CN1980792A - 共挤出的掩模层 - Google Patents

共挤出的掩模层 Download PDF

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CN1980792A
CN1980792A CNA2005800219319A CN200580021931A CN1980792A CN 1980792 A CN1980792 A CN 1980792A CN A2005800219319 A CNA2005800219319 A CN A2005800219319A CN 200580021931 A CN200580021931 A CN 200580021931A CN 1980792 A CN1980792 A CN 1980792A
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mask layer
inch
ionomer
polymeric
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D·C·史密斯
M·A·泰勒
H·L·斯卡廖内
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A Schulman Invision Inc
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Abstract

描述了含有掩模层和聚合物层的共挤出多层板。掩模层对聚合物层的粘合程度低，因而它能够被除去。在热成型及其它二次加工步骤中，掩模层可以被附着在聚合物层上。该多层板可以包含任意数量的其它层。

Description

共挤出的掩模层
相关申请
本申请要求2004年7月2日提交的美国临时申请系列号60/585,415的优先权，该申请通过引用结合到此。
技术领域
在加工、运输等过程中，聚合物表面使用保护性掩模层进行保护，以避免被损坏。
背景技术
有时候，在聚合物板状表面上施用层压掩模层，以保护该聚合物板状表面。掩模层通常使用粘合剂将其附着到聚合物板状表面上。层压工艺会在聚合物板状表面和掩模层之间留下形成空隙或气泡的薄间距。这些缺陷可能会导致聚合物板状表面的表面性质发生变化，例如，图像的光泽或分辨性(distinction)会发生变化。另外，聚合物表面和掩模层之间会形成污染，因而可能会导致其它表面变化。
发明内容
多层板包括掩模层和聚合物层。掩模层与聚合物层共挤出，并且掩模层与聚合物层之间的粘附程度低。在热成型和其它二次加工步骤中，掩模层可以被附着在聚合物层上。而且，掩模层不会使聚合物层的表面退化，并且可以起着潮气阻挡层的作用。多层板可以包含任意数量的其它层。
附图说明
图1所示为两层板的横截面图。
图2所示为其中顶层被部分分开的两层板的横截面图。
图3所示为三层板的横截面图。
图4所示为其中顶层被部分分开的三层板的横截面图。
具体实施方式
作为本领域普通技术人员如何制备及使用所要求发明的实例，本说明书示出了具有共挤出掩模层的多层板的一些实例。这些实例在此处进行描述，是为了满足实施的需要，并且它们只是最佳的方式，而并不是施加权利要求中所没有提及的限制。
多层板中的每一个掩模层都保护相邻底层的表面，但是对该底层的粘附性没有达到粘附程度。具体而言，掩模层可从该底层中剥离。然而，如果需要进行热成型或其它二次加工步骤，则掩模层与底层之间的粘附程度足以使掩模层在进行这些加工时保持位于多层聚合物膜或板上。基于最终产物的要求，可以选择掩模层，以使底层的表面质量不会退化或减小到预定可接受的程度之外。
如图1所示，通过共挤出，可以形成包含掩模层12和聚合物层14的两层板10。共挤出技术是众所周知的。一般而言，膜或板的共挤出指的是：多层聚合物膜安置在共平面内挤出，并使各个层彼此接触，同时聚合物膜仍然为熔融状态的工艺。如果各个聚合物层的分子结构存在相互作用，则聚合物为熔融状态时，这些相互作用通常也会发生。聚合物层之间的相互作用可以包括但不限制于物理相互作用，比如聚合物层之间的聚合物链的缠结；共价结合，比如聚合物层之间的聚合物链的交联；以及离子及其它静电相互作用。这种层之间的相互作用例如可以产生层之间的粘合。此处使用的粘合指的是施加在多层板的两个层之间的吸引力。粘合程度可以从层不能分离的高程度，到施加一些力就可以使层分离的较低粘合的程度，到层之间不存在粘合因而层可以彼此自由地相对移动的程度的宽范围内变化。
选择图1的掩模层12的材料，使得掩模层12与共挤出的聚合物层14的粘合程度低。换言之，掩模层12与聚合物层14彼此间的相互作用的程度低，因而当施加小于掩模层12的抗撕强度的力时，掩模层12与聚合物层14分离。图2示出了掩模层12与聚合物层14部分分离的多层膜。例如，将掩模层12从聚合物层14中除去所需的力可以在约0.05磅/英寸～约8磅/英寸之间。备选地，将掩模层12从聚合物层14中除去所需的力可以在约0.05磅/英寸～约6磅/英寸之间、在约0.05磅/英寸～约4磅/英寸之间、在约0.05磅/英寸～约2磅/英寸、或在约0.05磅/英寸～约1磅/英寸之间。粘合程度可以足够低，因而聚合物层14的表面不会因粘合自身或将掩模层12从聚合物层14中除去的工艺而退化。此处使用的术语“退化”意指底层表面的损坏或畸变。术语畸变要表示导致了图像光泽或分辨性的变化。使聚合物层14的表面退化的准确的粘合程度取决于用于形成聚合物层14的聚合物的物理性质。
