JP2017500229A - ポリマー多層フィルムの製造方法 - Google Patents
ポリマー多層フィルムの製造方法 Download PDFInfo
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- 229920000642 polymer Polymers 0.000 title claims abstract description 92
- 238000004519 manufacturing process Methods 0.000 title claims description 8
- 238000000034 method Methods 0.000 claims abstract description 44
- -1 polyethylene terephthalate Polymers 0.000 claims description 41
- QYMGIIIPAFAFRX-UHFFFAOYSA-N butyl prop-2-enoate;ethene Chemical compound C=C.CCCCOC(=O)C=C QYMGIIIPAFAFRX-UHFFFAOYSA-N 0.000 claims description 35
- 229920006245 ethylene-butyl acrylate Polymers 0.000 claims description 35
- 239000005043 ethylene-methyl acrylate Substances 0.000 claims description 35
- 229920006225 ethylene-methyl acrylate Polymers 0.000 claims description 35
- 229920006226 ethylene-acrylic acid Polymers 0.000 claims description 34
- 238000002844 melting Methods 0.000 claims description 28
- 230000008018 melting Effects 0.000 claims description 28
- 229920001577 copolymer Polymers 0.000 claims description 23
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 21
- 239000005020 polyethylene terephthalate Substances 0.000 claims description 21
- HGVPOWOAHALJHA-UHFFFAOYSA-N ethene;methyl prop-2-enoate Chemical compound C=C.COC(=O)C=C HGVPOWOAHALJHA-UHFFFAOYSA-N 0.000 claims description 18
- 239000005038 ethylene vinyl acetate Substances 0.000 claims description 18
- 229920003229 poly(methyl methacrylate) Polymers 0.000 claims description 18
- 239000004926 polymethyl methacrylate Substances 0.000 claims description 18
- QHZOMAXECYYXGP-UHFFFAOYSA-N ethene;prop-2-enoic acid Chemical compound C=C.OC(=O)C=C QHZOMAXECYYXGP-UHFFFAOYSA-N 0.000 claims description 17
- 229920001707 polybutylene terephthalate Polymers 0.000 claims description 17
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 claims description 17
- 239000004743 Polypropylene Substances 0.000 claims description 16
- 229920001038 ethylene copolymer Polymers 0.000 claims description 16
- 229920001903 high density polyethylene Polymers 0.000 claims description 15
- 239000004700 high-density polyethylene Substances 0.000 claims description 15
- 229920001684 low density polyethylene Polymers 0.000 claims description 15
- 239000004702 low-density polyethylene Substances 0.000 claims description 15
- 229920001179 medium density polyethylene Polymers 0.000 claims description 15
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- 230000008569 process Effects 0.000 claims description 14
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- 229920002292 Nylon 6 Polymers 0.000 claims description 10
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- 239000004676 acrylonitrile butadiene styrene Substances 0.000 claims description 10
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- 239000011521 glass Substances 0.000 claims description 5
- 230000015572 biosynthetic process Effects 0.000 claims description 4
- DQXBYHZEEUGOBF-UHFFFAOYSA-N but-3-enoic acid;ethene Chemical compound C=C.OC(=O)CC=C DQXBYHZEEUGOBF-UHFFFAOYSA-N 0.000 claims description 3
