CN103946018A - 金属化的聚乙烯层压体 - Google Patents

金属化的聚乙烯层压体 Download PDF

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CN103946018A
CN103946018A CN201280047375.2A CN201280047375A CN103946018A CN 103946018 A CN103946018 A CN 103946018A CN 201280047375 A CN201280047375 A CN 201280047375A CN 103946018 A CN103946018 A CN 103946018A
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M·K·班纳吉
C·R·阿比安卡尔
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Essel Propack Ltd
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Abstract

本发明提供金属化的聚乙烯层压体，其包括：聚乙烯外层；金属化的酸性共聚物层；与所述金属化的酸性共聚物层接触的聚乙烯内层；和任选的挤出的聚乙烯层；和聚乙烯密封剂层。

Description

金属化的聚乙烯层压体
技术领域
本发明涉及金属化的聚乙烯层压体。本发明的金属化的聚乙烯层压体可制成用于储存需要保持质地和气味的物品如食品以及化妆品的制品。与由现有技术已知的层压体制成的制品相比，所述制品显示增强的蒸汽和/或气体阻挡特性。本发明进一步涉及所述金属化的聚乙烯层压体的制造方法。
背景技术
层压体通常大量用于包括个人护理产品和食品的各种产品的包装和分配。由于固有的性质如力学物理性质、重量轻、耐久性、无毒性、耐光和耐热性以及化学惰性，层压体通常由塑料聚合物制成。上述性质使层压体成为在包装行业中应用的适合选择。
金属化的聚合物层压体是具有沉积或覆盖在聚合物层表面上的金属薄层的层压体。层压体的这种金属化在减轻重量的情况下赋予有光泽的金属外观。此外，金属化膜提供防护包括光、水、湿气和气体的因素的阻挡性。在挠性层压体制造业中，金属化的聚酯和BOPP通常是已知的。这些层压体通常通过将组件之一用作金属化层并使用溶剂基的粘合剂或不含溶剂的粘合剂粘合至密封剂层而形成。
由于双轴定向聚丙烯(BOPP)膜具有优异的湿气阻挡性、强度、透明性和表面光泽，它们广泛用作包装用膜；并且，为了使它们在展示时由于金属光泽而更好看，改进气体阻挡性和抑制另外由外界光如来自太阳光射线的紫外光引起的包装产品劣化，也广泛实施通过金属如铝使它们金属化。然而，由于BOPP膜的表面是无活性的，通常实施诸如电晕放电处理或火焰处理的处理使所述表面活化，以改进金属化时金属膜与基体材料之间的粘合性。
US4297187公开了在由氮气和二氧化碳组成的混合气体中的电晕放电处理。在所述电晕放电处理方法中，虽然更高的处理强度可使表面更加活化和改进金属膜与基体材料膜表层之间的粘合强度，但众所周知，这同时使基体材料劣化，因而所述基体材料膜表层可能从所述基体材料膜内部剥离。
US6190760公开了用于金属化的双轴定向聚丙烯薄膜，其包括由在155摄氏度至163摄氏度之间具有由于晶体熔化的吸热主峰并具有20-90mJ/g的晶体熔化热的聚丙烯树脂制成的表层，其是位于由等规聚丙烯制成的基体层至少一侧的层压层；以及所述表层的润湿张力为33-55Mn/M。US6190760还公开了一种金属化的双轴定向聚丙烯膜，其包括层压在所述用于金属化的双轴定向聚丙烯膜表层上的薄金属膜。US6190760进一步公开了一种使用所述金属化的双轴定向聚丙烯膜获得的层压体。US2011/0274892公开了包括衍生自非石油来源单体的生物基聚烯烃的双轴定向膜。US2011/0274892还公开了一种层压膜，其包括至少一个包括至少53pMC放射性碳(14C)含量的生物基聚烯烃层。所述层压膜可包括其它层，例如至少53pMC放射性碳含量的包括第二生物基聚烯烃树脂的层和金属层。
金属化的聚合物膜广泛地用于食品包装以及装饰用途。US2008/0226854描述了金属化膜，其含有覆盖在一种或多种乙烯酸性共聚物上的金属层和另一热塑性层。所讨论的现有技术通过引用方式以其整体并入本文。
在包装行业中，金属化膜提高了所包装产品的保存期限和吸引力，因而是优选的。金属化膜已成为包装中金属罐、玻璃或刚性结构的良好代替物，满足阻挡材料和共挤出结构的要求。
发明内容
