WO2009087659A2 - A multi-layer flexible sheet and method thereof - Google Patents

A multi-layer flexible sheet and method thereof Download PDF

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Publication number
WO2009087659A2
WO2009087659A2 PCT/IN2008/000758 IN2008000758W WO2009087659A2 WO 2009087659 A2 WO2009087659 A2 WO 2009087659A2 IN 2008000758 W IN2008000758 W IN 2008000758W WO 2009087659 A2 WO2009087659 A2 WO 2009087659A2
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WO
WIPO (PCT)
Prior art keywords
layer
polymer
flexible sheet
core
sheet
Prior art date
Application number
PCT/IN2008/000758
Other languages
French (fr)
Other versions
WO2009087659A8 (en
WO2009087659A3 (en
Inventor
Mrinal Kanti Banerjee
Original Assignee
Essel Propack Ltd.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Essel Propack Ltd. filed Critical Essel Propack Ltd.
Priority to US12/741,713 priority Critical patent/US9186872B2/en
Priority to CN200880114880.8A priority patent/CN101848812B/en
Priority to GB201009359A priority patent/GB2467696B/en
Publication of WO2009087659A2 publication Critical patent/WO2009087659A2/en
Publication of WO2009087659A3 publication Critical patent/WO2009087659A3/en
Publication of WO2009087659A8 publication Critical patent/WO2009087659A8/en

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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
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/16—Layered products comprising a layer of synthetic resin specially treated, e.g. irradiated
    • 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
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/306—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl acetate or vinyl alcohol (co)polymers
    • 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
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • 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
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B32B27/327—Layered products comprising a layer of synthetic resin comprising polyolefins comprising polyolefins obtained by a metallocene or single-site catalyst
    • 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
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
    • 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
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • 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
    • B32B15/082—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 comprising vinyl resins; comprising acrylic resins
    • 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
    • B32B15/095—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 comprising polyurethanes
    • 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
    • B32B2038/0092—Metallizing
    • 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
    • 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
    • B32B2255/00—Coating on the layer surface
    • B32B2255/20—Inorganic coating
    • B32B2255/205—Metallic coating
    • 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
    • B32B2255/26—Polymeric coating
    • 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
    • B32B2255/28—Multiple coating on one surface
    • 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
    • B32B2274/00—Thermoplastic elastomer material
    • 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
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/31—Heat sealable
    • 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
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/406—Bright, glossy, shiny surface
    • 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
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/514—Oriented
    • B32B2307/518—Oriented bi-axially
    • 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
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/546—Flexural strength; Flexion stiffness
    • 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
    • B32B2307/75—Printability
    • 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
    • B32B2310/14—Corona, ionisation, electrical discharge, plasma treatment
    • 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
    • B32B2439/40—Closed containers
    • 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
    • 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
    • B32B2597/00—Tubular articles, e.g. hoses, pipes
    • 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
    • B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
    • 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
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/15—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
    • 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
    • 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
    • B32B38/0008—Electrical discharge treatment, e.g. corona, plasma treatment; wave energy or particle 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/14—Printing or colouring
    • B32B38/145—Printing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31678—Of metal
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31678—Of metal
    • Y10T428/31681—Next to polyester, polyamide or polyimide [e.g., alkyd, glue, or nylon, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31678—Of metal
    • Y10T428/31692—Next to addition polymer from unsaturated monomers

Definitions

  • the present invention generally relates to multi layer flexible sheet to be used for containers, tubes etc. for packaging and dispensing paste, Gel and Cream type products.
  • Metal foils have long been used for manufacturing containers and tubes for packaging and dispensing various products, including paste, Gel and Cream type products. Such containers and tubes have frequently been made from a single foil layer. However, containers and tubes made from metal foil have had several disadvantages compared to containers made of plastic. Metal tubes tend to dent and deform more readily, crack with a moderate amount of flexure, often react with the filled product and they are more expensive. More recently, a large share of the tube market has been taken by flexible sheet structure materials having a multiplicity of polymeric layers. Typically, such tubes have an inner heat sealable layer, an outer heat sealable layer, and a barrier layer interposed therebetween. Additional layers may be used in conventional structures to provide other properties or qualities.
  • Layers of a non-polymeric nature such as paper and thin metal foils, may also be included in these sheet materials to provide specialized performance functions. It is known, for example, to provide a layer of thin aluminum foil as a high quality barrier layer and luster. When foil is used, it is common practice to use a highly adherent polymer to adhere the foil to its adjacent layers. However, Aluminum foil layer is considered as foreign material in the plastic multilayer and therefore not eco-friendly.
