CN1319730C - 聚烯烃薄膜、带或纱 - Google Patents

聚烯烃薄膜、带或纱 Download PDF

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CN1319730C
CN1319730C CNB028142438A CN02814243A CN1319730C CN 1319730 C CN1319730 C CN 1319730C CN B028142438 A CNB028142438 A CN B028142438A CN 02814243 A CN02814243 A CN 02814243A CN 1319730 C CN1319730 C CN 1319730C
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China
Prior art keywords
yarn
band
film
intermediate layer
layer
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CN1529655A (zh
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约阿希姆·洛斯
约翰内斯·安东尼厄斯·约瑟夫·雅各布斯
安东尼厄斯·安德烈亚斯·约翰内斯·玛丽亚·佩兹
蒂隆·席曼斯基
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Lankhorst Indutech BV
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Lankhorst Indutech BV
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Priority claimed from EP01202757A external-priority patent/EP1277573A1/en
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    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B32B27/327—Layered products comprising a layer of synthetic resin comprising polyolefins comprising polyolefins obtained by a metallocene or single-site catalyst
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    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/05—Filamentary, e.g. strands
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    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
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    • B29C48/91—Heating, e.g. for cross linking
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    • D01D5/42—Formation of filaments, threads, or the like by cutting films into narrow ribbons or filaments or by fibrillation of films or filaments
    • D01D5/426—Formation of filaments, threads, or the like by cutting films into narrow ribbons or filaments or by fibrillation of films or filaments by cutting films
