TWI617489B - 用於製造超音波封口之方法以及具有該封口之薄膜結構及軟容器 - Google Patents

用於製造超音波封口之方法以及具有該封口之薄膜結構及軟容器 Download PDF

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Publication number
TWI617489B
TWI617489B TW103111772A TW103111772A TWI617489B TW I617489 B TWI617489 B TW I617489B TW 103111772 A TW103111772 A TW 103111772A TW 103111772 A TW103111772 A TW 103111772A TW I617489 B TWI617489 B TW I617489B
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Taiwan
Prior art keywords
layer
sealing
newtons
multilayer film
ultrasonic
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TW103111772A
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English (en)
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TW201502013A (zh
Inventor
賽利 班薩森
約瑟夫Ｊ Ｉ 范唐
加根 塞尼
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陶氏全球科技有限責任公司
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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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • 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
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/82—Testing the joint
    • B29C65/8207—Testing the joint by mechanical methods
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/133—Fin-type joints, the parts to be joined being flexible
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/135—Single hemmed joints, i.e. one of the parts to be joined being hemmed in the joint area
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/431—Joining the articles to themselves
    • 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
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    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
    • B29C66/7311—Thermal properties
    • B29C66/73115—Melting point
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/92—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools
    • B29C66/924—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools
    • B29C66/9241—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force or the mechanical power
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/90—Measuring or controlling the joining process
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    • B29C66/929—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges
    • B29C66/9292—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges in explicit relation to another variable, e.g. pressure diagrams
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Abstract

本揭示係有關一種用以製造可超音波密封的薄膜結構及具有超音波封口的軟容器之方法。該薄膜結構包括一第一多層薄膜及一第二多層薄膜。每個多層薄膜皆包括一背托層及一密封層。每個密封層皆包括一具有下列性質之可超音波密封之以烯烴為基底的聚合物(USOP)：(a)熔化熱，△Hm，小於130焦耳/克；(b)波峰熔化溫度，Tm，低於125℃；(c)剪力儲存模數(G’)，從50MPa至500MPa；及(d)剪力損耗模數(G”)，大於10MPa。
