Recyclable, Easily Tearable Packaging Laminate Having a Good Barrier Effect, and Method for The Production Thereof
20210237949 · 2021-08-05
Inventors
Cpc classification
B32B2553/00
PERFORMING OPERATIONS; TRANSPORTING
B29C48/21
PERFORMING OPERATIONS; TRANSPORTING
B32B2255/10
PERFORMING OPERATIONS; TRANSPORTING
B29L2031/712
PERFORMING OPERATIONS; TRANSPORTING
B29K2023/065
PERFORMING OPERATIONS; TRANSPORTING
B29C55/005
PERFORMING OPERATIONS; TRANSPORTING
B32B38/0012
PERFORMING OPERATIONS; TRANSPORTING
B32B27/16
PERFORMING OPERATIONS; TRANSPORTING
B32B2270/00
PERFORMING OPERATIONS; TRANSPORTING
B32B7/12
PERFORMING OPERATIONS; TRANSPORTING
B32B27/306
PERFORMING OPERATIONS; TRANSPORTING
B29C48/022
PERFORMING OPERATIONS; TRANSPORTING
B65D65/40
PERFORMING OPERATIONS; TRANSPORTING
B32B27/327
PERFORMING OPERATIONS; TRANSPORTING
B32B27/20
PERFORMING OPERATIONS; TRANSPORTING
B29C48/0018
PERFORMING OPERATIONS; TRANSPORTING
International classification
B65D65/40
PERFORMING OPERATIONS; TRANSPORTING
B29C48/00
PERFORMING OPERATIONS; TRANSPORTING
B29C48/21
PERFORMING OPERATIONS; TRANSPORTING
B29C55/00
PERFORMING OPERATIONS; TRANSPORTING
B32B27/20
PERFORMING OPERATIONS; TRANSPORTING
B32B27/30
PERFORMING OPERATIONS; TRANSPORTING
B32B38/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The present teaching relates to a recyclable, easily tearable packaging laminate having a good barrier effect, including a first laminate layer and a second laminate layer. The first laminate layer is a co-extruded and bidirectionally stretched composite consisting of a substrate layer having an HDPE content of at least 60 vol. %, a connecting layer and a barrier layer consisting of a barrier polymer, preferably polyamide or ethylene vinyl alcohol copolymer, having a thickness of maximum 20% of the total thickness of the first laminate layer. The connecting layer is arranged between the substrate layer and the barrier layer, and the first laminate layer is connected, at its barrier layer, to the second laminate layer.
Claims
1. A method for producing a packaging laminate comprising: co-extruding a first laminate layer consisting of a substrate layer having an HDPE content of at least 60 vol. %, a connecting layer and a barrier layer consisting of a barrier polymer, having a thickness of maximum 20% of the total thickness of the first laminate layer, wherein the connecting layer is arranged between the substrate layer and the barrier layer, bidirectionally stretching the co-extruded first laminate layer, connecting the bidirectionally stretched first laminate layer to a second laminate layer having a polyethylene content of at least 80 vol. %, wherein the second laminate layer is connected to the barrier layer of the first laminate layer.
2. The method according to claim 1, wherein the first laminate layer is printed, metallized or coated on the barrier layer before being connected to the second laminate layer.
3. The method according to claim 1, wherein the first laminate layer is connected, at the substrate layer, to a further single- or multilayer laminate layer having a polyethylene content of at least 80 vol. %.
4. The method according to claim 3, wherein the first laminate layer is printed, metallized or coated on the barrier layer and/or on the substrate layer before being connected to the further laminate layer.
5. The method according to claim 3, wherein at least one layer of the further laminate layer is printed, metallized or coated.
6. The method according to claim 3, wherein the first laminate layer is connected, at its substrate layer, to a further multilayer laminate layer in the form of a unidirectionally or bidirectionally stretched fourth laminate layer, which has a substrate layer having an HDPE content of at least 60 vol. %, a barrier layer consisting of a barrier polymer, and a connecting layer arranged therebetween, the barrier layer of the fourth laminate layer being connected to the substrate layer of the first laminate layer.
7. The method according to claim 1, wherein the first laminate layer is connected to a second laminate layer which consists of a substrate layer having an HDPE content of at least 60 vol. %, a connecting layer, a barrier layer consisting of a barrier polymer, having a thickness of maximum 20% of the total thickness of the second laminate layer, and a sealing layer, the layers being co-extruded, the connecting layer of the second laminate layer being arranged between the substrate layer and the barrier layer of the second laminate layer and the sealing layer being arranged on the substrate layer, and the co extruded second laminate layer being stretched in the machine direction or bidirectionally, and the barrier layer of the second laminate layer being connected to the barrier layer of the first laminate layer.