- 229920000092 linear low density polyethylene Polymers 0.000 claims description 3
- 239000004707 linear low-density polyethylene Substances 0.000 claims description 3
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 claims description 3
- 229920000219 Ethylene vinyl alcohol Polymers 0.000 claims 1
- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 claims 1
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 claims 1
- RZXDTJIXPSCHCI-UHFFFAOYSA-N hexa-1,5-diene-2,5-diol Chemical compound OC(=C)CCC(O)=C RZXDTJIXPSCHCI-UHFFFAOYSA-N 0.000 claims 1
- 238000010521 absorption reaction Methods 0.000 abstract description 4
- 238000001914 filtration Methods 0.000 abstract description 3
- 239000010408 film Substances 0.000 description 68
- 239000000463 material Substances 0.000 description 11
- 229920010126 Linear Low Density Polyethylene (LLDPE) Polymers 0.000 description 6
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- 239000000126 substance Substances 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 3
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- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
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- 239000011112 polyethylene naphthalate Substances 0.000 description 2
- 229920000098 polyolefin Polymers 0.000 description 2
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 2
- 239000010409 thin film Substances 0.000 description 2
- WSQZNZLOZXSBHA-UHFFFAOYSA-N 3,8-dioxabicyclo[8.2.2]tetradeca-1(12),10,13-triene-2,9-dione Chemical compound O=C1OCCCCOC(=O)C2=CC=C1C=C2 WSQZNZLOZXSBHA-UHFFFAOYSA-N 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 150000001336 alkenes Chemical class 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 229920001400 block copolymer Polymers 0.000 description 1
- 229920006026 co-polymeric resin Polymers 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 239000000498 cooling water Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 238000005530 etching Methods 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 230000009477 glass transition Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000011256 inorganic filler Substances 0.000 description 1
- 229910003475 inorganic filler Inorganic materials 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
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- 239000002861 polymer material Substances 0.000 description 1
- 229920000193 polymethacrylate Polymers 0.000 description 1
- 229920005606 polypropylene copolymer Polymers 0.000 description 1
- 229920005629 polypropylene homopolymer Polymers 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 238000003672 processing method Methods 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
- 229920005604 random copolymer Polymers 0.000 description 1
- 239000012748 slip agent Substances 0.000 description 1
- KKEYFWRCBNTPAC-UHFFFAOYSA-L terephthalate(2-) Chemical compound [O-]C(=O)C1=CC=C(C([O-])=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-L 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
