WEB MATERIAL PROCESSING MACHINE, METHOD FOR PRODUCING A MULTI-LAYERED WEB MATERIAL AND PACKAGING MATERIAL

Abstract

A web material processing machine (10) for producing a multi-layered material (12), especially a multi-layered packaging material (13), is presented. It comprises a first vacuum coating unit (28) for deposing a film of a first coating material on a web material (16) to be processed. Moreover, it is equipped with an extrusion coating unit (32) for extruding a film of an extrusion material on the web material (16). The extrusion coating unit (32) is positioned behind the first vacuum coating unit (28) with respect to a processing direction (20). Additionally, a method for producing a multi-layered web material (12) is explained. Furthermore, a multi-layered packaging material (13) is described.

Claims

1. An in-line web material processing machine for producing a multi-layered material, especially a multi-layered packaging material, in particular a monomaterial, the in-line web material processing machine comprising: a first vacuum coating unit for deposing a film of a first coating material on a web material to be processed, and an extrusion coating unit for extruding a film of an extrusion material on the web material to be processed, wherein the web material and the extrusion material are made essentially of the same material, wherein the extrusion coating unit is positioned behind the first vacuum coating unit with respect to a processing direction; and wherein the first vacuum coating unit and the extrusion coating unit are arranged inside a vacuum chamber.

2. The in-line web material processing machine according to claim 1, wherein no processes relating to adhesion or lamination are included.

3. The in-line web material processing machine according to claim 1, wherein the material used for the web material and the extrusion material comprises PE, PP, a biopolymer, or biodegradable plastics.

4. The in-line web material processing machine according to claim 1, further comprising: a second vacuum coating unit for deposing a film of a second coating material on the web material to be processed, wherein the second vacuum coating unit is positioned between the first vacuum coating unit and the extrusion coating unit with respect to the processing direction in the vacuum chamber.

5. The in-line web material processing machine according to claim 4, wherein at least one of the first vacuum coating unit and the second vacuum coating unit is a vapor deposition unit.

6. The in-line web material processing machine according to claim 4, wherein at least one of the first vacuum coating unit and the second vacuum coating unit comprises a processing drum for supporting the web material to be processed, wherein at least one of the processing drums is additionally associated with the extrusion coating unit and serves as a support for the web material to which the extrusion material is applied.

7. The in-line web material processing machine according to claim 1, further comprising: a printing unit for printing on the web material to be processed.

8. The in-line web material processing machine according to claim 7, wherein the printing unit is positioned behind the extrusion coating unit with respect to a processing direction in the vacuum chamber and is adapted for printing on the film of extrusion material.

9. A method for producing a multi-layered web material in-line, especially a multi-layered packaging material, in particular a monomaterial, the method comprising: providing a substrate in the form of a continuous web or a discrete web, deposing a film of a first coating material, especially a metal or a metal oxide, on the substrate, and subsequently extruding a film of an extrusion material on the film of first coating material; wherein the substrate and the extrusion material are made essentially of the same material and the method is performed in a vacuum chamber.

10. The method for producing a multi-layered web material according to claim 9, wherein no operations relating to adhesion or lamination processes are included.

11. The method according to claim 10, further comprising: deposing a film of a second coating material, especially a metal or a metal oxide, on the film of first coating material and extruding the film of extrusion material on the film of second coating material.

12. The method according to claim 10, wherein an ink is printed on the film of extrusion material.

13. The method according to claim 10, wherein the method is executed under vacuum.

14. A packaging material, in particular monomaterial especially for packaging food, the packaging material comprising: a single flexible substrate in the form of a continuous web or a discrete web, a film of a first coating material, especially a metal or a metal oxide, being arranged on the substrate, and a film of an extrusion material being provided on top of the film of first coating material; wherein the substrate and the extrusion material are made essentially of the same material.

15. The packaging material according to claim 14, wherein a film of a second coating material, especially a metal or a metal oxide, is arranged between the film of first coating material and the film of extrusion material.