8. A packaging laminate comprising a first laminate layer and a second laminate layer, wherein the first laminate layer is a co-extruded and bidirectionally stretched composite consisting of a substrate layer having an HDPE content of at least 60 vol. %, a connecting layer and a barrier layer consisting of a barrier polymer, having a thickness of maximum 20% of the total thickness of the first laminate layer, wherein the connecting layer is arranged between the substrate layer and the barrier layer, and the first laminate layer is connected, at its barrier layer, to the second laminate layer.
9. The packaging laminate according to claim 8, wherein the barrier layer of the first laminate layer is printed, metallized or coated.
10. The packaging laminate according to claim 8, wherein the first laminate layer is connected, at its substrate layer, to a further single- or multilayer laminate layer having a polyethylene content of at least 80 vol. %.
11. The packaging laminate according to claim 10, wherein at least one layer of the further laminate layer is printed, metallized or coated.
12. The packaging laminate according to claim 10, wherein the further laminate layer is a fourth laminate layer in the form of a co-extruded composite stretched in the machine direction or bidirectionally and consisting of a substrate layer having an HDPE content of at least 60 vol. %, a barrier layer consisting of a barrier polymer, and a connecting layer arranged therebetween, and in that the substrate layer of the first laminate layer is connected to the barrier layer of the fourth laminate layer.
13. The packaging laminate according to claim 8, wherein the second laminate layer is a co-extruded laminate stretched in the machine direction or bidirectionally and consisting of a substrate layer having an HDPE content of at least 60 vol. %, a connecting layer, a barrier layer consisting of a barrier polymer, having a thickness of maximum 20% of the total thickness of the second laminate layer, and a sealing layer, the connecting layer of the second laminate layer being arranged between the substrate layer and the barrier layer of the second laminate layer and the sealing layer being arranged on the substrate layer, and in that the barrier layer of the second laminate layer is connected to the barrier layer of the first laminate layer.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] In the following, the present teaching will be explained in greater detail with reference to
[0021]
[0022]
[0023]
[0024]
[0025]
DETAILED DESCRIPTION
[0026]
[0027] The first laminate layer 2 in the packaging laminate 1 is stretched in the machine direction (MDO) and in the transverse direction (TDO), i.e., bidirectionally, and has an asymmetrical layer structure comprising a substrate layer 4 and a barrier layer 6 interconnected by a connecting layer 5. The thickness of the first laminate layer 2 is preferably 10 to 40 μm.
[0028] The substrate layer 4 has a content of high-density polyethylene (HDPE) of at least 60 vol. %, preferably at least 70 vol. % and very particularly preferably at least 80 vol. %. The HDPE content can reach up to 100 vol. %, however, due to common additives (such as slip additives, anti-block additives, fillers, etc.), 100 vol. % is usually not reached. An HDPE is understood to be a PE having a density between 0.94 and 0.97 g/cm.sup.3. The remainder is a compatible polyolefin material, preferably a linear low-density polyethylene (LLDPE) (having a density between 0.87 and 0.94 g/cm.sup.3), a low-density polyethylene (LDPE) (having a density between 0.915 and 0.935 g/cm.sup.3) or a metallocene linear low-density polyethylene (mLLDPE), in particular so as to increase toughness. In principle, any type of polyethylene is suitable as a compatible polyolefin material, in particular also ethylene copolymers, such as ethylene vinyl acetate copolymer (EVA), ethyl methacrylate (EMA), ethylene/acrylic acid copolymer (EAA) or ethylene butyl acrylate copolymer (EBA). Polypropylene (PP) or a cyclic olefin copolymer (COC) can also be used as a compatible polyolefin material in an amount of no more than 20 vol. %. In the case of PP, a polypropylene random copolymer with ethylene as comonomer (usually 5 to 15%), a polypropylene copolymer with ethylene or a polypropylene homopolymer that is sufficiently compatible with linear PE types, such as mLLDPE, LLDPE or HDPE, is preferably used in order to achieve at least limited recyclability.
[0029] The HDPE and the compatible polyolefin material can be present in the substrate layer 4 as a blend. The substrate layer 4 can, however, also have a multilayer structure (extruded or co-extruded) comprising one (or more) HDPE layer and one (or more) layer of the polyolefin material.
[0030] The thickness of the substrate layer 4 is preferably 5 to 35 μm.