本发明涉及金属化的聚乙烯层压体，其包括：聚乙烯外层；金属化的酸性共聚物层；与所述金属化的酸性共聚物层接触的聚乙烯内层；和任选的挤出的聚乙烯层；和聚乙烯密封剂层。
参考下述描述，将更好地理解本主题的这些及其他特征、方面和优点。提供本发明内容以简要介绍概念的选择。本发明内容并不意于确定本发明的关键特征或基本特征，其也不意于限制所述主题的范围。
附图说明
参照下述描述和附图，将更好地理解所述主题的上述及其他特征、方面和优点，其中：
图1示出根据本主题的实施方案的金属化的聚乙烯层压体。
图2示出根据本主题的另一个实施方案的金属化的聚乙烯层压体。
图3示出根据本主题的实施方案的如图1或图2所示的金属化层压体的制造方法。
具体实施方式
本发明提供金属化的聚乙烯层压体，其包括：聚乙烯外层；金属化的酸性共聚物层；与所述金属化的酸性共聚物层接触的聚乙烯内层；和任选的挤出的聚乙烯层；和聚乙烯密封剂层。在另一方面，本发明还提供由这种层压体制成的层压制品。
层压体通常由在挤出时使用热聚合物熔体或者使用粘合剂而粘合在一起的多个层或膜制成。通常，层压体成形为三个层，即外层、中间层和内层，在外层与中间层之间以及中间层与内层之间均具有连接层(tie layer)。外层通常充当印刷层，主要由聚乙烯组成。层压体的中间层通常由铝或乙基乙烯醇(ethyl vinyl alcohol)(EVOH)、尼龙(聚酰胺)形成，其充当对大气和湿气的阻挡层。目前制造的由层压层制成的管包括铝阻挡层压体(ABL)或塑料阻挡层压体。层压体的内层主要由聚乙烯组成，其充当密封剂层。当层压体已经加工和成形为储存容器时，所述内层防止储存容器中包装的内容物与中间层之间接触。不同层之间的连接层充当将所述层粘合在一起并形成层压体的粘合剂。此外，所述层压体也可成形为多层结构。
通常，聚合物膜的金属化是有益的，因为赋予所述聚合物膜层压体适合的阻挡性。其适合于需要保持质地和气味的易变质的物品如食品、物品如化妆品。此外，当包装上述物品时，蒸汽和/或气体阻挡性是重要的。
在本发明的实施方案中，所述金属化的聚乙烯层压体进一步包括与所述金属化的酸性共聚物层接触的酸性共聚物层；和与上述酸性共聚物层接触的第二金属化的酸性共聚物层。所述酸性共聚物层和第二金属化的酸性共聚物层位于所述第一金属化的酸性共聚物层和聚乙烯内层之间。
在本发明的又一实施方案中，所述金属化的聚乙烯层压体中的聚乙烯层是多层聚乙烯膜；优选两层或三层膜。当所述聚乙烯膜是两层时，所述层的厚度可以是30μ和60μ，而在三层聚乙烯膜情况下，各层的厚度可以是30μ、60μ和30μ。
所述金属化的聚乙烯层压体中的聚乙烯密封剂层可以是总厚度为50μ的单层或多层。在本发明的另一个实施方案中，所述金属化的聚乙烯层压体中的聚乙烯密封剂层是多层膜，优选三层膜。
在本发明的另一个实施方案中，所述金属化的聚乙烯层压体中的聚乙烯层是线性低密度聚乙烯和低密度聚乙烯的组合。根据该实施方案，所述金属化的聚乙烯层压体的聚乙烯外层和聚乙烯内层可以是线性低密度聚乙烯和低密度聚乙烯的组合。低密度聚乙烯通常具有0.918g/cc至0.935g/cc范围、优选0.918g/cc的密度；线性低密度聚乙烯具有0.912g/cc至0.940g/cc范围、优选0.927g/cc的密度。
在本发明的又一实施方案中，所述金属化的聚乙烯层压体中的酸性共聚物是乙烯丙烯酸共聚物。可用于根据本发明的金属化的聚乙烯层压体的各种酸性共聚物例如是酸含量百分比在7%至9%范围内变化的来自EXXONMOBIL的Escore、来自DOW的Primacore和来自Dupont的Nucrel。
乙烯丙烯酸(EAA)作为酸性共聚物赋予所述均聚物膜良好的金属粘合性。EEA层充当极性表面，实现与金属膜的良好粘合。这又允许所述均聚物膜与金属膜粘合。
所述金属膜可以是预定厚度在40-700埃单位范围内的铝。在优选实施方案中，所述金属膜是铝。
在另一个实施方案中，所述金属化的聚乙烯层压体包括具有至少一个酸性共聚物层的多层聚乙烯膜，其后是将所述具有至少一个金属化的酸性共聚物层的多层聚乙烯膜与具有至少一个也金属化的酸性共聚物层的另一聚乙烯单层或多层进行接合的粘合剂层或连接层。
优选地，本发明提供一种金属化的聚乙烯层压体，其包括：总厚度为120μ的多层聚乙烯外层；与所述多层聚乙烯接触的厚度为25μ的酸性共聚物层；与所述酸性共聚物层接触的厚度为25μ的金属化的酸性共聚物层；与所述金属化的酸性共聚物层接触的厚度为75μ的聚乙烯内层；厚度为25μ的挤出的聚乙烯层；和厚度为50μ的聚乙烯密封剂层。
本发明的另一个实施方案提供一种金属化的聚乙烯层压体，其包括：总厚度为90μ的多层聚乙烯外层；与所述多层聚乙烯接触的厚度为30μ的金属化的酸性共聚物层；与所述金属化的酸性共聚物层接触的厚度在20μ至30μ范围内的酸性共聚物层；与上述酸性共聚物层接触的厚度为30μ的另一金属化的酸性共聚物层；和与上述金属化的酸性共聚物层接触的厚度为90μ的聚乙烯内层。
