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WO1999025552A1 - Films coextrudes et procedes de fabrication et d'utilisation correspondants - Google Patents

Films coextrudes et procedes de fabrication et d'utilisation correspondants Download PDF

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Publication number
WO1999025552A1
WO1999025552A1 PCT/US1998/024297 US9824297W WO9925552A1 WO 1999025552 A1 WO1999025552 A1 WO 1999025552A1 US 9824297 W US9824297 W US 9824297W WO 9925552 A1 WO9925552 A1 WO 9925552A1
Authority
WO
WIPO (PCT)
Prior art keywords
ply
plies
film
coextruded
polyethylene
Prior art date
Application number
PCT/US1998/024297
Other languages
English (en)
Inventor
John P. Heaton
Wayne R. Osgood
Original Assignee
Huntsman Packaging Corporation
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 Huntsman Packaging Corporation filed Critical Huntsman Packaging Corporation
Priority to AU14596/99A priority Critical patent/AU1459699A/en
Publication of WO1999025552A1 publication Critical patent/WO1999025552A1/fr

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Classifications

    • 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
    • B32B7/06—Interconnection of layers permitting easy separation
    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/14—Printing or colouring
    • B32B38/145—Printing
    • 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

Definitions

  • This invention relates to coextruded films and, more specifically, coextruded films for use in printing, lamination and packaging applications.
  • this invention relates to the production and lamination of single web, multi-ply, coextruded films in trapped printing and packaging applications.
  • Laminated films are used for, among other things, forming product packaging having trapped printing.
  • laminated trapped print films have been formed from two separate films of single wound sheeting (“SWS”) using conventional printing and laminating equipment having two separate unwind or supply rolls.
  • trapped printed films have been formed from a single roll of double wound sheeting (“DWS”) or duplex film, eliminating the need for separate film supply rolls.
  • DWS double wound sheeting
  • Such a DWS process is described in U.S. Patent No. 4,995,927 to Garrett, which is incorporated herein by reference in its entirety.
  • two layers of film are typically formed by a blown extrusion process, treated for printing or laminating on one or both outside surfaces, and then wound together in two layers on a single roll for later use.
  • the treated two-layer DWS roll is then typically unwound and passed through a conventional printing process for printing on one treated outside surface, adhesive may be applied, and then rewound onto a single product roll.
  • the outermost layer of the DWS product roll Prior to use for packaging or finish rewinding, the outermost layer of the DWS product roll is typically unwound for one turn and cut off. The roll is then unwound so that two adjacent layers are unwound together, with the formerly outside treated surfaces being sandwiched between the layers, thereby creating packaging or a similar product with the ink trapped between the two treated surfaces.
  • a DWS or duplex film trapped printing process eliminates the need for two separate supply rolls and associated laminating equipment, it requires extrusion and treatment of two separate layers of film. Furthermore, such two-layer or two-web films may have adverse effects when used in a conventional printing press due to the DWS layers or webs not having sufficient attraction to each other. Lack of sufficient attraction between adjacent webs or layers may result in film wrinkling, sliding, ply wander, formation of trapped air bubbles, ply separation, etc. when the film is run through a conventional printing press. This is because conventional printing equipment is typically designed for handling single web material. In addition, using a typical blown extrusion DWS process, the variety of laminates that may be produced is typically limited to two web laminates having layers of the same thickness and composition.
  • this invention is a single web coextruded film including two or more plies of coextruded polymeric material, the two or more plies being substantially separable at a coextrusion interface defined therebetween into two or more separate delaminated plies.
  • the film may also include at least one third ply; wherein at least one of the first or second plies is disposed in contact with the at least one third ply; and wherein the third ply comprises a material that is similar to the material of the at least one of first or second plies.
  • this invention is a process for making film, including coextruding two or more plies of polymeric material into a single web film; the two or more plies being substantially separable at a coextrusion interface defined therebetween into two or more separate delaminated plies.
  • the film may also include at least one third ply; wherein at least one of the first or second plies is disposed in contact with said at least one third ply; and wherein the third ply comprises a material that is similar to the material of the at least one of said first or second plies.
  • this invention is a process of preparing a trapped film lamination, including printing on at least one outside surface of a single web film having two outside surfaces; wherein the single web film comprises two or more plies of coextruded polymeric material and is treated for printing or lamination on at least one of the outside surfaces; and wherein the two or more plies are substantially separable at a coextrusion interface into two or more separate delaminated plies; and winding the printed film onto a product roll so that the outside surfaces are disposed in contact with each other to form the trapped print lamination.
  • this invention is a process of preparing a trapped print film, including the step of printing on at least one surface of a film having two surfaces, the film being treated for printing or lamination on both surfaces and including two or more plies of coextruded polymeric material.
  • the two or more plies of polymeric material are substantially separable into two or more separate delaminated plies.
  • the process also includes the step of winding the film onto a roll.
  • this invention is a process of preparing a trapped print film having two surfaces, including the step of coextruding two or more plies of polymeric material, the two or more plies being substantially separable into two or more separate delaminated plies.
  • the process also includes the step of printing on at least one surface of the film, the film being treated for printing or lamination on both surfaces and including two or more plies of coextruded polymeric material.
  • the two or more plies are substantially separable into two or more separate delaminated plies.
  • the process also includes the step of winding the film onto a roll.
  • this invention is a process of preparing a trapped print film, including the steps of coextruding a single web film having two outside surfaces and including two or more plies of polymeric material.
  • the two or more coextruded plies are substantially separable at a coextrusion interface into two or more separate delaminated plies.
  • the process also includes the steps of printing on at least one outside surface of the single web film, winding the single web film onto a product roll, wherein the outside surfaces of the single web film adhere to each other within the roll and wherein the printing is trapped therebetween, and unwinding the film from the product roll so that at least two of the two or more delaminated plies separate from each other at the coextrusion interface and the film unwinds from the product roll with the printing trapped between the adhered surfaces of the film.
