaneously providing a charged particle beam to the at least one barrier layer of the coated flexible substrate and the flexible substrate in a substantially oxygen-free atmosphere.
Description
Technical Field
Embodiments of the present disclosure relate to a method of processing a coated flexible substrate for packaging applications.
Background
Coated flexible substrates made of a polymeric flexible substrate and a barrier layer deposited on the polymeric flexible substrate are known in the packaging industry for packaging food, chemicals, pharmaceutical or agricultural products and for protecting these packaged articles from harmful moisture and/or oxygen.
The most commonly used coated flexible substrates include polymeric flexible substrates having at least one barrier layer deposited thereon. Currently, in most cases, metals (e.g., aluminum and tin plated), polymers (e.g., EVOH or PVDC), polymers coated with thin metal or oxide layers are used as barrier materials. To produce such coated flexible substrates, one or more barrier layers may be deposited at the surface of the polymeric flexible substrate by an evaporation process. In some cases, an uppermost layer made of a polymer is additionally disposed on the barrier layer.
While such commonly used barrier layers provide good protection against moisture and/or oxygen, their barrier properties are observed to degrade over time. Furthermore, in case of damage of the barrier layer, for example, during transportation of the article protected by the coated flexible substrate, the barrier properties of the coated flexible substrate may also be reduced. Furthermore, protecting very sensitive items (such as electronic devices) from moisture and/or oxygen requires coated flexible substrates with very low oxygen permeability.
Thus, there is a continuing need for methods for generally improving the barrier properties of coated flexible substrates for packaging applications.
Disclosure of Invention
In view of the foregoing, a method of processing a coated flexible substrate for packaging applications is provided. It is an object of the present disclosure to provide a method of improving the oxygen barrier properties of coated flexible substrates for packaging applications. Furthermore, it is an object of the present disclosure to improve the oxygen barrier (oxygen barrier) properties of coated flexible substrates without the need for additional barrier materials or complex production systems. Therefore, the method has low manufacturing cost and high production efficiency. Further, it is an object of the present disclosure to provide a coated flexible substrate with additional protection to an article that may function in the event of damage to a barrier layer disposed on the flexible substrate or when oxygen reaches the flexible substrate after diffusing through the barrier layer disposed on the flexible substrate. Furthermore, it is an object of the present disclosure to create new functions in an existing flexible substrate of a coated flexible substrate that act as oxygen scavengers, providing additional oxygen barrier properties.
Further aspects, benefits and features of the present disclosure are apparent from the claims, description and drawings.
According to one aspect of the present disclosure, a method of processing a coated flexible substrate for packaging applications is provided. The method of processing a coated flexible substrate includes providing a coated flexible substrate comprising: a flexible substrate comprising a first surface and a second surface opposite the first surface, and at least one barrier layer on the first surface of the flexible substrate. The method further includes simultaneously providing a charged particle beam to the at least one barrier layer of the coated flexible substrate and the flexible substrate in a substantially oxygen-free atmosphere.
Brief description of the drawings
So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments. The drawings relate to embodiments and are described as follows:
FIG. 1 illustrates a flow chart showing a method of processing a coated flexible substrate for packaging applications according to embodiments described herein;
FIG. 2 illustrates a schematic diagram showing a method of processing a coated flexible substrate for packaging applications, including microscopic views of the coated flexible substrate, according to embodiments described herein;
fig. 3A-3C illustrate schematic cross-sectional side views of a coated flexible substrate for packaging applications according to embodiments described herein;
fig. 4 shows a schematic diagram of an apparatus for processing a coated flexible substrate for packaging applications according to embodiments described herein.
Detailed Description
Reference will now be made in detail to the various embodiments, one or more examples of which are illustrated in each figure. In the following description of the figures, like reference numerals refer to like parts. Generally, only the differences with respect to the respective embodiments are described. Each example is provided by way of explanation and is not intended as a limitation of the present disclosure. Additionally, features illustrated or described as part of one embodiment can be used on or in conjunction with other embodiments to yield yet a further embodiment. The description is intended to include such modifications and variations.