該多層薄膜係安排成該第一多層薄膜的密封層係與該第二多層薄膜的密封層接觸。當以4牛頓/毫米的密封力進行超音波密封時，該密封層形成一具有密封強度30牛頓/15毫米至80牛頓/15毫米的超音波封口。

Description

用於製造超音波封口之方法以及具有該封口之薄膜結構及軟容器 發明領域
本揭示係有關一種用於製造可超音波密封的薄膜結構及具有超音波封口之軟容器之方法。
發明背景
與習知的熱封比較，在軟包裝中使用超音波密封提供諸如下列能力的性能優勢：(i)穿過污染物而密封，(ii)形成較窄的密封區域，及(iii)以較高的線速度及在較低的溫度環境下形成封口。合適於超音波熔接法的包裝系統包括垂直或水平式成型充填密封(form-fill-sealing)。雖然有這些利益，但超音波封口具有明顯缺點。由於在超音波錐(horn)與砧之間的接觸幾何形狀及振盪變形，超音波封口經常導致明顯的材料流出及聚合物擠出離開該密封區域。此超音波封口的“擠出”現象可造成損傷，及最後破壞在所形成的超音波封口中之積層結構。層階變化，即，在錐與砧之間之材料厚度的梯段式變化(諸如夾邊(gusset)與摺邊，及鰭狀封口截面)特別容易在經超音波式密封的情況下受損傷。在 這些區域中不合格的封口會降低密封強度(如藉由剝除測試來測量)、可能會破壞在密封區域中的積層物、並產生通道漏洩而對具有鋁薄層或諸如乙烯乙烯醇共聚物(EvOH)之阻障性聚合物薄層的包裝積層物造成阻障性質的喪失。
已提出減輕前述問題之方法，包括(i)最佳化該接觸幾何形狀，特別是導能器；及(ii)控制在封口期間之錐位移，但此二者遭遇到極限。
小心地選擇聚合物及最佳化該多層結構提供另一種減輕上述問題的途徑。因此，需要鑑別出可超音波密封及提供相當於習知熱封所達到之封口強度的聚合物及結構。對超音波密封方法所存在的進一步需求係增加超音波密封強度。對克服接觸幾何形狀最佳化或密封力位移之調整的缺點之增強型超音波封口亦存在有需求。對滿足更多方用途的軟容器需求之改良型可超音波密封的薄膜進一步存在有需求。
發明概要
本揭示係有關一種用於製造超音波封口之方法，及包含該超音波封口的薄膜結構及軟容器。除了接觸幾何形狀最佳化及密封力調整外，本方法包括根據影響在超音波密封區域中之材料流動的四個因素來選擇一用於超音波密封的聚合物。此外，該方法包括特製該薄膜組成物及結構用以進一步改良超音波密封強度。
本揭示提供一種用於製造超音波封口的方法。該 超音波封口係在二種聚合物膜間形成。該方法包括製備一多層薄膜，其具有一背托層及一密封層。該密封層包括一可超音波密封之以烯烴為基底的聚合物(USOP)。該USOP係根據下列性質選擇：(a)熔化熱，△Hm，小於130焦耳/克；(b)波峰熔化溫度，Tm，低於125℃；(c)剪力儲存模數(G’)，從50MPa至500MPa；及(d)剪力損耗模數(G”)，大於10MPa。
該方法包括讓該第一多層薄膜的密封層與該第二多層薄膜的密封層接觸以形成一密封區域。該方法包括讓該密封區域接受超音波能量。該方法包括在二個密封層間形成一超音波封口，該超音波封口具有密封強度30牛頓/毫米至80牛頓/毫米。
本揭示提供一種薄膜結構。該薄膜結構包括一第一多層薄膜及一第二多層薄膜。每個多層薄膜皆包括一背托層及一密封層。每個密封層包括一具有下列性質之可超音波密封之以烯烴為基底的聚合物(USOP)：(a)熔化熱，△Hm，小於130焦耳/克；(b)波峰熔化溫度，Tm，低於125℃；(c)剪力儲存模數(G’)，從50MPa至500MPa；及(d)剪力損耗模數(G”)，大於10MPa。
該多層薄膜係安排成該第一多層薄膜的密封層係與該第二多層薄膜的密封層接觸。當以4牛頓/毫米密封力進行超音波密封時，該密封層形成一具有密封強度30牛 頓/15毫米至80牛頓/15毫米之超音波封口。
本揭示提供一種軟容器。該軟容器包括一第一多層薄膜及一第二多層薄膜。每個多層薄膜皆包括一背托層及一密封層。該密封層包括一具有下列性質之可超音波密封之以烯烴為基底的聚合物(USOP)：(a)熔化熱，△Hm，小於130焦耳/克；(b)波峰熔化溫度，Tm，低於125℃；(c)剪力儲存模數(G’)，從50MPa至500MPa；及(d)剪力損耗模數(G”)，大於10MPa。
該多層薄膜係安排成每個多層薄膜的密封層係彼此接觸，及該第二多層薄膜係疊印在該第一多層薄膜上以形成一公用周圍邊緣。該軟容器包括一2疊區域及一4疊區域。當該等區域係以4牛頓/毫米密封力進行超音波密封時，該2疊區域及4疊區域每個形成一具有密封強度30牛頓/15毫米至80牛頓/15毫米的超音波封口。
圖1係一標繪圖，其顯示出根據本揭示的具體實例之G’對G”的繪圖。
圖2A係一根據本揭示的具體實例之圖式表示，其係一具有扁平超音波封口幾何形狀的軟容器。
圖2B係一根據本揭示的具體實例之圖式表示，其顯示出一具有扁平封口幾何形狀的超音波封口。
圖3A係一根據本揭示的具體實例之圖式表示，其係一具有2疊區域及4疊區域的軟容器。
圖3B係一根據本揭示的具體實例之圖式表示， 其顯示出一具有2疊/4疊封口幾何形狀之2疊區域及4疊區域的超音波封口。
圖4顯示出用於根據本揭示的具體實例之超音波密封薄膜結構之超音波密封強度對密封力的曲線圖。
圖5顯示出用於根據本揭示的具體實例之超音波密封薄膜結構之超音波密封強度對密封力的曲線圖。
圖6顯示出用於根據本揭示的具體實例之超音波密封薄膜結構之超音波密封強度對密封力的曲線圖。
圖7顯示出用於根據本揭示的具體實例之超音波密封薄膜結構之超音波密封強度對密封力的曲線圖。
圖8顯示出用於根據本揭示的具體實例之超音波密封薄膜結構之超音波密封強度對密封力的曲線圖。
較佳實施例之詳細說明
本揭示提供一種用於製造超音波封口的方法。該超音波封口係在二層聚合物膜間形成。該方法包括製備一多層薄膜，其具有一背托層及一密封層。該密封層包括一可超音波密封之以烯烴為基底的聚合物(USOP)。該USOP係根據下列性質選擇：(a)熔化熱，△Hm，小於130焦耳/克；(b)波峰熔化溫度，Tm，低於125℃；(c)剪力儲存模數(G’)，從50MPa至500MPa；及(d)剪力損耗模數(G”)，大於10MPa。
該方法包括讓該第一多層薄膜的密封層與該第二多層薄膜的密封層接觸以形成一密封區域。該方法包括讓該密封區域接受超音波能量。該方法包括在二層密封層間形成一超音波封口，該超音波封口具有密封強度30牛頓/毫米至80牛頓/毫米。