  • separate film ply materials are typically selected from different categories of materials to achieve a dissimilar film combination which creates a delamination interface.
  • Any number of plies may be used and are structured so that at least one delamination interface exits.
  • a delamination interface exists when two adjacent plies consist of dissimilar materials which together possess a bond strength typically less than about 50 grams/inch, more typically less than about 10 grams/inch, and most typically less than about 5 grams/inch, although it is possible that a delamination interface having bond strength equal to or greater than about 50 grams/inch may also be employed.
  • two dissimilar layers each consisting of one or more plies.
  • the plies in the same layer will typically be similar to each other.
  • the adjacent plies between the dissimilar layers will typically be dissimilar to each other, thereby creating a delamination interface.
  • these types of structures include, but are not limited to, nylon/polyethylene which delaminate at the Nylon-polyethylene interface, and HDPE/LDPE Nylon which delaminate at the LDPE-Nylon interface to form nylon/HDPE/LDPE.
  • a "sacrificial" or delamination layer may be employed between two similar materials, creating two delamination interfaces.
  • the sacrificial layer may be made up of one or more plies that are dissimilar to the adjacent plies of the adjacent layers.
  • the sacrificial layer is typically removed or stripped out during the delamination of the surrounding coextruded plies.
  • Examples of these type of structures include, but are not limited to, HDPE Nylon/LDPE where the Nylon delaminates from both the HDPE and LDPE and may be stripped out leaving a HDPE/LDPE laminate, LDPE/PET/PP where the PET delaminates from both the LDPE and PP and may be stripped out to leave a PP/LDPE laminate, and HDPE/LDPE/Nylon/PP where the Nylon delaminates from both the LDPE and PP and may be stripped out leaving a PP/HDPE/LDPE laminate.
  • dissimilar plies may be made similar by placing plies of materials between the dissimilar plies that are similar to both of the dissimilar plies. This may be useful, for example, when multiple delamination interfaces exist, but when it is desirable to use only one. This may also be useful when only a very thin layer of one of the dissimilar materials is desired. Examples of this include, but are not limited to, a HDPE/LDPE/Nylon/tie layer/HDPE structure, where the tie layer is a material such as maleic anhydride grafted polymer (e.g., Dupont "BYNEL”) that is similar to both the Nylon and the HDPE, and therefore links together what would otherwise be a delamination interface.
  • a HDPE/LDPE/Nylon/tie layer/HDPE structure where the tie layer is a material such as maleic anhydride grafted polymer (e.g., Dupont "BYNEL”) that is similar to both the Nylon and the HDPE, and therefore links together what would otherwise be a
  • the only delamination interface is between the Nylon and LDPE, so upon delamination, this creates the structure LDPE/HDPE/tie layer/Nylon.
  • the bulk of the structure may be HDPE with relatively thin layers of LDPE and Nylon.
  • FIG. 1 is a simplified schematic of a blown coextrusion process for creating two-ply dissimilar material single web films according to one embodiment of the disclosed method.
  • FIG. 2 is a simplified cross-sectional view of supply rolls of single web two-ply coextruded film according to one embodiment of the disclosed method.
  • FIG. 3 is a simplified perspective view of layers of a coextruded single web two-ply film according to one embodiment of the disclosed method.
  • FIG. 3A is a simplified cross-sectional view of a coextruded single web two-ply film according to one embodiment of the disclosed method.
  • FIG. 4 is a simplified schematic of a process for forming a printed film roll according to one embodiment of the disclosed method.
  • FIG. 5 is a simplified cross-sectional view of a printed product roll being unwound according to one embodiment of the disclosed method.
  • FIG. 6 is a simplified cross-sectional view showing the process of peeling back one of the coextruded layers to rearrange the structure to its finished form according to one embodiment of the disclosed method.
  • FIG. 7 is a simplified cross-sectional view of a coextruded film structure according to one embodiment of the disclosed method.
  • FIG. 8 is a simplified cross-sectional view of the coextruded film structure of FIG. 7 wound into a roll.
  • FIG. 9 is a simplified cross-sectional view of a laminate structure according to one embodiment of the disclosed method formed by unwinding the rolled structure of FIG. 8.
  • FIG. 10 is a simplified cross-sectional view of a coextruded film structure according to one embodiment of the disclosed method.
  • FIG. 11 is a simplified cross-sectional view of a laminate structure according to one embodiment of the disclosed method formed by processing the coextruded film structure of FIG. 10. The intermediate step is not shown.
  • FIG. 12 is a simplified cross-sectional view of a coextruded film structure according to one embodiment of the disclosed method.
  • FIG. 13 is a simplified cross-sectional view of a structure formed by winding the coextruded film structure of FIG. 12 onto a roll according to one embodiment of the disclosed method.
  • FIG. 14 is a simplified cross-sectional view of a laminated structure according to one embodiment of the disclosed method formed by unwinding the film structure of FIG. 13.
  • FIG. 15 is a simplified cross-sectional view of a coextruded film structure according to one embodiment of the disclosed method.
  • FIG. 16 is a simplified cross-sectional view of a laminated film structure according to one embodiment of the disclosed method formed by processing the coextruded film structure of FIG. 15. The intermediate step is not shown.
  • FIG. 17 is a simplified cross-sectional view of a coextruded packaging film structure according to one embodiment of the disclosed method.
  • FIG. 18 is a simplified cross-sectional view of the intermediate structure with bonding agent applied to ply B according to one embodiment of the disclosed method formed from the coextruded film structure of FIG. 17.
  • FIG. 19 is a simplified cross-sectional view of a laminated film structure according to one embodiment of the disclosed method formed by winding the film structure of FIG. 18 upon itself.
  • FIG. 20 is a simplified cross-sectional view of a laminated film structure according to one embodiment of the disclosed method formed by unwinding the laminated film structure of FIG. 19 with "delamination" between the B and C layers.
  • FIG. 21 is a simplified cross-sectional view of a coextruded film structure according to one embodiment of the disclosed method.
  • FIG. 22 is a simplified cross-sectional view of the intermediate structure with bonding agent (print and adhesive) applied to the coextruded film structure of FIG. 21 according to one embodiment of the disclosed method.
  • FIG. 23 is a simplified cross-sectional view of a laminated film structure according to one embodiment of the disclosed method formed by processing the laminated film structure of FIG. 22. The intermediate step is not shown.