Coated flexible substrates (e.g., made from polymeric flexible substrates and barrier layers deposited on polymeric flexible substrates to prevent moisture and/or oxygen diffusion or through coated flexible substrates) are known in the packaging industry for packaging food, chemicals and pharmaceutical products, as well as technical or other agricultural products. However, the barrier properties of the coated flexible substrate have been observed to degrade over time. For example, in the event that a barrier layer deposited on a flexible substrate is damaged during transport of an article protected by the coated flexible substrate, the barrier properties of the coated flexible substrate are reduced. In addition, after a period of time, oxygen diffuses through a barrier layer disposed on the flexible substrate, which also reduces protecting the article from oxygen, for example. Furthermore, protecting certain articles (e.g., electronic devices) from oxygen requires coated flexible substrates with very low oxygen permeability.
However, it is an object of the present disclosure to provide a method of improving the oxygen barrier properties of coated flexible substrates for packaging applications. Examples of packaging applications may include modified atmosphere (modified atmosphere) packaging. In particular, providing a charged particle beam to a coated flexible substrate comprising at least one barrier layer and a flexible substrate in a substantially oxygen-free atmosphere facilitates creating new functionality, thereby acting as an oxygen scavenger in an existing flexible substrate of the coated flexible substrate. The newly created function provides additional oxygen barrier properties to the coated flexible substrate.
Furthermore, providing a charged particle beam to a coated flexible substrate comprising at least one barrier layer and a flexible substrate in a substantially oxygen-free atmosphere causes polymer chains of a portion of the flexible substrate to break, which imparts additional oxygen barrier properties to the flexible substrate. In other words, radicals are generated in the coated flexible substrate due to the charged particle beam providing to the coated flexible substrate and the corresponding breaking of the polymer chains of the portion of the flexible substrate. The free radicals act as oxygen scavengers once oxygen reaches the flexible substrate after diffusion through the at least one barrier layer, for example once the at least one barrier layer is damaged during transport of the article to be protected.
It is an object of the present disclosure to improve the oxygen barrier properties of coated flexible substrates without the need for additional barrier materials or complex production systems. Thus, the method of the present disclosure proceeds at low manufacturing cost and high production efficiency.
Referring exemplarily to fig. 1, a method 100 of processing a coated flexible substrate for packaging applications in accordance with the present disclosure is described. Beginning at start 110, method 100 may include providing a coated flexible substrate comprising: a flexible substrate comprising a first surface and a second surface opposite the first surface, and at least one barrier layer on the first surface of the flexible substrate (stage 120). Further, the method 100 of processing a coated flexible substrate for packaging applications may include simultaneously providing a charged particle beam to at least one barrier layer of the coated flexible substrate and the flexible substrate in a substantially oxygen-free atmosphere (stage 130). The method 100 may end at end 140.
Before describing various additional embodiments of the present disclosure in more detail, some aspects are described in relation to some terms used herein.
In the present disclosure, a "flexible substrate"May be characterized in that the substrate is bendable. For example, the flexible substrate may be a foil or a roll. In particular, it should be understood that embodiments as described herein may be used to process any kind of coated flexible substrate for packaging applications. The flexible substrate as described herein may comprise a substrate material selected from the group consisting of: polyethylene, polypropylene, polyisobutylene, polyvinylidene chloride, polytetrafluoroethylene, polyamide, polyethylene terephthalate, polystyrene, polyvinyl alcohol, polyvinyl acetate, polyethyl methacrylate, and combinations thereof. In particular, the flexible substrate is a polymeric flexible substrate. Substrate thickness T of flexible substrate S May be T S T.ltoreq.250. Mu.m, in particular 5. Mu.m S T.ltoreq.150. Mu.m, more particularly 5. Mu.m.ltoreq.T S Less than or equal to 100 μm, e.g. T S =50μm±1nm. It should be appreciated that a thickness T as specified herein is selected S The flexible substrate of (2) may be beneficial in providing for breaking of polymer chains of portions of the flexible substrate and, thus, providing free radicals to act as oxygen scavengers without degrading the mechanical properties of the flexible substrate.