本方法使用一超音波密封裝置於二層聚合物膜間製造一超音波封口。該超音波密封裝置包括下列構件。
(1)一砧，於此放置欲在壓力下接觸之薄膜。該砧允許在密封區域中將高頻率振動傳至該等薄膜。該砧包括一導能器，其接觸該等薄膜之一。
(2)一超音波堆(ultrasonic stack)，包括(a)一轉換器(將電訊號轉換成機械振動)，(b)一增幅器(修改振動的振幅)及(c)一超音波錐(將該機械振動施加至欲焊接或密封的部分)。該錐亦指為超音波發生器(sonotrode)。調整該超音波堆的全部三種元件之頻率以便在相同超音波頻率下共振(典型從15kHz、20kHz、30kHz、35kHz至40kHz或70kHz)。
讓該聚合物膜接受超音波能量造成該塑膠由於吸收振動能量而局部熔化。該振動係引進穿越該欲焊接的接合點。
超音波密封係有別於並排除熱封。熱封程序包括熱金屬封顎，其係從開口位置移動至關閉位置。在關閉位置中，該熱金屬顎與該薄膜的最外層直接接觸一段時間(停留時間)、一預定的密封壓力及一預定的密封溫度。在停留 時間期間，熱透過該薄膜的最外層轉移以熔化及熔融該相對的內密封層而形成熱封口。通常來說，該最外層具有比該密封層高的熔化溫度。就此來說，雖然該密封層係熔化形成封口，但該薄膜的最外層不熔化及不黏住或實質上不黏住該封顎。可對該封顎條施加表面處理以進一步減低對薄膜之黏著性效應。在該封顎再打開後，將該薄膜冷卻至室溫。
在熱封時，該相對的薄膜經由材料互擴散於界面處連結在一起，此係藉由將熱流從封條傳導至密封界面而促進，藉此該熱封條的溫度及停留時間係關鍵的獨立變量。在半結晶聚合物密封物如例如聚乙烯的情況中，對形成強封口來說，需要將該熱封條溫度設定成至少在與該密封物完成熔化相應之溫度處。
相反地，在超音波密封時，該封條(錐與砧對)典型係在周溫下，且超音波產生及流動係相依性變量，其係由接觸幾何形狀、振盪振幅及頻率、靜止負載及材料選擇所支配。在界面處達成完全熔化所需要的超音波能量係在該聚合物內內部地產生。對所提供的頻率及接觸幾何形狀來說，該影響超音波封口形成之製程變量係掁盪的振幅及經由錐所施加的疊印密封力。促進超音波密封所需要的高溫係藉由變形能量部分消散進超音波中而內部產生，如由該聚合物的黏彈性特徵支配。所消散的能量引起溫度增加，其量大小依該系統的超音波能力而定。
在習知的超音波焊接系統中，該密封力平移該錐 掁盪的振幅以在該材料內振盪變形，及不知不覺地導致該砧逐漸穿透進該密封區域中。從該砧延伸進該密封區域中之導能器的輪廓及半球狀形狀進一步放大在該密封區域中的應力集中，進一步加重過量材料繞著該砧流動的問題。
對在線性黏彈性條件下的振盪變形來說，每單位體積的超音波產生速率(拉伸變形的每正弦週期)係顯示在方程式(I)中：Q=πfε 2E" (I)
其中f係振盪頻率；ε係變形振幅；及E”係損耗模數。
方程式(I)顯示出對所提供的變形振幅及頻率來說，超音波產生速率係與損耗模數呈線性速率，然而該振盪振幅係與第二功率具相依性。方程式(I)直接應用至超音波封口有問題，因為(i)該變形係不均勻，(ii)該材料在該密封區域中的實質量係非等溫的，及(iii)在上述方程式中的振幅ε並非該錐的振幅，而是施加至該材料之變形的振幅，其與在密封週期期間改變的密封力相依。
1.背托層及密封層
該方法包括製備一多層薄膜。該多層薄膜具有一背托層、一密封層及選擇性黏著層。合適於該背托層的材料之非限制性實施例包括聚(對酞酸乙二酯)(PET)、聚醯胺、以丙烯為基底的聚合物(諸如雙軸定向的聚丙烯或BOPP)、及金屬箔(諸如鋁箔)。
該多層薄膜的密封層包括一可超音波密封之以烯烴為基底的聚合物(USOP)。
考慮到上述方程式(I)，申請人已發展出決定一聚合物是否適合於超音波密封之參數。首先，對快速超音波化來說，根據在超音波產生速率與損耗模數間之程度，在錐掁盪開始時具有高損耗模數的聚合物係想要的。
其次，超音波產生速率在變形振幅上的平方相依性建議較低堅硬度的聚合物係想要的，因為對所提供的密封力來說，此將允許在該聚合物中實現較大的變形振幅。即使增加在錐上的密封力可提高在掁盪開始時於該聚合物中之變形振幅，最小密封力來產生超音波封口係想要的，以避免該聚合物在熔化後擠壓出。因為半結晶聚合物的模數在熔化後可降低多於二個級數大小，使用大的密封力將導致熔化物從該密封區域過量擠壓出。為了保證最小密封力有最大超音波產生，想要選擇具有低模數的聚合物，以便在密封週期中較早產生最大的振幅掁盪。在週圍條件下具有較低模數的聚合物亦在固體與熔融狀態模數間具有較小的差異，此係防止材料在熔化時過度流動的額外因素。根據前述，在變形開始時，具有高損耗模數結合低儲存模數特徵的聚合物係想要。
第三，由於黏彈性消散產生的超音波提高溫度，因此該半結晶在界面處熔化，因此允許形成強的封口。對快速超音波密封特徵來說，具有較低的超音波熔化且結合用於完成熔化的低溫之聚合物係想要的。對此聚合物來說， 對將聚合物轉換成熔化物所需要之掁盪週期可明顯地短，因此較短的循環時間。
第四，想要具有快速鬆弛時間的聚合物以防止可推出該密封區域的高應力熔化物之固化。可藉由一或多個下列因素獲得快速鬆弛時間，包括較低分子量、窄的分子量分佈及減少的或無長鏈分枝。擠出的聚合物材料小珠在剝離幾何形狀中形成初始應力區域，因此，此小珠對週圍材料的強黏附力和缺乏大的凍結應力係對高剝離強度有益的。差的黏附力或具有凍結取向之區域可在剝離測試期間對裂痕之初始及傳播提供較低阻抗的路徑。
第五，對改良可嵌縫性(caulkability)，即，密封物流入間隙中及繞著污染物之能力來說，具有低分子量的聚烯烴係想要。超音波密封不由熱黏性強度限制(如係熱封般)，因為超音波密封使用冷封工具，其允許當與該工具接觸時有效率地冷卻該封口。此冷卻部分可在振盪終止後併入該密封循環中，因此允許熱黏性強度及聚合物之固化快速積聚，比在習知的超音波密封中可行者更快。
因此，經由本超音波密封方法啟動具有可嵌縫性及包裝循環時間之組合的組成物。在其它條件相同的情況下，較低分子量的聚烯烴將比高分子量聚烯烴在超音波密封上有較好的表現。