  • FIG. 24 is a simplified schematic of application of print and/or adhesive layer to a single web coextruded multi-ply film according to one embodiment of the disclosed method.
  • FIG. 25 is a simplified schematic showing sequential separation of separate plies of the coextruded film of FIG. 24 according to one embodiment of the disclosed method.
  • FIG. 26 is a simplified schematic showing delamination of the plies of the coextruded film of FIG. 25 according to one embodiment of the disclosed method.
  • single web multi-ply coextruded films and processes for making and using such films.
  • Such films may also be referred to as single web multiple layer films, with a given "layer” being understood to comprise one or more plies.
  • the disclosed coextruded films may be used to form trapped print laminations without the need for extrusion and treatment of two separate layers or webs of film.
  • the disclosed process employs a single web or SWS coextruded film comprised of multiple plies that may be delaminated. after process lamination and/or printing, when a film roll is unwound.
  • the laminated roll may be unwound at the coextruded interface, instead of at the interface between the two film webs as in conventional methods.
  • the disclosed multi-ply film is coextruded in a single web, sufficient attractive forces between the coextruded plies exist to allow the film to be run through a conventional printing press, typically without the problems of wrinkling, slipping, etc. that are typically encountered with two layer or two web DWS films.
  • films with multiple plies of different gauge and polymeric material may advantageously be produced.
  • a separate polypropylene ply that is very thin e.g., 0.2 mils
  • a thicker ply of polyethylene e.g. , 1.5 mils
  • a blown or cast line produced, coextruded, single web film on a roll may be used to construct a trapped film lamination with a one step printing, laminating, and rewinding process.
  • a coextruded single web film may comprise two or more plies made of similar and dissimilar materials that may be separated apart or delaminated when so desired.
  • dissimilar materials means any two or more materials suitable for forming respective plies of a single web film that, when coextruded, lack strong adhesion properties in relation to each other and therefore allow the plies to be delaminated at a delamination interface without tearing or destruction of the materials. Such materials include those which lack melt adhesion properties relative to each other. Typically, dissimilar materials possess a bond strength between the materials of less than about 50 grams/inch, more typically less than about 10 grams/inch, and most typically less than about 5 grams/ inch, although it is possible that dissimilar materials having bond strengths equal to or greater than about 50 grams/inch may also be employed.
  • any two or more coextruded dissimilar materials meeting the dissimilar material definition in this paragraph are defined herein to be “substantially separable.” Once such coextruded materials have been separated apart, they are described herein, among other things, to be “delaminated” or “separated” plies.
  • Similar materials means any materials that are suitable for forming two or more plies of a single web film that, when co-extruded, adhere to each other and which therefore require a separate ply of delamination material therebetween to allow the plies to separate apart or be delaminated during a roll unwinding process.
  • Such materials typically include those which have melt adhesion properties relative to each other.
  • similar materials possess a bond strength sufficient to cause destruction or tearing of the materials during delamination or separation.
  • the disclosed films may be employed in any process where delamination of films is desirable including, for example, processes described elsewhere herein.
  • the materials are polymeric materials that may be blended materials or single component polymers, although other suitable materials may be employed including, but not limited to, those materials listed in Table 1, including mixtures thereof.
  • the first material type labeled "similar materials”
  • Dissimilar materials would be expected to be dissimilar to the above named “similar materials” and have relatively low bond strengths when coextruded with “similar materials.” Thus, when materials from the "similar materials” list and the “dissimilar materials” list are coextruded in adjacent plies, their interface would be expected to be a suitable delamination interface for the purpose of this invention.
  • the disclosed coextruded single web films are wound in a roll about a core.
  • one or more of the film outside surfaces may be corona treated or otherwise chemically altered to increase the wetability and adhesion of the surface.
  • any such treatments known to those of skill in the art may be employed including, but not limited to, treatment with chemical oxidants. corona treatment, flame treatment, washing, etc.
  • coextruded multi-ply films may be unwound and fed through a printing press, reverse printed (adhesive inks and/or a separate adhesive may be added or used at this point), and rewound about a core to form a roll of printed film.
  • the disclosed method allows a coextruded single web film to be employed, higher production efficiencies may be realized and a higher quality of film and film laminations may be produced than with conventional double wound rolls of single web film This is because the film responds to processing as a single web without the attendant ply separation difficulties described previously.
  • a multi-ply film may be coextruded, treated, and/or processed through a secondary slitting and rewinding process to finish the roll, as in previous DWS methods such as those described in U.S. Patent No. 4,995,927, which has been incorporated herein by reference.
  • a secondary slitting and rewinding process to finish the roll, as in previous DWS methods such as those described in U.S. Patent No. 4,995,927, which has been incorporated herein by reference.
  • nylon may be used as the B ply of an A/B/A printed coextrusion in which the outside A plies are polypropylene ("PP"), the outside surfaces of which are typically treated and/or printed.
  • the nylon B ply may be delaminated from the outer polypropylene A plies and may be wound up at the slitter in a separate roll from the remaining polypropylene plies which are now configured as A/A plies with trapped print therebetween.
  • any combination of two or more plies of dissimilar materials suitable for forming a coextruded film in which the films may be separated apart or delaminated later may be employed.
  • a single web coextruded film may be comprised of two dissimilar film plies.
  • three or more dissimilar film plies, or a mixture of dissimilar and similar plies may be employed.
  • each ply may be of a dissimilar material or, alternatively, similar and dissimilar materials may alternate in such a manner that the film may be delaminated as so desired.
  • Many other combinations of dissimilar and similar materials and/or delamination plies are also possible.
  • Typical examples of material categories that similar and/or dissimilar materials may be selected from include, but are not limited to, olefins (LDPE, HDPE, EVOH, LLDPE, EVA, metallocene-catalyzed PE, polypropylene, polybutylene (PB), etc.), nylons (6, 66, copolymers, etc.), PETs, styrenics (polystyrene (PS), SBR, HIPS, Phillips "K-RESIN”, etc.), halogenated polymers (polyvinyl chlorides, poly vinylidene chlorides, CPVC, etc.), Ionomers (Surlyns, TPX).