In the present disclosure, the term "charged particles" may be understood as particles that are charged. For example, the charged particles may be ions or electrons. According to one embodiment, the charged particles are electrons.
In the present disclosure, the term "barrier layer" may be understood as a coating, layer or film that provides oxygen barrier properties, in particular oxygen and moisture (oxygen and moisture barrier) properties, to a coated flexible substrate. The barrier layer and/or at least one barrier layer may have oxygen barrier properties, in particular oxygen barrier and moisture properties.
For example, when referring to the term "on … …", such as on at least one barrier layer on a first surface of the flexible substrate, it is to be understood that, starting from the flexible substrate, at least one barrier layer is positioned on the flexible layer. In other words, the term "on … …" is used to define the order of at least one barrier layer of a flexible substrate, a plurality of barrier layers of a flexible substrate, and/or a flexible substrate, where the starting point is the flexible substrate. This is independent of whether the coated flexible substrate is depicted upside down.
Fig. 2 illustrates a schematic diagram showing a method 100 of processing a coated flexible substrate for packaging applications, including microscopic views of the coated flexible substrate, according to embodiments described herein. In particular, the coated flexible substrate may comprise: a flexible substrate 210 comprising a first surface and a second surface opposite the first surface, and at least one barrier layer 220 on the first surface of the flexible substrate 210. In some embodiments, the at least one barrier layer 220 may be directly on the first surface of the flexible substrate 210.
According to some embodiments, which may be combined with other embodiments, providing a coated flexible substrate may further comprise providing at least one barrier layer 220 on the first surface of the flexible substrate 210, in particular directly on the first surface of the flexible substrate 210.
In some embodiments, providing the coated flexible substrate may further comprise providing the coating composition on the at least one barrier layer 220, particularly directly on the at least one barrier layer 220, for example, in a substantially oxygen-free atmosphere. In this case, the coated flexible substrate may further include a coating composition. Furthermore, simultaneously providing the charged particle beam 240 to the at least one barrier layer 220 of the coated flexible substrate and the flexible substrate 210 in a substantially oxygen-free atmosphere may further comprise simultaneously providing the charged particle beam 240 to the coating composition in a substantially oxygen-free atmosphere. In some embodiments, the coating composition may include acrylate monomers, methacrylate monomers, acrylate oligomers, methacrylate oligomers, and combinations thereof.
The coating composition may form an uppermost layer on the at least one barrier layer 220, for example, after curing or polymerization by providing a charged particle beam. The uppermost layer may provide mechanical protection to at least one barrier layer, for example, against mechanical damage. The uppermost layer may also have oxygen barrier properties, particularly moisture and oxygen barrier properties. The coating composition may be provided on the at least one barrier layer 220 by using a coating method, in particular by a solution coating method, in particular by selection of the solution coating methodA group consisting of: gravure coating (gravy coating), flow coating (flow coating), curtain coating (curtain coating), dip coating, spray coating, print coating, and combinations thereof. In some embodiments, the thickness T of the uppermost layer c T may be 0.1 μm c T.ltoreq.1.5. Mu.m, in particular 0.1. Mu.m c T.ltoreq.0.7. Mu.m, more particularly 0.1. Mu.m c ≤0.5μm。
As exemplarily shown in fig. 2, the charged particle beam 240 may be provided by a charged particle source 230 positioned on at least one barrier layer 220 or on the coating composition according to embodiments that may be combined with other embodiments described herein. Such a location of the charged particle source 230 may be beneficial because curing or polymerization of the coating composition on the at least one barrier layer 220 may additionally be performed during processing of the coated flexible substrate for packaging applications according to the present disclosure. Thus, in embodiments in which the at least one barrier layer 220 has a coating composition thereon, providing the charged particle beam 240 to the coating composition of the coated flexible substrate, the at least one barrier layer 220, and the flexible substrate 210 simultaneously in a substantially oxygen-free atmosphere may further comprise curing or polymerizing the coating composition on the at least one barrier layer 220, for example, by employing the charged particle beam 240. According to the present invention, curing or polymerizing the coating composition on the at least one barrier layer 220 and processing the coated flexible substrate for packaging applications may be performed simultaneously.