考慮到前述原理，本方法包括選擇一可超音波密封之以烯烴為基底的聚合物用於密封層。如於本文中所使用，“可超音波密封之以烯烴為基底的聚合物”(或USOP)係 以烯烴為基底的聚合物，其當接受超音波能量時形成一封口及具有下列性質每種：(a)熔化熱，△Hm，小於130焦耳/克及藉由示差掃描卡計(DSC)測量，如描述於本文；(b)波峰熔化溫度，Tm，低於125℃及藉由(DSC)方法測量，如描述於本文；(c)在10℃下的剪力儲存模數(G’)，從50MPa至500MPa，其中G’係藉由描述於本文的動態機械熱分儀(DMTA)測量之模數的同相組分；及(d)在10℃下的剪力損耗模數(G”)，大於10MPa，其中G”係藉由描述於本文的動態機械熱分儀(DMTA)測量之模數的不同相組分。
在具體實例中，該USOP係一種以烯烴為基底的聚合物，其當接受超音波能量時形成一封口及具有下列性質每種：(a)熔化熱，△Hm，從50焦耳/克至小於130焦耳/克；(b)波峰熔化溫度，Tm，大於90℃至低於125℃；(c)在10℃下的剪力儲存模數(G’)，從50MPa至350MPa；及(d)剪力損耗模數(G”)，大於10MPa至40MPa。
在具體實例中，該可超音波密封之以烯烴為基底的聚合物係一種以丙烯為基底的塑性體或彈性體(“PBPE”)。“以丙烯為基底的塑性體或彈性體”(或“PBPE”)包含至少一 種具有至少50重量百分比來自丙烯的單元及至少約5重量百分比來自除了丙烯外的共單體之單元的共聚物。此PBPE型式的聚合物進一步描述在USP 6,960,635及6,525,157中，其以參考之方式併入本文。此PBPE可從Dow Chemical Company，以Versify之商品名；或從ExxonMobil Chemical Company，以VISTAMAXX之商品名商業購得。
在具體實例中，該PBPE具有的進一步特徵包含(A)在60至少於100重量%間，在80至99間，或在85至99間之來自丙烯的單元；及(B)在大於零至40重量%間，或在1至20、4至16間，或在4至15間之來自乙烯的單元及選擇性一或多種C4-10 α-烯烴；及包括平均至少0.001，至少0.005，或至少0.01個長鏈分枝/1000個總碳，其中用語“長鏈分枝”指為比短鏈分枝多至少一個(1)碳之鏈長度，及其中“短鏈分枝”指為比在共單體中的碳數少二個(2)碳之鏈長度。例如，丙烯/1-辛烯互聚物具有長度至少七個(7)碳的長鏈分枝之骨架，但是這些骨架亦具有長度僅六個(6)碳的短鏈分枝。在丙烯/乙烯共聚物互聚物中最大的長鏈分枝數不超過3個長鏈分枝/1000個總碳。
在具體實例中，該PBPE共聚物具有熔化溫度(Tm)從55℃至低於125℃。
合適於USOP的PBPE之非限制性實施例包括VERSIFY 2000及VERSIFY 2200，其可從Dow Chemical Company購得。
在具體實例中，該可超音波密封之以烯烴為基底 的聚合物係一種線性低密度聚乙烯。線性低密度聚乙烯(“LLDPE”)在聚合形式中包含主要重量百分比之來自乙烯的單元，以該LLDPE的總重量為基準。在具體實例中，該LLDPE係一種乙烯與至少一種乙烯化不飽和共單體的互聚物。在一個具體實例中，該共單體係一種C3-C20 α-烯烴。在另一個具體實例中，該共單體係一種C3-C8 α-烯烴。在另一個具體實例中，該C3-C8 α-烯烴係選自於丙烯、1-丁烯、1-己烯或1-辛烯。在具體實例中，該LLDPE係選自於下列共聚物：乙烯/丙烯共聚物、乙烯/丁烯共聚物、乙烯/己烯共聚物、及乙烯/辛烯共聚物。在進一步具體實例中，該LLDPE係一種乙烯/辛烯共聚物。
在具體實例中，該LLDPE具有密度在範圍0.865克/立方公分至0.940克/立方公分內，或0.90克/立方公分至0.94克/立方公分。該LLDPE具有熔化指數(MI)從0.1克/10分鐘至10克/10分鐘，或0.5克/10分鐘至5克/10分鐘。
該LLDPE可以Ziegler-Natta觸媒；或單中心觸媒，諸如釩觸媒；局限幾何構型觸媒；及金屬茂觸媒製造。在具體實例中，該LLDPE係以Ziegler-Natta型式觸媒製造。該LLDPE係線性及不包括長鏈分枝，且係與分枝或不均勻分枝的聚乙烯之低密度聚乙烯(“LDPE”)不同。LDPE具有相當大數量從主聚合物骨架延伸出的長鏈分枝。LDPE可使用自由基起始劑在高壓下製備，及其典型具有密度0.915克/立方公分至0.940克/立方公分。
在具體實例中，該LLDPE係一種經Ziegler-Natta 催化的乙烯及辛烯共聚物及具有密度0.90克/立方公分至0.93克/立方公分，或0.92克/立方公分。合適之經Ziegler-Natta催化的LLDPE之非限制性實施例有以DOWLEX之商品名出售的聚合物，其可從Dow Chemical Company，Midland，Michigan購得。
合適於USOP的LLDPE之非限制性實施例包括DOWLEX 5056G，其可從Dow Chemical Company購得。
在具體實例中，該可超音波密封之以烯烴為基底的聚合物係一種超低密度聚乙烯。超低密度聚乙烯(“ULDPE”)在聚合形式中包含主要重量百分比之來自乙烯的單元，以該ULDPE的總重量為基準。在具體實例中，該ULDPE係一種乙烯與至少一種乙烯化不飽和共單體的互聚物。在一個具體實例中，該共單體係一種C3-C20 α-烯烴。在另一個具體實例中，該共單體係一種C3-C8 α-烯烴。在另一個具體實例中，該C3-C8 α-烯烴係選自於丙烯、1-丁烯、1-己烯或1-辛烯。在具體實例中，該ULDPE係選自於下列共聚物：乙烯/丙烯共聚物、乙烯/丁烯共聚物、乙烯/己烯共聚物、及乙烯/辛烯共聚物。在進一步具體實例中，該ULDPE係一種乙烯/辛烯共聚物。
在具體實例中，該ULDPE具有密度在範圍0.900克/立方公分至0.915克/立方公分內。該ULDPE具有熔化指數(MI)從0.1克/10分鐘至10克/10分鐘，或0.5克/10分鐘至5克/10分鐘。
合適於USOP的ULDPE之非限制性實施例包括 ATTANE 4100及ATTANE SL4102，其可從Dow Chemical Company購得。
在具體實例中，該可超音波密封之以烯烴為基底的聚合物係一種聚烯烴塑性體(或POP)。合適的POP之非限制性實施例包括乙烯/辛烯塑性，體諸如AFFINITY PL 1881G，其可從Dow Chemical Company購得。
在具體實例中，該可超音波密封之以烯烴為基底 的聚合物係一種乙烯/丙烯酸共聚物(或EAA)。合適的乙烯/丙烯酸共聚物之非限制性實施例係PRIMACOR 1410，其可從Dow Chemical Company購得。
在具體實例中，該USPO係聚丁烯。