  • Table 1 An example of a specific set of exemplary similar materials along with sets of exemplary materials that would be dissimilar to the similar set may be found in Table 1 , although it will be understood with benefit of this disclosure that other examples exist.
  • two or more plies of dissimilar polymeric materials are typically coextruded into a single web film.
  • the two or more dissimilar materials are selected such that they do not melt together at processing temperatures, which typically range from about 100°F to about 600°F, more typically from about 350°F to about 560°F, and most typically from about 450°F to about 550°F.
  • melt adhesive force may be avoided.
  • Such combinations of materials, when coextruded, typically form single web film structures having two or more plies which may be separated.
  • a separate "sacrificial" delamination ply may be coextruded or otherwise placed between the plies of dissimilar materials in those cases where the different materials have some adhesion or affinity for each other.
  • plies of dissimilar materials are typically coextruded in contact with each other, while “sacrificial" delamination plies are typically employed where similar or the same materials are used to form separate plies of a multi-ply coextruded film.
  • a dissimilar film combination may be determined, for example, by selecting at least one compound from the rows labeled "Dissimilar Materials” in Table 1, and one or more other compounds from the rows labeled "Similar Materials” and/or "Dissimilar Materials” in Table 1.
  • Table 2 lists known characteristics of similarity and dissimilarity of just a few of the possible materials that may be employed in the practice of the disclosed method.
  • a combination of materials is represented by the intersection of a column representing one compound and a row representing another material.
  • those combinations of materials labeled with "S” represent similar film material combinations
  • those combinations labeled "D” represent dissimilar film material combinations.
  • Those intersections marked with a "--” represent combinations having characteristics that are unknown.
  • Examples of combinations of specific dissimilar materials suitable for use in the disclosed method include, but are not limited to, nylon and polyethylene, ethylene vinyl alcohol copolymer (“EVOH”) and polyethylene, PET polyester and polyethylene.
  • a two ply film comprising dissimilar polymeric plies of nylon and polyethylene is employed. These plies are typically coextruded without a separate sacrificial delamination ply, although a delamination ply may be employed if so desired.
  • two or more similar polymeric materials may be employed to form a single web film.
  • a sacrificial delamination ply is typically employed between the similar film plies so that the film plies may be separated apart or delaminated later.
  • the two or more film plies and the delamination ply are coextruded together.
  • Materials suitable for forming similar plies of a single web multiple ply coextruded film include any material which may be suitable for extrusion into a single web coextruded film.
  • the materials may be considered similar, for example, when they melt of otherwise permanently adhere together during a coextrusion process.
  • Examples of typical categories of such polymeric materials suitable for this purpose include, but are not limited to, those materials listed in Table 1.
  • Table 1 a similar film material combination may be determined, for example, by selecting at least two compounds from the rows labeled "Similar Materials" in Table 1.
  • specific examples of similar film material combinations are listed in Table 2, as described above.
  • Typical combinations of similar plies that may be employed in a single web film with a delamination ply (such as a sacrificial ply of nylon) therebetween include, but are not limited to, polyethylene-polyethylene, polyethylene-polypropylene, polypropylene- polypropylene, etc. Blends of polymeric materials may also be employed.
  • Materials suitable for forming a sacrificial delamination ply between two plies of coextruded film include any material which is suitable for allowing delamination of or separation of the coextruded plies.
  • a delamination ply typically possesses the characteristic of lacking strong adhesion properties in relation to one or both adjacent coextruded plies and therefore allow the plies to be delaminated without tearing or destruction of the materials.
  • Such materials include those materials which lack melt adhesion properties relative to the material of one or both adjacent coextruded plies (typically a polymer or polymer blend).
  • a delamination ply material possesses a bond strength with one or both adjacent plies of less than about 50 grams/inch, more typically less than about 10 grams/inch, and most typically less than about 5 grams/ inch, although it is possible that delamination ply materials having bond strengths equal to or greater than about 50 grams/inch may also be employed.
  • a delamination ply may be sacrificial or integral.
  • a sacrificial delamination ply is typically removed or stripped out and disposed of during delamination of the surrounding coextruded ply.
  • a sacrificial delamination ply typically possesses the above- described delamination ply properties (or is dissimilar in nature) in relation to both adjacent coextruded plies.
  • Examples of sacrificial delamination plies that would work with combinations of similar materials such as polyethylene-polyethylene, polyethylene-polypropylene, polypropylene-polypropylene include, but are not limited to, nylons, PS, TPX, PETG, etc.
  • An integral delamination ply is typically allowed to remain attached to one of the coextruded plies following delamination of the plies.
  • Examples of typical categories of materials suitable for use as an integral delamination ply include, but are not limited to, materials that possess "similar material" characteristics (as described above) relative to one of the adjacent coextruded plies.
  • Other examples include delamination plies attached to one of the adjacent coextruded plies with a tie layer which has a melt adhesion and sealing ability relative to both types of polymer (i.e., both the polymer of the delamination ply and the coextruded adjacent ply).
  • Such tie layers include any tie layer or tie material known to those skilled in the art.
  • tie layers include, but are not limited to ionomers (such as Surlyn), maleic anhydride grafted polymers, EAA, etc. as a tie layer between a nylon delamination ply and olefins.
  • ionomers such as Surlyn
  • maleic anhydride grafted polymers such as Surlyn
  • EAA maleic anhydride grafted polymers
  • specific examples of tie layers include, but are not limited to, Dupont's "BYNEL” series, Equistar's "PLEXAR” series, and Morton's "TYMOR” series. In other cases, for example for use with polypropylenes, EVA. EMA, EMMA, etc. may be employed as a tie layer.
  • a single multi-ply coextruded film may optionally comprise one or more plies (or subplies) other than delamination plies.
  • Such other plies may include seal layers, tie layers, resistance layers, etc. and mixtures thereof. Consequently, a dissimilar or similar film ply may comprise several laminar components or plies, with the components or plies having the dissimilar or similar characteristic (as desired) typically oriented to be on the outer surfaces of a single web film for contact with, and adhesion to, outer surface of surrounding film layers. It is also possible that a layer of single web of film may have one outside surface that comprises dissimilar material and another outside surface that comprises similar material.