- B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
- B26F1/26—Perforating by non-mechanical means, e.g. by fluid jet
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
- B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
- B26F1/18—Perforating by slitting, i.e. forming cuts closed at their ends without removal of material
- B26F1/20—Perforating by slitting, i.e. forming cuts closed at their ends without removal of material with tools carried by a rotating drum or similar support
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
- B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
- B26F1/18—Perforating by slitting, i.e. forming cuts closed at their ends without removal of material
- B26F1/22—Perforating by slitting, i.e. forming cuts closed at their ends without removal of material to form non-rectilinear cuts, e.g. for tabs
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
- B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
- B26F1/38—Cutting-out; Stamping-out
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
- B26F3/00—Severing by means other than cutting; Apparatus therefor
- B26F3/06—Severing by using heat
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
- B26F3/00—Severing by means other than cutting; Apparatus therefor
- B26F3/06—Severing by using heat
- B26F3/08—Severing by using heat with heated members
- B26F3/10—Severing by using heat with heated members with heated rollers or discs
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/001—Combinations of extrusion moulding with other shaping operations
- B29C48/0011—Combinations of extrusion moulding with other shaping operations combined with compression moulding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- 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
- B29C48/07—Flat, e.g. panels
- B29C48/08—Flat, e.g. panels flexible, e.g. films
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
- B29C48/18—Articles comprising two or more components, e.g. co-extruded layers the components being layers
- B29C48/21—Articles comprising two or more components, e.g. co-extruded layers the components being layers the layers being joined at their surfaces
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/30—Extrusion nozzles or dies
- B29C48/35—Extrusion nozzles or dies with rollers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
- B29C48/91—Heating, e.g. for cross linking
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
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- B29C48/911—Cooling
- B29C48/9135—Cooling of flat articles, e.g. using specially adapted supporting means
- B29C48/914—Cooling of flat articles, e.g. using specially adapted supporting means cooling drums
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
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- B29C48/911—Cooling
- B29C48/9135—Cooling of flat articles, e.g. using specially adapted supporting means
- B29C48/915—Cooling of flat articles, e.g. using specially adapted supporting means with means for improving the adhesion to the supporting means
