Method of manufacturing laminated material

 

(57) Abstract:

The invention relates to a method of manufacturing a layered material with good integrity, for example the packaging laminate. According to the invention, the first plastic strip (10A) and a second plastic tape (10B) are brought together and permanently connected with one another by means of the simultaneous application of heat and pressure for the formation of layered material (10). Moreover, the first and/or second tape consist of or have termoplastovoy floor (12), which ekstragiruyut at a temperature that is significantly above the normal melting point of extruded thermoplastic. Before merging the tape is passed through a high-frequency electric field to promote adhesion without the use of any chemical binders. The method preferably is reduced to the practical use of rollers (20, 21), which have different hardness, while relatively soft roller (20) is located with the ability to move towards a relatively more rigid roller (21) in such a way that the gap between the rollers 20 and 21), through which are passed the consolidated tape, can be adjusted on the right giving the emergence of a relatively more rigid roller (21) in the surface of the compressible relatively soft roller (20). 7 C.p. f-crystals, 4 Il.

The invention relates to a method of manufacturing the layered material, for example a packaging laminate, in which the first plastic tape and the second plastic strip are brought together and permanently connected to one another by simultaneous application of heat and pressure.

Packaging laminates containing interconnected layers of plastic and/or other materials are often used for packaging of single use, and they are available for sale not only in the form of a simple, flexible packaging laminates, containing a limited number of layers, but also in the form of complex rigid packaging laminates containing multiple layers in properly selected mutual combinations.

Regardless of whether the packaging material to one or another type, it is important that the individual packaging laminated material was such as when a package made from the packaging laminate, creating the best conditions for safe storage of the product. Thus, the packaging laminated material must possess not only the mechanical and chemical, but also other desirable and nety material should of course, to be economically viable and easily manufactured and molded in a package in a reasonable industrial scale.

Known packaging laminate for the manufacture of packaging single use, retains its shape, which includes a core layer of paper or cardboard, which gives the package a required mechanical strength and dimensional stability, and external coating of thermoplastic, preferably polyethylene, which makes packaging impermeable with respect to moisture and liquids. The outer thermoplastic coating also have the advantage that they can be welded /or fusing/ the way in which thermoplastic surfaces facing each other, can be fused and connected with the application of heat and pressure with the formation of mechanically strong and sealed seams or joints, when the packaging laminated material is processed into packaging.

Also known packaging laminated material for the manufacture of the above packages one-time use, which includes a core layer of paper or cardboard outer coating of thermoplastic, preferably polyethylene, and, in addition, one or more of topolnica packaging laminated material, aluminum foil /Alufoil"/ one side of the base layer, between the base layer and the outer thermoplasty layer of the packaging laminate to make the packaging impermeable to oxygen, when it should be used with products that are sensitive to oxygen. In another packaging laminated material is one or more polymer layers instead of or in addition to the above material "Alufoil" to give the package the proof in the case of oxygen and/or tightness in respect of certain kinds of aromatic chemicals, essential oils, etc. that may be present in the product. Examples of such insulating polymers used so far, are polyesters, polyamides, polyvinyl pyrrolidone, a copolymer of ethylene and vinyl alcohol /EvOH/ etc. Another example of an insulating material may be silicon oxide /SiOx/, which also gives the package a proof in the case of oxygen and substances of the above type.

Simple, flexible packaging laminates for packaging type bags can, for example, include two mutually United plastic layer and located between the layer of material "Alufoil or insulating polymer of the above type.

How flexible is satisfactory, the manufacture of strips of plastic or other material with a plastic coating, which are brought together and permanently connected to one another by applying heat and pressure. For example, in conventional packaging laminated material pre-fabricated tape of paper with a plastic coating comes with pre-fabricated tape of an insulating polymer film, and they are passed through the gap between two rotating pressure rollers, at the same time between the tapes served binder or sealant plastic acting as a binder, to permanently connect the ribbon between them. One and/or other tape can be pre-processed so-called primer, which is applied to the contact surface, respectively, of the tape or tapes and which is activated by the application of heat during the process of layering to improve or make possible the adhesion between the tapes. In the production of flexible packaging laminates, containing only two plastic layer, use the appropriate method, in which the first pre-fabricated plastic tape and the second pre-manufactured plastic tape are brought together and passed together through passtwo or sealing plastic, acting as a binder, to permanently connect them together. In this case one tape and/or other tape can be pre-treated substance that promotes adhesion /primer/, which is activated by application of heat in the process of layering.