在具體實例中，該USOP係一種以丙烯為基底的三元共聚物，諸如丙烯/丁烯/乙烯三元共聚物。
該方法包括讓該第一多層薄膜的密封層接觸該第二多層薄膜的密封層以形成一密封區域。該第二多層薄膜可係一與該第一多層薄膜相同或不同的多層薄膜之一種組分。該第二多層薄膜的密封層之組成物可與該第一多層薄膜的密封層之組成物相同或不同。
在具體實例中，該第二多層薄膜具有與該第一多層薄膜相同的材料組成物及結構。
該方法進一步包括讓該密封區域接受(i)超音波能量；及(ii)2牛頓/毫米，或3牛頓/毫米，或4牛頓/毫米至5牛頓/毫米，或6牛頓/毫米之密封力，及在該密封層間形成一具有下列密封強度的超音波封口：30牛頓/15毫米，或31 牛頓/15毫米，或32牛頓/15毫米，或33牛頓/15毫米，或34牛頓/15毫米，或35牛頓/15毫米，或36牛頓/15毫米，或37牛頓/15毫米，或38牛頓/15毫米，或39牛頓/15毫米，或40牛頓/15毫米，或45牛頓/15毫米，或50牛頓/15毫米，或55牛頓/15毫米，或60牛頓/15毫米，或65牛頓/15毫米，以至70牛頓/15毫米，或75牛頓/15毫米，或80牛頓/15毫米。
超音波能量及密封力參數之非限制性實施例係提供在下列表A中。該接受步驟可包括顯示在下列表A中之參數的任何組合。
申請人發現滿足對USOP的需求之聚合物材料(性質(a)-(d))意外地能夠使用最小密封力(2-6牛頓/毫米)形成強的超音波封口(30-80牛頓/毫米)。不由特別的理論限制，咸信選擇具有前述提及的性質(a)-(d)之USOPs協同性最小化製造出合適的超音波封口所需要之密封力。最小密封力(2-6牛頓/毫米)有利地(i)減低在薄膜聚合物上的應力，(ii)減低或消除對其它薄膜層(諸如例如阻障層)的損傷，(iii)減低或消除聚合物從該密封區域“擠壓出去”，及(iv)當污染物係存在於該密封區域中時能夠形成封口。特製化性質(a)-(d)以與特定的超音波密封應用相稱，本方法有利地藉由使用 較少能量(最小化負載強度)及最小化封口缺陷來增加製造效率，其各者在軟袋之商業規模製造期間，如例如在FFS製造中係優良的。
在具體實例中，該第一多層薄膜的密封層及該第二多層薄膜的密封層係相同的材料。
在具體實例中，該多層薄膜係自身摺疊，如此相對的密封層彼此面對及形成該密封區域。在此具體實例中，該第一多層薄膜係該摺疊薄膜的第一部分，及該第二多層薄膜係該自身摺疊的摺疊薄膜之第二部分。換句話說，該第二多層薄膜係該多層薄膜之一部分，其係摺疊在上面且以與該密封層相對的關係放置。該操控係將單一多層薄膜以彼此相對的關係來放置相同密封層的部分，以例如在一成型充填密封包裝系統中發生形成一封口。
在具體實例中，於該密封區域中的薄膜部分係與超音波密封裝置的錐及砧接觸。該方法包括在形成步驟期間移動該錐一段0微米，或大於0微米，或2微米，或5微米至10微米，或15微米，或20微米的距離。在密封方法期間之錐位移可例如以雷射感應器測量。本方法以此方式有利地減低或消除在該超音波密封方法期間錐位移進該密封區域中。
在具體實例中，該背托層係聚(對酞酸乙二酯)(或PET)及該密封層係單層及包括USOP。存在於該密封層中的USOP係選自於ULDPE及POP。該方法包括讓該密封區域接受超音波能量及4牛頓/毫米至6牛頓/毫米，或4牛頓/毫米的 密封力，及形成一具有密封強度37牛頓/毫米至55牛頓/毫米的超音波封口。
在具體實例中，該背托層係BOPP及該密封層係單層及包括選自於ULDPE、PBPE及POP的USOP。該方法包括讓該密封區域接受超音波能量及3牛頓/毫米至6牛頓/毫米或4牛頓/毫米的密封力；及形成一具有密封強度55牛頓/15毫米至80牛頓/15毫米的超音波封口。
在具體實例中，該密封層包括一共擠壓結構。該共擠壓結構包括一面對層、一核心層及一內層。該背托層係積層至該共擠壓結構。此形成一具有下列層結構的多層薄膜：背托/黏著/內/核心/面對。該面對層係該接觸層。該內層係設置在該背托層與核心層間。該核心層包括一選自於ULDPE、PBPE及POP的USOP。該方法包括讓該密封區域接受超音波能量及4牛頓/毫米的密封力，及形成一具有密封強度35牛頓/毫米至55牛頓/毫米的超音波封口。
在具體實例中，該封口包括該共擠壓結構。該共擠壓結構包括面對層、核心層及內層。該核心層及選擇性該內層包括一USOP。該面對層係缺乏USOP。該方法包括形成一具有密封強度35牛頓/毫米至50牛頓/毫米的超音波封口。隨著適合的USOP選擇，本方法有利地能夠將該USOP放置在該共擠壓層之一中，其非該面對層。申請人意外地發現具有性質(a)-(d)的USOP之選擇不需要該USOP係存在於該面對層中來產生強的超音波封口(30-80牛頓/毫米)。
2.摻合物
在該第一多層薄膜及該第二多層薄膜中的任何層可係二或更多種組分之摻合物。
在具體實例中，該多層薄膜包括係該密封層的共擠壓結構。該核心層及選擇性該內層包括一低密度聚乙烯與USOP的摻合物。該面對層係缺乏LDPE。用語“低密度聚乙烯”或“LDPE”係一種在壓力鍋中或以高壓聚合方法，諸如管式高壓聚合方法製得的聚乙烯。在進一步具體實例中，該LDPE排除線性低密度聚乙烯及高密度聚乙烯。該LDPE具有熔化指數(MI)從0.2克/10分鐘，或0.5克/10分鐘至10克/10分鐘，或20克/10分鐘，或50克/10分鐘。
該LDPE具有密度0.915克/立方公分至0.925克/立方公分，或0.930克/立方公分，0.935克/立方公分，或0.940克/立方公分。
在具體實例中，該多層薄膜包括一阻障層。該阻障層係一設置在該背托層與該密封層間之內層。合適於阻障層的聚合物包括HDPE、LLDPE、LDPE、乙烯乙烯基醇共聚物(EVOH)、經馬來酸酐修改的聚乙烯、聚醯胺(PA)、環烯烴共聚物(COC)、乙烯醋酸乙烯酯(EVA)、丙烯同元聚物(PP)、及偏二氯乙烯聚合物、及其組合。
在許多商業應用中，一起使用二層可超音波密封的軟薄膜，如此該第二多層薄膜係疊印在該第一多層薄膜上，以便該第一多層薄膜的密封層係與該第二多層薄膜的密封層接觸。在其它應用中，可摺疊單一多層薄膜或單一薄片，如此相同密封層的二個表面彼此接觸。
本方法可包含二或更多個揭示於本文的具體實例。
3.薄膜結構
