CN1946609B - 粘附有活性薄膜的柔性包装材料及其制造方法 - Google Patents

粘附有活性薄膜的柔性包装材料及其制造方法 Download PDF

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CN1946609B
CN1946609B CN2005800130080A CN200580013008A CN1946609B CN 1946609 B CN1946609 B CN 1946609B CN 2005800130080 A CN2005800130080 A CN 2005800130080A CN 200580013008 A CN200580013008 A CN 200580013008A CN 1946609 B CN1946609 B CN 1946609B
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P·J·萨戈纳
J·R·弗里德曼
J·P·吉罗
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Abstract

本发明涉及将活性薄膜(5)粘附在柔性包装材料上的方法，该方法包括下列步骤：对箔(2)加热，将活性薄膜(5)贴在箔(2)上，对活性薄膜(5)与箔(2)的复合体施加足够的压力并对箔(2)充分加热以使活性薄膜(5)粘附在箔(2)上。在一个实例中，活性薄膜(5)包含两种成分，其中该两种成分是活性剂和聚合物。在另一个实例中，活性剂是吸收材料。

Description

粘附有活性薄膜的柔性包装材料及其制造方法
技术领域
本发明涉及通过使活性薄膜热贴合在柔性包装材料上而将活性薄膜粘附在该柔性包装材料上的方法。本发明还涉及通过使活性薄膜热贴合在柔性包装材料的热合层上而制得的包含活性薄膜的柔性包装材料。 
背景技术
许多产品(例如诊断用试条、药丸和药片)对环境因素如水汽和/或氧气是敏感的。试图保护这些产品免受环境因素影响的一种常规方法是将这类产品包装在贴箔袋中。此外，还可将松散的干燥剂夹入贴箔袋中以调节包装内环境。 
发明内容
在本发明的一个实施方案中，将活性薄膜粘附在柔性包装材料上的方法包括下列步骤：对箔进行加热，将活性薄膜贴在该箔上，对活性薄膜与箔的复合材料施加足够的压力并对箔充分加热，以使活性薄膜粘附在箔封合层上，在本发明的另一个实施方案中，将活性薄膜粘附在柔性包装材料上的方法包括下列步骤：由箔卷料供料辊将箔送入，由活性薄膜供料辊将活性膜送入，将活性膜切成预定长度，对箔加热，将切好的活性薄膜贴在箔上，以及对活性薄膜与箔的复合材料施加足够的压力并对箔充分加热以使活性薄膜粘附在箔封合层上。 
附图说明
下列附图只是用来说明本发明，而不是将本发明限定在附图所示的实施方案范围内。 
图1展示的是本发明的一个实施方案的将粘附有活性薄膜的连续主膜卷贴合在加热板上的盖箔料带上的侧视图； 
图2展示的是本发明一个实施方案的盖箔上热贴合有活性薄膜的组合的泡罩包装的截面图。
图3展示的是本发明另一个实施方案的成品包装的照片，其中示出了热贴合有活性膜的盖体(不含上面的顶片)及活性膜和封合部位。 
除了那些已公开的优点和改进之外，通过下面说明并结合附图就会清楚地了解本发明的其它目的和优点。附图是本说明书的组成部分，包括本发明的说明性实施方案，并对本发明的多个目的和特征进行了说明。 
具体实施方案
本文公开了本发明实施方案的细节，然而，应当知道，公开的实施方案只是用来说明本发明可以各种形式来实施。此外，与本发明各种实施方案有关的每一实施例只是说明性的而不是对本发明的限制。而且，附图并不一定是按比例的，为了显示特定部件的细节，一些特征可能已被扩大。因此，公开在本文中的具体结构性和功能性的细节不应被解释为是对本发明的限制，而只是作为向技术熟练人员介绍的本发明各种用途的代表。 
在一个实施方案中，本发明涉及通过使活性薄膜热贴合在柔性包装材料的封合层上而将活性薄膜热粘附在柔性包装材料上的方法。在一个实例中，活性薄膜在包装材料中的用量是根据包装产品的储存时间的特定要求来确定的。活性薄膜包含活性剂。在一个具体实施方案中，添加在活性薄膜中的活性剂的量可为约30-约80％，更具体为约40-约60％(以薄膜总重量计)。 