[0031] The barrier layer 6 consists of a barrier polymer, i.e., a polymer having a sufficient barrier property, in particular against oxygen, water vapor and/or aroma. The barrier polymer is preferably a polyamide (PA) or an ethylene vinyl alcohol copolymer (EVOH). EVOH is preferred as the barrier polymer. The barrier layer 6 has a thickness of maximum 20%, preferably 5 to 10%, of the total thickness of the first laminate layer 2, i.e., a maximum of 2 to 8 μm. As a result of the low thickness of the barrier layer 6, recyclability is not impaired.
[0032] The connecting layer 5 is used to connect the barrier layer 6 and the substrate layer 4. A sufficient bond strength has to be achieved, in particular in order to reliably prevent undesired delamination of the first laminate layer 2. Suitable connecting layers 5 preferably consist of polymers of increased polarity, for example based on polyolefins (such as PE or PP) modified with maleic acid anhydride, ethylene vinyl acetate copolymer (EVA), ethylene/acrylic acid copolymer (EAA), ethylene butyl acrylate copolymer (EBA), or similar polyolefin copolymers. The thickness of a connecting layer 5 is at most 10% of the total thickness of the first laminate layer 2, typically 1 to 5 μm.
[0033] The second laminate layer 3 consists predominantly of a PE, wherein the PE content with respect to the total polymer amount of the second laminate layer 3, without any added mineral fillers or other fillers, should be at least 80 vol. %. Various PE types can be used, i.e., LDPE, LLDPE, MDPE, HDPE, in pure form or as a blend, or in the form of copolymers or also in multiple layers. The thickness of the second laminate layer 3 is typically between 20 and 200 μm, depending on the application of the packaging laminate 1.
[0034] In the second laminate layer 3 too, the remainder will of course consist of a compatible polyolefin material, as described above, in order to achieve the desired recyclability.
[0035] By using predominantly PE and compatible materials in the packaging laminate 1, a particularly recyclable laminate can be produced that can be easily and cost-effectively recycled using conventional methods in mechanical recycling.
[0036] The first laminate layer 2 is produced by co-extrusion, because this provides for particularly simple, cost-effective production. Preferably, the known blown film or flat film extrusion process is used.
[0037] After co-extrusion, the first laminate layer 2 is stretched bidirectionally, i.e., in the machine direction (usually the longitudinal or extrusion direction) and in the transverse direction (rotated 90° with respect to the machine direction). The degree of stretching in the machine direction and in the transverse direction need not be the same. The degree of stretching in the machine direction is preferably at least 4:1 to 8:1. The degree of stretching in the transverse direction is preferably at least 5:1 to 10:1. The stretching can take place in-line (i.e., immediately after co-extrusion) or off-line (i.e., at a later point in time after co-extrusion). The stretching can take place in the machine direction first and then in the transverse direction, or it is also conceivable for the stretching to take place in both directions at the same time. The stretching typically takes place at approx. 10° C. to 30° C., typically approx. 20° C., below the lowest melting temperature (for HDPE, approx. 128° C. to 130° C.) in the first laminate layer 2.
[0038] It should be noted here that, with blown film extrusion and flat film extrusion, the extrusion gap (1.5 to 2.5 mm for blown film) or the gap of the extrusion die is significantly larger than the end thickness of the extruded film (typically between 10 and 200 μm). For this purpose, the extruded melt is elongated at temperatures well above the melting point of the extruded polymer, giving it its final thickness. In blown film extrusion, for example, the melt is typically elongated in the transverse direction by approximately a factor of 2 to 3 (what is referred to as the blow-up ratio) and in the longitudinal direction by a factor of 1:10 to 1:100 (what is referred to as the drawdown ratio). However, this elongation during extrusion cannot be compared to stretching a plastics film, since stretching is usually carried out at temperatures just below the melting point of the polymer, in order to permanently align the disordered polymers and the partially crystalline regions by stretching in the stretching direction.
[0039] An asymmetrical structure of the first laminate layer 2 consisting primarily of polyethylene with bidirectional stretching is untypical and has so far been avoided in practice, in particular with blown film, since it had been assumed that such a structure would curl, in particular due to water absorption of the polar barrier layer 6, which would make further processing more difficult or impossible. It has been shown, however, that, with the specific design of the structure, curling occurs to an acceptable degree that does not hinder further processing. To this end, it is advantageous for the first laminate layer 2 to be connected to the second laminate layer 3 very soon after production in order to above all reduce the water absorption of the barrier layer 6. In certain circumstances, it may also be necessary or expedient to protect the co-extruded film roll comprising the first laminate layer 2 from water absorption by means of suitable packaging until lamination.
