GB2571255A - Film lamination process - Google Patents

Film lamination process Download PDF

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Publication number
GB2571255A
GB2571255A GB1802427.3A GB201802427A GB2571255A GB 2571255 A GB2571255 A GB 2571255A GB 201802427 A GB201802427 A GB 201802427A GB 2571255 A GB2571255 A GB 2571255A
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United Kingdom
Prior art keywords
layer
film
component layer
film component
adhesive
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Granted
Application number
GB1802427.3A
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GB2571255B (en
GB201802427D0 (en
Inventor
William Jarman Robert
Tiw Shipman James
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Camvac Ltd
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Camvac Ltd
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Publication date
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Priority to GB1802427.3A priority Critical patent/GB2571255B/en
Publication of GB201802427D0 publication Critical patent/GB201802427D0/en
Publication of GB2571255A publication Critical patent/GB2571255A/en
Application granted granted Critical
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/0007—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality
    • B32B37/003—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality to avoid air inclusion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/04—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the partial melting of at least one layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B2037/1253—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives curable adhesive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B2038/0052—Other operations not otherwise provided for
    • B32B2038/0076—Curing, vulcanising, cross-linking
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2250/00—Layers arrangement
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/24—All layers being polymeric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2255/28—Multiple coating on one surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/554—Wear resistance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • B32B2307/7242—Non-permeable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • B32B2307/7242—Non-permeable
    • B32B2307/7244—Oxygen barrier
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • B32B2307/7242—Non-permeable
    • B32B2307/7246—Water vapor barrier
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/60—In a particular environment
    • B32B2309/68—Vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2310/00—Treatment by energy or chemical effects
    • B32B2310/04—Treatment by energy or chemical effects using liquids, gas or steam
    • B32B2310/0445—Treatment by energy or chemical effects using liquids, gas or steam using gas or flames
    • B32B2310/0454—Hot air
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2310/00—Treatment by energy or chemical effects
    • B32B2310/08—Treatment by energy or chemical effects by wave energy or particle radiation
    • B32B2310/0806—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation
    • B32B2310/0825—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation using IR radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2323/00—Polyalkenes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2333/00—Polymers of unsaturated acids or derivatives thereof
    • B32B2333/04—Polymers of esters
    • B32B2333/08—Polymers of acrylic acid esters, e.g. PMA, i.e. polymethylacrylate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2439/00—Containers; Receptacles
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    • B32B2439/46—Bags
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2439/00—Containers; Receptacles
    • B32B2439/70—Food packaging
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2553/00—Packaging equipment or accessories not otherwise provided for
    • B32B2553/02—Shock absorbing
    • B32B2553/026—Bubble films
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method

Landscapes

  • Engineering & Computer Science (AREA)
  • Quality & Reliability (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)

Abstract

A first film 16 having an adhesive layer (62, figure 5) is pressed into contact with a second film 22 in a union region 23 within an evacuated container E. The preferred adhesive is a solvent free acrylate or polyolefin. Preferably reactive and/or heated gas (G1, G2, figure 4) is introduce at or adjacently upstream of the nip region 23, so as to partially heat the adhesive and initiate or aid curing. The preferred apparatus includes electron beam, ultraviolet (UV) or plasma devices (66, figure 5, 76, figure 6), infrared (IR) heaters (42, figure 3) and/or heated pressing rolls 18 for a similar purpose. The feed (14, 20) and take-up (26) rollers may be inside or outside (figure 2) the vacuum chamber E. The preferred 1st 16 and 2nd 22 films have metal and adhesive layers. The apparatus is also claimed. The multilayer film is used to package oxygen and moisture sensitive food or entrap gas.

Description

Film Lamination Process
Background
Multi-layer films having enhanced barrier properties for gas and/or vapour can be produced by depositing alternate layers of cured polymer and metal or compounds onto a substrate using processes such as vacuum deposition. These films are useful for packaging of oxygen or moisture sensitive foodstuffs, encapsulation of gas or moisture sensitive components, and a variety of other functional applications requiring barrier properties.