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    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
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    • D01F8/06—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyolefin as constituent
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Abstract

本发明涉及AB或ABA型的单轴向拉伸的聚烯烃多层薄膜、带或纱，其拉伸比为高于12，E-模量为至少10GPa，基本上由选自聚乙烯和聚丙烯的聚烯烃中间层B、以及一层或两层选自与中间层B材料同类的聚烯烃其它层A组成，所述其它层A的材料的DSC熔点低于所述中间层B的材料的DSC熔点，其中所述中间层B占材料的50-99重量%，所述其它层A为1-50%。本发明还涉及制备此类薄膜、带或纱的方法。

Description

聚烯烃薄膜、带或纱
技术领域
本发明涉及一种聚烯烃多层薄膜、带或纱，其适用于制备增强性织物材料或非织物型材料，尤其用于增强和/或硬化产品。单或多层带聚烯烃薄膜一般通过吹塑薄膜或流延薄膜挤出来制备。在制备过程的某些阶段可拉伸材料，以便增加该材料的强度及挺度。
背景技术
聚烯烃带及纱通常由单层或多层型的聚烯烃薄膜通过切割薄膜至希望的宽度来制备。在制备过程的某些阶段可拉伸材料，以便增加该材料的强度及挺度。
US-A 5,578,370公开了一种由聚丙烯薄膜形成的热塑性复合材料，所述聚丙烯薄膜用进一步包括丙烯单元的乙烯共聚物层涂覆。该经涂覆的层比聚丙烯核心具有更低的软化点。该文献公开了在热烘箱中拉伸材料至拉伸比为20∶1。实例说明该复合材料可具有高达2.5GPa的弹性拉伸模量。
JP-A 2000-8244公开了用于增强片状层的扁纱布，其由ABA型的复合纱制得，其中B层为聚丙烯，A层是基于一种乙烯-α-烯烃共聚物或掺合的两种乙烯-α-烯烃共聚物。该纱的制备是通过挤出该两种材料，切开薄膜并将其拉伸至拉伸比为3-12。在编织之后，将材料进行热处理，使纱结合在一起。
EP-A 366,210公开了一种三层拉伸聚烯烃层压材料，其包括聚丙烯和/或LLDPE的核心层及由丁烯-1聚合物制得的表层。该材料可用于包装领域。此材料具有很差的机械性能。
EP-A 776,762公开了基于共挤塑聚烯烃材料的聚烯烃带或纱，其拉伸比为6-10。此材料被描述为适用于制备各种布、皮带材料等。
发明内容
虽然上述文献中材料的性能很好，但是需要进一步改进，尤其在拉伸强度方面。本发明的第一个目标是提供一种具有改进机械性能的带或纱。
在复合材料中，纱或布通常用于增强作用。多数通常所用的为玻璃纤维材料。然而，玻璃纤维材料具有以下缺点：它们使回收掺杂它们的材料是极困难的。如果玻璃纤维可由聚合纤维或其它聚合增强成分取代，这将是非常有用的，由此使回收复合材料更容易。玻璃纤维的主要优点之一在于其挺度，这通常是聚合纤维或其他增强组分的弱点。因此，本发明的进一步目标是提供聚合材料，其具有足够的挺度以便能够在复合材料中取代玻璃纤维。
关于回收由聚烯烃薄膜、带及纱制得的产品，如果材料的所有组分都可归类为相同材料如聚丙烯或聚乙烯(包括它们的共聚物，其中丙烯及乙烯分别形成主要的单体单元)，将是有利的其优点是所得的回收材料仍是一种材料，而不是多种组分的混合物(无污染)。
本发明涉及一种单轴向拉伸的AB或ABA型的聚烯烃多层薄膜、带或纱，其拉伸比为高于12，E-模量为至少10GPa，基本上由选自聚乙烯和聚丙烯的聚烯烃中间层(B)、以及一层或两层选自与中间层(B)材料同类的聚烯烃其它层(A)组成，所述其它层(A)的材料的DSC熔点低于所述中间层(B)的材料的DSC熔点，其中中间层(B)占材料的50-99重量％，其它层为1-50％。
惊奇地发现此多层材料(也称作层压材料)在机械强度、挺度等方面具有优良性能。由于其组成，聚乙烯或聚丙烯都可适合用作单组分材料，这在回收中是有利的。更具体而言，可回收作为部分中间层组分的生产废料。另外，关于在产品使用寿命之后回收组分方面，考虑消费品如汽车等的生产者的需要，使组分仅由一类材料组成是重要的。
本文中所用的E-模量为通过ISO 527所测量的值。