Furthermore, the location of the charged particle source 230 allows the coating composition on the at least one barrier layer 220 to cure or polymerize without having to pass the charged particle beam 240 across the substrate thickness T of the flexible substrate 210 S And thus, the barrier layer of the at least one barrier layer 220 is cured or polymerized with a reduced charged particle energy E. Furthermore, such a location of the charged particle source 230 may be beneficial because free radicals generated in the flexible substrate may act as an oxygen scavenger only once oxygen diffuses through the at least one barrier layer to the flexible substrate or once the at least one barrier layer is damaged, for example during transportation of an article protected by the coated flexible substrate. However, it should be appreciated that the location of the charged particle source 230 is not limited to at least one barrierLocations on the layer 220 or on the coating composition, and any suitable location that allows the coating composition to cure or polymerize on the at least one barrier layer 220 may be used.
It should be appreciated that embodiments of the present disclosure are not limited to a charged particle source 230 for providing a charged particle beam 240. Embodiments described herein are used to explain the concept of a method of processing a coated flexible substrate for packaging applications. Thus, it should be appreciated that more than one charged particle source for providing the charged particle beam 240 may be implemented.
In some embodiments, the charged particle beam 240 may have a cone shape. For example, the tapered shape may be substantially symmetrical about the main direction of the respective beam. In fig. 2, a main direction 240M is indicated.
According to some embodiments, which may be combined with other embodiments, the charged particle energy E of the charged particles of the charged particle beam 240 may be 5 keV.ltoreq.E.ltoreq.250 keV, particularly 30 keV.ltoreq.E.ltoreq.220 keV, and more particularly 50 keV.ltoreq.E.ltoreq.220 keV. In some embodiments, the charged particle dose of the charged particle beam 240 may be 1000 to 1 x 10 5 Gray, in particular 3000 to 1X 10 4 Gray, more particularly 3000 to 8000 Gray. It should be appreciated that the value of the charged particle energy E of the charged particles of the charged particle beam 240 and the value of the charged particle dose of the charged particle beam may be adjusted depending on the material and/or the thickness of the at least one barrier layer and/or the flexible substrate.
As exemplarily indicated by the double-headed arrow in fig. 2, the flexible substrate may be moved in the transport direction T, for example, when processing a coated flexible substrate for packaging applications according to the methods of the present disclosure. Thus, the method of processing a coated flexible substrate for packaging applications may further comprise moving the coated flexible substrate in a transport direction T. For example, moving the coated flexible substrate may include moving the coated flexible substrate at 1 m/s.ltoreq.V s 15m/s, in particular 2m/s, V s 10m/s or less, more particularly 3m/s or less V s 7m/s, e.g. V s =4.5 m/s±0.5m/s or V s Velocity v=6.0 m/s±0.5m/s s The coated flexible substrate is moved. According to another example, the coated flexible substrate is movedVelocity V s Can be 12 m/s.ltoreq.V s ≤15m/s。
As exemplarily shown in fig. 2, the charged particle beam 240 simultaneously provided to the at least one barrier layer 220 of the coated flexible substrate and the flexible substrate 210 in a substantially oxygen-free atmosphere may simultaneously penetrate the at least one barrier layer 220 of the coated flexible substrate and the flexible substrate 210. In embodiments in which the at least one barrier layer 220 has a coating composition thereon, the coating composition, the at least one barrier layer 220, and the charged particle beam 240 of the flexible substrate 210 that are simultaneously provided to the coated flexible substrate under a substantially oxygen-free atmosphere may simultaneously penetrate the coating composition, the at least one barrier layer 220, and the flexible substrate 210 of the coated flexible substrate.