  • metalized such as film base laminate Polyester, Polypropylene, polyamide, polyethylene consists of usage of pre-metalized polyester or polypropylene film and, sandwiching and laminating metalized film with inner and outer thermoplastic film such as low density polyethylene, linear low density polyethylene, co-polymer of ethylene.
  • these metalized film base laminate gets delaminated at metal and film interface thereby having problems in stability.
  • the present invention provides a method for manufacturing a multi-layer flexible sheet comprising steps of metalizing atleast one of the surfaces of a core polymer layer; priming the metalized surface of the core polymer layer with a primer; extrusion laminating the primed surface of the core polymer layer with polyolefin and/or co-polymer of polyolefin; and co-extruding first heat sealable layer over the extrusion laminated layer.
  • the method also include a step of plasma treating atleast the core polymer layer prior to metalizing the plasma treated layer of the core polymer layer.
  • the method includes further step of priming of non- metalized of the core layer of the multi layer sheet and extrusion coating the said primed surface with a second heat sealable layer after the co-extruding first heat sealable layer; or priming atleast one of the polymer side of the core layer of the multilayer sheet and extrusion coating with a second heat sealable layer prior to or after metalizing the core polymer layer.
  • the present invention provides multilayer flexible sheet comprising a core layer having one of the polymer sides plasma treated, a metal layer deposited on the plasma treated side of the core layer, a primer layer applied on the metalized surface of the core layer, an extrusion polymer lamination layer of polyolefin and/or co-polymer of polyolefin and a heat sealable layer on the extrusion polymer lamination layer.
  • the multilayer flexible sheet of present invention also comprises a second heat sealable layer coextruded on the polymer side of the core polymer layer along with a primer and extrusion layer.
  • the second heat sealable layer is a high clarity polymer selected from a group of metallocene linear low density polyethylene, blend of linear low density polyethylene and low density polyethylene, blend of metallocene low density polyethylene and low density polyethylene etc. which increases glossiness thereby increasing lustrous effect of the sheet.
  • the primer in combination with the extrusion polymer lamination layer forms a tight bonding between the metalized surface of the core layer and the heat sealable layer.
  • Fig. 1 is a cross sectional view of a multilayer sheet structure of a preferred embodiment of the present invention
  • Fig 2 is a flow chart of one of the preferred methods of manufacturing of a multilayer sheet structure of the present invention.
  • the present invention provides a method for manufacturing a multilayer flexible sheet and a multilayer flexible sheet.
  • the method for manufacturing a multilayer sheet comprises steps of metalizing atleast one of the surfaces of a core polymer layer; priming the metalized surface of the core polymer layer with a primer; extrusion laminating the primed surface of the core polymer layer with polyolefin and/or co-polymer of polyolefin; and co-extruding first heat sealable layer over the extrusion laminated layer.
  • the method of the present invention may comprise further steps of priming of non- metalized or polymer side of the core layer of the multilayer sheet and extrusion coating with an outer layer.
  • the method may comprise priming non-metalized or polymer side of the core layer of the multilayer sheet and extrusion coating with an outer layer before the priming of the metalized layer of the core layer.
  • a multilayer polymer sheet of the present invention atleast comprises a core layer having one of the polymer sides plasma treated, a metal layer deposited on the plasma treated side of the core layer, a primer layer applied on the metalized surface of the core layer, an extrusion polymer lamination layer of polyolefin and/or co-polymer of polyolefin and a heat sealable layer on the extrusion polymer lamination layer
  • Fig 1 which shows the multilayer flexible sheet (100) according to the present invention, comprising an heat sealable layer (H), a core layer (A) having one surface side bonded with the heat sealable layer (H) with an extrusion layer (G) and a primer (F), a metalized layer (B) on another surface side of the core polymer layer, a primer layer (C) on the metalized surface, an extruded polymer lamination layer (D) of polyolefin and/or co-polymer of polyolefin, and a heat sealable layer (E).
  • Fig. 2 shows a flow chart of a method for manufacturing the multi layer sheet according to preferred embodiment of the present invention.
  • the method is carried out on a system (200) which is a rearrangement of conventionally known system which generally comprises un-winders (210) and winder (230), plasma treating system and vacuum metalizer (220), Extrusion coating and laminating units (240) with inline electronic and priming units (250), multi slitter (not shown), surface and/or reverse printing press (not shown).