At the same time, although the above-described conventional methods of coating film can produce packaging laminates with a high degree of integrity and good internal cohesion between the included layers of material, they all have serious drawbacks and inconveniences due to the use of binders /adhesives, primers/, which is often associated with organic solvents, dangerous for the environment. Even if there are binders and adhesives that do not use such solvents, so far has proved difficult for their successful implementation in industrial packaging laminated materials with the desired integrity and cohesion, and; in addition, in certain cases, it was inevitable the use of binders or adhesives, solvent-based permanent connection films or tapes of plastics that cannot be formed is of applying heat and pressure /welding/.

Therefore, the aim of the present invention is to eliminate the above described disadvantages and inconveniences and offer improved method of manufacture of the layered material, for example a packaging laminate.

Another objective of the present invention is the production of a packaging laminate with a high degree of integrity and internal cohesion in rational industrial scale without the use of binders or adhesives, dangerous for the environment.

These and other objectives are achieved according to the present invention using the method specified in paragraph 1 of the claims, while the dependent claims set out also distinctive features of preferred embodiments of the method.

Subjecting the corresponding surface of the plastic tape, intended to bring together and connect with one another, processing for activation without the use of any chemical binders, it is possible according to the present invention to connect the tape with one another through excellent internal cohesive force of communication, regardless, are the contact surfaces of the tapes from blastmedia, that otherwise would require the use of intermediate binders or sealing layer, so that it was possible to connect a single tape with the other.

Non-chemical treatment for activating the surface of the tape preferably is carried out directly before mixing together and in principle is based on the idea that high-frequency electric field through which is passed the appropriate ribbon, activates surface molecules or parts of molecules in the plastic or the plastic so that the plastic will be mutually active and can constantly be connected to one another.

Such processing methods for surface activation as such are known and include, for example, so-called plasma processing, the processing in the corona discharge, flame treatment and the other, while, as it turned out in relation to this invention, the treatment for surface activation using corona discharge technology /process in the corona discharge/, possibly in combination with ozone, is particularly useful and very practical for permanent connection of plastic tapes which are otherwise incompatible or difficult to bonding and the NTA with a plastic coating must feel on another tape from a plastic, which is hard connected with polyethylene without the use of chemical binders /adhesives/. However, according to the present invention such tapes can be easily connected with one another with formation of a completely holistic and securely glued packaging laminate, subjecting the ribbon to the above treatment to activate the surface, and according to one particularly preferred variant implementation of the present invention as above-mentioned polyethylene coating on the paper tape used plastic film which is extruded at a temperature of extrusion /Those/ considerably higher than the temperature /Tm/, which usually melted polyethylene. Practical experiments, which were conducted in accordance with the present invention, unexpectedly showed that polyethylene film extruded at different temperatures, show a different susceptibility to treatment to activate the surface and provide different adhesive strength of the bonding or adhesion to other compatible hard plastics. In particular, it was found that the adhesion strength increases if the polyethylene film extruded at a temperature of you who is polyethylene. The exact decomposition temperature of the polyethylene to some extent depends on its quality and can be different for polyethylene of varying quality, but this temperature can easily be determined by a specialist for each of the polyethylene of suitable quality by conducting simple experiments.

According to another preferred variant implementation of the present invention tapes are brought together and together pass through a gap between two rotating pressure rollers with different surface hardness, of which one roller /preferably relatively soft roller/ is to move towards a relatively more solid roller so that it was possible to install a suitable gap /pressure between the rollers during the passage of the tape through the gap. Practical experiments, which again was conducted in accordance with the present invention, unexpectedly showed that good results in the layering can be achieved by the arrangement of the rollers so that the width of the gap between the rollers or its value in the longitudinal direction of the tape was provided by the indentation relatively solid roller in the surface relatively me hepatectomy adhesion. In this respect, especially good was the combination of rollers, in which a relatively soft roller made of steel, plated rubber, is with the ability to press relatively hard roller with a steel cylindrical core, covered on the outside with Teflon or other heat resistant material which does not stick to the plastic. An additional advantage according to the present invention will be achieved when the steel roller, rubber clad, will also be covered outside of Teflon or other suitable heat resistant material, which helps to eliminate priglawenie or adhesion of the plastic to the surface of the roller.