In some embodiments, simultaneously providing the charged particle beam 240 to the at least one barrier layer 220 of the coated flexible substrate and the flexible substrate 210 in a substantially oxygen-free atmosphere may further include adjusting at least one of a charged particle energy E of charged particles of the charged particle beam 240 and a charged particle dose of the charged particle beam 240. In embodiments in which the at least one barrier layer 220 has a coating composition thereon, simultaneously providing the charged particle beam 240 to the coated flexible substrate, the at least one barrier layer 220, and the flexible substrate 210 under a substantially oxygen-free atmosphere may further comprise adjusting at least one of a charged particle energy E of charged particles of the charged particle beam 240 and a charged particle dose of the charged particle beam 240.
Accordingly, the change in the charged particle energy E of the charged particles of the charged particle beam 240 adjusts the average penetration depth 210p of the charged particle beam 240 in the flexible substrate 210. Thus, breaks in polymer chains and corresponding radicals of the flexible substrate 210 may be generated at different penetration depths in the flexible substrate 210. Furthermore, the variation of the charged particle dose of the charged particle beam 240 adjusts the number of breaks of polymer chains and corresponding radicals of the flexible substrate 210 at the average penetration depth 210p in the flexible substrate 210.
The term "penetration depth" in the present disclosure refers to the charged particle beam 240 being, for example, positioned or deposited, for example, in a thickness direction from the flexible substrate 210 with at leastThe first surface of one barrier layer begins to penetrate the distance of the flexible substrate 210. In some embodiments, the average penetration depth 210p of the charged particles of the charged particle beam 240 in the flexible substrate 210 from the first surface is equal to the substrate thickness T of the flexible substrate S At least 10%, in particular the substrate thickness T of the flexible substrate S At least 40%, more particularly the substrate thickness T of the flexible substrate S At least 70% of (c).
Fig. 3A-3C illustrate schematic cross-sectional side views of a coated flexible substrate for packaging applications according to embodiments described herein. In fig. 3A to 3C, a coated flexible substrate according to the present invention includes: a flexible substrate 310, the flexible substrate 310 comprising a first surface and a second surface opposite the first surface, and at least one barrier layer 320 on the first surface of the flexible substrate 310, in particular directly on the first surface of the flexible substrate 310.
In some embodiments, as exemplarily shown in fig. 3A, a coated flexible substrate according to the present disclosure may include a flexible substrate 310 including a first surface and a second surface opposite the first surface, and a barrier layer 320 on the first surface of the flexible substrate 310, particularly directly on the first surface of the flexible substrate 310.
In some embodiments, as exemplarily shown in fig. 3B, a coated flexible substrate according to the present disclosure may include: a flexible substrate 310 including a first surface and a second surface opposite the first surface; a first barrier layer 320a on the first surface of the flexible substrate 310, in particular directly on the first surface of the flexible substrate 310; and a second barrier layer 320b on the first barrier layer 320a, in particular directly on the first barrier layer 320 a. Thus, the at least one barrier layer 320 may include a first barrier layer 320a and a second barrier layer 320b. As an example, the first barrier layer 320a may include aluminum or aluminum oxide. In addition, the second barrier layer 320b may include an organic material such as an acrylate monomer, a methacrylate monomer, an acrylate oligomer, a methacrylate oligomer, a polyacrylate, a polymethacrylate, a melamine resin, and combinations thereof.
In some embodiments, as exemplarily shown in fig. 3C, a coated flexible substrate according to the present disclosure may include: a flexible substrate 310 including a first surface and a second surface opposite the first surface; a first barrier layer 320a on the first surface of the flexible substrate 310, in particular directly on the first surface of the flexible substrate 310; a second barrier layer 320b on the first barrier layer 320a, in particular directly on the first barrier layer 320 a; and a third barrier layer 320c on the second barrier layer 320b, in particular directly on the second barrier layer 320b. Accordingly, the at least one barrier layer 320 may include a first barrier layer 320c, a second barrier layer 320b, and a third barrier layer 320c. As an example, the first barrier layer 320a may include aluminum or aluminum oxide. In addition, the second barrier layer 320b may include silicon dioxide. In addition, the third barrier layer 320c may include an organic material such as acrylate monomers, methacrylate monomers, acrylate oligomers, methacrylate oligomers, polyacrylates, polymethacrylates, melamine resins, and combinations thereof. As another example, the first barrier layer 320a may include polyvinyl alcohol and/or polyvinyl alcohol. Further, the second barrier layer 320b may include aluminum, aluminum oxide, and/or silicon dioxide. In addition, the third barrier layer 320c may include an organic material such as acrylate monomers, methacrylate monomers, acrylate oligomers, methacrylate oligomers, polyacrylates, polymethacrylates, melamine resins, and combinations thereof.