  • a core polymer layer (A) is un-winded from a un-winder.
  • one of the sides of the core polymer layer (A) is plasma treated and then subjected to metallization to form a metallic layer (B) on the plasma treated side of the core polymer layer while a primer layer (F) is applied on the other side of the core polymer layer (H) (herein after referred to as outer layer).
  • a second heat sealable layer (A) is un-winded and extruded with the polymer side layer of the core polymer layer on the primer (F).
  • a primer (C) is then applied on the metalized layer (B) and then extruded with polyolefin or co-polymer of polyolefin (D) which is then further coextruded with the first heat sealable layer (E) (herein after referred to as inner layer).
  • first heat sealable layer (herein after referred to as inner layer).
  • priming of non- metalized of the core layer of the multi layer sheet and extrusion coating the said primed surface with outer layer can be done after the co-extruding inner layer or before metallization of the core layer.
  • the method may comprise step of printing of outer layer before extrusion laminated over the polymer side of the core member.
  • the core polymer layer of the multi layer sheet comprises at least three layers of polymer sheet selected from the group which includes Polyester, Biaxially oriented Polypropylene, Cast Polypropylene, High Density Polyethylene, Ethylene vinyl alcohol, Polyamide, and skin layers of grafted co-polymer of ethylene, random co-polymer of propylene or thermoplastic elastomers made of either chemical coating or co- extrusion coating.
  • polymer sheet selected from the group which includes Polyester, Biaxially oriented Polypropylene, Cast Polypropylene, High Density Polyethylene, Ethylene vinyl alcohol, Polyamide, and skin layers of grafted co-polymer of ethylene, random co-polymer of propylene or thermoplastic elastomers made of either chemical coating or co- extrusion coating.
  • the second heat sealable layer is a high clarity polymer selected from a group of metallocene linear low density polyethylene, blend of linear low density polyethylene and low density polyethylene, blend of metallocene low density polyethylene and low density polyethylene etc which increases glossiness thereby luster of the sheet.
  • the metal is deposited on the core polymer by a well know vacuum deposition method layer to an optical density of about ranging from 1.5 to 2.8.
  • metal to be deposited is selected from a group including Aluminum, alloys of Aluminum, Copper, Silver, Gold and preferable metal for deposition according to the present invention is Aluminum.
  • the primer used for the both side of the core layer may be same or different.
  • the primer in combination with the extruded polyolefin or copolymer of polyolefin forms a tight bonding between the metalized surface of the core layer and the inner layer.
  • the primer is selected from a group which includes two component polyurethane, partially crossed linked acrylic co-polymers and the like.
  • Preferable primer to achieve tight bonding according to the present invention is two component polyurethane.
  • the inner layer and the outer layer of the multilayer are multilayered thermo-plastic film made up of at least 3 layers of the thermoplastic film and minimum thickness of about 25 micron.
  • the inner layer comprises 5-9 layers of co- extruded barrier thermoplastic film.
  • the outer layer comprises 3-5 layers of thermoplastic film.
  • interlayer bond strength of the inner layer and outer layer is equal to or more than 0.3 kg per 15 mm laminate strip.
  • the multi-layer flexible sheet of the present invention is about 100-500 micron thick and has surface gloss more than 250 at an angle of 20° measured by Gloss meter conforming to ASTM D-523.
  • the multi-layer flexible sheet of the present invention has surface gloss more than 500 at an angle of 20° measured by Gloss meter conforming to ASTM D-523. Therefore the tubes made from the sheets of the present invention have more lustrous look than presently available tubes made of the metal foils.
  • Example 1 illustrates the process of the invention in greater details, but, does not limit the present invention in any manner to the specific embodiments as presented therein:
  • a multilayer flexible sheet was prepared by plasma treating one of the sides of the core polyester and vacuum metalized the plasma treated side.
  • the primer 'two component polyurethane' was applied on the metalized layer and polyolefin was extrusion laminated over the primer and then inner heat sealable layer of Polyethylene was coextruded over the polyolefin layer.
  • the polymer side of the core polyester was also coextruded along with primer and extrusion.
  • the gloss value was measured from the polymer side of the core layer i.e. from the outer layer at an angle of 20° measured by Gloss meter conforming to ASTM D-523.