It is known to create multi-layer films by way of lamination. A first film component layer, which can comprise one or more layers of material, can have an adhesive layer provided on a major surface of the first film component layer to form an adhesive surface. A major surface of a second film component layer, which can also comprise one or more layers of material, is then pressed against the adhesive surface to form the laminate film. Heat can be applied to one or both of the component layers before and/or during union of the component layers. The film component layers can each be formed as elongate webs which are moved by rollers during the lamination process, in a reel to reel process.
The present inventor has devised a new lamination process that can reduce the likelihood of barrier property degradation during multi-layer film manufacture.
Summary
According to a first aspect of the present invention there is provided a film lamination process comprising the steps of:
providing, within a vacuum chamber, a first film component layer including an adhesive layer, the adhesive layer defining an adhesive surface;
providing, within the vacuum chamber, a second film component layer which is distinct from the first component layer; and moving the first and/or second film component layers within the vacuum chamber to define a union region where the second film component layer is pressed into contact with the adhesive surface to form a laminated multi-layer film within the vacuum chamber.
While it is known to perform film processing steps such as metallisation within a vacuum chamber, the present inventor has recognised that it would be possible to form a laminated multi-layer film within a vacuum chamber. This can prevent damage of barrier layers applied by metallisation techniques (for example but not limited to metals, inorganic oxides or inorganic nitrides) from downstream processing by immediately encapsulating them. Additionally, in-vacuum lamination can reduce the likelihood of unwanted particles being trapped between the first and second component layers during the lamination process, which can reduce the likelihood of barrier property degradation during multi-layer film manufacture.
An adhesive layer can comprise any adhesive which can be run in a vacuum chamber and which does not have excessive outgassing properties in such an environment, as outgassing can cause a significant loss in vacuum. The adhesive can for example comprise solvent free adhesives, PSA adhesives, hot melt adhesives, thermally laminatable polymers such as cured acrylates, cured acrylate coatings or polyolefines, including polypropylene and high and low density polyethylene. Thus, such adhesives can define the adhesive surface.
The adhesive need not require the presence of atmospheric gases in order to either cure or achieve the required bond strength between two film layers. In such cases, lamination within a high vacuum can have advantages as the absence of atmospheric gases can prevent the adhesive going off prematurely by reaction with atmospheric gases and/or can avoid air or other gas being trapped between the two layers of the laminate, causing air or gas bubbles. Examples of adhesives which do not require the presence of atmospheric gases in order to either cure or achieve the required bond strength between two film layers are some solvent free adhesives, PSA adhesives, and hot melt adhesives, thermally laminatable polymers such as cured acrylates, cured acrylate coatings or polyolefines.
Alternatively, as described in more detail below, where the adhesive requires or is aided by a degree of reaction with atmospheric or other gases, gas can be injected into the chamber at or close to the point of lamination to react with the adhesive system and cause/initiate curing and/or sufficient bond to be achieved. The gas can comprise a gas that is used to cure the adhesive such as oxygen or mixes of oxygen in an inert or other carrier gas, air, water vapour (steam) or mixes of water vapour in inert or other carrier gases, humidified gases or gas mixes.
The vacuum can be between lxlO2 mbar and lxlO'7 mbar or more preferably between
1x10° mbar and lxlO'4mbar or more preferably still between lxlO'1 and lxl0'3mbar.
The second layer can be pressed into contact with the adhesive surface by a pair of union members, which can be plates in a static lamination process or rollers in a reel to reel process.
One or more of the union members can be heated so as to define heated external surfaces which direct heat to the first film component layer and/or the second film component layer to at least partially melt the adhesive surface and/or to aid in curing.
The process can further comprise directing a flux of gas between one or more of the union members and the first and/or second layer and/or between the first and second layer. This gas can aid thermal transfer between the union members, the first film component layer, and/or the second film component layer.
The gas can be heated such that the gas carries heat through the vacuum to heat the first film component layer and/or the second film component layer to pre heat and/or at least partially melt the adhesive surface to aid in curing.
The gas can be air or any other suitable gas however, inert or gases such as but not limited to N2 or Ar are preferred in certain embodiments of the invention.
