CN105026152A - 用于制造柔性包装膜的组合物及方法 - Google Patents

用于制造柔性包装膜的组合物及方法 Download PDF

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CN105026152A
CN105026152A CN201480012507.7A CN201480012507A CN105026152A CN 105026152 A CN105026152 A CN 105026152A CN 201480012507 A CN201480012507 A CN 201480012507A CN 105026152 A CN105026152 A CN 105026152A
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film
density polyethylene
blown film
hdpe
inorganic filler
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艾希莉·雷多尔夫
布拉德·德韦恩·罗杰斯
本杰明·苏西
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Frito Lay North America Inc
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Abstract

用于制造柔性包装膜的组合物和方法，所述柔性包装膜高装填有至少一种无机填料。包含至少重量计50％的无机填料的HDPE吹塑膜沿机器方向被定向，以增加产率和拉伸强度，并减少厚度变化，以提高印刷质量。

Description

用于制造柔性包装膜的组合物及方法
发明背景
技术领域
本发明涉及一种可以在产品中使用的定向的(oriented)柔性膜材料以及制造定向的柔性膜的方法。
相关技术的描述
多层膜结构常用于需要具有良好的阻隔性、密封性和图形能力特性的柔性包装中。为了保护包装内的产品免受光、氧气或水分的侵害，在一层或多层中的阻隔性能是重要的。存在这样的需求，例如对于食品的保护，如果没有足够的阻隔性能来阻挡例如光、氧气或水分等这样的物质进入包装内，食品可能遭受风味损失、老化或变质的风险。为了使柔性包装形成密闭或气密密封，密封性能是重要的。如果没有气密密封，任何由膜提供的阻隔性能都不能有效地抵抗氧气、水分、或香味在包装内的产品与外界之间的传递。图形能力是需要的，因为图形能力能使消费者快速地识别出他或她正寻求购买的产品，并使食品制造商能标出所包装的食物的营养成分，并能够使价格信息(例如条码)被置于产品上。
现有技术中的一种制备聚合物膜的方法是吹塑膜挤出工艺。通过将熔融的聚合物树脂从一环形模具挤出形成吹塑膜。气体被吹到聚合物膜环上，以使其伸展，并产生具有扩展直径的气泡。然后气泡被辊(可选地被狭缝)压平成一个双层片材，并卷绕到存储辊上。
使用吹塑膜在后续的印刷和包装操作中有几个缺点。吹塑膜在压制和卷绕过程中具有例如皱纹和折叠等的缺陷，这使得其在印刷及包装中的利用是不经济的。图形印刷工艺需要光滑、均匀的表面，以产生有吸引力的和有功能性的膜。而且，相比由其它工艺生产的膜，吹塑膜通常很厚。因此，吹塑膜的产率(其可以用每磅聚合物平方英寸来表示)是非常低的。此外，吹塑膜与其他的膜相比，具有低的拉伸强度。
发明内容
在本发明的一个实施例中，一种制造柔性包装膜的方法包括以下步骤：提供吹塑膜，所述吹塑膜包含高密度聚乙烯树脂和按重量计至少50％的无机填料，并具有初始厚度；将所述吹塑膜沿机器方向进行定向，以产生具有最终厚度的定向膜，所述最终厚度小于所述初始厚度至少35％。在另一个实施例中，定向步骤生产具有10％或更小的厚度变化系数的定向膜。在另一个实施方案中，无机填料包括滑石，粘土，二氧化硅，硅藻土，高岭土，云母，石膏，硝酸钾，氯化钠，金属氯化物，白云石，膨润土，蒙脱石，金属硫酸盐，硝酸铵，钠硝酸盐，二氧化钛和碳酸钙中的至少一种。