At least one of the at least one barrier layer 320 or the barrier layers of the at least one barrier layer 320, such as the first barrier layer 320a, the second barrier layer 320b, or the third barrier layer 320c, may comprise a material selected from the group consisting of: aluminum, aluminum oxide, aluminum nitride, silicon dioxide, organic materials, and combinations thereof. Examples of organic materials are polyvinyl alcohol, polyvinylidene chloride, acrylate monomers, methacrylate monomers, acrylate oligomers, methacrylate oligomers, polyacrylates, polymethacrylates, melamine resins and combinations thereof. However, it should be understood that the material of at least barrier layer 320 or at least one of the barrier layers of at least one barrier layer 320 is not limited to aluminum, aluminum oxide, aluminum nitride, silicon dioxide, organic materials, and combinations thereof, and that any suitable material having oxygen barrier properties, particularly moisture and oxygen barrier properties, may be used as the material of at least one of the barrier layers 320 or at least one of the barrier layers 320.
In some embodiments, at least one of the at least one barrier layer 320 or the barrier layers of the at least one barrier layer 320, e.g., the first barrier layer 320a, the second barrier layer 320b, or the third barrier layer 320c, may be an oxygen barrier (oxy gen barrier). In some embodiments, at least one of the at least one barrier layer 320 or the barrier layer of the at least one barrier layer 320, e.g., the first barrier layer 320a, the second barrier layer 320b, or the third barrier layer 320c, may be a moisture and oxygen barrier.
In some embodiments, the coated flexible substrate treated according to the methods of the present disclosure has a water vapor transmission rate (WVTR; in grams/cm 2 Day) and/or Oxygen Transmission Rate (OTR) may be less than 10, particularly less than 1, more particularly about 0.5. Oxygen and water vapor transmission rates can be determined according to ASTM D3985-17 and ASTM F1249-20 using Mocon Oxtran 2/22 and Sysetch Illinois 8001 for oxygen permeation and Mocon Permatran-W3/33 and Sysetch Ilinois 7001 for water vapor permeation.
According to some embodiments, at least one of the at least one barrier layer 320 or the barrier layer of the at least one barrier layer 320 (e.g., the first barrier layer 320a, the second barrier layer 320b, or the third barrier layer 320 c) may be fabricated by chemical vapor deposition or physical vapor deposition (e.g., sputtering or evaporation). Examples of physical vapor deposition may be electron beam physical vapor deposition and sputter deposition. In some embodiments, providing a coated flexible substrate may include depositing at least one barrier layer on the flexible substrate, particularly directly on the flexible substrate.
Alternatively, for example, when at least one of the barrier layers (e.g., at least one barrier layer 320)For example, when the first barrier layer 320a, the second barrier layer 320b, or the third barrier layer 320 c) is liquid and comprises an organic material (e.g., polyvinyl alcohol, acrylate monomer, methacrylate monomer, acrylate oligomer, methacrylate oligomer, polyacrylate, polymethacrylate, melamine resin, and combinations thereof), at least one of the at least one barrier layer 320 or the barrier layer(s) 320 (e.g., the first barrier layer 320a, the second barrier layer 320b, or the third barrier layer 320 c) may be formed by using a coating method and particularly by a solution coating method (particularly selected from the group consisting of: gravure coating, flow coating, curtain coating, dip coating, spray coating, and combinations thereof) is disposed on the flexible substrate 310. In some embodiments, the thickness T of the at least one barrier layer 320 b T is 0.05 μm b T.ltoreq.5. Mu.m, in particular 0.1. Mu.m b T.ltoreq.2. Mu.m, more particularly 0.1. Mu.m b ≤1μm。
According to one aspect of the present disclosure, a coated flexible substrate for packaging applications is provided. In some embodiments, the coated flexible substrate may be a substrate that has been processed by the methods of the present disclosure. The coated flexible substrate may include: a flexible substrate including a first surface and a second surface opposite the first surface; and at least one barrier layer on the first surface of the flexible substrate. In some embodiments, the at least one barrier layer may be directly on the first surface of the flexible substrate. Properties of at least one barrier layer of a flexible substrate for packaging applications and of a treated coated flexible substrate, such as substrate thickness T s The substrate material, the thickness Tb and the material of the at least one barrier layer are as described in the present disclosure. In some embodiments, the coated flexible substrate has a water vapor transmission rate (WVTR; in grams/cm), for example, after having been treated according to the methods of the present disclosure 2 Day) and/or Oxygen Transmission Rate (OTR) may be less than 10, particularly less than 1, more particularly about 0.5. Oxygen and water vapor transmission rates may be determined as described in this disclosure.