According to another variant implementation of the present invention, two United tape skipped not one gap between the rollers and through many consecutive gaps between the rollers. In this case, production and technological benefits will be achieved if the temperature in each respective pair of rollers will be different and progressively increase to the required final temperature for the last pair of rollers. Other additional advantages are achieved according to the present invention, and the same roller, common to all pairs of rollers, with the relatively softer rollers in each corresponding pair of rollers will be positioned around the circumference of the common roller.

Other advantages and distinctive features of the process according to the present invention will be apparent from the following detailed description of the present invention with reference to the accompanying drawings. On the accompanying drawings:

Fig. 1 schematically shows the principle of the production of the laminate according to one variant of the method of the present invention.

Fig. 2 schematically shows the principle of the production of the laminate according to another variant implementation of the method according to the present invention and

Fig. 3 and 4 schematically show the cross-section of materials of various types produced by the method according to the present invention.

Although the present invention will hereinafter be described with particular reference to the packaging laminated material, however it should be noted that in the broadest sense the present invention, of course, is not limited solely to the practical application, selected as one of the many other possible layered materials, the components of such a packaging laminate, specially selected in the following description are only examples among many other possible variants of its parts.

To avoid any possible misunderstanding, one must also add that the phrase "plastic tape", which is often found in the description and in the appended claims, refers to not only a single layer of tape consisting exclusively of plastics, but also multi-layered tape, with at least one outer plastic layer, which is appropriately imposed on one side of the tape.

As for the drawings, in Fig. 1 schematically shows the principle of the production well United into one layered material or a packaging laminate 10 according to the method according to one variant of implementation of the present invention, in which the first plastic tape 10a and the second plastic tape 10b are brought together and permanently connected to one another by simultaneous application of heat and pressure for the formation of the finished packaging laminate 10.

In the shown embodiment of the invention the tape 10a may, as is evident from policeacademy for packaging purposes and the outer layer 12 of thermoplastic, preferably polyethylene, superimposed on one side of the base layer. Tape 10a, which leaves the roll /not shown/ in the direction of the arrow, is pre-fabricated tape of material produced by known techniques in the extrusion process, in which the selected thermoplastic extruded on one side of the paper or cardboard layer 11 for the formation of the outer thermoplastische cover 12. According to the present invention has been particularly beneficial /as mentioned/ ekstradiroval thermoplastic at a temperature of extrusion Teexceeding the temperature Tmin which usually melted thermoplastic. For polyethylene, the temperature of extrusion Teapproximately 280oC.

As can be seen from the enlarged circled the circumference of the segment of tape B, the second tape 10b includes, for example, pre-fabricated ribbon-like plastic film. Examples of plastics which can be covered with printed paint, suitable for the manufacture of this plastic film may be polyethylene terephthalate, oriented polyethylene terephthalate, polyethylene of high dublenochnogo pressure, polypropylene, oriented polypropylene, a copolymer of ethylene and vinyl alcohol, and others. In addition, the second tape 10b may include many naplastovany layers, of which the above-mentioned plastic film is placed as the outer layer in these alternative layered materials /not shown/. The second tape 10b may also include layers of other materials than plastic, as for example, aluminum /foil "Alufoil"/ oxide /silicon film of SiOx/ etc., the choice of the component parts of the second tape 10b is determined by the applications of the packaging laminate 10, i.e., ultimately the purpose of packaging produced from the packaging laminate 10. If the packaging laminate 10 is intended for packaging for the storage of products that are sensitive to oxygen, such as juice, wine, edible oil and so on, then the second tape 10b is composed of a suitable material having good insulating properties with respect to oxygen, for example, of a copolymer of ethylene and vinyl alcohol, which also gives the package a good insulating properties against odorous substances present in the product, essential oils, etc. of the Packaging laminate 10, Emami neopterygii properties what makes packaging laminated material is very useful for packaging long-term storage of citrus juices.

