Film laminate comprising a sealing layer
10611535 · 2020-04-07
Assignee
Inventors
Cpc classification
F04B39/0044
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B32B2307/746
PERFORMING OPERATIONS; TRANSPORTING
B65D75/04
PERFORMING OPERATIONS; TRANSPORTING
B65D65/40
PERFORMING OPERATIONS; TRANSPORTING
F04B39/0027
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B39/127
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B32B3/30
PERFORMING OPERATIONS; TRANSPORTING
B32B2581/00
PERFORMING OPERATIONS; TRANSPORTING
International classification
B65D65/40
PERFORMING OPERATIONS; TRANSPORTING
B32B3/30
PERFORMING OPERATIONS; TRANSPORTING
F04B39/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04B39/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B65D75/04
PERFORMING OPERATIONS; TRANSPORTING
Abstract
In order to improve the sealing properties and the sliding properties of a sealing film, it is provided that surface structures are provided on a first side of the sealing film, wherein the largest thickness of the sealing film is at least 10% greater than the smallest thickness of the sealing film, and the largest lateral extension of the surface structures is smaller than 500 m and a slip additive is added to the sealing film in an amount that yields an S-value of less than 10,000, and preferably less than 5,000.
Claims
1. A bag packaging, produced from a film laminate comprising a carrier layer and a sealing film forming a sealing layer, the bag packaging being produced by folding and sealing the film laminate, whereby overlapping sealed seams are created, characterized in that the sealing film comprises a sealable polymer having a layer thickness in the range of 10 m to 100 m, wherein surface structures being incorporated on a first side of the sealing film at least in areas where sealing takes place, wherein the largest thickness of the sealing film being at least 10% greater than the smallest thickness of the sealing film and the largest lateral extension of the surface structures being smaller than 500 m, the sealing film has an S-value of less than 10,000, the S-value defined as a product of a thickness of the sealing film in micrometer and an amount of slip additive in parts per million, in that the surface structures are formed on a first side of the sealing film and an opposite second side of the sealing film is joined to the carrier layer of the film laminate, in that during sealing, adjoining film laminates with the sealing film are pressed together and compressed, in particular in the overlapping region of multiple sealed seams, so as to avoid the formation of air channels in the overlapping region, a coefficient of friction of the sealing film against steel is in the range of 0.15 to 0.30.
2. The bag packaging according to claim 1, wherein the sealing film is produced without adding slip additive.
3. The bag packaging according to claim 1, wherein the largest thickness of the sealing film is no more than 300% greater than the smallest thickness of the sealing film.
4. The bag packaging according to claim 1, wherein the largest lateral extension of the surface structures is smaller than 400 m.
5. The bag packaging according to claim 1, wherein the surface structures are oriented diagonally to the longitudinal direction of the sealing film.
6. The bag packaging according to claim 1, wherein the surface structures protrude from the first side of the sealing film.
7. The bag packaging according to claim 1, wherein the surface structures are formed as depressions on the first side of the sealing film.
8. The bag packaging according to claim 1, wherein the surface structures have a hexagonal base surface area.
9. The bag packaging according to claim 1, wherein the sealing film is a polyolefin film, and preferably a polyethylene film or a polypropylene film, preferably produced by way of a flat film extrusion process or a blown film extrusion process.
10. The bag packaging according to claim 1, wherein the sealing film is free of antiblock additives.
11. The bag packaging according to claim 1, wherein the sealing layer has an average layer thickness in the range of 10 m to 100 m.
12. The bag packaging according to claim 1, wherein the carrier layer comprises a base layer.
13. The bag packaging according to claim 1, wherein the carrier layer comprises a base layer and a barrier layer, wherein the barrier layer is arranged between the base layer and the sealing layer.
14. The bag packaging according to claim 1, wherein the sealable polymer has a layer thickness in the range of 10 m to 80 m.
15. The bag packaging according to claim 1, wherein the sealable polymer has a layer thickness in the range of 20 m to 70 m.
16. The bag packaging according to claim 1, wherein the slip additive is added to the sealing film in an amount that yields an S-value of less than 5,000.
17. The bag packaging according to claim 2, wherein the largest thickness of the sealing film is no more than 300% greater than the smallest thickness of the sealing film.
18. The bag packaging according to claim 1, wherein the largest lateral extension of the surface structures is smaller than 250 m.
19. The bag packaging according to claim 1, wherein the sealing layer has an average layer thickness in the range of 10 m to 80 m.
20. The bag packaging according to claim 1, wherein the sealing layer has an average layer thickness in the range of 20 m to 70 m.
21. A sealing film, comprising: a sealable polymer having a thickness in the range of 10 m to 100 m; surface structures incorporated on a first side of the sealing film in areas where sealing takes place; a largest thickness of the sealing film is at least 10% greater than a smallest thickness of the sealing film; a largest lateral extension of the surface structures is smaller than 500 m; the sealing film has an S-value of less than 10,000, the S-value defined as a product of a thickness of the sealing film in micrometer and an amount of slip additive in parts per million; the sealing film has a coefficient of friction against steel in the range of 0.15 to 0.30.