  • the details of the multilayer sheet are given as below:

Abstract

The present invention provides a method for manufacturing a multilayer flexible sheet and a multilayer flexible sheet. The method for manufacturing a multilayer sheet comprises steps of metalizing atleast one of the surfaces of a core polymer layer; priming the metalized surface of the core polymer layer with a primer; extrusion laminating the primed surface of the core polymer layer with polyolefin and/or co-polymer of polyolefin; and co-extruding first heat sealable layer over the extrusion laminated layer. The multilayer polymer sheet of the present invention atleast comprises a core layer having one of the polymer sides plasma treated, a metal layer deposited on the plasma treated side of the core layer, a primer layer applied on the metalized surface of the core layer, an extrusion polymer lamination layer of poiyolefin and/or co¬ polymer of polyolefin and a heat sealable layer on the extrusion polymer lamination layer.

Description

A MULTI-LAYER FLEXIBLE SHEET AND METHOD THEREOF
TECHNICAL FIELD OF THE INVENTION:
The present invention generally relates to multi layer flexible sheet to be used for containers, tubes etc. for packaging and dispensing paste, Gel and Cream type products.
BACKGROUND OF THE INVENTION:
Metal foils have long been used for manufacturing containers and tubes for packaging and dispensing various products, including paste, Gel and Cream type products. Such containers and tubes have frequently been made from a single foil layer. However, containers and tubes made from metal foil have had several disadvantages compared to containers made of plastic. Metal tubes tend to dent and deform more readily, crack with a moderate amount of flexure, often react with the filled product and they are more expensive. More recently, a large share of the tube market has been taken by flexible sheet structure materials having a multiplicity of polymeric layers. Typically, such tubes have an inner heat sealable layer, an outer heat sealable layer, and a barrier layer interposed therebetween. Additional layers may be used in conventional structures to provide other properties or qualities. Layers of a non-polymeric nature, such as paper and thin metal foils, may also be included in these sheet materials to provide specialized performance functions. It is known, for example, to provide a layer of thin aluminum foil as a high quality barrier layer and luster. When foil is used, it is common practice to use a highly adherent polymer to adhere the foil to its adjacent layers. However, Aluminum foil layer is considered as foreign material in the plastic multilayer and therefore not eco-friendly. On the other hand, commonly available metalized such as film base laminate Polyester, Polypropylene, polyamide, polyethylene consists of usage of pre-metalized polyester or polypropylene film and, sandwiching and laminating metalized film with inner and outer thermoplastic film such as low density polyethylene, linear low density polyethylene, co-polymer of ethylene. However, these metalized film base laminate gets delaminated at metal and film interface thereby having problems in stability.
Also, today, surface gloss or luster effect plays an important role in marketing the product. However, tubes find in the market are not more lustrous as surface gloss of these presently available multi-layer metal sheets used for tubes for packaging and dispensing the product is less than about 250 at an angle of 20° measured by Gloss meter and conforming to ASTM D-523.
SUMMARY OF THE INVENTION:
It is an object of the present invention to provide a multi layer flexible sheet to be used for containers, tubes etc. for packaging and dispensing paste type products solving atleast one of the above mentioned problems. It is further object of the invention to provide a method for producing the same. In one embodiment, the present invention provides a method for manufacturing a multi-layer flexible sheet comprising steps of metalizing atleast one of the surfaces of a core polymer layer; priming the metalized surface of the core polymer layer with a primer; extrusion laminating the primed surface of the core polymer layer with polyolefin and/or co-polymer of polyolefin; and co-extruding first heat sealable layer over the extrusion laminated layer. According o the present invention the method also include a step of plasma treating atleast the core polymer layer prior to metalizing the plasma treated layer of the core polymer layer.
The method includes further step of priming of non- metalized of the core layer of the multi layer sheet and extrusion coating the said primed surface with a second heat sealable layer after the co-extruding first heat sealable layer; or priming atleast one of the polymer side of the core layer of the multilayer sheet and extrusion coating with a second heat sealable layer prior to or after metalizing the core polymer layer.
In another embodiment, the present invention provides multilayer flexible sheet comprising a core layer having one of the polymer sides plasma treated, a metal layer deposited on the plasma treated side of the core layer, a primer layer applied on the metalized surface of the core layer, an extrusion polymer lamination layer of polyolefin and/or co-polymer of polyolefin and a heat sealable layer on the extrusion polymer lamination layer. The multilayer flexible sheet of present invention also comprises a second heat sealable layer coextruded on the polymer side of the core polymer layer along with a primer and extrusion layer.