In Fig. 1 the first tape 10a through the first bending roller 13 moves to the position 14 to activate the surface of the outer thermoplastische cover 12, the first tape 10a at position 14, where the rotating drum 15 serving as an electrode, and a grounded grid 16 at least partially surrounding the periphery of the drum 15 and bounding together with the drum 15, the passage 17 through which is passed a belt 10a in contact with the periphery of the drum 15. In the passage 17 between the drum 15 serving as an electrode, and a grid 16 generates a high-frequency electric field through which is passed the tape 10a to activate the surface of the outer thermoplastische cover 12 in order to improve its adhesion.

From position 14 tape 10a is activated surface through the other bending roller 18 is supplied to the gap 19 between the two rotating pressure rollers 20 and 21 for connection with the second tape 10b, simultaneously with coiled coil 22. The second tape 10b also passes through the position 23 to activate the surface of the plastic in the second tape in the same manner as in the first tape 10a. How about surrounding the periphery of the drum 24, and with it restricts the passage 26, through which is passed the second tape 10b. In this case, the passage 26 also generates a high-frequency electric field through which the activated surface of the second plastic tape 10b to improve its adhesion.

From the position 23 of the second tape 10b is activated surface through the bending roller 27 is supplied to the gap 19 between the rollers 20 and 21 for connection with the first tape 10a their plastic with an active surface facing termoplastovoy the floor with the activated surface 12 on the first tape 10a. Two of the consolidated tape 10a and 10b are passed through the gap between the pressure rollers 20 and 21, which are due to the applied pressure and heat shrink together two tapes for education is well combined into one packaging laminate 10, which is removed from the periphery of the roller 21 by the receiving roller 28 located near the roller 21.

For treatment to activate the surface, held at positions 14 and 23, it is possible to successfully apply the method of processing in the corona discharge, even though there may be other similar surface treatments such as plasma treatment, flame treatment, etc. which all are it have mutually different surface hardness, it is shown in the drawing, a lower roller 20 is preferably relatively soft roller of the two rollers. In addition, the roller 20 is located with the ability to move relative to the roller 21 to regulate the right of the gap, while the larger roller 21 /which is relatively more rigid/ is fixed.

As mentioned earlier, relatively more solid roller 21 may be made of steel, while the relatively soft roller 20 may have a cylindrical steel core, outside coated rubber with a lower surface hardness than the steel core roller 20. Is preferred that a relatively more solid roller 21 had the outer coating of Teflon, which helps to eliminate gluing or sticking.

In Fig. 2 schematically shows the production of a laminate or layered packaging material using the method according to another variant implementation of the present invention. The method according to Fig. 2 is similar to the above method according to Fig. 1 and therefore, for clarity, apply the same digital denote similar or corresponding parts and components with the addition of odnoslovnym way the fact that the first tape 10'a and the second tape 10'b are shown together on the combination of the rollers 20', 21', which, as shown in Fig. 2, has three separate pairs of rollers 20', 21' and the corresponding gaps 19' between them, through which in turn ignored the consolidated tape for the formation of the packaging laminate 10' with good integrity. Therefore, the combination of rollers 20' 21' includes a first pair of rollers 20, 21', the second pair of rollers 20', 21' and a third pair of rollers 20', 21', and the roller 21' in each respective pair of rollers is preferably one and only one and the same clip for all pairs of rollers, while the rollers 20' in each respective pair of rollers spaced around the periphery of the common roller 21', as shown in Fig.2. In this embodiment of the invention shows a smaller roller 20' in each respective pair of rollers 20', 21' is also with the ability to move relative to shown larger roller 21' to establish the appropriate degree of compression /pressure/. Is preferred that the rollers 20' and 21' had mutually different surface hardness, so that the lower roller 20' was relatively soft roller of the two rollers, and the bigger the roller 21' is the s T1, T2 and T3 with the increase of temperature in the longitudinal direction of the tape, i.e., T1 < T2 < T3. Each corresponding lower roller 20' is preferably made of stainless steel, while the more common roller 21', similar to the roller in Fig. 1 may have a cylindrical core made of stainless steel, outside is clad rubber. In addition, to prevent adhesion or sticking of the roller 21' may have an outer coating of Teflon.