  • any suitable material and/or method known in the art may be used.
  • plies may be joined back-to-back with any suitable tie layer known to those of skill in the art including but not limited to "SURLYN" available from Dupont, or mixtures thereof.
  • tie layers typically are materials suitable for joining or permanently adhering dissimilar materials together, and are typically extruded as a ply during the coextrusion process.
  • a single web coextruded film of dissimilar or similar materials is coextruded using any suitable method for coextrusion known to those of skill in the art including, but not limited to, "Flat-Die”.
  • "Cast” or “Blown” film processes and may include downstream operations such as roll or tenter frame orientation.
  • one or both sides of a single web coextruded film is treated for printing or lamination.
  • any materials suitable for surface treating may be employed, including, but not limited to, corona, flame, etc.
  • Such treating material is typically applied prior to winding the film onto, for example, a supply roll, typically a treatment having a level of about 36 to about 45 dynes is employed, although other treatment levels (below equal to or below about 36, or equal to or greater than about 45 dynes) are possible.
  • a single web coextruded multi-ply film is typically employed in a printing or trapped printing process, which may be performed on any suitable printing equipment, including conventional printing equipment, to produce a multi-ply film with buried printing. Most typically, both outside surfaces of a single web coextruded multi-ply film are treated prior to printing with materials as previously described.
  • the embodiment of FIG. 1 is one possible method in which supply rolls 10 and 11 of two-ply dissimilar material single web films 13 and 15 respectively, may be simultaneously created. Such supply rolls may be transported and used in other processes, typically a printing process in which a trapped print process is formed. Prior to forming supply rolls 10 and 11, dual layer or dual web film 12
  • FIG. 1 also pictures an optional treating step for treating the outside surfaces of the coextruded film prior to winding on a supply roll. It will be understood with the benefit of the present disclosure that rather than winding the produced and treated film on a supply roll, that films 13 and 15 may be further processed or routed directly to a printing press or other equipment for further processing.
  • film 12 (comprising two webs of two-ply dissimilar film 13 and 15) is coextruded from first extruder 14 and second extruder 16, in this case screw type extruders.
  • Outside surfaces 18 and 20 of film 12 (the outside surfaces of respective coextruded films 13 and 15) of the coextruded film may then be treated using optional conventional treater 22.
  • treatment is optional or that any other suitable treating method known in the art may be employed including, but not limited to, corona treatment, flame treatment, chemical treatment, etc.
  • films 13 and 15 may be separated prior to treating so that both outside surfaces of each respective film 13 and 15 may be treated. In such a case films 13 and 15 may be rejoined after treatment for trimming, or alternately may remain separated throughout the remainder of a process.
  • film 12 may then be trimmed, for example, using a conventional film cutter 40 or any other suitable film trimming method known in the art. Trimmed material 42 may be optionally recycled to the appropriate resin source, if desired.
  • film 12 is separated at point 17 into two film components 13 and 15, and then wound to create supply roll 10 of single web two-ply coextruded film 13 comprising dissimilar plies 26 and 28, and supply roll 11 of single web two-ply coextruded film 15 comprising dissimilar plies 30 and 32, which may be separated as illustrated in FIG. 2.
  • film 12 may be wound on a roll as is, and unwound and separated as described above at a later time.
  • two dissimilar resin sources 30 and 32 are used to create coextruded film 12 (which comprises separate two-ply coextruded films 13 and 15).
  • Dissimilar resin sources 30 and 32 may be any two dissimilar materials including those disclosed elsewhere herein, and may have other differing properties such as varying degrees of transparentness and opaqueness.
  • FIG. 1 illustrates one example of an extrusion process for producing two single web, two-ply coextruded rolls, it will also be understood with benefit of this disclosure that cast extrusion or other suitable film extrusion methods may be used to produce single films having two or more plies of similar and/or dissimilar materials, including using a process similar to that illustrated in FIG. 1.
  • FIG. 3 and FIG. 3A illustrate respective perspective and cross-sectional views of a typical embodiment of coextruded single web dissimilar material two-ply film having a nylon ply 90. and a polyethylene ply 92.
  • a low adhesion coextrusion interface 94 is present as shown.
  • FIG. 4 illustrates a typical embodiment of a process in which a supply roll, for example, a supply roll 10 created by the process of FIG. 1, is printed and processed to form a printed film roll 50.
  • a supply roll 10 typically is unwound or used to otherwise feed the disclosed coextruded single web multi-ply film into or through a conventional printing press 52, which may print on either or both outside surfaces 56 and 58 of film 13.
  • a printing press may print legends, designs, etc. 70 onto one or both outside surfaces 56 and 58 of film 13.
  • outside surfaces 56 and 58 are typically treated previously or concurrently with printing (not shown) for printing or lamination, although this is just optional.
  • any suitable type of ink known to those of skill in the art may be employed for printing including conventional inks, or special inks such as adhesive inks, if so desired. Laminating inks with good adhesion to the printed surface may be employed if so desired, for better results.
  • any separate adhesive and/or adhesive inks suitable for binding together outer surfaces (such as surfaces 56 and 58 of film 13 in FIG. 4) of a multi-ply single web film to form an adhesive interface 62 in order to facilitate delamination at the coextrusion interface may be employed. This is illustrated further in FIG.
  • the bond strength created between the outside surfaces of a multi-ply coextruded film (such as surfaces 56 and 58 in FIG. 5) by the adhesive or adhesive ink should be greater than the bonding attraction or force that exists between the coextruded plies of the single web multi-ply coextruded film (such as at coextrusion interface 60 in FIG. 5), such that the plies are preferentially separated during delamination at the coextrusion interface rather than at the adhesive interface (such as adhesion interface 58 in FIG. 5).
  • suitable adhesives include, but are not limited to, polymeric adhesives such as poly vinylidene chlorides (“PVDC”), acrylics, urethanes, polyesters, polyurethanes, etc.
  • PVDC adhesive such as "SERFENE”
  • LAMAL urethane adhesive
  • Suitable alternatives to adhesive or adhesive ink may be applied to one or more outside surfaces of a film to serve the same function (or to supplement the function) of an adhesive.
  • Such alternatives include, for example, water or water vapor just prior to rewinding onto a product roll.
  • adhesive may be applied in any suitable manner, including using one or more rollers 66 as shown in FIG. 4.