16. The packaging material according to claim 14, wherein the material used for the web material and the extrusion material comprises PE, PP, a biopolymer, or biodegradable plastics.

17. The packaging material according to claim 15, wherein no laminated or glued structures are included.

18. The packaging material according to claim 14, wherein a layer of ink is provided on top of the film of extrusion material.

Description

The invention will now be described with reference to the enclosed drawings. In the drawings,

[0046] FIG. 1 schematically shows a web material processing machine according to the invention which is adapted for performing a method according to the invention and producing a packaging material according to the invention using process drums (FIG. 1a), and using a free span arrangement (FIG. 1b).

[0047] FIG. 2 shows a cross-section of a packaging material according to the invention which has been produced on the machine of FIG. 1 using the method according to the invention.

[0048] FIG. 3 schematically shows a web material processing machine according to another embodiment of the invention which is adapted for performing a method according to the invention and producing a packaging material according to the invention.

[0049] FIGS. 1a and 1b shows a web material processing machine 10 for producing a multi-layered material 12. In the example shown the multi-layered material 12 is a packaging material 13 used for packaging food.

[0050] The web material processing machine 10 comprises an unwinder 14 for supplying a web material 16 to be processed in the form of an endless web.

[0051] The web material 16 is flexible.

[0052] Additionally, the web material processing machine 10 has a rewinder 18 for winding up the produced multi-layered material 12, i.e. the packaging material 13.

[0053] In a processing direction 20 a first processing drum 22 and a second processing drum 24 are interposed between the unwinder 14 and the rewinder 18.

[0054] Moreover, first, second and third auxiliary drums 26a, 26b and 26c are provided to facilitate the flow of the web material 16 through the web material processing machine 10.

[0055] It is noted that the web material 16 cooperates with several drums while being processed in the web material processing machine 10, but it is unwound from a drum, namely the unwinder 14, only once, and wound-up on a drum, namely the rewinder 18, only once during its entire processing.

[0056] The material processing machine 10 according to the preferred embodiment shown in FIGS. 1a and 1b includes a vacuum separation 27 which provides two vacuum regimes 29, 31.

[0057] According to FIG. 1a a first vacuum coating unit 28 is arranged adjacent to the first processing drum 22. It is adapted for deposing a film of a first coating material on the web material 16.

[0058] The first vacuum coating unit 28 uses the first processing drum 22 as a support for the web material 16.

[0059] Furthermore, a second vacuum coating unit 30 is provided adjacent to the second processing drum 24. The second vacuum coating unit 30 is adapted for deposing a film of a second coating material on the web material 16.

[0060] It uses the second processing drum 24 as a support for the web material 16.

[0061] Both the first vacuum coating unit 28 and the second vacuum coating unit 30 are vapor deposition units.

[0062] Additionally, an extrusion coating unit 32 is provided, which is adapted for extruding a film of an extrusion material on the web material 16.

[0063] The extrusion coating unit 32 is associated with the second processing drum 24.

[0064] This means that the extrusion coating unit 32 uses the second processing drum 24 as a support for the web material 16 to which the extrusion material is applied.

[0065] Moreover, the web material processing machine 10 comprises a printing unit 34 which is adapted for printing an ink on the web material 16.

[0066] Along the processing direction 20 the above-mentioned units are arranged in the following order: first vacuum coating unit 28, second vacuum coating unit 30, extrusion coating unit 32, printing unit 34.

[0067] The web material processing machine 10 also comprises a vacuum chamber 36.

[0068] All above-mentioned units, i.e. the first vacuum coating unit 28, the second vacuum coating unit 30, the extrusion coating unit 32 and the printing unit 34 are arranged within the vacuum chamber 36.

[0069] Also the processing drums 22, 24, the auxiliary drums 26a, 26b, 26c, the unwinder 14 and the rewinder 18 are located inside the vacuum chamber 36.

[0070] The vacuum chamber 36 according to the preferred embodiment shown in FIG. 1a includes a vacuum separation 27 which provides two vacuum regimes 29, 31. The first vacuum regime is built around the vacuum coating units 28, 30 and provides a higher vacuum whereas the second vacuum regime 31 is provided for the rest of the units, providing a lower vacuum and a higher pressure.