在一个实施例中，定向步骤包括在1.1：1和3.0：1之间的拉伸比。在另一个实施例中，该方法还包括用一个或多个表层层压所述定向膜的步骤，所以表层可以包括EAA(乙烯丙烯酸)，EVOH(乙烯-乙烯醇)，尼龙，HDPE(高密度聚乙烯)，LDPE(低密度聚乙烯)，LLDPE(线型低密度聚乙烯)，PGA(聚乙醇酸)，或PBS(聚丙烯酸苯乙烯)中的至少一种。
在本发明的一个实施例中，柔性包装膜包括吹塑膜，所述吹塑膜包含高密度聚乙烯树脂和按重量计至少50％的无机填料，其中，所述吹塑膜已沿机器方向被定向而达到最终厚度，所述最终厚度小于初始厚度的至少35％。在另一个实施例中，所述吹塑膜具有10％或更小的厚度变化系数。
无机填料可以包括滑石，粘土，二氧化硅，硅藻土，高岭土，云母，石膏，硝酸钾，氯化钠，金属氯化物，白云石，膨润土，蒙脱石，金属硫酸盐，硝酸铵，硝酸钠，钛氧化钛，碳酸钙中的至少一种。
在另一个实施例中，所述膜还包含在所述吹塑膜上的至少一个表层，所述表层可以包括EAA(乙烯丙烯酸)，EVOH(乙烯-乙烯醇)，尼龙，HDPE(高密度聚乙烯)，LDPE(低密度聚乙烯)，LLDPE(线型低密度聚乙烯)，PGA(聚乙醇酸)，或PBS(聚丙烯酸苯乙烯)中的至少一种。
附图的简要描述
对本发明的相信为新颖的特征在所附的权利要求中进行了阐述。但是，在结合附图进行阅读时，通过参考对示例性实施例的以下详细描述，将能够获得对本发明本身和所使用的优选模式，以及本发明的目的和优点的最好的理解，其中：
图1描述了用于制造吹塑膜的***的一个实施例；
图2示出用于将吹塑膜沿机器方向进行定向的***的一个实施例。
详细描述
在一个实施例中，本发明针对的是用于在多层柔性膜包装中使用的定向的吹塑膜。图1描述了用于生产本发明中的吹塑膜的***(有时被称为高茎吹塑膜生产线)的一个实施例。聚合物树脂、添加剂和其它成分在料斗102中进行混合，并被供给到挤出机104，在该挤出机内，各成分被熔融和混合，并且随着气体被吹送离开模具106到达聚合物膜管108，各成分被从环形模具106(或环模)挤出。气体有助于拉伸和扩大聚合物管108的直径。聚合物管108在辊110之间被压平，以产生一个双层片材112。然后该双层片材112被卷绕到存储辊上，或者被进行分切操作114。片材112可以在一侧切开，并展开成一个有双层片大约两倍宽的单层片。可替代地(如图1所示)，片材112可在两侧被切开，被分离成两个单层片116，每个单层片的宽度约等于该双层片的宽度，并被卷绕到存储辊118和120上。
生产吹塑膜的主要成本之一是被投入到挤出机中的原料的成本。例如，在意图用于低成本的产品的包装膜中使用高密度聚乙烯(HDPE)树脂会过于昂贵。本申请人提出通过将大量的无机填料加入初始的成分混合物中来降低原料的成本。该无机填料替代了产生吹塑膜所需的很大一部分聚合物树脂。
无机填料的非限制性的实例包括，但不限于：滑石，粘土，二氧化硅，硅藻土，高岭土，云母，石膏，硝酸钾，氯化钠，金属氯化物，白云石，膨润土，蒙脱石，金属硫酸盐，硝酸铵，硝酸钠，二氧化钛和碳酸钙。
申请人已发现，当在HDPE聚合物树脂混合物中包含按重量计50％以上的无机填料时，所得到的吹塑薄膜会包括一些特性，这些特性使其作为产品的包装膜的一部分在商业环境中的使用存在问题。首先，在高装填水平，拉伸模量被大幅降低，使薄膜起皱并在印刷过程中折叠。如果在该膜上施加额外张力以解决此问题，则该膜会显示出显著“缩幅”，这降低了总产率。另外，这种吹塑膜的表面与不含大量填料的膜的表面相比，其相对粗糙。光滑的印刷表面对于产品包装的印刷一致性和生动的图形能力是理想的。
这些问题可通过将高装填的(highly loaded)HDPE吹塑膜沿机器方向进行定向的方法来克服。其中一个实施例在图2中示出。膜首先在夹持辊202和第一加热辊204和第二加热辊206之间通过。然后将膜在慢拉伸辊208和快拉伸辊210之间进行拉伸。退火辊212和214，以及冷却辊216和218完成定向过程。