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
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- B32B37/153—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state at least one layer is extruded and immediately laminated while in semi-molten state
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- Life Sciences & Earth Sciences (AREA)
- Forests & Forestry (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Laminated Bodies (AREA)
- Extrusion Moulding Of Plastics Or The Like (AREA)
- Shaping Of Tube Ends By Bending Or Straightening (AREA)
Abstract
Description
本出願は、2013年12月12日に出願された米国特許仮出願第61/915196号の利益を主張するものであり、その出願の開示内容全体は本明細書において参照により援用される。
少なくとも第1及び第2のポリマー層をニップに押し出してポリマー多層フィルムを提供する工程であって、ニップが、ポリマー多層フィルムの第1の主表面を介して押痕を付与する構造化表面を有する第1のロールを含み、第1の層が、第1の融点を有する第1のポリマーを含み、第2の層が、第2の融点を有する第2のポリマーを含み、第1及び第2の融点間の絶対差が少なくとも20℃(幾つかの実施形態では、少なくとも30℃、40℃、50℃、60℃、又は更には少なくとも70℃)であり、ポリマー多層フィルムの第1の主表面が第1の層の主表面であり、かつポリマー多層フィルムの第2の主表面が第2の層の主表面である、工程と、
押痕を有する第1の主表面を冷却ロールに通すと同時に、ポリマー多層フィルムの、概ね対向する第2の主表面に熱源を適用する工程であって、熱源からの熱の適用が開口部の形成をもたらして、概ね対向する第1及び第2の主表面と、第1及び第2の主表面間に延在する開口部の列と、少なくとも第1及び第2の層と、を有するポリマー多層フィルムを提供し、第1の層が第1のポリマーを含み、第2の層が第2のポリマーを含み、ポリマー多層フィルムの第1の主表面が第1の層の主表面であり、ポリマー多層フィルムの第2の主表面が第2の層の主表面である、工程と、
を含む。
1.ポリマー多層フィルムの製造方法であって、
少なくとも第1及び第2のポリマー層をニップに押し出してポリマー多層フィルムを提供する工程であって、ニップが、ポリマー多層フィルムの第1の主表面を介して押痕を付与する構造化表面を有する第1のロールを含み、第1の層が、第1の融点を有する第1のポリマーを含み、第2の層が、第2の融点を有する第2のポリマーを含み、第1及び第2の融点間の絶対差が少なくとも20℃(幾つかの実施形態では、少なくとも30℃、40℃、50℃、60℃、又は更には少なくとも70℃)であり、ポリマー多層フィルムの第1の主表面が第1の層の主表面であり、かつポリマー多層フィルムの第2の主表面が第2の層の主表面である、工程と、
押痕を有する第1の主表面を冷却ロールに通すと同時に、ポリマー多層フィルムの、概ね対向する第2の主表面に熱源を適用する工程であって、熱源からの熱の適用が開口部の形成をもたらして、概ね対向する第1及び第2の主表面と、第1及び第2の主表面間に延在する開口部の列と、少なくとも第1及び第2の層と、を有するポリマー多層フィルムを提供し、第1の層が第1のポリマーを含み、第2の層が第2のポリマーを含み、ポリマー多層フィルムの第1の主表面が第1の層の主表面であり、ポリマー多層フィルムの第2の主表面が第2の層の主表面である、工程と、
を含む、ポリマー多層フィルムの製造方法。
2.第1の融点が第2の融点よりも高い、例示的実施形態1に記載の方法。
3.第2の融点が第1の融点よりも高い、例示的実施形態1に記載の方法。
4.第1のポリマーが第1のビカー温度を有し、第2のポリマーが第2のビカー温度を有し、第1及び第2のビカー温度が異なる、例示的実施形態1〜3のいずれか一つに記載の方法。
5.第1及び第2のガラスビカー温度が少なくとも20℃(幾つかの実施形態では、少なくとも30℃、40℃、50℃、又は更には少なくとも60℃)異なる、例示的実施形態4に記載の方法。
6.ポリマー多層フィルムが、50マイクロメートル超(幾つかの実施形態では、少なくとも75マイクロメートル超、100マイクロメートル超、150マイクロメートル超、200マイクロメートル超、250マイクロメートル超、500マイクロメートル超、750マイクロメートル超、1000マイクロメートル超、1500マイクロメートル超、2000マイクロメートル超、又は2500マイクロメートル超であり、幾つかの実施形態では、125マイクロメートル〜1500マイクロメートルの範囲内、又は更には125マイクロメートル〜2500マイクロメートルの範囲内)の厚さを有する、例示的実施形態1〜5のいずれか一つに記載の方法。
7.ポリマー多層フィルムが、少なくとも30開口部/cm2(幾つかの実施形態では、少なくとも100開口部/cm2、少なくとも200開口部/cm2、少なくとも250開口部/cm2、少なくとも300開口部/cm2、少なくとも400開口部/cm2、少なくとも500開口部/cm2、少なくとも600開口部/cm2、少なくとも700開口部/cm2、少なくとも750開口部/cm2、少なくとも800開口部/cm2、少なくとも900開口部/cm2、少なくとも1000開口部/cm2、少なくとも2000開口部/cm2、少なくとも3000開口部/cm2又は更には少なくとも4000開口部/cm2、幾つかの実施形態では、30開口部/cm2〜200開口部/cm2、200開口部/cm2〜500開口部/cm2、又は更には500開口部/cm2〜4000開口部/cm2の範囲内)を有する、例示的実施形態1〜6のいずれか一つに記載の方法。
8.開口部の直径が、25マイクロメートル超(幾つかの実施形態では、50マイクロメートル超、75マイクロメートル超、100マイクロメートル超、150マイクロメートル超、200マイクロメートル超、250マイクロメートル超、500マイクロメートル超、750マイクロメートル超、1000マイクロメートル超、1500マイクロメートル超、2000マイクロメートル超、又は2500マイクロメートル超、幾つかの実施形態では、25マイクロメートル〜1500マイクロメートルの範囲内、又は更には25マイクロメートル〜2500マイクロメートルの範囲内)である、例示的実施形態1〜7のいずれか一つに記載の方法。
9.開口部を有するポリマー多層フィルムの少なくとも第1及び第2の層を分離する工程を更に含む、例示的実施形態1〜8のいずれか一つに記載の方法。