The quantity of gas delivered can be between 50cm3/min and 20dm3/min as measured at lOlkPa and 20°C. The volume of gas required will largely be dependent on the size, or width for a roll to roll process, of the laminate being produced. Thus, a larger or wider laminate will require more gas than a small or narrow one. Thus this gas can aid in the lamination process substantially without affecting the benefits provided by laminating within the vacuum chamber.
The process can comprise a step of applying infra-red, electromagnetic radiation to the first film component layer and/or the second film component layer within the vacuum chamber to pre heat and/or at least partially melt the adhesive surface to aid in curing.
The step of moving the first film component layer and/or the second film component layer can comprise feeding the first film component layer and the second film component layer from respective source rollers into contact with one another and then winding the laminated multi-layer film around a target roller.
One or both of the source rollers and/or the target roller can be located within the vacuum chamber.
Alternatively, one or both of the source rollers and/or the target roller can be located outside of the vacuum chamber, with the first film component layer and/or the second film component layer and/or the laminated multi-layer film each entering and/or exiting the vacuum chamber via a slot which closely conforms in shape to the cross section thereof so as to inhibit gas passage through the slot. This can enable the first film component layer and/or the second film component layer to be at least partially pre-heated outside of the vacuum layer to aid in melting the adhesive layer within the vacuum chamber. While this can increase the likelihood of unwanted particles being trapped between the first and second component layers during the lamination process, the likelihood is significantly less than would be the case in a conventional laminating process.
The first film component layer and/or the second film component layer can each comprise a multi-layer film, for example having one or more alternate layers of cured polymer and metal or compounds on a plastics material substrate.
A major surface of the second film component layer can define a second adhesive layer. Where the first component layer and/or the second component layer are each provided with a layer of cured acrylate defining a major outer surface, this can be heated as part of the process to define the adhesive layer.
Permeability to oxygen, other non-condensable gases or water vapour may be at least one order of magnitude lower than the inherent permeability of the component layer substrate when the described process is used to deposit combinations of inorganic and organic layers (such as aluminium or aluminium oxide and polymerised radiation curable material) onto the same component layer substrate.
The polymerised radiation curable material may form a coating on the substrate that provides abrasion protection to any underlying functional layers during conversion or use.
In accordance with a second aspect of the present invention, there is provided an apparatus for carrying out the method of the first aspect, the apparatus comprising:
a vacuum chamber; and a pair of union members for moving first and/or second component layers within the vacuum chamber to define a union region where the second component layer is pressed into contact with an adhesive surface of the first component layer to form a laminated multi-layer film within the vacuum chamber.
Optional features of the method of the first aspect can be applied to the apparatus of the second aspect in an analogous manner.
Description of the Drawings
By way of example only, certain embodiments of the invention will now be described by reference to the accompanying drawings, in which:
Figure 1 is a diagram of an in-vacuum lamination apparatus according to an embodiment of the invention;
Figure 2 is a diagram of an in-vacuum embodiment of the invention;
Figure 3 is a diagram of an in-vacuum embodiment of the invention;
Figure 4 is a diagram of an in-vacuum embodiment of the invention;
lamination apparatus according to a further lamination apparatus according to a further lamination apparatus according to a further
Figure 5 is a diagram of an in-vacuum lamination apparatus according to a further embodiment of the invention including in-line coating and curing with an acrylate for use as an adhesive system for applying the adhesive layer in the vacuum chamber;
Figure 6 is a diagram of an in-vacuum lamination apparatus according to a further embodiment of the invention including an alternative adhesive system; and
Figure 7 is a flow chart illustrating a method according to an embodiment of the invention.
Embodiments of the Invention
Figure 1 shows an in-vacuum lamination apparatus generally at 10. The apparatus 10 is configured to perform a film lamination process according to an embodiment ofthe invention.
The apparatus 10 comprises a vacuum chamber 12 configured to define an enclosure E arranged to be run at a vacuum, such as between lxlO'1 and lxlO'3 mbar. However, in some embodiments the pressure may be as high as 1x10° mbar or as low as lxlO'7 mbar. In this embodiment the vacuum chamber 12 is completely sealed.