通过使层压制品(薄膜/带/纱)的材料组分具有极高的总拉伸比：高于12，优选高于15，例如至少为20并甚至高达50或更高，所产生的材料可有利地用于各种增强作用中，可在各种增强应用中取代例如玻璃纤维，可用于各种高温领域中，例如用于汽车或航空领域中。通常，本发明的材料尤其适用于(轻重量)建筑领域、高压领域及医疗领域。可在房屋、船舶、汽车等的建造中使用该材料，但也在高压部件如管道(用于石油开采等)中或在制造ortheses中作为增强层。
在本发明的上下文中，材料已限定为满足总拉伸比(TSR)的最低水平。TSR限定为由各相异性熔化物至最终带或纱的拉伸程度。这至少部分由松紧辊之间的速度差限定。TSR的实际值可由最终薄膜、带或纱的双折射率和/或E-模量(在拉伸方向上)决定。该TSR尤其应用于中间层，该中间层优选为高结晶材料。其它层的材料通常是较少结晶的。其它层的功能是特别提供了当热处理材料的织物、无纺布或纤维(staple)/堆积物时使薄膜、带、纤维或纱结合的可能性。
用于制备本发明的薄膜、带或纱的基础材料是聚丙烯或聚乙烯。
当使用聚丙烯作为制备薄膜、带或纱所用的基础材料时，用于中间层或核心层B的材料优选为均聚丙烯，其优选具有相对高的分子量，例如通过凝胶渗透色谱(GPC)测定的重均分子量(MW)为至少250000g/mol，熔化温度为至少160℃。应注意虽然中间层优选仅由一种材料组成，但是在回收生产废料时，微量的其它层材料也可在核心层中存在。这通常不超过10wt.％。
在一个实施方案中，核心层(B)为聚丙烯，在该实施方案中的外层材料如上所述也是聚丙烯，优选为丙烯与乙烯或另一种α-烯烃的共聚物。其重要方面是通常如ISO 11357-3所限定的DSC软化点所示的材料软化点低于中间层的软化点，差值至少为10℃。层B和层A的软化点之间的最大差值不是特别严格规定的。由于生产实践的原因，该差值通常低于约70℃。尤其使用软化点的差值在15-40℃的范围内的薄膜、带或纱已达成极好的结果。
使用无规共聚物如丙烯-乙烯无规共聚物作为外层A已达成极好的结果。利用茂金属催化剂制备的聚烯烃(优选聚丙烯均聚物或聚丙烯共聚物)用作外层A，代替共聚物或与其结合使用。使用这样的茂金属基统计聚合物(statistical polymer)已达成了特别好的结果。茂金属的适当实例是rac-[Me2Si(2-Me-4-(1-萘基)茚基)2]ZrCl2H(公开于H.Brintzinger，D.Fischer，R.Muelhaupt，B.Rieger，R.Waymouth，Angew.Chem.107(1995)1255及W.Kaminsky，Macromol.Chem.Phys.197(1996)3907)。
由于本发明的产品通常以薄膜、带或纤维彼此有角度的形式使用(织物、非织物材料)，外层使织物、堆积的或钩钉(staple)的材料的热处理成为可能，由此使单个的薄膜/纤维/纱或带结合在一起，产生极高结构规整性的复合材料(例如织物材料)。通过由中间层的软化点在足够大的范围内选择软化点，可进行不妨碍材料本身性能的热处理。
在本发明的一个实施方案中，外层A至少由乙烯丙烯共聚物组成，乙烯含量为75-99mol％，丙烯含量为1-25mol％。在中间层B为聚乙烯的实施方案中，使用这样的外层已达成很好的结果。
作为外层A的材料，尤其在中间层为聚丙烯的情况下，优选使用的丙烯乙烯共聚物的乙烯含量为1-25mol％，以及丙烯含量为75-99mol％。已发现此种共聚物(作为外层A)、特别是此种无规共聚物高度满意地粘着到中间层。进一步发现包括此类共聚物的带、纱或薄膜的复合材料具有极好的强度、耐冲击性及耐磨性。也可使用这些材料中两种材料的混合物。
在使用聚乙烯的情况下，基本上采取同样的措施。作为中间层，优选使用HDPE，即密度至少为950kg/m3的聚乙烯。通过GPC测定的重均分子量(MW)优选至少250000g/mol，而熔点为130℃或更高。应注意虽然中间层优选仅由一种材料组成，但在回收生产废料时，在核心层中也可存在微量的其它层材料。这通常不超过10wt.％。
其它层的材料的特征在于其也是聚丙烯，但是在此具有较低的熔点，其差值为至少10℃。适合的聚乙烯为无规或嵌段乙烯共聚物、LLDPE、LDPE、VLDPE等。
对于两类层材料，应注意它们通常含有常规添加剂，包括但不限于染料及颜料、阻燃剂、UV-稳定剂、抗氧剂、碳黑等。
在较不忧选的本发明一般方法中，每一外层本身由两层或更多个别层组成。在三层构造(ABA)中，两个外层的组成可略微不同。