对于本发明来说，活性薄膜可包含一种或多种下列“活性剂”：吸收材料，防粘材料，和/或活化材料。可列举的活性剂包括(但不受此限制)干燥剂，氧气吸收剂，气味吸收剂，乙烯吸收剂，CO2吸收剂，香味/香气释放剂和/或营养物质释放剂。 
吸收材料的实例包括(但不受此限制)一种或多种干燥化合物。例如，本发明可采用的主要有三类干燥化合物。第一类包括能与水结合成水合物的化学化合物。这类干燥剂的实例是往往会吸收水分或湿气形成稳定水合物的无水盐类。在与湿气的反应中，通过相互化学作用形成能保持水分并能阻止水分释放的稳定化合物。第二类干燥剂化合物是那些认为反应性的化合物。这些化合物通常会与水或湿气发生化学反应并形成与水相结合的新化合物。这些新形成的化合物通常在低温下是不可逆的，需要足够的能量才能再生而使它们可重新作为干燥剂使用。这些反应型干燥剂主要用于溶剂的干燥并可作为必需保持低水分状态的聚合物的吸水材料。第三类干燥剂是通过物理吸收而获得吸收湿气的能力。吸收过程是由干燥剂颗粒中的细毛细管对湿气的抽吸作用来完成的。毛细管的孔径以及毛细管的密度决定了干燥剂的吸收性能。这类物理吸收干燥剂的实例包括分子筛、硅胶、白土(如蒙脱土)、某些合成聚合物(例如用于婴儿尿布中的聚合物)以及淀粉。由于这些物理吸收型干燥剂是惰性和非水溶性的，因而优选用于许多领域中。 
在另一个实施方案中，吸收材料可以是：(1)金属和合金例如(但不受此限制)镍、铜、铝、硅、焊锡、银、金，(2)镀金属的颗粒如镀银的铜、镀银的镍、镀银的玻璃微球，(3)无机物质如BaTiO3、SrTiO3、SiO2、Al2O3、ZnO、TiO2、MnO、CuO、Sb2O3、WC、熔凝硅石、煅制二氧化硅、无定形熔凝硅石、溶胶-凝胶二氧化硅、溶胶-凝胶钛酸盐、混合钛酸盐、离子交换树脂、含锂陶瓷、多孔玻璃微球，(4)碳基材料如碳、活性炭、炭黑、Ketchem black、金刚石粉、(5)弹性体如聚丁二烯、聚硅氧烷，以及半金属、陶瓷。在另一实施例中，吸收材料可以是氧化钙。在存在湿气和二氧化碳的情况下，氧化钙能转变成碳酸钙。因此，氧化钙可用作需要吸收二氧化碳的场合中的吸收材料。这类应用领域包括会释放二氧化碳的新鲜食物(例如水果和蔬菜)的保藏。 
在另一个实施方案中，活化材料包括那些需要特定的液体、蒸汽或气体来活化的，活化后又会释放所要求的蒸汽、液体或气体的材料。在一个实施方案中，采用以湿气来活化该材料。在另一实施方案中，采用氧气来活化该材料。在再一个方案中，采用以酸来活化该材料。在再一个实施方案中，采用以碱来活化该材料。在再一个实施方案中，可能会释放各种物质。这类物质可呈包括任何会释放并分散于周围大 气中的适当形式，包括固态、凝胶态、液态及有时为气态。这些物质具有多种功能，包括可作为芳香剂或香味源，可作为具有生物活性的成分如生物杀伤剂、抗微生物剂、农药、驱虫剂、诱铒、芳香药物等，可作为增湿或干燥物质，或者可释放气飘(air-borne)的活性化学品如腐蚀抑制剂、催熟剂及气味掩蔽剂。 
在再一个活化材料的实施方案中，某些催化反应可产生过氧化氢副产物。释放的过氧化氢如果直接与食物的湿表面相接触，则对于延长食物如肉类、家禽和鱼的储存期是有利的。另一方面，过氧化氢的产生量可能会因酶系统中包含过氧化氢酶而减少。 
在一个实施方案中，活性薄膜的厚度可为约0.05毫米-约1.0毫米，更具体为约0.2-约0.6毫米。在一个实例中，活性薄膜可以为单层或多层结构。在另一个实例中，膜层之一可以是经FDA或EV批准的能与药物或食物直接接触的膜层，另一层可包含活性层。 
在再一个实施方案中，活性薄膜可由两种组分-薄膜和活性剂制成。在另一个实施方案中，活性薄膜可以由至少三种成分制成。在下述一个或多个美国专利：5911937、6214255、6130263、6080350和6174952、6124006以及6221446中已公开了三种成分的组合物的一个实例的各成分和制造方法。在另一个实施方案中，活性薄膜可以由热塑性树脂(例如聚丙烯、聚乙烯以及它们的混合物)构成。 
在一个实例中，活性薄膜是以挤塑方法制造的并收集成为连续主膜卷。例如，可将该主膜卷切割成较窄膜卷。在一个实施方案中，将活性薄膜的连续膜卷提供给终端用户-食物、药物或医疗器械用户用作成品包装材料。 