Within the vacuum chamber there is provided a first source roller 14. A first film component layer 16 is wound around the first source roller 14. The first film component layer extends from the source roller through a pair of union members 18, which are rollers in this embodiment.
A second source roller 20 is also rotatably mounted within the vacuum chamber. A second film component layer 22 is wound around the second roller 20 and extends from the second roller 20 through the union member rollers 18.
The first film component layer 16 includes an adhesive layer defining an adhesive surface which faces the second film component layer 22 as the film component layers 16, 22 pass through the union members 18.
The union members 18 are arranged so that one or both of them are pushed into contact with the other so as to apply an even pressure between them that presses the second film component layer 22 into contact with the adhesive surface of the first film component layer 16. The pressure applied between the union members 18 can be varied, the pressure required being dependent on numerous factors including the material type, material thickness, adhesive, and width being laminated. Thus, the pressure between the union members 18 defines a union region or nip region 23 where the second film component layer is pressed into contact with the adhesive surface to form a laminated multi-layer film 24 within the vacuum chamber.
A target roller 26 is also rotatably mounted within the vacuum chamber 12. The laminated multilayer film 24 is wound around the target roller 26 to create a reel of laminated multilayer film.
Figure 2 shows an in-vacuum lamination apparatus according to a further embodiment of the invention generally at 30. The apparatus 30 is similar to the apparatus 10 with the exception that the first and second source rollers 14, 20 and the target roller 26 are located outside of the vacuum chamber 12. One or more inlet ports 34 are provided in the vacuum chamber through which the first and second film component layers 16, 22 are fed. Positioning rollers 32 can be used to guide the first and second film component layers 16, 22 to the union member rollers 18. In Figure 2 the optional positioning rollers 32 are displayed inside the vacuum chamber 12 but may optionally be positioned outside it. Further additional positional rollers can also be included internally and/or externally to the vacuum chamber.
Additionally, the vacuum chamber 12 includes an outlet port 36 through which the laminated multilayer film exits to be wound around the target roller 26.
It is advantageous that the ports 34 and 36 closely conform to the combined cross sectional area of the film component layers 16, 22, 24 plus any gap intended to be between them, so as to minimise gas flow into the enclosure E of the chamber 12 of the exterior of the vacuum chamber 12. Additionally, ports 34 and/or 36 may consist of any device or devices known in the art so as to minimise the ingress of atmospheric gas into the enclosure E of the chamber 12.
Figure 3 shows an in-vacuum lamination apparatus according to a further embodiment of the invention generally at 40. The apparatus 40 is similar to the apparatus 10 and for brevity only the differences will be described. It should however, be noted that the apparatus 40 could be configured as apparatus 30 with the source rollers and target rollers outside the enclosure E of the chamber 12. The apparatus 40 differs from the apparatus 10 of Figure 1 in that it includes a heating device within the enclosure E of the chamber 12 to preheat and/or partially melt the adhesive layer upstream of the nip region. In this embodiment, heating is provided by an infrared energy unit 42 positioned within the vacuum chamber to direct electromagnetic energy IR at the first and/or second film component layers to preheat and/or to partially melt the adhesive surface.
Figure 4 shows an in-vacuum lamination apparatus according to a further embodiment of the invention generally at 50. Apparatus 50 is similar to the apparatus 40 shown in Figure 3. However, in the apparatus 50 gas inlets 52 are mounted within the enclosure E of the vacuum chamber 12. These are configured to deliver a gas G1 between the first film 16 and the corresponding union member 18 and/or between the second film and corresponding union member 18. Where one or both the union members 18 are heated the gas G1 has the advantage of improving thermal transfer between the union member(s) 18 and the film(s) 16, 22. The gas G1 can be heated prior to being delivered by inlets 52 into the vacuum chamber enclosure E. The gas G1 can be any suitable gas. Example gases for G1 can include but are not limited to air, Ar or N2. In some embodiments the gas inlets 52 may be combined within the union members 18.