[0040] The main advantage of the untypical asymmetrical structure of the first laminate layer 2 is, however, that only a single expensive and not very rigid connecting layer 5 is required. The costs for the first laminate layer 2 can thus be reduced and a more rigid first laminate layer 2 can be achieved. The higher rigidity is particularly advantageous when the packaging laminate 1 is used to produce a pouch.
[0041] Further advantages of the first laminate layer 2 according to the present teaching result from the stretching. This stretching results in a high level of transparency, in particular of the substrate layer 4. By stretching the barrier layer, approximately three to four times higher barrier values are achieved by comparison with an unstretched barrier polymer of the same type, and therefore a less expensive barrier polymer can be used with the same barrier effect. This can significantly reduce the cost of the first laminate layer 2. In addition, less barrier polymer is required for the same barrier effect, which also improves recyclability.
[0042] The first laminate layer 2 is preferably produced using the multistage blown film extrusion process (e.g., triple or double bubble process), because this results in fewer edge trimmings resulting from production, which leads to lower costs for the packaging laminate 1, especially with the expensive barrier polymers. In blown film extrusion, more viscous HDPE materials having an MFI (mass flow index) of less than 3 can also be used. Such HDPE materials have a higher molecular weight and improved mechanical properties, which is favorable for use in a packaging laminate 1. However, such a material would tear particularly easily in the longitudinal direction and even lead to undesired splicing in the longitudinal direction. This undesirable property can be eliminated by integrating the HDPE material having an MFI of less than 3 in a first laminate layer 2, as described, and uniform tearing in both directions can even be achieved.
[0043] A bidirectionally stretched first laminate layer 2, comprising a substrate layer 4, a barrier layer 6 and a connecting layer 5, as mentioned, does not tend to splice in the longitudinal direction after the first step of stretching in the machine direction, despite the high HDPE content of 60 vol. %, in particular even with very high HDPE contents of greater than 80 vol. % to 100 vol. %, as was surprisingly found. This effect occurs both with an asymmetrical structure of the first laminate layer 2 and with a symmetrical structure of the first laminate layer 2.
[0044] It was surprisingly found that such a bidirectionally stretched first laminate layer 2 is substantially equally tearable in both directions, i.e., in the machine direction and transverse direction, and has controlled tear behavior.
[0045] For the first laminate layer 2 used as a barrier film 11 according to the present teaching, symmetrical structures are also possible (as shown in
[0046] Such a first laminate layer 2 alone as a barrier film 11 is also considered to be part of the present teaching and is characterized in particular by at least one substrate layer 4 which has an HDPE content of at least 60 vol. %, preferably at least 80 vol. %, and which is connected to a barrier layer 6 as described above by means of a connecting layer 5 as described above. The substrate layer 4 can also have a multilayer structure. In addition, for a symmetrical structure, the barrier layer 6 can be connected to a further substrate layer 4 as described above by means of a further connecting layer 5 as described above. Such a barrier film 11 is produced by co-extrusion and subsequent bidirectional stretching. The degree of stretching is preferably at least 4:1 to 8:1 in the machine direction and at least 5:1 to 10:1 in the transverse direction. The stretching can take place in-line (i.e., immediately after co-extrusion) or off-line (i.e., at a later point in time after co-extrusion), and either first longitudinally and then transversally or longitudinally and transversally at the same time.
[0047] To produce the packaging laminate 1, the stretched first laminate layer 2 and the second laminate layer 3 are interconnected, preferably by extrusion lamination, extrusion coating or adhesive lamination, the second laminate layer 3 being connected to the barrier layer 6 of the first laminate layer 2. In extrusion coating, the second laminate layer 3 is extruded onto the barrier layer 6 of the first laminate layer 2, preferably also with an adhesion promoter therebetween. In lamination, the second laminate layer 3 is connected to the barrier layer 6 by means of a suitable laminating adhesive, for example based on polyurethane adhesives or polyolefin copolymers for extrusion lamination. The thickness of the laminating adhesive is preferably 2 to 5 g/m.sup.2 for conventional adhesives based on polyurethane or 5 to 20 g/m.sup.2 for extrusion lamination.
[0048] When there are suitable second laminate layers 3, it has been found that the entire packaging laminate 1 also adopts the tear properties of the first laminate layer 2, i.e., the packaging laminate 1 can also be torn by hand equally easily in both directions. The first laminate layer 2 thus imparts the tear properties to the packaging laminate 1.