掩模层12的厚度和弹性可能影响掩模层12能够从聚合物层上除去的容易程度。通常地，对于给定的材料，掩模层12越厚，则其具有的结构完整程度可能对其从聚合物层14中剥离或除去的能力影响越大。另外地，用于掩模层12的材料的弹性与厚度一起也能够影响掩模层12从聚合物层14中剥离或除去的能力。可以用于形成掩模层12的材料的实例包括但不限制于线性低密度聚乙烯、低密度聚乙烯、聚乙烯-辛烯、聚乙烯-己烯、聚乙烯-丁烯、聚丙烯、聚酰胺、聚碳酸酯、ABS，SEBS，TPE、交联的热塑性硫化橡胶、以及这些的共聚物或混合物。这些材料还可以包括用于改善它们性能的各种添加剂。当聚酰胺用于掩模层12时，掩模层12的厚度的实例在约25～约75微米之间。
用于形成掩模层12的材料的选择取决于用于聚合物层14的材料。如上所讨论的，掩模层12与聚合物层14之间的分子相互作用是决定掩模层12是否对聚合物层14的粘合程度低的因素。因此，在选择好用于聚合物层14的聚合物之后，选择形成掩模层12的聚合物。例如，聚合物层14可以是，但并不限制于，离聚物。有益的离聚物可以为，但不限制于，乙烯与部分被锌、钠、镁或锂离子中和的α，β-烯键式不饱和C3-C8羧酸形成的共聚物。当乙烯与α，β-烯键式不饱和C3-C8羧酸形成的共聚物用于聚合物层时，能够用于掩模层12的聚合物的实例为聚酰胺。
将掩模层12除去之后的聚合物层14的表面光泽度被认为是在确定用于掩模层12及聚合物层14的材料的结合时需要考虑的因素。在这种情况下的光泽指的是掩模层12被除去之后的聚合物层14的表面的″光亮″。更具体而言，表面光泽可以被描述为光从表面的反射(与颜色无关)。为了测量表面的光泽，可以使在特定角度的单束光离开表面偏转到检测器上。该检测器然后测量所接收的光强度。然后，与检测器连接的控制器及显示单元可以提供能够被转变成光泽值的强度值或者该控制器可以直接显示光泽值。光泽值越高，则表面越光亮。
光泽的标准测试方法是ASTM D 523。在ASTM D 523中，单束光的标准角为60°，但是在特殊情况下，也可以使用20°和85°的角。对于此处描述的多层板，如果聚合物层14在掩模层12被除去时需要高的光泽，则可规定，在60°下测量的光泽度大于约85。备选地，可以规定，聚合物层14在掩模层12被除去时在60°下测量的光泽度大于约90、大于约95或大于约100。
多层板可以具有任意数量的其它层。其它层能够表现出各种功能，包括提供色彩或结构刚性。图3所示为三层板的实例。在图3中，三层板20包括掩模层22、清澈的(clear)离聚物层24和聚合物层26。掩模层22和聚合物层26具有与上述掩模层12和聚合物层14相同的性质。清澈的离聚物层24只是没有加入颜料的如上所述的离聚物层。多层板还能够包括一个或多个另外的衬里层。这些衬里层可以是但不限制于聚丙烯、TPO、聚乙烯、聚酰胺、聚酯、丙烯腈丁二烯苯乙烯共聚物以及它们的混合物。
具有掩模层的多层板可以进行热成型，例如形成汽车的缓冲器，或进行其它二次加工步骤。如果具有掩模层的多层板进行热成型或进行其它二次加工步骤，则可以选择掩模层，以使其在热成型或二次加工步骤过程中能够附着在下面的聚合物层上。在这些步骤中，掩模层的存在将有助于保护下面聚合物层的表面。将在热成型过程中附着于下面聚合物层上的掩模层除去所需要的力为约0.05磅/英寸～约8磅/英寸。备选地，将在热成型过程中附着于下面聚合物层上的掩模层除去所需要的力为约0.05磅/英寸～约6磅/英寸、为约0.05磅/英寸～约4磅/英寸、为约0.05磅/英寸～约2磅/英寸或为约0.05磅/英寸～约1磅/英寸。即使多层板不进行热成型或其它二次加工步骤，掩模层的存在也有助于在运输或处理多层板过程中保护下面聚合物层的表面。
此处描述的多层板的掩模层可以用作下面聚合物层的潮气阻挡层。一些聚合物能够从直接接触的水或从环境大气湿度中吸收潮气。通常，当给定聚合物产物进行热成型或二次加工步骤时，该聚合物产物必要进行干燥。如果聚合物产物在进行热成型或二次处理步骤中没有进行干燥，则被吸入聚合物产物中的任何水份在进行热成型或二次加工步骤中都会释放出来，从而导致板外观的畸变。作为实施例，离聚物材料根据用于中和离聚物的离子而具有不同程度的吸湿(不同离子以不同的速率吸湿)。因此，当离聚物材料用于多层板的下面聚合物层时，如果所选择的材料合适，则掩模层可以起着潮气阻挡层的作用，因而可以使多层板在没有先干燥的情况下进行加工。
这里写出的说明书陈述了本发明的最佳方式，并且描述了本发明，因而本领域的技术人员能够通过在权利要求中所述特征的实例，制备及使用本发明。本发明的可专利性范围由权利要求限定，并且可以包括本领域技术人员所能想到的其它实例。这样的其它实例可以是在本申请日之前或之后得到的实例，并且如果它们具有的特征并不是与本权利要求的文字语言不同，或者如果它们包括与权利要求的文字语言无实体上差异的等价特征，则它们也都在本权利要求的范围之内。