According to the present invention, the second heat sealable layer is a high clarity polymer selected from a group of metallocene linear low density polyethylene, blend of linear low density polyethylene and low density polyethylene, blend of metallocene low density polyethylene and low density polyethylene etc. which increases glossiness thereby increasing lustrous effect of the sheet. According to the present invention the primer in combination with the extrusion polymer lamination layer forms a tight bonding between the metalized surface of the core layer and the heat sealable layer.
BRIEF DESCRPTION OF THE DRAWINGS:
The accompanying figures together with the detailed description below are incorporated in and form part of the specification serve further illustrate various embodiments and to explain various principles and advantages all in accordance with the present invention:
Fig. 1 is a cross sectional view of a multilayer sheet structure of a preferred embodiment of the present invention;
Fig 2 is a flow chart of one of the preferred methods of manufacturing of a multilayer sheet structure of the present invention.
DETAILED DESCRPTION OF THE INVENTION
In general, the present invention provides a method for manufacturing a multilayer flexible sheet and a multilayer flexible sheet.
The method for manufacturing a multilayer sheet comprises steps of metalizing atleast one of the surfaces of a core polymer layer; priming the metalized surface of the core polymer layer with a primer; extrusion laminating the primed surface of the core polymer layer with polyolefin and/or co-polymer of polyolefin; and co-extruding first heat sealable layer over the extrusion laminated layer.
The method of the present invention may comprise further steps of priming of non- metalized or polymer side of the core layer of the multilayer sheet and extrusion coating with an outer layer. Alternatively the method may comprise priming non-metalized or polymer side of the core layer of the multilayer sheet and extrusion coating with an outer layer before the priming of the metalized layer of the core layer.
In general, a multilayer polymer sheet of the present invention atleast comprises a core layer having one of the polymer sides plasma treated, a metal layer deposited on the plasma treated side of the core layer, a primer layer applied on the metalized surface of the core layer, an extrusion polymer lamination layer of polyolefin and/or co-polymer of polyolefin and a heat sealable layer on the extrusion polymer lamination layer Referring to Fig 1 which shows the multilayer flexible sheet (100) according to the present invention, comprising an heat sealable layer (H), a core layer (A) having one surface side bonded with the heat sealable layer (H) with an extrusion layer (G) and a primer (F), a metalized layer (B) on another surface side of the core polymer layer, a primer layer (C) on the metalized surface, an extruded polymer lamination layer (D) of polyolefin and/or co-polymer of polyolefin, and a heat sealable layer (E).
Fig. 2 shows a flow chart of a method for manufacturing the multi layer sheet according to preferred embodiment of the present invention. The method is carried out on a system (200) which is a rearrangement of conventionally known system which generally comprises un-winders (210) and winder (230), plasma treating system and vacuum metalizer (220), Extrusion coating and laminating units (240) with inline electronic and priming units (250), multi slitter (not shown), surface and/or reverse printing press (not shown). As shown in Figure 2, a core polymer layer (A) is un-winded from a un-winder. According to the present invention one of the sides of the core polymer layer (A) is plasma treated and then subjected to metallization to form a metallic layer (B) on the plasma treated side of the core polymer layer while a primer layer (F) is applied on the other side of the core polymer layer (H) (herein after referred to as outer layer). Simultaneously, a second heat sealable layer (A) is un-winded and extruded with the polymer side layer of the core polymer layer on the primer (F). As shown in Figure 2, a primer (C) is then applied on the metalized layer (B) and then extruded with polyolefin or co-polymer of polyolefin (D) which is then further coextruded with the first heat sealable layer (E) (herein after referred to as inner layer). Alternatively, priming of non- metalized of the core layer of the multi layer sheet and extrusion coating the said primed surface with outer layer can be done after the co-extruding inner layer or before metallization of the core layer.
According to an embodiment of the invention, the method may comprise step of printing of outer layer before extrusion laminated over the polymer side of the core member.
According to the present invention, the core polymer layer of the multi layer sheet comprises at least three layers of polymer sheet selected from the group which includes Polyester, Biaxially oriented Polypropylene, Cast Polypropylene, High Density Polyethylene, Ethylene vinyl alcohol, Polyamide, and skin layers of grafted co-polymer of ethylene, random co-polymer of propylene or thermoplastic elastomers made of either chemical coating or co- extrusion coating.