本方法製造出密封薄膜結構。在具體實例中，該方法製造出一薄膜結構。該薄膜結構包括一第一多層薄膜及一第二多層薄膜。每個多層薄膜皆包括一背托層及一密封層。每個密封層皆包括一具有下列性質之可超音波密封之以烯烴為基底的聚合物(USOP)：(a)熔化熱，△Hm，小於130焦耳/克；(b)波峰熔化溫度，Tm，低於125℃；(c)剪力儲存模數(G’)，從50MPa至500MPa；及(d)剪力損耗模數(G”)，大於10MPa。
該多層薄膜係安排成該第一多層薄膜的密封層係與該第二多層薄膜的密封層接觸。當以4牛頓/毫米的密封力進行超音波密封時，該密封層形成一具有密封強度30牛頓/15毫米至80牛頓/15毫米的超音波封口。
在具體實例中，當以4牛頓/毫米進行超音波密封時，該密封層形成一具有下列密封強度的超音波封口：30牛頓/15毫米，或31牛頓/15毫米，或32牛頓/15毫米，或33牛頓/15毫米，或34牛頓/15毫米，或35牛頓/15毫米，或36牛頓/15毫米，或37牛頓/15毫米，或38牛頓/15毫米，或39牛頓/15毫米，或40牛頓/15毫米，或45牛頓/15毫米，或50牛頓/15毫米，或55牛頓/15毫米，或60牛頓/15毫米，或65牛頓/15毫米，至70牛頓/15毫米，或75牛頓/15毫米，或80 牛頓/15毫米。
在具體實例中，該薄膜結構的背托層係一種選自於PET、聚醯胺、BOPP、金屬箔及其組合的材料。
在具體實例中，該薄膜結構的USOP係一種選自於PBPE、LLDPE、ULDPE、POP及其組合的材料。
在具體實例中，該多層薄膜包括一阻障層。
在具體實例中，該第一多層薄膜及該第二多層薄膜係單一軟薄片的組分。該單一軟薄片經摺疊以將該第二多層薄膜疊印在該第一多層薄膜上。
在具體實例中，該薄膜結構包括一多層薄膜，其中該背托層包括BOPP及該密封層係一包含選自於ULDPE、POP及PBPE的USOP之單層。當以4牛頓/毫米的密封力進行超音波密封時，該密封層形成一具有密封強度55牛頓/15毫米至80牛頓/15毫米的超音波封口。
在具體實例中，該薄膜結構包括一多層薄膜，其中該背托層係PET及該密封層係一包含選自於ULDPE、POP及PBPE的USOP之單層。當以4牛頓/毫米的密封力進行超音波密封時，該密封層形成一具有密封強度37牛頓/15毫米至55牛頓/15毫米的超音波封口。
在具體實例中，該薄膜結構包括一多層薄膜，其中該密封層係一種共擠壓結構，其包括一面對層、一核心層及一內層。該面對層包括一選自於ULDPE、POP及PBPE的USOP。當以4牛頓/毫米密封力進行超音波密封時，該密封層形成一具有密封強度35牛頓/15毫米至55牛頓/15毫米 的超音波封口。
在具體實例中，該薄膜結構包括一多層薄膜，其中該密封層係一種共擠壓結構，其包括一面對層、一核心層及一內層。該核心層及內層之至少一層包括一選自於ULDPE、POP及PBPE的USOP。該面對層係缺乏USOP。當以4牛頓/毫米的密封力進行超音波密封時，該密封層形成一具有密封強度35牛頓/15毫米至50牛頓/15毫米的超音波封口。
在具體實例中，該薄膜結構包括一多層薄膜，其中該第二多層薄膜係疊印在該第一多層薄膜上以形成一公用周圍邊緣。該超音波封口係沿著該公用周圍邊緣設置。
在具體實例中，該超音波封口係一硬質封口。
在具體實例中，該超音波封口係一易碎的封口。
在具體實例中，本揭示包括一包含本薄膜結構的軟容器。合適的軟容器之非限制性實施例包括小袋、囊袋、自立袋(stand-up pouch)及成型充填封口袋。
本薄膜結構可包含二或更多個揭示於本文的具體實例。
4.軟容器
本方法製造出軟容器。在具體實例中，該軟容器包括一第一多層薄膜及一第二多層薄膜。每個多層薄膜皆包括一背托層及一密封層。該密封層包括一具有下列性質之可超音波密封之以烯烴為基底的聚合物(USOP)：(a)熔化熱，△Hm，小於130焦耳/克； (b)波峰熔化溫度，Tm，低於125℃；(c)剪力儲存模數(G’)，從50MPa至500MPa；及(d)剪力損耗模數(G”)，大於10MPa。
該多層薄膜係安排成該每個多層薄膜的密封層係彼此接觸，及該第二多層薄膜係疊印在該第一多層薄膜上以形成一公用周圍邊緣。該軟容器包括一2疊區域及一4疊區域。當該等區域係以4牛頓/毫米的密封力進行超音波密封時，該2疊區域及該4疊區域每個形成一具有密封強度30牛頓/15毫米至80牛頓/15毫米的超音波封口。
在具體實例中，該2疊區域及該4疊區域係以4牛頓/毫米進行超音波密封，及形成一具有下列密封強度的超音波封口：30牛頓/15毫米，或31牛頓/15毫米，或32牛頓/15毫米，或33牛頓/15毫米，或34牛頓/15毫米，或35牛頓/15毫米，或36牛頓/15毫米，或37牛頓/15毫米，或38牛頓/15毫米，或39牛頓/15毫米，或40牛頓/15毫米，或45牛頓/15毫米，或50牛頓/15毫米，或55牛頓/15毫米，或60牛頓/15毫米，或65牛頓/15毫米，至70牛頓/15毫米，或75牛頓/15毫米，或80牛頓/15毫米。
在具體實例中，該2疊區域包括至少一部分的公用周圍邊緣。
在具體實例中，該4疊區域包括至少一部分的縱封口。
在具體實例中，該軟容器的多層薄膜包括一選自於PET及BOPP的背托層。
在具體實例中，該軟容器包括一多層薄膜，其中該密封層係一單層及包括一選自於由ULDPE、POP、PBPE及其組合所組成之群的USOP。
在具體實例中，該2疊區域係一夾邊封口。
在具體實例中，該4疊區域係一截面鰭狀封口。
合適的軟容器之非限制性實施例包括小袋、囊袋、自立袋及成型充填封口袋。
合適於由該軟容器裝承的內容物之非限制性實施例包括食品(飲料、湯、起司、穀類、點心、餅乾、馬鈴薯片)、液體、洗髮精、油類、蠟類、潤膚劑、乳液、潤膚膏、藥劑、糊膏、界面活性劑、凝膠、黏著劑、懸浮液、溶液、酵素、肥皂、化粧品、擦劑、可流動的微粒、及其組合。
本軟容器可包含二或更多個揭示於本文的具體實例。
定義
除非描述出相反的事物、從上下文隱含或在技藝中常用，否則全部的份及百分比皆以重量為基準，及全部測試方法係從現在開始至本揭示的提交期。
如於本文中所使用，用語“組成物”包括一材料的混合物，其包含該組成物和從該組成物之材料形成的反應產物及分解產物。
用語“包含”及其派生詞不想要排除任何額外的組分、步驟或程序存在，不論其是否揭示於本文。為了避 免任何懷疑，於本文中透過使用用語“包含”所主張的全部組成物可包括任何額外的添加劑、佐藥或化合物，不論是聚合物或其它，除非有描述出相反的事物。反之，用語“基本上由...組成”則從任何後繼列舉之範圍中排除任何其它組分、步驟或程序，除了對可操作性非屬基本者外外。用語“由...組成”排除未特別描述或列出的任何組分、步驟或程序。用語“或”除非另有指明，否則係指個別或呈任意組合之所列成員。