本发明产品的主要部分由中间层(B)组成。在优选实施方案中，中间层的量为50-99wt.％，优选为60-90wt.％。材料的余量由外层(A)组成。
在实际应用中，带、薄膜或纱的厚度通常高达300μm，优选为25-300μm。这由原始薄膜厚度及拉伸比控制，在此情况下为松紧辊的速度比。带的宽度可在很大范围内改变，例如由25μm至50μm或更高。薄膜的宽度也可在很大范围内改变，例如从1cm至150cm或更高。
如上所示，本发明的材料具有很好的机械性能。例如E-模量至少为10GPa，优选至少为12.5GPa。拉伸强度可容易地为至少0.25GPa，甚至高达至少0.4GPa(通过ISO 527测量的值)。在本发明材料中可得到的强度的上限为约理论值的一半。这意味着通常对于聚丙烯来说上限值为1GPa，而对于聚乙烯来说上限值为5GPa。
本发明的薄膜、带或纱可用于制备各种材料，例如背景技术中所述的材料。
本发明薄膜的用途的实施方案之一为制备增强性材料，例如从薄膜缠绕或钩钉/堆叠、和/或压实该材料。优选该材料随后经热处理和压制。通过此热处理，个别纤维粘结在一起。以此办法确保该钩钉/堆叠材料的规整度。进行所述热处理的温度介于外层(A)材料和中间层(B)材料的软化点之间。经热处理的材料的令人惊奇的性能是改进耐磨性并抑制诸单个薄膜的分层作用。
在热处理期间，优选施加压力，尤其是如果热处理板类材料或成形物品至一定温度，在该温度下中间层(B)的材料具有收缩的趋势(由于聚合物链变形至更无规的构造)。例如，聚丙烯趋向于在高于100-115℃的温度下收缩。优选此压力为至少5×105帕。通过在2×106-7×106帕的压力下压实材料，所得材料的机械性能方面已经得到了很好的结果。
可选地或者与施加压力相结合，可在热处理期间夹住该材料，以便避免收缩。
本发明的带或纱的用途的优选实施方案之一是制备(增强性)布，例如通过由带、纤维或纱来编织、缠绕、切断、钩钉、和/或压实该布。优选该材料随后经热处理和压制。通过此热处理，个别纤维粘结在一起。以此办法确保该布的规整度。进行所述热处理的温度介于外层(A)材料和中间层(B)材料的软化点之间。经热处理的材料的令人惊奇的性能是改进耐磨性并抑制诸单个薄膜的分层作用。
通常通过共挤出各个层进行本发明的材料的制备。通常使用铸型挤出，其中挤出机具有平面染料板，而没有轮廓。当制备薄膜时，可于共挤出及冷却之后拉伸材料。在制备带或纱时，可将材料切割成所需要宽度的单股(于共挤出及冷却之后)，随后拉伸。
拉伸可以是单阶段或多阶段拉伸。在每个步骤中的拉伸比为1.1-50，优选2-10，更优选3-8，全部的拉伸比对于测定本文所定义的TSR是重要的。在带、薄膜或纱的第一拉伸阶段拉伸比为4-5的多阶段拉伸过程中，经拉伸的带、纱或薄膜的机械性能方面已达成了很好的结果。
优选在20-250℃的温度拉伸材料。优选在低于中间层B所用材料的DSC熔点的温度下拉伸(下文中称为“冷拉伸”。使用冷拉伸方法，其中至少拉伸阶段之一在低于外层DSC熔点的温度下实施，已经达成了很好的结果，所述温度为25-75℃，更优选为30-60℃。
在多阶段拉伸的情况下，第一拉伸优选在相对低温下实施，更优选在30-60℃下实施，随后的一个或多个拉伸阶段优选在相对高温下实施，例如在介于60℃和外层DSC熔点之间的温度下。由此可达成尽可能高的拉伸。随后在至少100℃的温度下拉伸得到了好结果。优选在直到断裂(在拉伸过程中)的拉伸比基本最大化的温度下实施随后的拉伸。已经发现了与拉伸最大化的温度相对接近的温度，所制备的薄膜、带或纱具有非常好的机械性能，如很高的E-模量。拉伸最大化的温度可由本领域技术人员以常规方法确定。
在两个拉伸步骤之间可包括退火步骤。这可在最后拉伸之后实施。
本发明的材料，包括单个的薄膜、带、纱/纤维或由它们制备的布或钩钉/堆积的材料，可合适地用于掺入基质材料中，例如作为增强性材料。其实例是各种复合材料纤维增强塑料、汽车领域如保险杠、仪表板、发动机罩等、航空工业中的应用如用于飞机的结构材料等。其他应用已在上文论述。
具体实施方式
现在在以下实施例的基础上阐述本发明，但不能将实施例理解为限制本发明。
实施例1
使用共挤出管，制备薄膜，该薄膜由DSC软化温度为152℃的聚丙烯核心层B及两个DSC软化温度为135℃的丙烯无规共聚物表层A组成(ABA结构)。重量比A∶B∶A为5∶90∶50。
薄膜在55℃以1∶5的比例拉伸，随后在128℃以1∶3.4的比例拉伸，由此制得拉伸比为1∶17及厚度为70μm的经拉伸薄膜。
该经拉伸薄膜的弹性模量为15.8GPa，强度为585MPa。