Figure 4 additionally shows another optional gas inlet 54 arranged to deliver a gas G2. The inlet 54 is arranged to direct a flux of second gas towards the union region. In this embodiment, the gas G2 can aid in thermal transfer between the two films 16 and 22. The second gas G2 can also be or contain a reactive species so as to react with an adhesive system that requires or benefits from reaction with such species to cure. Example second gases G2 can include but are not limited to oxygen or mixes of oxygen in an inert or other carrier gas, air, water vapour (steam) or mixes of water vapour in inert or other carrier gases, humidified gases or gas mixes. Where a reactive gas is not required or desirable, but inlet for the purpose of improving thermal transfer, G2 can consist of an inert or largely inert gas. Example gases for such a use can include but are not limited to air, Ar or N2. Thus, gases G1 and G2 can be the same gas.
Figure 5 shows an in-vacuum lamination apparatus according to an embodiment of the invention generally at 60. It shows an embodiment of the invention displaying in-line coating with an acrylate for use as an adhesive system. Put another way, the apparatus of this embodiment enables the adhesive layer to be applied within the vacuum chamber 12. The apparatus 60 is largely similar to 10 in Figure 1. A first film component layer 16 from the first source roller 14 has an acrylate layer 62 applied via application system 64. The acrylate layer is then cured by the curing system 66 to form a cured acrylate layer 62'. The first film component layer 16 with cured acrylate coating 62' is then laminated downstream to the second film component layer 22 from second source roller 20.
The acrylate application system 64 can be via flash evaporation and condensation by a process as described in EP2951850. The curing system 66 can be any system that can run in a vacuum, examples include but are not limited to electron-beam, UV and plasma curing.
Figure 6 shows an in-vacuum lamination apparatus according to an embodiment of the invention generally at 70. It shows an embodiment of the invention displaying an alternative inline coating with an adhesive system. The apparatus 70 is largely similar to 60 and for brevity only differences will be discussed. In this embodiment an adhesive layer 72 is applied at an application station 74. The adhesive applied can be any suitable adhesive such as solvent free adhesives, hot melt adhesives, acrylates or acrylate coatings. The application station 74 may be any suitable system such as direct gravure, indirect gravure, reverse gravure, flexo, slot dye, extrusion dye, and/or curtain.
Where the adhesive layer used for lamination is to be a cured acrylate / cured acylate layer an additional curing source 76 is located immediately after the application station 74. This curing source 76 may optionally also be used in combination with other adhesive systems.
In any embodiment, the union members can be heated, for example by internal piping channelling hot fluid.
In any embodiment, the first and/or second film component layers 16, 22 can each comprise a multilayer film, for example having one or more alternate layers of cured polymer and metal or compounds on plastics material substrate.
In any embodiment barrier layers such as but not limited to metals, inorganic oxides or inorganic nitrides can be applied to the first film component layer 16 and/or the second film component layer 20 by any in vacuum technique known in the art. Examples techniques include but are not limited to metallisation, reactive metallisation, sputter coating, PECVD and ALD.
Multilayer films including a cured acrylate layer can be provided by a process as described in EP2951850. Additionally in any embodiment such layers can be applied to the first film component layer 16 and/or the second film component layer 20 in line with the lamination.
Figure 7 shows a flowchart illustrating a film lamination process according to an embodiment of the invention.
At step 80 the process comprises providing, within a vacuum chamber, a first film component layer including an adhesive layer, the adhesive layer defining an adhesive surface.
At step 82 the process comprises providing, within the vacuum chamber, a second film component layer which is distinct from the first component layer.
At step 84 the process comprises moving the first and/or second film component layers within the vacuum chamber to define a union region where the second film component layer is pressed into contact with the adhesive surface to form a laminated multi-layer film within the vacuum chamber.
Although the invention has been described above with reference to one or more preferred embodiments, it will be appreciated that various changes or modifications can be made without departing from the scope of the invention as defined in the appended claims. The word comprising can mean including or consisting of and therefore does not exclude the presence of elements or steps other than those listed in any claim or the specification as a whole. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.