如於本文中所使用，用語“以乙烯為基底的聚合物”指為一聚合物，其呈聚合形式時包含主要量的乙烯單體(以該聚合物的重量為基準)，及選擇性可包含一或多種共單體。
如於本文中所使用，用語“以烯烴為基底的聚合物”指為一聚合物，其呈聚合形式時包含主要量的烯烴單體，例如乙烯或丙烯(以該聚合物的重量為基準)。
如於本文中所使用，用語“以丙烯為基底的聚合物”指為一聚合物，其呈聚合形式時包含主要量的丙烯單體(以該聚合物的重量為基準)，及選擇性可包含一或多種共單體。
如於本文中所使用，用語“丙烯/乙烯共聚物”指為一聚合物，其呈聚合形式時包含主要量的丙烯單體(以該聚合物的重量為基準)，及少數量的乙烯共單體及選擇性可包含一或多種額外的共單體。
測試方法
密度係根據ASTM D792測量。
DMTA(動態機械熱分儀)
樣品係在185℃下從顆粒壓模成型，及以10±5℃/分鐘之平均冷卻速率固化。從經模塑的薄片切出矩形樣品用於測量。在溫度從-100℃至接近樣品完全熔化的溫度之範圍內，使用TA Instruments的旋轉流變計ARES進行扭轉式動態機械測量。溫度以5℃的步階提高，其中每步階的熱煉時間係120秒。以10弧度/秒的頻率對30毫米長、12.7毫米寬及2.8毫米厚的矩形樣品施加0.1%的動態振盪變形。使用所測量的扭力來計算儲存及損耗剪切模數，G’及G”，如為溫度的函數。
示差掃描卡計(DSC)
使用示差掃描卡計(DSC)來測量聚合物(例如，以乙烯為基底的(PE)聚合物)的熔化及結晶行為。首先，在約175℃下將該樣品熔化加壓成薄膜，然後冷卻至室溫。以模衝機切割出約5至8毫克的聚合物薄膜樣品，稱重及將其放入DSC平底鍋中。對在平底鍋上蓋子捲邊以保證密閉環境。將該樣品平底鍋放進充入氮氣之經校正的DSC槽中，然後對PE來說，以大約10℃/分鐘之速率加熱至溫度180℃。將該樣品保持在此溫度下三分鐘。然後，以10℃/分鐘之速率將該樣品冷卻至-40℃，記錄結晶蹤跡，及在此溫度下保持等溫三分鐘。其次，以10℃/分鐘之速率再加熱該樣品直到完全熔化，及使用所產生的第二熔化蹤跡來計算熔化熱及熔化溫度。結晶性百分比係藉由將從第二加熱曲線所測量 的熔化熱(Hm)除以理論熔化熱對PE來說係292焦耳/克(165焦耳/克，對PP來說)，及將此量乘以100來計算(例如，結晶%=(Hm/292焦耳/克)x100(對PE來說))。
除非其它方面有描述，否則波峰熔點(Tm)係從第二加熱曲線測量及與在吸熱時的最高波峰溫度相應。該結晶溫度(Tc)係從冷卻曲線(波峰Tc)測定。
熔融流動率或MFR係根據ASTM D 1238，條件230℃/2.16公斤測量。
熔化指數或MI係根據ASTM D 1238，條件190℃/2.16公斤測量。
密封強度
使用100毫米寬的樣品，藉由將密封條排列在該構成吹膜的交叉方向上來進行密封。切割出三個15毫米寬的樣品用於密封強度測量。重覆該程序三次以獲得總共九個用於密封強度測試的樣品。該密封強度係根據DIN 55529測量。對50毫米長以T型剝離幾何形狀負載的臂桿來說，拖拉速率係100毫米/分鐘。密封強度係從該力量拉伸曲線的最大值決定。所報導的值係九個樣品的密封強度之平均及標準偏差。
現在，將在下列實施例中詳細地描述本揭示的某些具體實例。
實施例
1.材料
用於發明實施例及比較性樣品的材料係提供在 下列表1中。
圖1顯示出數種USOPs包括表1的USOPs之G’對G” 的標繪圖。
實施例1
該密封層可係一藉由吹膜擠出(blown film extrusion)形成的單層結構或共擠壓結構。
1.單層吹膜係在具有45毫米(28L/D)擠壓器及150毫米直徑模具的Covex吹膜線上製備。對LLDPE及乙烯共聚物來說，該模具間隙係1.5毫米；對LDPE來說，1.0毫米；及對丙烯共聚物來說，2.0毫米。50微米標準規格的薄膜係使用吹開比(blow-up ratio)2.5在22.5公斤/小時下製造。熔化溫度係220℃。該薄膜係經電暈處理用於44達因表面張力。
2.共擠壓的多層吹膜係在特徵為二個50毫米表皮擠壓器(30L/D)及一個65毫米核心層擠壓器(30L/D)及200毫米直徑裝備有膜泡內冷卻(internal bubble cooling)的模具之Alpine線上製備。該模具間隙係2.5毫米。50微米標準規格的薄膜係以115公斤/小時之總輸出速率，對三層結構使用1：3：1的標稱厚度比率製造。該吹開比係2.5及該熔化溫度係約230℃。該薄膜係在密封物的側邊上經電暈處理用於44達因表面張力。
多層薄膜係藉由將一背托層(12微米PET層或20微米BOPP層)積層到50微米密封層(單層結構或共擠壓結構任一種)上製造。該背托層係使用黏著層積層至該密封層。該積層物係經烘箱硬化以完全硬化該黏著劑及形成該可超音波密封的軟薄膜結構。當該密封層係該共擠壓結構時，該多層薄膜具有下列層組態：背托(12或20)/黏著/內(10)/核 心(30)/面對(10)，其中在圓括號中係厚度，微米)。
該多層薄膜係在提供於下列表2中之條件下超音波封口。
表2提供使用來評估該多層薄膜的超音波密封條件。
將相對的多層薄膜之密封層放置成彼此接觸及接受在上述表2中的超音波密封條件。
圖2A係一以如在圖2B中圖式表示的扁平封口幾何形狀來製造之超音波封口的示意圖。
圖3A係一以如在圖3B中圖式表示的2疊/4疊封口幾何形狀製造之2疊區域及4疊區域的超音波封口的示意圖。
下列表3提供本發明的超音波熱封及比較性樣品之性質。
討論
圖4-6顯示出具有單層密封層及PET背托層或BOPP背托層之多層薄膜的超音波密封強度(USS)對密封力曲線。
圖7顯示出單層密封層及共擠壓密封層之USS對密封力。在實施例6中的單層封口係與在實施例16中的面對層(AFFINITY 1881G)相同。在實施例5中的單層封口係與在實施例17中的面對層(ATTANE 4102)相同。在實施例8中的單層係與在實施例18中的面對層(VERSIFY 2200)相同。
圖8顯示出以2疊/4疊封口幾何形狀製得的超音波封口之USS對密封力曲線。