在再一个实施方案中，本发明可用于对环境因素如湿气敏感的产品(例如诊断试条)中。在一个实例中，本发明将活性薄膜粘附在封合部位以外的箔材料上，所以不会影响封合。当打开包装时，活性薄膜仍能可靠地附在箔上，不会影响用户取用产品。 
在另一实施方案中，为了将活性薄膜切片贴合在箔上，通过对箔加热，并利用箔上热合层而将活性薄膜粘附在箔材上。由于通过适当地选择 粘合区域将活性薄膜粘附在箔上，因而活性薄膜保持在包装内部的密封范围内，所以不会影响包装的密封性。 
在再一个实施方案中，活性薄膜是通过采用如热贴合等方法粘附的，该法是利用箔的热合性能，因而不需要添加其它可能会与产品发生相互作用的材料如粘合剂。对本发明目的来说，术语“热贴合”是指利用箔中的热合材料，对箔施以足够的热量以保证活性薄膜贴合在箔上。 
在一个实施方案中，箔材料是由一般的制袋原材料构成的。在一个实例中，箔材料是一种包含聚酯薄膜层、粘合剂、铝箔材料以及聚合物(例如LLDPE)薄膜的复合材料。 
图1展示的是本发明的一个实施方案的将连续主膜卷上的活性薄膜贴在送入加热台面上的盖箔料带上的侧视图。活性薄膜由供料辊1送入贴膜器头4，盖箔2由供料辊经加热台3送入加热台3和贴膜器头4包括贴膜器子系统。在贴膜头4处，活性薄膜5被切成预定长度。在加热台3处，盖箔被充分加热使聚合物热合层软化。在贴膜器头4与加热台3之间施加足够的压力，将已切的活性薄膜5推压在盖箔2软化的聚合物层上，从而将活性薄膜(5)粘附在盖箔的软化的聚合物层上。 
图2展示的是盖箔上热贴合有活性薄膜的组装的泡罩包装的截面图。活性薄膜1粘附在盖箔2上。 
图3展示的是产品在热合部位外贴有活性薄膜的箔袋包装。图3展示的也是一种成品包装。 
下面对本发明的一个实例进行说明。应知道这仅仅是一个实施例，而不是将本发明限定在该说明范围内。在这一实例中，采用常规高速制袋设备将活性薄膜贴合在柔软的袋中。一种常用的制造软袋设备的实例是HM-2系列制袋机，(由Siebler Romaco，Remchingen，Germany制造)。这种制袋机有四条装料、热合口袋的作业线。制袋机装载一个或多个活性薄膜的连续膜卷，采用下列顺序将活性薄膜贴合在箔袋上： 
1.由连续膜卷供给上面和底面软膜部分； 
2.每一作业线由一个活性薄膜膜卷供料； 
3.送入单位长度活性薄膜； 
4.将活性薄膜切成预定长度(每一作业线中)； 
5.对软膜封合层充分加热以使封合层软化(但不熔化)； 
6.将切出的活性薄膜贴压在软化的封合层材料上，对切出的活性薄膜施加恒定的压力； 
7.通过箔中热合层粘附活性薄膜，将切出的膜片粘附在软包装上。 
对这一实例来说，封合层是由聚乙烯(LLDPE)或Serl yn所构成的。箔袋材料是由Alcan(PHARMA CENTER SHELBYVILLE，INC)，Shelbyvi1le，KY，USA制造的，产品号92037。封合层的熔点约150-170℃。 
采用的活性薄膜厚度为0.4毫米，切成约12.5毫米×15.0毫米小片。所用的活性薄膜掺混有分子筛干燥剂在塑性材料中。活性薄膜是由CSP Technologies，Auburn，AL制造的。所用的活性薄膜是M-0002-掺混有分子筛干燥剂的聚乙烯基薄膜。该活性薄膜是用双螺杆挤塑机制造的。共混物在挤塑机中挤塑成薄膜状或片材状。然后，将该挤出料送入三辊轧光机组，在三辊机中轧成所需厚度的活性薄膜并将熔融物料冷却成固态。在三辊轧光机组中，物料通过两个轧辊之间的间隙，再通过中心辊的表面、通过第二间隙，经下辊下面，然后传向薄膜收卷机。每一辊的辊隙压力和温度是分别控制的。控制条件是根据所采用的材料和所要求成品膜的物理性能来确定的。根据所要求的产出，辊隙或按轻触方式设定或采用固定辊隙。使活性薄膜通过NDC厚度仪，该厚度仪有一个发射和测量能透过该薄膜的γ-射线的往复移动头。横向和纵向数据经收集并显示在触摸屏上。然后，活性薄膜被切成所要求的宽度，并采用单轴中心驱动薄膜收卷机进行收卷。 
虽然上面已通过一些优选实施方案对本发明进行了说明，但鉴于本文中公开内容，其它实施方案对于技术熟练人员来说也是显而易见 的。因此，本发明不受所列举的优选实施方案限制，本发明范围只是由所附权利要求书确定的。 