在本发明的实施方案中，图1示出了所述层压体的示例性结构。根据图1的多层金属化的层压体100包括至少一个聚乙烯(PE)膜102、至少一个酸性共聚物膜104(优选乙基丙烯酸(EAA))和至少一个金属膜106(优选铝膜)。金属膜106沉积在具有PE膜108的EAA层107的表面上。在下文中，聚乙烯膜102可互换地称为PE膜102，酸性共聚物膜104可互换地称为EAA膜104。
在一个实施方案中，PE膜102是多层的，其可以是双层或三层膜。在双层PE膜102的情况下，所述层的厚度可以是30μ和60μ。在三层PE膜102的情况下，各层的厚度可以是30μ、60μ和30μ。
在图1的金属化的层压体100中，PE膜108与聚乙烯挤出层109接触，其后是可以为单层或多层的PE密封剂层110。该PE密封剂层110优选是三层膜。
在本发明的另一个实施方案中，图2示出了本主题的层压体的另一示例性结构。图2提供了一种金属化的层压体200，其包括具有用金属层206金属化的酸性共聚物层204的PE膜202。所述金属化层206与连接层或粘合剂层201接触。该连接层201将金属化层206与另一金属层207接合。金属层207是金属化于具有PE膜209的酸性共聚物层208上的层。所述PE膜202和209可以是多层膜。
本发明的金属化的聚乙烯层压体可使用真空金属化或等离子体处理或等离子体金属化方法来制备。用于获得所述金属化的聚乙烯层压体的金属化工艺优选使用等离子体处理。等离子体处理增大待金属化的表面积，促进金属化工艺。
除了除去湿气及其它有机污染物和粉尘颗粒之外，等离子体以各种方式与金属片(web)的表面相互作用。其也通过引入极性基团起到增加成核位点数量的作用，产生具有均匀表面形态和更少缺陷的覆盖层，从而促进高的金属粘合性和良好的金属化膜与金属的粘合强度。其也有助于提高膜的阻挡性。
在本发明的又一实施方案中，图3示出本主题的金属化的层压体的制备方法。在步骤301中，由PE和EAA的挤出吹塑膜制造PE膜。结果，所述PE膜的一侧上覆盖有EAA膜。在步骤302中，接着通过使高温流化的等离子体经过所述EAA膜表面来等离子体处理所述EAA膜，以使所述EAA膜适合于金属化。此外，在步骤303中，接着用金属使所述EAA膜金属化。最后，在步骤304中，层压所述PE膜、EAA连接层和金属。所述层压可具有另一具有EAA层的金属化PE膜，具有连接层或粘合剂层使这两个金属化PE膜接合。
所述层压也可具有所述金属化的PE膜、和具有EAA层与PE挤出层的非金属化的PE膜。
步骤305至306示出常规的管制造步骤，其中在步骤305中固化所述层压体，随后在步骤306中切割所述层压体。此外，在步骤307中印刷刚切割的层压体，最后在步骤308中，进行制管工艺。
在本发明的实施方案中，所述金属化的聚乙烯层压体可制成层压管。
实施例
现将用工作例来说明本发明，所述工作例是用来说明本发明的实施，并非用来限制性隐含对本发明的范围有任何的限制。其它实施方案也是可以的。
实施例1：
总厚度为120μ的三层聚乙烯外膜与厚度为25μ的乙烯丙烯酸连接层接触。所述连接层将所述聚乙烯层粘合至厚度也为25μ的金属化的乙烯丙烯酸层。所述金属化的乙烯丙烯酸层与组合厚度为75μ的另一多层聚乙烯膜接触。该多层聚乙烯膜通过厚度为25μ的挤出的聚乙烯层粘合至多层密封剂层。所述金属化的聚乙烯层压体的结构如下所示：
30μPE/60μPE/30μPE//25μEAA(连接层)//金属化的25μEAA膜/50μPE/25μPE//25μ挤出PE(连接层)//12.5μPE/25μPE/12.5μPE。
实施例2：
总厚度为90μ的双层聚乙烯外膜与厚度为30μ的金属化的乙烯丙烯酸层接触，所述金属化的乙烯丙烯酸层又通过厚度在20μ至30μ范围内的乙烯丙烯酸连接层粘合至厚度为30μ的另一金属化的乙烯丙烯酸层。厚度为90μ的两层聚乙烯内膜与上述金属化的乙烯丙烯酸层接触。
所述金属化的聚乙烯层压体的结构如下所示：
30μPE/60μPE/金属化的30μEAA//20μ至30μ连接层或粘合剂层(EAA)//金属化的30μEAA/60μPE/30μPE。
本主题的前述类型及其等同物具有许多优点，包括以下所述的那些：
1.本发明提供金属化的聚乙烯层压体，其在制成制品时呈现出良好的气体和蒸汽阻挡性。
2.本发明提高了产品的吸引力。
3.本发明还以成本有效方式提供金属化的聚乙烯层压体。
尽管参考其某些优选实施方案已相当详细地描述了本主题，但其它实施方案也是可能的。同样地，本发明的精神和范围并不应限于其所包含的优选实施方案的描述。