Claims (20)

1.一种共挤出的多层板，其包括：
聚合物层；以及
掩模层，其与聚合物层共挤出，并且与所述聚合物层的粘合程度低。
2.权利要求1的多层板，其中所述掩模层不会使所述聚合物层的表面退化。
3.权利要求1的多层板，其中当所述掩模层被除去时，所述聚合物层在60°下测量的光泽度大于约85。
4.权利要求1的多层板，其中所述掩模层用作湿气阻挡层。
5.权利要求1的多层板，其中除去掩模层需要的力为约0.05磅/英寸～约8磅/英寸。
6.权利要求1的多层板，其中除去掩模层需要的力为约0.05磅/英寸～约4磅/英寸。
7.权利要求1的多层板，其中除去掩模层需要的力为约0.05磅/英寸～约2磅/英寸。
8.权利要求1的多层板，其中所述聚合物层包含离聚物。
9.一种共挤出的多层板，其包括：
聚合物层；
清澈的离聚物层；以及
掩模层，其与清澈的离聚物层共挤出，并且所述聚合物层与所述清澈的离聚物层的粘合程度低。
10.权利要求9的多层膜或板，其中所述掩模层不会使清澈的离聚物层的表面退化。
11.权利要求9的多层膜或板，其中当所述掩模层被除去时，所述清澈的离聚物层在60°下测量的光泽度保持大于约85。
12.权利要求9的多层膜或板，其中所述掩模层用作湿气阻挡层。
13.权利要求9的多层膜或板，其中除去所述掩模层需要的力为约0.05磅/英寸～约8磅/英寸。
14.权利要求9的多层膜或板，其中除去所述掩模层需要的力为约0.05磅/英寸～约4磅/英寸。
15.权利要求9的多层膜或板，其中除去所述掩模层需要的力为约0.05磅/英寸～约2磅/英寸。
16.权利要求9的多层膜或板，其中所述聚合物层是有颜色的。
17.权利要求9的多层膜或板，其中所述聚合物层包含离聚物。
18.一种共挤出的多层板，其包括：
有颜色的离聚物层；
清澈的离聚物层；以及
掩模层，其与清澈的离聚物层及聚合物层共挤出，并且与所述清澈的离聚物层的粘合程度使得所述掩模层被除去所需的力为约0.05磅/英寸～约8磅/英寸，并且所述掩模层用作潮气阻挡层。
19.权利要求18的多层膜或板，其中所述掩模层不会使清澈的离聚物层的表面退化。
20.权利要求18的多层膜或板，其中当所述掩模层被除去时，所述清澈的离聚物层在60°下测量的光泽度保持大于约85。
CNA2005800219319A 2004-07-02 2005-06-29 共挤出的掩模层 Pending CN1980792A (zh)

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