虽然图2中所示出的过程描绘了所使用的多个辊，在其最广泛的方面，机器方向定向可以通过使用两个或多个独立的被驱动辊来实现，其中膜在相邻的辊之间被拉伸。优选地，这些辊中的一个或多个辊被加热到温度刚好低于正被定向的聚合物膜的熔点的温度。拉伸比可以从1.1：1变化到3.0：1。该拉伸比在本文中被定义为：未定向的膜的厚度：定向的膜的厚度。
可以在上述的分切工序之前或之后对吹塑膜进行机器定向处理。
该定向处理在几个方面对高装填膜有改进。首先，它改善了膜的拉伸强度。在一系列的测试中，将包含约50％重量的碳酸钙填料的吹塑的HDPE膜利用类似于上述参考图2所述的方法沿机器方向进行定向，这些试验的结果如下所述。
在一个试验中，定向前的平均初始厚度为1.5密耳的HDPE吹塑膜，拉伸强度为1164克力。当该1.5密耳的膜被定向至最终厚度为1.0密耳时，拉伸强度被提高到1607克力(增加38％)。当1.5密耳的膜被定向至最终厚度为0.7密耳时，拉伸强度被提高到1665克力(增加43％)。
在另一个试验中，定向前的平均初始厚度为2.0密耳的HDPE吹塑膜，拉伸强度为1788克力。当2.0密耳的膜被定向至最终厚度为1.0密耳时，拉伸强度被提高到2016克力(增加13％)。类似地，当2.0密耳的膜被定向至最终厚度为0.8密耳时，拉伸强度被提高到2180克力(增加22％)。使用英斯特朗(Instron)4444拉伸试验设备对各膜的拉伸强度进行测量。机械力被施加到一个1英寸×4英寸的膜样品，并测量样品断裂所需的伸长率和力。
改进拉伸强度并不是对吹塑膜进行上述机器定向处理的唯一优点。下表显示了使用装载有大约50％重量的碳酸钙的高密度聚乙烯树脂制成的几种吹塑膜中的每一种的产率，以千平方英寸每磅(MSI/磅)为单位。“基膜”列表示未经历机器方向定向处理的吹塑膜。“MDO膜”列是已被定向成最终平均厚度为0.8密耳的膜。
表1:由机器方向定向引起的产率提高
如表1中的数据所示，对高装填的吹塑膜进行定向可以极大地提高产率，因此提高使用一片吹塑膜可以制成的包装的数量。因此，膜厚度可以降低至少约35％，而且总产率可提高40％以上。
由机器方向定向步骤提供的另一个优点是，MOD膜中的厚度变化或表面粗糙度被降低，用扫描电子显微镜对沿机器方向进行定向处理之前和之后的高装填的吹塑的HDPE膜的样品的截面进行了分析。MDO薄膜的顶部表面和底部表面都显示出厚度变化显著减小和更光滑的表面。光滑的表面在高清晰度印刷工艺中很重要。
在一个例子中，对具有1.5密耳的标称厚度的基膜和具有0.5密耳的标称厚度的MDO膜的厚度变化进行了测量。MDO膜显示出在平均厚度的标准偏差(或厚度系数变化)上具有改进，以及在相对于平均厚度的最小厚度和最大厚度上具有改进。在一个实施方案中，本发明的MDO薄膜具有10％或更小的厚度变化系数(标准偏差除以平均厚度)。
可以使用本领域已知的方法将本发明的柔性膜层压成一层或多层包装膜。例如，包含本文所述的MDO膜的一个或多个芯层可以与一个或多个表层层压在一起，这可以用于促进金属粘附，密封，或其他的表面特性。表层的例子包括EAA(乙烯-丙烯酸)，EVOH(乙烯-乙烯醇)，尼龙，HDPE(高密度聚乙烯)，LDPE(低密度聚乙烯)，LLDPE(线性低密度聚乙烯)，PGA(聚羟基乙酸)，或PBS(聚丙烯酸苯乙烯)。根据本发明的一个实施例的多层包装薄膜的总厚度范围为0.5密耳至3.0密耳。然后包装膜可用于使用本领域中市售的例如立式成型充填封口(VFFS)机等设备来生产柔性产品包装。
除非另外指出，在本说明书和权利要求书中使用的所有表示成分含量、性质(例如分子量)、反应条件等的数字在所有例子中都应被理解为由术语“约”修饰。因此所有数字，除非另外指出与此相反，在以下的说明书和所附权利要求中阐述的数值参数皆为近似值，该近似值可以根据试图由本发明获得的所需的性能进行变化。至少，并非试图将申请的等同原则限制于本权利要求的范围，每个数值参数应当至少依据所披露的有效数字的数值、并采用一般四舍五入技术进行理解。
虽然参考优选实施例已经对本发明进行了特别示出和描述，但是本领域的技术人员可以理解，在不脱离本发明的精神和范围的情况下，在形式和细节上可以对其进行各种变化。