[0049] The second laminate layer 3 preferably forms a sealing layer 7 which, in packaging made from the packaging laminate 1, usually faces the packaged product. The packaging is produced by cutting, folding and heat sealing the packaging laminate 1. Possible forms of packaging are sachets, bags, pouches, etc.
[0050] The second laminate layer 3 can also have a multilayer structure, for example extruded or co-extruded, as indicated in
[0051] In a further embodiment of the packaging laminate 1, as shown in
[0052] It is also indicated in
[0053] It is also possible to metallize and/or print and/or coat (for example with aluminum oxide or silicon oxide) the stretched first laminate layer 2 on the barrier layer 6 after stretching and before connecting the first laminate layer 2 to the second laminate layer 3. Metallization with aluminum is preferred. The HDPE substrate layer 4 is sufficiently transparent, especially after stretching, so that the printed image, the metallization or the coating is visible through the substrate layer 4. For printing purposes, the barrier layer 6 can also be pretreated on the surface to be printed, for example by corona or flame treatment, in order to improve the adhesion of the printed layer to the barrier layer 6. However, alternatively or additionally, the substrate layer 4 can also be printed, metallized or coated, both on the side facing the barrier layer 6 and on the other side, if necessary again after surface treatment. Common printing processes can be used for this, for example gravure printing or flexographic printing.
[0054] The third laminate layer 8 could also be printed, metallized or coated on one or both sides, in addition to or as an alternative to the printing, metallization or coating of the first laminate layer 2.
[0055] In an advantageous design of the embodiment in
[0056]
[0057] In this embodiment too, the fourth laminate layer 2′ can be printed, metallized or coated on the substrate layer 4′ and/or on the barrier layer 6′, in addition to or as an alternative to the printing, metallization or coating of the first laminate layer 2. In a particularly advantageous embodiment, the fourth laminate layer 2′ is printed, preferably on its barrier layer 6′, and the first laminate layer 2 is metallized, preferably on its barrier layer 6 or substrate layer 4. The barrier effect of the packaging laminate 1 can thus be increased. However, a coating of aluminum oxide or silicon oxide can also be provided on the barrier layer 6 or substrate layer 4 of the first laminate layer 2 in order to further increase the barrier effect.
[0058]
[0059] In this embodiment, the bidirectionally stretched first laminate layer 2 and the second laminate layer 3 stretched in the machine direction or bidirectionally are interconnected at the abutting barrier layers 6, 6″, preferably by adhesive lamination by means of an adhesive layer 9. A suitable laminating adhesive is, for example, an adhesive based on polyurethane or a polyolefin copolymer. The thickness of the lamination layer 9 is preferably 2 to 5 g/m.sup.2.
[0060] In this embodiment, too, one (or more) of the layers of the packaging laminate 1 can be printed, metallized or coated.
[0061] Of course, in this embodiment, a further laminate layer 10 (for example a third laminate layer 8 or fourth laminate layer 2′ as described above) could also be provided on the first laminate layer 2, as indicated in
[0062] The packaging laminate 1 according to the present teaching thus has at least an asymmetrical, bidirectionally stretched first laminate layer 2 consisting of at least 60 vol. % HDPE and comprising a substrate layer 4, a barrier layer 6 and a connecting layer 5, and a second laminate layer 3 which is connected to said first laminate layer, forms a sealing layer 7 and has a PE content of at least 80 vol. %. As described above, a further single- or multilayer laminate layer 10 (e.g., a third laminate layer 8 or fourth laminate layer 2′) having a PE content of at least 80 vol. % can be arranged on this packaging laminate 1 on the side of the first laminate layer 2 that faces away from the second laminate layer 3. This further single- or multilayer laminate layer 10 is thus connected to the substrate layer 4 of the first laminate layer 2.
[0063] In packaging made from a packaging laminate 1 according to the present teaching, the sealing layer 7 of the packaging laminate 1 advantageously faces the inside of the packaging.
[0064] By printing at least one layer of the first laminate layer 2, the second laminate layer 3 or the further laminate layer 10 of a packaging laminate 1 according to the present teaching with a barrier lacquer, for example polyvinyl alcohol (PVOH), the barrier effect of the packaging laminate 1 can also be further increased. Such lacquer layers can be applied very thinly, typically in the range of 0.5 to 2.0 g/m.sup.2, and thus do not impair the recyclability of the packaging laminate 1.
[0065] Finally, it should be noted that each of the above-described individual layers in the first laminate layer 2, the second laminate layer 3 or the further laminate layer 10 can themselves also have a multilayer structure.