[0071] FIG. 1b) shows a processing machine 10 according to another embodiment of the invention. Instead of using process drums 22, 24 to guide the web during vacuum coating by the vacuum coating units, the web is in a free span arrangement.

[0072] The arrangement corresponds to the arrangement according to FIG. 1a with the difference that instead of using process drums for passing the web through a first vacuum coating unit 28 and a second vacuum coating unit 30, the web is span between two rollers 23a and 23b or 25a and 25b respectively. The two rollers 23a and 23b or 25a and 25b, respectively span the web while it passes the vacuum deposition step in the vacuum coating unit 28 and/or 30.

Both the first vacuum coating unit 28 and the second vacuum coating unit 30 are vapor deposition units.

[0073] Although described as either using process drums or free span arrangement, it is obvious that a processing machine according to the invention could also include a mixture, meaning at least one vapor deposition coating unit with a process drum and at least one vapor deposition coating unit with a free span arrangement.

[0074] During operation of the web material processing machine 10, the multi-layered material 12 is produced as follows.

[0075] At first, a substrate 38 is provided in the form of the web material 16 to be processed. In the example shown the substrate 38 is a polypropylene foil (cf. FIG. 2).

[0076] Then a film of a first coating material 40 is deposed on the substrate 38 by the first vacuum coating unit 28.

[0077] The film of first coating material 40 acts as a barrier preventing moisture and gases from penetrating through the multi-layered material 12.

[0078] In the example shown the first coating material 40 is aluminum oxide.

[0079] After that a film of a second coating material 42 is deposed on the film of the first coating material 40 by the second vacuum coating unit 30.

[0080] Also the film of second coating material 42 acts as a barrier preventing moisture and gases from penetrating through the multi-layered material 12.

[0081] In the present example, the second coating material 42 is silicon oxide.

[0082] Since the first coating material 40 and the second coating material 42 are different from one another, the respective material properties regarding the impermeability with respect to moisture and/or gases are at least partially complementing each other.

[0083] Thereafter, a film of an extrusion material 44 is coated on top of the second coating material 42 by the extrusion coating unit 32.

[0084] The film of extrusion material 44 is a protective layer protecting the film of first coating material 40 and the film of second coating material 42 from environmental influences such as chemical or mechanical stress.

[0085] In the example shown the extrusion material 44 is polypropylene and thus the same material as the substrate 38.

[0086] Subsequently, an ink 46 is printed on top of the extrusion material 44 by the printing unit 34.

[0087] The ink 46 is dried inside the printing unit 34 by an electron beam.

[0088] As has already been mentioned before, all of the above production steps are executed under vacuum inside the vacuum chamber 36.

[0089] The resulting packaging material 13, thus, comprises a first layer being formed by the single flexible substrate 38.

[0090] On top of the substrate, a layer of first coating material 40 is arranged.

[0091] The film of second coating material 42 is positioned on top of the layer of first coating material 40.

[0092] It is covered by the film of extrusion material 44.

[0093] The layer of ink 46 is provided on top of the film of extrusion material 44.

[0094] Consequently, the packaging material 13 comprises in total five layers, wherein the layer of ink 46 only serves optical purposes.

[0095] Depending on the structure to be produced the arrangement of the modules can change. FIG. 3 therefore shows another possibility of a processing machine, where the web unrolls from the unwinder 14, passes through an extrusion coater, after that though a first vacuum coating unit 28 and then through a second vacuum coating unit 30, after that an extrusion top coating unit 32 before it is rewinded by the rewinder 18.

[0096] The different moduls can be joined for vacuum regimes or have all their proper vacuum regime, as needed. This is also flexible to choose.

[0097] As the different layers have different dynamic rates the processing machine 10 might according to a preferred embodiment accommodate this fact by providing different drum sizes to compensate the different deposition rates. The same can be used to optimize the thickness of the layers.