Referring exemplarily to fig. 4, an apparatus 400 for processing a coated flexible substrate 440 for packaging applications in accordance with the present disclosure is described. According to embodiments, which may be combined with other embodiments described herein, the apparatus 400 comprises a processing drum 410 for guiding the coated flexible substrate 440. In addition, the apparatus 400 comprises a printing arrangement 420 for printing, for example, a coating composition on at least one barrier layer of the coated flexible substrate 440. For example, the at least one barrier layer may comprise aluminum or aluminum oxide. In addition, the apparatus 400 includes a charged particle source 430 for processing the coated flexible substrate 440.
Referring exemplarily to fig. 4, the printing arrangement 420 may comprise a supply device 421 for supplying the coating composition. For example, the supply 421 may be a single body reservoir. Further, the printing arrangement 420 can include a first roller 422 (e.g., an anilox roller) and a second roller 424 (e.g., a transfer roller). In particular, the first roller 422 may be arranged parallel to the processing drum 410 and the second roller 424. Between the transfer roller and the processing drum 410, the coated flexible substrate 440 may be transported during processing, such as by coating or printing a coating composition on at least one barrier layer of the coated flexible substrate 440. Thus, it should be appreciated that the coating composition may be applied from the reservoir to the surface of the first roller 422 (e.g., the surface of an anilox roller) as the surface of the first roller 422 passes through the reservoir. Further, as exemplarily shown in fig. 4, the typical printing arrangement 420 comprises a doctor blade assembly (doctor blade assembly) 423 having at least one elongated doctor blade extending in a parallel direction of the rotational axis of the first roller 422.
This written description uses examples to disclose the disclosure, including the best mode, and also to enable any person skilled in the art to practice the described subject matter, including making and using any devices and performing any incorporated methods. While various specific embodiments have been disclosed in the foregoing, the mutually exclusive features of the embodiments described above may be combined with each other. The scope of patent protection is defined by the claims and other examples are intended to be within the scope of the claims, provided that these other examples have structural elements that do not differ from the literal language of the claims, or provided that the claims include equivalent structural elements with insubstantial differences from the literal language of the claims.
While the foregoing is directed to embodiments, other and further embodiments may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
Claims (15)
1. A method of processing a coated flexible substrate for packaging applications, comprising:
providing the coated flexible substrate, the coated flexible substrate comprising:
a flexible substrate comprising a first surface and a second surface opposite to the first surface, and
-at least one barrier layer on the first surface of the flexible substrate;
a charged particle beam is simultaneously provided to the at least one barrier layer of the coated flexible substrate and the flexible substrate in a substantially oxygen-free atmosphere.
2. The method of claim 1, wherein the charged particle beam is provided from a charged particle source positioned on the at least one barrier layer.
3. The method of processing a coated flexible substrate of claim 1 or 2, wherein simultaneously providing a charged particle beam to the at least one barrier layer of the coated flexible substrate and the flexible substrate in a substantially oxygen-free atmosphere further comprises adjusting at least one of a charged particle energy E of the charged particles of the charged particle beam and a charged particle dose of the charged particle beam.