22. The sealing film according to claim 21, wherein the S-value is 0.
23. A bag packaging produced by a film laminate, comprising: the sealing film of claim 21; a carrier layer joined to the sealing film on a second side of the sealing film opposite the first side; the film laminate folded and sealed to created overlapping sealed seams, the sealing film pressed together and compressed to avoid the formation of air channels in the overlapping sealed seams.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The present invention will be described in more detail hereafter with reference to
(2)
(3)
(4)
(5)
(6)
DETAILED DESCRIPTION
(7)
(8) The sealing film 10 has surface structures 14 formed therein, such as embossed therein, on a first side 15. In
(9) The surface structures 14 can be designed in a wide variety of manners, for example pyramidal as indicated in
(10) In the examples of
(11) Particularly advantageous properties of the sealing film 10 arise in the case of a hexagonal base surface area, as shown in
(12) Naturally, different shapes of the surface structures 14 than those shown in
(13) The surface structures 14 can be introduced by any arbitrary suitable method, such as by embossing the sealing film 10 using embossing rollers after blown film extrusion or flat film extrusion (off-line process). The surface structures 14 can also be produced in-line, utilizing the melting heat from the film production process.
(14) The decisive factor for the desired properties of the sealing film 10 according to the invention is the dimensions of the surface structures 14. For this reason, the largest thickness h.sub.2 of the sealing film 10 must be at least 10% greater than the smallest thickness h.sub.1 of the sealing film 10 since otherwise it is not possible to displace sufficient material on overlapping sealed seams. For practical reasons, or for manufacturing-related restrictions, it is advantageous if the largest thickness h.sub.2 is no more than 300% greater than the smallest thickness h.sub.1 of the sealing film 10. In particular, the surface structure 14 of the sealing film 10 should not be visible to the naked eye, but at the most manifest itself in higher mattness of a homogeneous surface of the sealing film 10.
(15) These thicknesses h.sub.1, h.sub.2 can be ascertained in practice using the sufficiently known microtomy process. Thin sections (microtome sections) of a portion of the sealing film 10 are produced, which are then analyzed under the microscope.
(16) The largest thicknesses h.sub.2 of the portion of the sealing film 10 in
(17) Likewise, the largest lateral extensions b.sub.1, b.sub.2 in the surface area of the sealing film 10 must be smaller than 500 m, preferably smaller than 400 m and especially particularly advantageously smaller than 250 m, so that the surface structures 14 are not visible to the naked eye. In the example according to
(18) After the sealing film 10 is evenly embossed, it is generally sufficient to analyze a small embossed region of the sealing film 10, such as two or three juxtaposed surface structures 14, by way of microtome sections. Such a region is considered to be representative of the entire sealing film 10 comprising surface structures 14.
(19) It is likewise conceivable to create multiple microtome sections of the sealing film 10, and to ascertain the thicknesses, or the lateral extensions, for each individual microtome section as described above. From this, it is then possible to calculate mean values across all microtome sections, which are then used as the smallest thickness, the largest thickness, and the largest lateral extension.
(20) It is important to limit the largest lateral extension so as to prevent air inclusions and leaks during sealing and, above all, so as not to generate any visually undesirable orange peel, caused by the surface structures 14, on the usually high-gloss visible side of the sealing film 10. The surface structures 14 should be so small than these do not cause any undesirable visual effects to the naked eye.
(21) When the largest thickness h.sub.2 of the sealing film 10 is at least 10% greater than the smallest thickness h.sub.1 of the sealing film 10 (optionally the mean values thereof), and the largest lateral extension (b.sub.1, b.sub.2) of the surface structures 14 (optionally the mean values thereof) is smaller than 500 m, the surface structures 14 are not visible to the naked eye at the typical layer thickness of the sealing film 10 in the range of 10 m to 100 m, but are only discernible under the microscope or magnifying glass. The surface structures 14 only manifest themselves to the naked eye by a matte, satin-finish appearance of the embossed surface of the sealing film 10.
(22) The effect of the surface structures 14 during sealing is that, compared to a conventional, substantially smooth sealing film 10, the sealing film 10 has increased compressibility, which allows potentially occurring differences in thickness during sealing to be better compensated for. At the same time, the amount of material required for the sealing film 10 can thus be reduced since the mean thickness of the sealing film 10 comprising surface structures is smaller than a conventional smooth sealing film 10.
(23) Due to the surface structures 14 of the sealing film 10, however, it can also be achieved at the same time that less slip additive, or even no slip additive, must be added to achieve a certain advantageous coefficient of friction (COF) of the sealing film 10. Due to the negative properties of slip additives mentioned above, this represents a particular advantage of the surface structures 14. It was established that the S-value for the sealing film 10 should be smaller than 10,000 to at least adequately reduce the disadvantages. However, it is especially particularly advantageous if the added amount of slip additive is zero, which is to say if no slip additive at all is present in the sealing film 10.
(24) The influence of the surface structures 14 on the COF will be described hereafter based on the following Tables 1 and 2.