  • an adhesive is typically applied to all but the outside edges of the outside surface of the film just prior to rewinding, but may be dried in a secondary oven in-line, if necessary.
  • a coextruded multi-ply single web film may be treated on either or both outside surfaces prior to printing.
  • the film may be pretreated following coextrusion, but prior to winding on a supply roll (such as supply rolls 10 and 11 of FIG. 1).
  • a supply roll such as supply rolls 10 and 11 of FIG. 1
  • either or both sides of a multi-ply coextruded single web film may be treated after unwinding from a supply roll and prior to printing, or alternatively, not treated at all.
  • a supply roll having a film treated on one surface prior to winding onto the supply roll may be further treated for printing or lamination after unwinding of the supply roll but prior to printing or other subsequent operation.
  • various embodiments of the process using different treating schemes, treatment and/or printing of one or both sides of a coextruded multi-ply, single web film are possible. These include, but are not limited to, embodiments similar to those described in U.S. Patent No. 4,995,927. which has been incorporated herein by reference. Such embodiments include treatment of one or both sides of the film as the supply roll is unrolled prior to printing. In one embodiment, one of the outside surfaces is treated during the extrusion process and then the opposite or both sides is treated on-line during the printing/laminating process.
  • operating conditions are typically similar to those employed in conventional processes.
  • suitable operation conditions include, but are not limited to, normal unwind and rewind tensions used in standard printing press operations, and normal or conventional temperatures used in drying operations, as further described in U.S. Patent No. 4,995,927, which has been incorporated herein by reference.
  • rewind tensions may be elevated slightly and/or rewinding temperature may be elevated to allow for improved adhesive flow and better surface contact between the laminated surfaces in the rewind roll, if so desired.
  • increased tension and temperature should not exceed values where film distortion will occur, in those cases where such distortion is of concern.
  • selected tension and temperature for any given situation may vary depending on the composition and extensibility of the coextruded film.
  • rewinding temperature may be elevated from the conventional room temperature range (e.g., about 70°F to about 85°F) to a higher range of from about 100°F to about 110°F.
  • rewinding tension may be increased, for example, from about 20% - 30%, or about 25% for polyethylene.
  • Other values of elevated tension and/or temperature are also possible, and no elevation of either tension or temperature is necessary, unless so desired.
  • FIG. 6 illustrates a product roll 50 with printing 70 (legends, designs, images, etc.) rolled up in the layers of two-ply single web coextruded film.
  • outer film ply 28 of roll 50 is typically configured such that the printing 70 lies between adjacent plies of the wound single-web coextruded film on roll 50 for unwinding.
  • the outermost surface 58 of coextruded single web multi-ply film will typically either be a surface on which printing or images 70 from a printing press 52 or other printing device are printed.
  • the outermost ply 28 of the outermost layer of multi-ply single web coextruded film is typically delaminated or separated from coextruded adjacent ply 26 and unwound from roll 50 by making one full turn of coextruded film ply 28 about roll 50 as illustrated in process in FIG. 6.
  • one full turn of the outermost layer of coextruded single web multi-ply film may be unwound from roll 50 and separated such that only the innermost ply 26 may be wrapped about the roll 50 so that inner most ply 26 becomes the outermost ply on printed product roll 50.
  • printed roll 50 may be unwound so that plies 26 and 28 are unwound with printed legends or images 70 buried between treated surfaces 56 and 58. This results in trapped or buried printing in which the printing is not exposed to solvents, abrasives, or other external action when the printed film is used, for example, in packages.
  • FIG. 5 illustrates a cross section of adjacent plies 26 and 28 of a completed printed product roll 50, ready for packaging or other manufacturing use. As can be seen, printing or images 70 are disposed between plies 26 and 28.
  • a trapped printed roll may be utilized in any manufacturing or other operation in which trapped printed films are useful, including, but not limited to, those applications described in U.S. Patent No. 4,995,927.
  • Example 1 Base film is ABCDA blown extruded film with individual plies HDPE/PE (seal layer)/nylon/tie-layer/HDPE laminate laminated to make the following buried print structure: nylon/tie-layer/HDPE//ink/adhesive//HDPE/PE seal layer.
  • a PE seal layer may be, for example, LDPE. 25
  • the above described coextruded multi-ply single web film may be constructed for use in products, for example, that are configured for filling using vertical form fill and seal equipment.
  • products include, but are not limited to, products such as stand-alone bags, including, but not limited to, dry breakfast cereal stand-alone bags.
  • Examples 2-4 Table 3 provides a list of abbreviations which apply throughout the specification, and particularly to Examples 2-4.
  • Examples 2-4 describe typical embodiments of multi-ply coextruded single web films that may be formed using the disclosed method. Possible end-uses for each film are listed in parenthesis, although other end uses are also possible.
  • Example 2 Clear HPP/DIS/White HPP - (Bottle labels)
  • the DIS layer in this case may be Nylon or any material that is dissimilar to and would not "bond" to PP.
  • the white HPP provides a good opaque back surface for displaying a printed legend or images and the lamination protects the print from the harsh washing and filling environments and scuffing in downstream distribution handling.
  • Example 3 LLDPE/DIS/TPX/TL/LLDPE - (High O 2 produce package)
  • Example 4 PP/SAC/DIS/PP - (Candy bag, snack bag)
  • the "DIS” would adhere well to the polypropylene, but not to the sacrificial layer.
  • the "SAC” layer may be nylon and the "DIS” layer may be another layer of PP, or a layer of PE, etc.
  • Example 5 6 and 7 were evaluated using the PVDC adhesive.
  • Examples 5 and 8-10 were evaluated with both the PVDC and Urethane adhesives.
  • Example 7 Description and Evaluation: (A95-044) This PS/PE 2-ply co-extrusion worked satisfactorily. However, a partial delamination (segmented peeling) of the PS ply from the PE ply was noted. This may be due to the PS film not being ductile enough to peel completely off the PE ply. PS by itself, as a film, is very brittle and "splitty". The PS ply is also similar in polarity, to the adjacent PE web causing high interfacial adhesion or blocking. The PS used was a standard "Crystal Styrene" (100% amorphous) from Huntsman.
  • KR-10 K-RESIN Styrene- Butadiene block copolymer
  • Example 8 Description and Evaluation: 3 -Ply A/B/A Coextrusion (A95-048)
  • Some possible construction options include: (1) Laminating the PE/PE plies together and removing/reclaiming/reselling the nylon ply separately. The film surfaces of the nylon are extremely smooth and glossy due to a very low or no, shear interface with the PE skins during extrusion. High shear between the polymer and die walls creates a rough surface at best.
  • a tie layer may be incorporated between the Nylon and one of the LDPE layers and the nylon used as an aroma or 0 2 barrier.