Claims (11)

1.一种制造柔性包装膜的方法，包括以下步骤：
提供吹塑膜，所述吹塑膜包含高密度聚乙烯树脂和按重量计至少50％的无机填料，并具有初始厚度；
将所述吹塑膜沿机器方向进行定向，以产生具有最终厚度的定向膜，所述最终厚度小于所述初始厚度至少35％。
2.如权利要求1所述的方法，其中定向步骤还包括生产具有10％或更小的厚度变化系数的所述定向膜。
3.如权利要求1所述的方法，其中所述无机填料包括滑石、粘土、二氧化硅、硅藻土、高岭土、云母、石膏、硝酸钾、氯化钠、金属氯化物、白云石、膨润土、蒙脱石、金属硫酸盐、硝酸铵、钠硝酸盐、二氧化钛和碳酸钙中的至少一种。
4.如权利要求1所述的方法，其中定向步骤包括在1.1：1和3.0：1之间的拉伸比。
5.如权利要求1所述的方法，还包括用一个或多个表层层压所述定向膜的步骤。
6.如权利要求5所述的方法，其中所述一个或多个表层包括EAA乙烯丙烯酸、EVOH乙烯乙烯醇、尼龙、HDPE高密度聚乙烯、LDPE低密度聚乙烯、LLDPE线型低密度聚乙烯、PGA聚乙醇酸或PBS聚丙烯酸苯乙烯中的至少一种。
7.一种柔性包装膜，包括吹塑膜，所述吹塑膜包含高密度聚乙烯树脂和按重量计至少50％的无机填料，其中，所述吹塑膜已沿机器方向被定向而达到最终厚度，所述最终厚度小于初始厚度的至少35％。
8.如权利要求7所述的柔性包装膜，其中所述吹塑膜具有10％或更小的厚度变化系数。
9.如权利要求7所述的方法，其中所述无机填料包括滑石、粘土、二氧化硅、硅藻土、高岭土、云母、石膏、硝酸钾、氯化钠、金属氯化物、白云石、膨润土、蒙脱石、金属硫酸盐、硝酸铵、钠硝酸盐、二氧化钛、碳酸钙中的至少一种。
10.如权利要求7所述的柔性包装膜，还包括位于所述吹塑膜上的至少一层表层。
11.如权利要求10所述的方法，其中所述至少一层表层包括EAA乙烯丙烯酸、EVOH乙烯乙烯醇、尼龙、HDPE高密度聚乙烯、LDPE低密度聚乙烯、LLDPE线型低密度聚乙烯、PGA聚乙醇酸或PBS聚丙烯酸苯乙烯中的至少一种。
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