In Fig. 3 and 4 show different types of packaging laminated materials that can be produced by the method according to the present invention.

In Fig. 3 shows an example of a packaging laminate 30 for packaging with stable dimensions, which includes a base layer 31 of paper or paperboard of suitable packing quality, extruded thermoplastic layer 32 and outer layer 33 of an insulating material of the previously mentioned type, which is superimposed and constantly connected with thermoplasty coating 32 using the method according to the present invention.

In Fig. 4 shows an example of the packaging laminated material 40 for flexible packaging type bag, which includes a first layer 41 of the plastic procedure according to the invention. The material in each respective plastic layer 41 and 42 may be a polymer of the previously mentioned type. In yet another alternative embodiment of the invention the packaging laminated material 40 may also include one or more optional /not shown/ layers of plastic or other material, for example aluminum /foil "Alufoil"/ or silicon dioxide /SiOx/ between the two shows outer plastic layers 41 and 42.

In conclusion, it should again be noted that the present invention has been described above with particular reference to the accompanying drawings, is not limited to these variants of the invention described and shown as examples, and can be obvious to a person skilled modifications and changes without departure from the nature and limits of the inventive idea set forth in the accompanying claims.

1. Method of manufacturing laminated material, for example, the packaging laminate, in which the first plastic tape (10A, 10 a) and the second plastic strip (10b, 10'b) are brought together and permanently connected with one another by simultaneous application of heat and pressure, characterized in that the first (10A, 10 a) and/or WTO), which is significantly above the normal melting temperature (Tm) of extruded thermoplastic, i.e., Those > Tm, with the first (10A, 10 a) and second (10b, 10'b) tape before you merge them passed through a high-frequency electric field to promote adhesion without the use of any chemical binders.

2. The method according to p. 1, characterized in that the surface of the strips (10A, 10b, 10 a, 10'b) activate processing in the corona discharge and/or ozone.

3. The method according to p. 1 or 2, characterized in that the strips (10A, 10b, 10 a, 10'b) connect with one another and together flows through the gap between the rotating rollers(20, 21, 20', 21') in one or more pairs of such rollers with mutually different surface hardness, and relatively soft roller (20, 20') in each corresponding pair of rollers to press relatively hard roller (21, 21') and each corresponding to a gap between the support rollers with mutually different temperatures (T1, T2, T3), which are increased in the longitudinal direction of the tape, i.e., T1 < T2 < T3

4. The method according to p. 3, characterized in that use only one and the same relatively hard roller (21, 21') in each of the corresponding pairs of the corresponding pair of rollers distributed around the circumference of the common roller (21').

5. The method according to p. 3 or 4, wherein the relatively more solid roller (21, 21') in each corresponding pair of rollers down the heat to transfer to bend around the strips (10A, 10b, 10 a, 10'b).

6. The method according to any of paragraphs.3 to 5, characterized in that use relatively soft roller (20, 20') in each corresponding pair of rollers comprising a cylindrical steel core, rubber clad, while the relatively more solid roller (21, 21') consists of steel.

7. The method according to p. 6, characterized in that use relatively more rigid roller (21, 21') and/or relatively soft roller (20, 20') in each corresponding pair of rollers having outer coating of Teflon or other heat resistant material which does not stick to the plastic on the second tape (10'b).

8. The method according to any of paragraphs.1 to 7, characterized in that the first strip (10A, 10 a) has an outer covering (12, 12') of the polyethylene, and the second strip (10b, 10'b) comprises or consists of a plastic film selected from the group essentially containing polyethylene terephthalate, oriented polyethylene terephthalate, high density polyethylene, low density polyethylene, oriented polyethylene low is limer of ethylene and vinyl alcohol, and others.

 

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