According to the present invention, the second heat sealable layer is a high clarity polymer selected from a group of metallocene linear low density polyethylene, blend of linear low density polyethylene and low density polyethylene, blend of metallocene low density polyethylene and low density polyethylene etc which increases glossiness thereby luster of the sheet. According to the present invention the metal is deposited on the core polymer by a well know vacuum deposition method layer to an optical density of about ranging from 1.5 to 2.8. Generally, metal to be deposited is selected from a group including Aluminum, alloys of Aluminum, Copper, Silver, Gold and preferable metal for deposition according to the present invention is Aluminum. According to the present invention, the primer used for the both side of the core layer may be same or different. The primer in combination with the extruded polyolefin or copolymer of polyolefin forms a tight bonding between the metalized surface of the core layer and the inner layer. The primer is selected from a group which includes two component polyurethane, partially crossed linked acrylic co-polymers and the like. Preferable primer to achieve tight bonding according to the present invention is two component polyurethane. According to the present invention, the inner layer and the outer layer of the multilayer are multilayered thermo-plastic film made up of at least 3 layers of the thermoplastic film and minimum thickness of about 25 micron. According to the present invention, the inner layer comprises 5-9 layers of co- extruded barrier thermoplastic film.
According to the present invention, the outer layer comprises 3-5 layers of thermoplastic film.
According to the present invention, interlayer bond strength of the inner layer and outer layer is equal to or more than 0.3 kg per 15 mm laminate strip. The multi-layer flexible sheet of the present invention is about 100-500 micron thick and has surface gloss more than 250 at an angle of 20° measured by Gloss meter conforming to ASTM D-523. Generally, the multi-layer flexible sheet of the present invention has surface gloss more than 500 at an angle of 20° measured by Gloss meter conforming to ASTM D-523. Therefore the tubes made from the sheets of the present invention have more lustrous look than presently available tubes made of the metal foils.
The following example illustrates the process of the invention in greater details, but, does not limit the present invention in any manner to the specific embodiments as presented therein: Example 1
A multilayer flexible sheet was prepared by plasma treating one of the sides of the core polyester and vacuum metalized the plasma treated side. The primer 'two component polyurethane' was applied on the metalized layer and polyolefin was extrusion laminated over the primer and then inner heat sealable layer of Polyethylene was coextruded over the polyolefin layer. The polymer side of the core polyester was also coextruded along with primer and extrusion. The gloss value was measured from the polymer side of the core layer i.e. from the outer layer at an angle of 20° measured by Gloss meter conforming to ASTM D-523. The details of the multilayer sheet are given as below:
Figure imgf000009_0001
Figure imgf000010_0001
While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention under the description of the invention with the accompanying figures, but that the invention will include all embodiments falling within the scope of the appended claims:

Claims

CLAIMS:
1. A method for manufacturing a multi-layer flexible sheet, comprising steps of metalizing atleast one of the surfaces of a core polymer layer; priming the metalized surface of the core polymer layer with a primer; extrusion laminating the primed surface of the core polymer layer with polyolefin and/or co-polymer of polyolefin; and co-extruding first heat sealable layer over the extrusion laminated layer; wherein said extrusion laminated layer of polyolefin and/or co-polymer of polyolefin in combination with primer layer tightly bond the metalized surface of the core polymer layer with the heat sealable layer thereby producing a multi layer flexible sheet having high luster effect and stability.
2. A method for manufacturing a multi layer flexible sheet as claimed in claim 1 further including step of plasma treating atleast the core polymer layer prior to metalizing the plasma treated layer of the core polymer layer.
3. A method for manufacturing a multi layer flexible sheet as claimed in claim 1 , further comprising one of the following steps: a. priming of non- metalized of the core layer of the multi layer sheet and extrusion coating the said primed surface with a second heat sealable layer after the co-extruding first heat sealable layer; and b. priming atleast one of the polymer side of the core layer of the multilayer sheet and extrusion coating with a second heat sealable layer prior to or after metalizing the core polymer layer.
4. A method for manufacturing a multi layer flexible sheet as claimed in claim 3, wherein the second heat sealable layer can be printed before extrusion laminated over the polymer side of the core member.
5. A method as claimed in claim 3 or 4, wherein the second heat sealable layer is a high clarity polymer selected from a group of metallocene linear low density polyethylene, blend of linear low density polyethylene and low density polyethylene, blend of metallocene low density polyethylene and low density polyethylene etc which increases glossiness thereby increasing lustrous effect of the sheet.