  • Example 10 Description and Evaluation: (Sample A95 -049)
  • Examples 11-16 represent just a few possible structures of multi -ply single web coextruded films that may be formed, printed, and/or used for packaging according to embodiments of the disclosed method.
  • FIG. 7 shows a co-extrusion (blown or cast) structure A/B: where A and B may be plies or combination of plies of single or multiple polymers or blends and there is one (1) delamination interface shown as (> — ⁇ ) between A and B which may be separated.
  • FIG. 8 shows an A/B structure wound into a roll with adjacent A and B surfaces in contact after a bonding agent or mechanism (labeled as "bond") is applied to the outer A and/or B surfaces:
  • a bonding agent or mechanism may be, for example, print, adhesive, corona treat or any combination in which the force bonding adjacent A and B structures is greater than that of the delamination surface.
  • FIG. 9 shows a finished laminate structure composed of an A structure bonded to an adjacent B structure; achieved by unwinding the roll in such a way that A and B separate at the delamination surface at the start of unwind.
  • the standard method advantageously creates no extra layers that must be disposed of.
  • a and e are HDPE; b is tie layer; c is nylon; d is LDPE seal layer; "bond 1" is print + adhesive + corona treat; and bond 2 is corona treat.
  • FIG. 11 shows a finished B/bon ⁇ VA laminate structure found by processing the coextruded film of FIG. 10, and having a ply configuration of: LDPE/HDPE//adhesive/ print//HDPE/tie/nylon. An intermediate step similar to that illustrated in FIG. 8 is not shown. In this case “bond 1" and “bond 2" are combined to form the finished lamination structure.
  • FIG. 12 shows co-extrusion or laminated structure A/B/C: where A, B and C may be plies or combination of plies of single or multiple polymers or blends; and there are delamination surfaces shown as (> — ⁇ ) between A and B and between B and C which may be separated.
  • FIG. 13 shows an A/B/C structure wound into a roll with adjacent A and C surfaces in contact after a bonding mechanism ("bond") is applied to the outer A and/or C surfaces:
  • a bonding mechanism may be, for example, print, adhesive, corona treat or any combination in which the force bonding adjacent A and C structures is greater than that of the two delamination surfaces of B.
  • FIG. 14 shows a finished laminate structure composed of an A structure bonded to an adjacent C structure; achieved by unwinding the roll in such a way that A and C separate at the delamination surfaces at the start of unwind, and B structure is unwound to a separate roll.
  • bonding may be, for example, similar to that described above.
  • Layer B (referred to as a sacrificial layer) has been completely removed and is no longer part of the structure.
  • FIG. 15 shows a manufactured multi -ply structure configured as follows:
  • FIG. 16 shows the finished C/A laminate structure that results from lamination of the structure of FIG. 15. as follows: An intermediate step similar to that shown in FIG. 13 is not shown.
  • This example shows another way of looking at the layers of a structure with three or more plies from the perspective of the end use properties of the finished film. It demonstrates how the layers of a base film may be strategically configured to achieve the desired end product.
  • FIG. 17 shows a blown or cast co-extruded packaging film structure "A/C/B" which may be treated on one or both sides.
  • A, B, and C may be single ply layers or multiply layers.
  • the plies of B & C which contact each other are dissimilar and, therefore, form a delamination interface.
  • the C layer is the targeted outer layer of the finished product and could be designed to have specific properties required by the outside of the package such as slip properties, scuff resistance, resistance to heat for sealing, glossy or dull finish, etc.
  • the A layer is the center material(s) of the finished product, which may have important properties which are not required on the surface, such as, barrier properties (such as water vapor transmission rate (WVTR), oxygen transmission rate (OTR), etc.), low cost, general package forming characteristics, etc.
  • barrier properties such as water vapor transmission rate (WVTR), oxygen transmission rate (OTR), etc.
  • WVTR water vapor transmission rate
  • OTR oxygen transmission rate
  • low cost low cost
  • general package forming characteristics etc.
  • the B layer is the targeted inside layer of the finished product and may be designed to have specific properties required by the inside of the package such as sealing, anti-fog, etc.
  • FIG. 18 shows the application of a bonding layer which may include one or several layers of materials applied in the converting process, such as, ink for the printing of a legend, adhesive as a bonding agent, adhesive ink for a combination of the printing and bonding, etc.
  • FIG. 19 shows the structure of FIG. 18 wound upon itself in a roll.
  • FIG. 20 shows the finished laminate structure achieved by unwinding the roll in such a way that layer B delaminates from layer C at the delamination interface.
  • the finished structure ends up with the desired orientation of the layers so that the C-Layer is on the outside of the package, a printed legend is readable through the outside (C-Layer) of the package, and the B-Layer is on the inside of the package.
  • Example 15 This is a specific example using the co-extruded film from Example 12 and looking at it from the perspective used in Example 15.
  • FIG. 21 shows the co-extruded structure of FIG. 10, and labeled so that it is a "B/A/C/B" layer structure where the A-Layer is LDPE needed on the inside of the package for heat-sealing, the C-Layer is Nylon used on the outside of the package for heat resistance and as a flavor barrier, and the B-Layers are made up of HDPE for it's WVTR and package forming properties plus a tie-material used for its adhesion to both the Nylon C-Layer and the HDPE ply of the B-Layer.
  • A-Layer is LDPE needed on the inside of the package for heat-sealing
  • the C-Layer is Nylon used on the outside of the package for heat resistance and as a flavor barrier
  • the B-Layers are made up of HDPE for it's WVTR and package forming properties plus a tie-material used for its adhesion to both the Nylon C-Layer and the HDPE ply of the B
  • FIG. 22 shows the intermediate structure of FIG. 24 where the bonding layer is applied, consisting of an ink layer printed in reverse-print orientation so that the legend is readable through the C-Layer and an adhesive layer for strong bonding.
  • FIG. 23 shows the desired finished structure as A/B/C with all layers properly oriented for their desired use and with the print buried and protected in the middle of the structure.
  • the intermediate structure with the structure of FIG. 22 wound upon itself is not shown.
  • FIGS. 27-29 illustrate alternative views of a coextruded multi-ply single web film 13 having plies 26 and 28, and dissimilar coextrusion interface 62.
  • FIG. 24 shows application of print and/or adhesive layer 96 at station 52.
  • FIG. 25 shows sequential separation of ply 28 from ply 26 at coextrusion interface 62.
  • FIG. 26 shows unwinding of roll 50 following separation, in which print and/or adhesive 96 is trapped or buried between plies 26 and 28, which are held together by the adhesion force of adhesive and/or print layer 96. Unwinding continues with delamination of dissimilar plies 26 and 28 occurring at coextrusion interface 62.