4. The method of processing a coated flexible substrate according to any of the preceding claims, wherein the charged particle energy E of the charged particles of the charged particle beam is 5keV +.e +.250 keV, in particular 30keV +.e +.220 keV, and more in particular 50keV +.e +.220 keV.
5. The method of processing a coated flexible substrate according to any of the preceding claims, wherein the charged particle dose of the charged particle beam is 1000 to 1 x 10 5 Gray, especially 3000 to 1 x 10 4 Gray, more particularly 3000 to 8000 gray.
6. The method of processing a coated flexible substrate according to any one of the preceding claims, wherein an average penetration depth of the charged particles of the charged particle beam in the flexible substrate from the first surface is equal to a substrate thickness T of the flexible substrate S In particular a substrate thickness T of the flexible substrate of at least 10% S At least 40%, and more particularly the substrate thickness T of the flexible substrate S At least 70% of (c).
7. The method of processing a coated flexible substrate according to any of the preceding claims, wherein the flexible substrate has a substrate thickness T of 250 μιη or less S In particular 5 μm.ltoreq.T S Less than or equal to 150 μm, more particularly less than or equal to 5 μm T S ≤100μm。
8. The method of processing a coated flexible substrate according to any of the preceding claims, wherein the flexible substrate comprises a substrate material selected from the group consisting of: polyethylene, polypropylene, polyisobutylene, polyvinylidene chloride, polytetrafluoroethylene, polyamide, polyethylene terephthalate, polystyrene, polyvinyl alcohol, polyvinyl acetate, polyethyl methacrylate, and combinations thereof.
9. A method of processing a coated flexible substrate according to any preceding claim, wherein the charged particles are electrons.
10. A method of processing a coated flexible substrate according to any preceding claim, wherein the at least one barrier layer is an oxygen barrier.
11. The method of processing a coated flexible substrate according to any of the preceding claims, wherein the thickness T of the at least one barrier layer b T is 0.05 mu m or less b T.ltoreq.5. Mu.m, especially 0.1. Mu.m b T.ltoreq.2. Mu.m, more particularly 0.1. Mu.m b ≤1μm。
12. The method of processing a coated flexible substrate according to any of the preceding claims, wherein the at least one barrier layer comprises a material selected from the group consisting of: aluminum, aluminum oxide, aluminum nitride, silicon dioxide, organic materials, and combinations thereof.
13. The method of processing a coated flexible substrate of any preceding claim, wherein providing the coated flexible substrate further comprises providing a coating composition on the at least one barrier layer, and providing a charged particle beam further comprises simultaneously providing a charged particle beam to the coating composition in a substantially oxygen-free atmosphere.
14. The method of treating a coated flexible substrate of claim 13, wherein the coating composition comprises acrylate monomers, methacrylate monomers, acrylate oligomers, methacrylate oligomers, and combinations thereof.
15. The method of processing a coated flexible substrate according to any one of claims 13 and 14, wherein the coating composition forms an uppermost layer on the at least one barrier layer after polymerization by providing the charged particle beam.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| PCT/EP2020/087823 WO2022135724A1 (en) | 2020-12-23 | 2020-12-23 | Method of treating a coated flexible substrate for packaging applications |
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| CN116981722A true CN116981722A (en) | 2023-10-31 |
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| CN202080108170.5A Pending CN116981722A (en) | 2020-12-23 | 2020-12-23 | Method of processing coated flexible substrates for packaging applications |
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| JP (1) | JP2024505344A (en) |
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| US20030001108A1 (en) * | 1999-11-05 | 2003-01-02 | Energy Sciences, Inc. | Particle beam processing apparatus and materials treatable using the apparatus |
| US9452592B2 (en) * | 2007-08-28 | 2016-09-27 | Cryovac, Inc. | Multilayer film having an active oxygen barrier layer with radiation enhanced active barrier properties |
| US8460762B2 (en) * | 2009-12-16 | 2013-06-11 | Ideon Llc | Electron beam curable composition for curing in a vacuum chamber |
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