Claims (17)

Claims
1. A film lamination process comprising the steps of:
providing, within a vacuum chamber, a first film component layer including an adhesive layer, the adhesive layer defining an adhesive surface;
providing, within the vacuum chamber, a second film component layer which is distinct from the first component layer; and moving the first and/or second film component layers within the vacuum chamber to define a union region where the second film component layer is pressed into contact with the adhesive surface to form a laminated multi-layer film within the vacuum chamber.
2. The process of claim 1, wherein the adhesive comprises acrylate.
3. The process of claim 1, wherein the adhesive comprises a solvent free adhesive.
4. The process of claim 1, wherein the adhesive comprises a polyolefin.
5. The process of any preceding claim, further comprising directing a flux of gas at and/or adjacently upstream with respect to the union region between the first and second film component layers.
6. The process of claim 5, wherein the gas is a reactive gas that reacts with the adhesive so as to cause or initiate curing.
7. The process of any preceding claim, wherein the second layer is pressed into contact with the adhesive surface by a pair of union members.
8. The process of claim 7, wherein one or more of the union members are arranged to be heated so as to define heated external surfaces which direct heat the first film component layer and/or the second film component layer to at least partially melt the adhesive surface to aid in curing.
9. The process of any preceding claim when dependent on claim 5, wherein the gas is heated such that the gas carries heat through the vacuum to heat the first film component layer and/or the second film component layer to heat and/or at least partially melt the adhesive surface to aid in curing.
10. The process of any preceding claim when dependent on claim 5, wherein the quantity of gas delivered is less than 20dm3/min as measured at lOlkPa and 20°C.
11. The process of any preceding claim, further comprising a step of applying infrared, electromagnetic radiation to the first film component layer and/or the second film component layer within the vacuum chamber to pre heat and/or at least partially melt the adhesive surface to aid in curing.
12. The process of any preceding claim, wherein the step of moving the first film component layer and/or the second film component layer can comprises feeding the first film component layer and the second film component layer from respective source rollers into contact with one another and then winding the laminated multi-layer film around a target roller.
13. The process of claim 12, wherein one or both of the source rollers and/or the target roller are located within the vacuum chamber.
14. The process of claim 12, wherein one or both of the source rollers and/or the target roller are located outside of the vacuum chamber, with the first film component layer and/or the second film component layer and/or the laminated multi-layer film each entering and/or exiting the vacuum chamber via a slot which closely conforms in shape to the cross section thereof so as to inhibit gas passage through the slot
15. The first film component layer and/or the second film component layer can each comprise a multi-layer film, for example having one or more alternate layers of cured polymer and metal or compounds on a plastics material substrate.
16. The process of any preceding claim, wherein a major surface of the second film component layer defines a second adhesive layer.
17. In-vacuum film lamination apparatus comprising:
a vacuum chamber; and a pair of union members for moving first and/or second component layers within the vacuum chamber to define a union region where the second component layer is pressed into contact with an adhesive surface of the first component layer to form a laminated multi-layer film within the vacuum chamber.
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US20020028354A1 (en) * 2000-06-05 2002-03-07 Fuji Photo Film Co., Ltd. Floppy disk and method for manufacturing the same
CN101847667A (en) * 2010-01-06 2010-09-29 湖南寰球太阳能技术开发有限公司 Special back seal film for solar cell
WO2011156305A1 (en) * 2010-06-07 2011-12-15 E. I. Du Pont De Nemours And Company Method for preparing transparent multilayer film structures having a perfluorinated copolymer resin layer
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RU2021150C1 (en) * 1990-12-29 1994-10-15 Государственный научно-исследовательский, проектный и конструкторский институт сплавов и обработки цветных металлов "Гипроцветметобработка" Foiled polyimide production process
US20020028354A1 (en) * 2000-06-05 2002-03-07 Fuji Photo Film Co., Ltd. Floppy disk and method for manufacturing the same
CN101847667A (en) * 2010-01-06 2010-09-29 湖南寰球太阳能技术开发有限公司 Special back seal film for solar cell
WO2011156305A1 (en) * 2010-06-07 2011-12-15 E. I. Du Pont De Nemours And Company Method for preparing transparent multilayer film structures having a perfluorinated copolymer resin layer
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