Claims (10)

1.一种将活性薄膜粘附在柔性包装材料上的方法，该方法包括下列步骤：
对箔加热；
将活性薄膜贴合在箔上；
对活性薄膜与箔的复合体施加足够的压力，并对箔充分加热以使活性薄膜粘附在箔上，以及该活性薄膜保持在该柔性包装材料内部的密封范围内。
2.权利要求1的方法，其中活性薄膜由两种或三种成分组成，所述两种成分是活性剂和聚合物，和所述三种成分是活性剂、聚合物和沟流剂。
3.权利要求1的方法，其中活性薄膜包含至少三种成分，该三种成分是活性剂、聚合物和沟流剂。
4.权利要求2的方法，其中活性薄膜的厚度为0.05毫米-1.0毫米。
5.权利要求2的方法，其中活性薄膜只通过加热和对所述复合体施压而粘附在箔上，而不添加任何额外的粘合材料。
6.一种将活性薄膜粘附到柔性包装材料上的方法，该方法包括下列步骤：
由箔供料辊送入箔；
由活性薄膜供料辊送入活性薄膜；
将活性薄膜切成预定的长度；
对箔加热；
将切成的活性薄膜贴在箔上；以及
对活性薄膜和箔的复合体施加足够的压力并对箔充分加热以使活性薄膜粘附在箔上。
7.权利要求6的方法，其中活性薄膜由两种或三种成分组成，所述两种成分是活性剂和聚合物，和所述三种成分是活性剂、聚合物和沟流剂。
8.权利要求6的方法，其中活性薄膜包含至少三种成分，该三种成分是活性剂、聚合物和沟流剂。
9.权利要求7的方法，其中活性薄膜的厚度为0.05毫米-1.0毫米。
10.权利要求7的方法，其中活性薄膜只通过加热和对所述复合体施压而粘附在箔上，而不添加任何额外的粘合材料。
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