6. A method for manufacturing a multi layer flexible sheet as claimed in one of the claims 1 to 3, wherein the core polymer member includes Polyester, Biaxially oriented Polypropylene, Cast Polypropylene, High Density Polyethylene, Ethylene vinyl alcohol, Polyamide, and skin layers of grafted co-polymer of ethylene, random co-polymer of propylene or thermoplastic elastomers made of either chemical coating or co-extrusion coating.
7. A method for manufacturing a multi layer flexible sheet as claimed in claim 1 or 3, wherein the primer includes two component polyurethane, partially crossed linked acrylic co-polymers and preferably two component polyurethane.
8. A method for manufacturing a multi layer flexible sheet as claimed in claim 1 , wherein the sheet has metal deposited on the core polymer layer to an optical density of about ranging from 1.5 to 2.8.
9. A method for manufacturing a multilayer flexible sheet as claimed in claim 1 or 7, wherein the metal includes aluminum, alloys of Aluminum, Copper, Silver, and Gold, and preferably aluminum.
10. A method for manufacturing a multilayer flexible sheet as claimed in claim 1 or 7, wherein said method produces a multilayer flexible sheet having surface gloss above 250 measured at 20° in accordance to ASTM D-523.
11. A method for manufacturing a multilayer flexible sheet as claimed in claim 1 or 7, wherein said method produces a multilayer flexible sheet having surface gloss preferably more than 500 measured at 20° in accordance to ASTM D-523.
12. A method for manufacturing a multilayer flexible sheet as claimed in claim 1 , wherein interlayer bond strength of the said sheet between all the interfaces is atleast 0.3Kg per 15 mm strip.
13. A multilayer flexible sheet, comprising: a core polymer layer having one of the polymer sides plasma treated; a metal layer deposited on the plasma treated side of the core layer; a primer layer applied on the metalized surface of the core layer; an extrusion polymer lamination layer of polyolefin and/or co-polymer of polyolefin; and a first heat sealable layer coextruded on the extrusion polymer lamination layer; wherein the primer in combination with the extrusion polymer lamination layer forms a tight bonding between the metalized surface of the core layer and the heat sealable layer.
14. A multilayer flexible sheet as claimed in claim 13, further comprises a second heat sealable layer coextruded on the polymer side of the core polymer layer along with a primer and extrusion layer.
15. A multilayer flexible sheet as claimed in claim 13, wherein an optical density of metal over the core layer is of about ranging from 1.5 to 2.8.
16. A multilayer flexible sheet as claimed in claim 13, wherein the core polymer member comprises atleast three layers of polymer selected from group of Polyester, Biaxially oriented Polypropylene, Cast Polypropylene, High Density Polyethylene, Ethylene vinyl alcohol, Polyamide, and skin layers of grafted co-polymer of ethylene, random co-polymer of propylene or thermoplastic elastomers made of either chemical coating or co-extrusion coating
17. A multilayer flexible sheet as claimed in claim 13, wherein interlayer bond strength of the said sheet between all the interfaces is atleast 0.3 Kg per 15 mm strip.
18. A multilayer flexible sheet as claimed in claim 13, wherein the multilayer flexible sheet has thickness about 100 to 500 micron.
19. A multilayer flexible sheet as claimed in claim 13, wherein the sheet has surface gloss above 250 measured at 20° in accordance to ASTM D-523.
20. A multilayer flexible sheet as claimed in claim 13, wherein the sheet has surface gloss preferably more than 500 measured at 20° in accordance to ASTM D-523.
21. A multilayer flexible sheet as claimed in claim 13, wherein the first heat sealable layer comprises at least three layers of co-extruded barrier thermoplastic film and preferably 5-9 layers of co-extruded barrier thermoplastic film.
22. A multilayer flexible sheet as claimed in claim 14, wherein the second heat sealable layer comprises at least three layers of co-extruded barrier thermoplastic film and preferably 3-5 layers of co-extruded barrier thermoplastic film.
23. A multilayer flexible sheet as claimed in claim 14, wherein the second heat sealable layer is a high clarity polymer selected from a group of metallocene linear low density polyethylene, blend of linear low density polyethylene and low density polyethylene, blend of metallocene low density polyethylene and low density polyethylene etc. which increases glossiness thereby increasing lustrous effect of the sheet.
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