Landscapes

  • Extrusion Moulding Of Plastics Or The Like (AREA)

Abstract

L'invention concerne des procédés permettant de produire et de stratifier des films multicouche coextrudés en une seule bande. Ces films comprennent des films coextrudés constitués de plusieurs couches de matériaux différents pouvant être sensiblement séparés au niveau de la ou des faces de co-extrusion. Ces films peuvent également comprendre des films coextrudés constitués de plusieurs couches de matériaux similaires séparés par une couche de décollement pour pouvoir sensiblement séparer les matériaux similaires. Ces films peuvent être utilisés pour former des films imprimés à encre piégée destinés à l'emballage ou autres usages.
PCT/US1998/024297 1997-11-13 1998-11-13 Films coextrudes et procedes de fabrication et d'utilisation correspondants WO1999025552A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU14596/99A AU1459699A (en) 1997-11-13 1998-11-13 Coextruded films and processes for making and using same

Applications Claiming Priority (3)

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US6596497P 1997-11-13 1997-11-13
US60/065,964 1997-11-13
US09/192,158 1998-11-13

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102005046309A1 (de) * 2005-09-27 2007-04-05 Nordenia Deutschland Gronau Gmbh Verbundmaterial
EP2982488A1 (fr) * 2014-08-04 2016-02-10 Ube Engineering Plastics S.A. Procédé de fabrication de deux ou plusieurs films polymères simultanément sur une seule machine de fabrication de film
US9982167B2 (en) 2013-12-05 2018-05-29 Infiana Germany Gmbh & Co. Kg Precursor composite material, method for producing a precursor composite material, method for producing a composite material and use of a precursor composite material and of a composite material
CN118163445A (zh) * 2023-11-15 2024-06-11 浙江易优包装技术有限公司 一种表层含evoh的多层结构共挤薄膜材料及其制备方法

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EP0196727A1 (fr) * 1985-04-03 1986-10-08 Stamicarbon B.V. Sac multicouche avec un scellement ouvrable
EP0258527A1 (fr) * 1986-08-29 1988-03-09 RJR Archer, Inc. Pellicule multicouche pelable
EP0322199A2 (fr) * 1987-12-21 1989-06-28 W.R. Grace & Co.-Conn. Feuille barrière pelable pour des emballages sous vides et similaires
WO1993017863A1 (fr) * 1992-03-09 1993-09-16 Mobil Oil Corporation Films thermoplastiques thermosoudables
WO1994009985A1 (fr) * 1992-10-30 1994-05-11 Mobile Plastics Europe, Inc. Film detachable et procede de fabrication

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0196727A1 (fr) * 1985-04-03 1986-10-08 Stamicarbon B.V. Sac multicouche avec un scellement ouvrable
EP0258527A1 (fr) * 1986-08-29 1988-03-09 RJR Archer, Inc. Pellicule multicouche pelable
EP0322199A2 (fr) * 1987-12-21 1989-06-28 W.R. Grace & Co.-Conn. Feuille barrière pelable pour des emballages sous vides et similaires
WO1993017863A1 (fr) * 1992-03-09 1993-09-16 Mobil Oil Corporation Films thermoplastiques thermosoudables
WO1994009985A1 (fr) * 1992-10-30 1994-05-11 Mobile Plastics Europe, Inc. Film detachable et procede de fabrication

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102005046309A1 (de) * 2005-09-27 2007-04-05 Nordenia Deutschland Gronau Gmbh Verbundmaterial
DE102005046309B4 (de) * 2005-09-27 2008-07-03 Nordenia Deutschland Gronau Gmbh Verbundmaterial
US9982167B2 (en) 2013-12-05 2018-05-29 Infiana Germany Gmbh & Co. Kg Precursor composite material, method for producing a precursor composite material, method for producing a composite material and use of a precursor composite material and of a composite material
EP2982488A1 (fr) * 2014-08-04 2016-02-10 Ube Engineering Plastics S.A. Procédé de fabrication de deux ou plusieurs films polymères simultanément sur une seule machine de fabrication de film
CN118163445A (zh) * 2023-11-15 2024-06-11 浙江易优包装技术有限公司 一种表层含evoh的多层结构共挤薄膜材料及其制备方法

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