实施例2
将实施例中的一些薄膜加工成宽度为2.1mm的纱。编制该纱，制备织物材料(纺织材料)，该织物材料随后在150℃热处理以加固结构。最终材料准各向同性挺度为7GPa(通过ASTM 3039-76测定)，拉伸强度为超过270Mpa(通过ISO 527测定)。
实施例3
将实施例中的一些薄膜钩钉或堆积，并随后在150℃热处理以加固结构。最终材料准各向同性挺度为7GPa，拉伸强度为超过270Mpa。
实施例4
如实施例1所述制备薄膜，区别在于拉伸阶段在128℃的温度下实施。该材料(拉伸比为1∶14，厚度为70μm)的弹性模量为11.5GPa，拉伸强度为450Mpa。

Claims (24)

1.一种AB或ABA型的单轴向拉伸的聚烯烃多层薄膜、带或纱，其拉伸比为高于12，E-模量为至少10GPa，由选自聚乙烯和聚丙烯的聚烯烃中间层B、以及一层或两层选自与中间层B材料同类的聚烯烃其它层A组成，所述多层薄膜、带或纱是聚乙烯或聚丙烯的单组分材料，包括其中丙烯和乙烯分别形成大多数单体单元的共聚物，所述其它层A的材料的DSC熔点低于所述中间层B的材料的DSC熔点，其中所述中间层B占材料的50-99重量％，所述其它层A为1-50％。
2.如权利要求1的薄膜、带或纱，其中所述拉伸比为至少15。
3.如权利要求1或2的薄膜、带或纱，其中所述拉伸比为至少20。
4.如权利要求1或2的薄膜、带或纱，其中所述拉伸比为至多50。
5.如权利要求1或2的薄膜、带或纱，其中所述中间层及其它层的材料是以聚丙烯为基础。
6.如权利要求1或2的薄膜、带或纱，其中所述中间层及其它层的材料是以聚乙烯为基础。
7.如权利要求1或2的薄膜、带或纱，其中所述中间层的材料是重均分子量为至少250000g/mol的结晶聚合物。
8.如权利要求1或2的薄膜、带或纱，其中所述外层A至少由无规共聚物组成。
9.如权利要求1或2的薄膜、带或纱，其中所述外层A包括茂金属基均聚物或茂金属基共聚物。
10.如权利要求1或2的薄膜、带或纱，其中所述外层A至少由丙烯乙烯共聚物组成，该共聚物的乙烯含量为1-25mol％，丙烯含量为75-99mol％。
11.如权利要求1或2的薄膜、带或纱，其中所述外层A至少由丙烯乙烯共聚物组成，该共聚物的乙烯含量为75-99mol％，丙烯含量为1-25mol％。
12.如权利要求1或2的薄膜、带或纱，其厚度为25-300μm。
13.如权利要求1或2的薄膜、带或纱，其E-模量为至少12.5GPa。
14.织物或非织物复合材料，其由权利要求1-13之一的薄膜、带或纱制备。
15.如权利要求14的织物或非织物复合材料，其经过热处理。
16.复合材料，其包括用权利要求1-13之一的薄膜、带或纱增强的复合材料或权利要求14的织物或非织物复合材料。
17.拉伸比高于12的AB或ABA型单轴向拉伸的聚烯烃多层薄膜、带或纱的制备方法，其中，
(i)通过共挤出来提供AB或ABA型的聚烯烃多层薄膜、带或纱，其由选自聚乙烯和聚丙烯的聚烯烃中间层B、以及一层或两层选自与中间层B材料同类的聚烯烃其它层A组成，所述多层薄膜、带或纱是聚乙烯或聚丙烯的单组分材料，包括其中丙烯和乙烯分别形成大多数单体单元的共聚物，所述其它层A的材料的DSC熔点低于所述中间层(B)的材料的DSC熔点，而且所述中间层(B)占材料的50-99重量％，所述其它层为1-50％，以及
(ii)在低于所述中间层B的熔点的温度下，对共挤出的薄膜、带或纱进行单阶段或多阶段拉伸。
18.如权利要求17的单轴向拉伸的聚烯烃多层薄膜、带或纱的制备方法，所述薄膜、带或纱的E-模量至少为10GPa。
19.如权利要求17或18的方法，其中至少拉伸阶段之一在25-70℃的温度下实施。
20.如权利要求19的方法，其中所述薄膜、带或纱首先在25-70℃的温度下拉伸，然后在高于70℃的温度下拉伸。
21.如权利要求17或18的方法，其中所述带、薄膜或纱拉伸至总拉伸比为至少15。
22、如权利要求21的方法，其中所述带、薄膜或纱拉伸至总拉伸比为至少20。
23、如权利要求22的方法，其中所述带、薄膜或纱拉伸至总拉伸比为至多50。
24.如权利要求17或18的方法，其中制备权利要求2-13之一的带、薄膜或纱。
CNB028142438A 2001-07-19 2002-07-19 聚烯烃薄膜、带或纱 Expired - Lifetime CN1319730C (zh)

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