A.申請人發現USOP存在於：(i)單層密封層，(ii)共擠壓密封層的面對層，或(iii)共擠壓密封層的核心及/或內層中及缺乏面對層，及密封力產生具有密封強度35-55牛頓/毫米的超音波封口。換句話說，該USOP不需要在面對層中來促成強超音波封口之製造。
B.申請人發現當在該密封層中的USOP係對該背托層特製時，該背托層協同地促成補強的USS。當該背托層係BOPP時，4-6牛頓/毫米，或4牛頓/毫米的密封力製造出具有密封強度55牛頓/毫米至80牛頓/毫米的超音波封口。隨著適合地選擇該背托層及USOP，該層促成密封強度之改善。
C.申請人發現在具有2疊區域及4疊區域及以4牛頓/毫米的密封力超音波封口之軟薄膜容器中使用USOP具 有USS大於相同已經熱封的2疊/4疊封口之0.8(USS：PHSS比率大於0.8)。
特別想要本揭示不受限於包含於本文的具體實例及闡明，而是包括那些具體實例的修改形式，包括該等具體實例的部分及不同具體實的元件之組合，例如來自下列申請專利範圍之範圍內。

Claims (18)

  1. 一種用以製造超音波聚合物封口的方法，其包括：製備一包含背托層及密封層的多層薄膜，該密封層包含一具有下列性質之可超音波密封之以烯烴為基底的聚合物(USOP)：(a)熔化熱，△Hm，小於130焦耳/克；(b)波峰熔化溫度，Tm，低於125℃；(c)剪力儲存模數(G’)，從50MPa至500MPa；及(d)剪力損耗模數(G”)，大於10MPa；讓該多層薄膜的密封層與該第二多層薄膜的密封層接觸以形成一密封區域；讓該密封區域接受(i)超音波能量及(ii)2牛頓/毫米至6牛頓/毫米的密封力；及形成一具有密封強度30牛頓/15毫米至80牛頓/15毫米的超音波封口。
  2. 如請求項1之方法，其包括將該密封區域放置在一超音波密封裝置的錐與砧之間；及讓該密封區域接受(i)超音波能量及(ii)4牛頓/毫米的密封力。
  3. 一種薄膜結構，其包含：一第一多層薄膜及一第二多層薄膜，每個多層薄膜皆包含一為連續薄膜層之背托層及一密封層，每個密封層皆包含一具有下列性質之可超音波密封之以烯烴為基底的聚合物(USOP)：(a)熔化熱，△Hm，小於130焦耳/克；(b)波峰熔化溫度，Tm，低於125℃；(c)剪力儲存模數(G’)，從50MPa至500MPa；及(d)剪力損耗模數(G”)，大於10MPa；該多層薄膜係安排成該第一多層薄膜的密封層係與該第二多層薄膜的密封層接觸；及當以4牛頓/毫米的密封力進行超音波密封時，該密封層形成一具有密封強度30牛頓/15毫米至80牛頓/15毫米的超音波封口。
  4. 如請求項3之薄膜結構，其中該背托層係一種選自於由PET、聚醯胺、BOPP及金屬箔所組成之群的材料。
  5. 如請求項3或4之薄膜結構，其中該USOP係一種選自於由PBPE、LLDPE、ULDPE、POP及其組合所組成之群的材料。
  6. 如請求項3或4之薄膜結構，其中每個多層薄膜皆包含一阻障層。
  7. 如請求項3或4之薄膜結構，其中該第一多層薄膜及該第二多層薄膜係單一軟薄片的組分，該單一軟薄片經摺疊以將該第二多層薄膜疊印在該第一多層薄膜上。
  8. 如請求項3或4之薄膜結構，其中該背托層包含BOPP，及該密封層係一包含選自於由ULDPE、POP及PBPE所組成之群的USOP之單層，及當以4牛頓/毫米的密封力進行超音波密封時，該密封層形成一具有密封強度55牛頓/15毫米至80牛頓/15毫米的超音波封口。
  9. 如請求項3或4之薄膜結構，其中該背托層係PET及該密封層係一包含選自於由ULDPE、POP及PBPE所組成之群的USOP之單層，及當以4牛頓/毫米的密封力進行超音波密封時，該密封層形成一具有密封強度37牛頓/15毫米至55牛頓/15毫米的超音波封口。
  10. 如請求項3或4之薄膜結構，其中該密封層係一包含面對層、核心層及內層的共擠壓結構；該面對層包含一選自於由ULDPE、POP及PBPE所組成之群的USOP；及當以4牛頓/毫米的密封力進行超音波密封時，該密封層形成一具有密封強度35牛頓/15毫米至55牛頓/15毫米的超音波封口。
  11. 如請求項3或4之薄膜結構，其中該密封層係一包含面對層、核心層及內層的共擠壓結構；該核心層及內層之至少一層包含一選自於由ULDPE、POP及PBPE所組成之群的USOP；該面對層係缺乏USOP；及當以4牛頓/毫米的密封力進行超音波密封時，該密封層形成一具有密封強度35牛頓/15毫米至50牛頓/15毫米的超音波封口。
  12. 如請求項3或4之薄膜結構，其中該第二多層薄膜係疊印在該第一多層薄膜上以形成一公用周圍邊緣；及該超音波封口係沿著該公用周圍邊緣設置。
  13. 一種軟容器，其包含如請求項3-12之任何的薄膜結構。
  14. 一種軟容器，其包含：一第一多層薄膜及一第二多層薄膜，每個多層薄膜皆包含一為連續薄膜層之背托層及一密封層，該密封層包含一具有下列性質之可超音波封口之以烯烴為基底的聚合物(USOP)：(a)熔化熱，△Hm，小於130焦耳/克；(b)波峰熔化溫度，Tm，低於125℃；(c)剪力儲存模數(G’)，從50MPa至500MPa；及(d)剪力損耗模數(G”)，大於10MPa；其中該多層薄膜係安排成該每個多層薄膜的密封層係彼此接觸，及該第二多層薄膜係疊印在該第一多層薄膜上以形成一公用周圍邊緣；一2疊區域及一4疊區域；及當該等區域係以4牛頓/毫米的密封力超音波密封時，該2疊區域及該4疊區域各者形成一具有密封強度30牛頓/15毫米至80牛頓/15毫米的超音波封口。
  15. 如請求項14之軟容器，其中該2疊區域包含該公用周圍邊緣的至少一部分。
  16. 如請求項14或15之軟容器，其中該4疊區域包含一縱封口的至少一部分。
  17. 如請求項14或15之軟容器，其中該背托層係選自於由PET及BOPP所組成之群。
  18. 如請求項14或15之軟容器，其中該密封層係一單層及包含一選自於由ULDPE、POP、PBPE及其組合所組成之群的USOP。
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WO2014169005A1 (en) 2014-10-16
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JP2016525464A (ja) 2016-08-25
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