10.第1のポリマーが、ポリエチレンテレフタレート(PET)、コポリエステル(coPETg)、エチレンビニルアルコール(EVOH)、ポリアミド6、ポリアミド66、線形低密度ポリエチレン(LLDPE)、低密度ポリエチレン(LDPE)、中密度ポリエチレン(MDPE)、高密度ポリエチレン(HDPE)、アクリロニトリルブタジエンスチレン(ABS)、ポリカーボネート(PC)、ポリブチレンテレフタレート(PBT)、ポリメチルメタアクリレート(PMMA)又はポリプロピレンのうちの少なくとも1つであり、第2のポリマーが、エチレンアクリル酸(EAA)、エチレンブチルアクリレート(EBA)、エチレンビニルアセテート(EVA)、エチレンメチルアクリレート(EMA)、プロピレン系共重合体、又はエチレン系共重合体のうちの少なくとも1つである、例示的実施形態1〜9のいずれか一つに記載の方法。
穿孔多層ポリマーフィルムを、以下の手順を用いて調製した。2つの押出機を用いて25cm幅の3層マルチマニホールドダイ(Cloeren,Inc.,Orange TXから「CLOEREN」という商標名で入手されたもの)を給送することにより、層Aと層Bとからなる2層ポリマーフィルムを調製した。そのダイでは中心ポートを封鎖して不使用にした。下方向へ垂直に押出プロセスを行い、ツーリングロール(123)及び平滑なスチールバックアップロール(124)から構成されるニップに通した。図1に模式的に示した通り、層Aがツーリングロール(123)に接触し、層Bがバックアップロール(124)に接触するように、押出プロセスを構成した。図1に概略的に図示されているように製造されたポリマー多層フィルムを、図1A及び図1Bに示す。層Aのポリマーは、3.2cmの一軸押出機を装備していた。層Bのポリマーは、5.1cmの一軸押出機を装備していた。3つの押出機の加熱ゾーン温度を、下表1に示す。
冷却ロール(125)は、エッチング又は彫刻パターンのない平滑な表面ロールであった。
バーナー(126)は、30.5センチメートル(12インチ)の8ポートバーナー、アンチハウリングデザイン(米国特許第7,635,264号(Strobelら)に記載、その開示内容は本明細書に参照により援用されている)で、Flynn Burner Corporation,New Rochelle,NYから入手されたものであった。
巻戻し張力:22Newton(総張力)
巻取り張力:22Newton(総張力)
バーナー(126(133)BTU’s(kJ)2165BTU/cm/時(2284kJ/cm/時)
1%過剰酸素
バーナー(126)とフィルム表面との間の間隙:4.4mm
ライン速度:30.5m/分
冷却ロール(125)の冷却水設定点:15.5℃
Claims (12)
- ポリマー多層フィルムの製造方法であって、
少なくとも第1及び第2のポリマー層をニップに押し出してポリマー多層フィルムを提供する工程であって、前記ニップが、前記ポリマー多層フィルムの第1の主表面を介して押痕を付与する構造化表面を有する第1のロールを含み、前記第1の層が、第1の融点を有する第1のポリマーを含み、前記第2の層が、第2の融点を有する第2のポリマーを含み、前記第1及び第2の融点間の絶対差が少なくとも20℃であり、前記ポリマー多層フィルムの前記第1の主表面が前記第1の層の主表面であり、かつ前記ポリマー多層フィルムの前記第2の主表面が前記第2の層の主表面である、工程と、
前記押痕を有する第1の主表面を冷却ロールに通すと同時に、前記ポリマー多層フィルムの、概ね対向する第2の主表面に熱源を適用する工程であって、前記熱源からの熱の適用が開口部の形成をもたらして、概ね対向する第1及び第2の主表面と、前記第1及び第2の主表面間に延在する開口部の列と、少なくとも第1及び第2の層と、を有するポリマー多層フィルムを提供し、前記第1の層が前記第1のポリマーを含み、前記第2の層が前記第2のポリマーを含み、前記ポリマー多層フィルムの前記第1の主表面が前記第1の層の主表面であり、前記ポリマー多層フィルムの前記第2の主表面が前記第2の層の主表面である、工程と、
を含む、ポリマー多層フィルムの製造方法。 - 前記第1の融点が前記第2の融点よりも高い、請求項1に記載の方法。
- 前記第2の融点が前記第1の融点よりも高い、請求項1に記載の方法。
- 前記第1のポリマーが第1のビカー温度を有し、前記第2のポリマーが第2のビカー温度を有し、前記第1及び第2のビカー温度が異なる、請求項1〜3のいずれか一項に記載の方法。
- 前記第1及び第2のガラスビカー温度が少なくとも20℃異なる、請求項4に記載の方法。
- 前記第1及び第2のガラスビカー温度が少なくとも30℃異なる、請求項4に記載の方法。
- 前記第1及び第2の融点温度の絶対差が少なくとも50℃である、請求項1〜6のいずれか一項に記載の方法。
- 前記ポリマー多層フィルムの厚さが50マイクロメートル超である、請求項1〜7のいずれか一項に記載の方法。
- 前記ポリマー多層フィルムが少なくとも30開口部/cm2を有する、請求項1〜8のいずれか一項に記載の方法。
- 前記開口部の直径が25マイクロメートル超である、請求項1〜9のいずれか一項に記載の方法。
- 前記開口部を有する前記ポリマー多層フィルムの少なくとも前記第1及び第2の層を分離する工程を更に含む、請求項1〜10のいずれか一項に記載の方法。
- 前記第1のポリマーが、ポリエチレンテレフタレート、コポリエステル、エチレンビニルアルコール、ポリアミド6、ポリアミド66、線形低密度ポリエチレン、低密度ポリエチレン、中密度ポリエチレン、高密度ポリエチレン、アクリロニトリルブタジエンスチレン、ポリカーボネート、ポリブチレンテレフタレート、ポリメチルメタアクリレート又はポリプロピレンのうちの少なくとも1つであり、前記第2のポリマーが、エチレンアクリル酸、エチレンブチルアクリレート、エチレンビニルアセテート、エチレンメチルアクリレート、プロピレン系共重合体又はエチレン系共重合体のうちの少なくとも1つである、請求項1〜11のいずれか一項に記載の方法。
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CN105813814A (zh) | 2016-07-27 |
US20170165862A1 (en) | 2017-06-15 |
KR20160098318A (ko) | 2016-08-18 |
WO2015088773A1 (en) | 2015-06-18 |
EP3079867A1 (en) | 2016-10-19 |
KR102272976B1 (ko) | 2021-07-06 |
CN105813814B (zh) | 2017-09-12 |
US9962851B2 (en) | 2018-05-08 |
JP6491211B2 (ja) | 2019-03-27 |
EP3079867B1 (en) | 2018-05-30 |
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