Claims (11)

1.一种金属化的聚乙烯层压体，其包括：
聚乙烯外层；
第一金属化的酸性共聚物层；
与所述金属化的酸性共聚物层接触的聚乙烯内层；
和任选的
挤出的聚乙烯层；和
聚乙烯密封剂层。
2.根据权利要求1所述的金属化的聚乙烯层压体，其进一步包括：
酸性共聚物层；和
第二金属化的酸性共聚物层；
其中所述酸性共聚物层和第二金属化的酸性共聚物层位于所述第一金属化的酸性共聚物层和聚乙烯内层之间。
3.根据权利要求1或2所述的金属化的聚乙烯层压体，其中所述聚乙烯层是多层聚乙烯膜。
4.根据权利要求3所述的金属化的聚乙烯层压体，其中所述多层聚乙烯膜是厚度在90μ至120μ范围内的两层膜。
5.根据权利要求1所述的金属化的聚乙烯层压体，其中所述聚乙烯密封剂层是多层膜，如三层膜。
6.根据权利要求5所述的金属化的聚乙烯层压体，其中所述聚乙烯密封剂层的总厚度为50μ。
7.根据权利要求1所述的金属化的聚乙烯层压体，其中所述聚乙烯层是线性低密度聚乙烯和低密度聚乙烯的组合。
8.根据权利要求1或2所述的金属化的聚乙烯层压体，其中所述酸性共聚物是乙烯丙烯酸共聚物。
9.根据权利要求1或2所述的金属化的聚乙烯层压体，其包括：
总厚度为120μ的多层聚乙烯外层；
与所述多层聚乙烯接触的厚度为25μ的酸性共聚物层；
与所述酸性共聚物层接触的厚度为25μ的金属化的酸性共聚物层；
与所述金属化的酸性共聚物层接触的厚度为75μ的聚乙烯内层；
厚度为25μ的挤出的聚乙烯层；和
厚度为50μ的聚乙烯密封剂层。
10.根据权利要求1或2所述的金属化的聚乙烯层压体，其包括：
总厚度为90μ的多层聚乙烯外层；
与所述多层聚乙烯接触的厚度为30μ的金属化的酸性共聚物层；
与所述金属化的酸性共聚物层接触的厚度在20μ至30μ范围内的酸性共聚物层；
与上述酸性共聚物层接触的厚度为30μ的其它金属化的酸性共聚物层；和
与上述金属化的酸性共聚物层接触的厚度为90μ的聚乙烯内层。
11.一种层压管，其由根据权利要求1至10中任一项所述的金属化的聚乙烯层压体制成。
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