(25) TABLE-US-00001 TABLE 1 COF sealing Slip COF steel film No. Material Thickness Embossing additive stat./dyn. stat./dyn. 1 LLDPE C8 70 m No 500 ppm 0.21/0.18 0.32/0.25 2 LLDPE C8 70 m No None Cannot be Cannot be measured measured 3 LLDPE C8 70 m Diagonal pyramid, None 0.25/0.17 0.93/0.83 square base surface area, diagonal of pyramid 185 m, lateral extension b.sub.1/b.sub.2 = 130 m, h.sub.1 = 55 m, h.sub.2 = 85 m 4 LLDPE C4 50 g/m.sup.2 Pyramid, hexagonal None 0.20/0.18 0.38/0.35 base surface area, lateral extension b.sub.1 = 120 m, h.sub.1 = 40 m, h.sub.2 = 60 m 5 LDPE/LLDPE 50 g/m.sup.2 Recessed pyramids, None 0.25/0.24 0.34/0.35 square base surface area, diagonal of pyramid 220 m, lateral extension b.sub.1/b.sub.2 = 150 m, h.sub.1 = 42 m, h.sub.2 = 58 m
(26) Sealing film no. 1 is a conventional sealing film made of LLDPE C8 having a thickness of 70 m, comprising no surface structures 14 and erucamide (ESA) as a slip additive in an amount of 500 ppm, yielding an S-value of 35,000. This allows the sealing film to achieve a COF against steel and against itself which is favorable for processing the sealing film.
(27) The comparative example in the form of sealing film no. 2 demonstrates the influence of the slip additive on the COF when no surface structures 14 are embossed. Here, the COF can no longer be measured by way of the above test specification. The COF is so high in such a sealing film that the test block would jump during the measurement of the COF, which renders measuring impossible.
(28) Sealing film no. 3 is likewise produced without slip additive, yielding an S-value of 0, but is provided with surface structures 14 according to the invention. The indicated thickness of 70 m (corresponds approximately to a basis weight of 65 g/m.sup.2) is the starting thickness prior to embossing the surface structures 14. The surface structures 14 are designed as pyramids protruding from the plane here, having a square base surface area and a side length of 130 m. The pyramids are applied diagonally to the longitudinal direction of the sealing film 10 (as in
(29) Sealing film no. 4 having a basis weight of 50 g/m.sup.2 (corresponds to a thickness of approximately 40 to 60 m prior to embossing) has a different surface structure 14. Here, this is designed as protruding pyramids having a hexagonal base surface area and a width b.sub.1 of 120 m (see
(30) In sealing film no. 5, recessed pyramids (according to
(31) Table 2 includes another comparative example for a sealing film 10 made of a different polyolefin, which is a metallocene LLDPE (mLLDPE) here.
(32) TABLE-US-00002 TABLE 2 COF sealing Slip COF steel film No. Material Thickness Embossing additive stat./dyn. stat./dyn. 1 mLLDPE 60 g/m.sup.2 Diagonal pyramid, None 0.32/0.26 Cannot be square base surface measured area, diagonal of pyramid 185 m, lateral extension b.sub.1/b.sub.2 = 130 m, h.sub.1 = 50 m, h.sub.2 = 80 m 2 mLLDPE 60 g/m.sup.2 Diagonal pyramid, Yes 0.30/0.24 0.35/0.32 square base surface 800 ppm area, diagonal of pyramid 185 m, lateral extension b.sub.1/b.sub.2 = 130 m, h.sub.1 = 50 m, h.sub.2 = 80 m
(33) From the comparative example according to Table 2, the influence of the surface structures 14 on the COF in identically embossed sealing films with and without slip additive is apparent. The mLLDPE, which is very tacky in itself, has approximately the same COF against steel even without slip additive. Against itself, this type of surface structure 14 cannot be measured due to the meshing of the pyramids. A film made of the same material having no surface structures 14, however, would no longer be measurable even against steel. Such films are often used in industrial applications as self-adhesive surface protective films.
(34) The sealing film 10 according to the invention is preferably used in a film laminate 16, composed of a, usually imprinted, base layer 12 made aluminum, paper or plastic, and a sealable sealing layer 11 made of the sealing film 10, as is shown in
(35) For the use of the film laminate 16 as a packaging, the layer thickness of the base layer 12 is typically in the range of 8 m to 100 m, for example 8 m to 40 m for BOPET, or 15 m to 40 m for aluminum, 10 m to 50 m for BOPP, and up to 100 m for paper. The layer thickness of the sealing layer 11 is typically in the range of 10 m to 100 m, preferably in the range of 10 m to 80 m, and especially particularly advantageously in the range of 20 m to 70 m, and the layer thickness of the barrier layer 13 is typically in the range of 6 m to 25 m for aluminum, or analogous to the above-described thicknesses for the base layer 12 for metallized polymer films. However, it is also conceivable that the barrier layer 13 is incorporated into the sealing layer 11, for example in the form of a polyethylene-ethylene vinyl alcohol (PE-EVOH) copolymer film, whereby a separate barrier layer 13 can be dispensed with. The layer thicknesses of potentially interposed adhesive layers are typically in the range of 1 m to 5 m. The carrier layer 18, however, may also include other layers. Likewise, it may be provided that the carrier layer 18 is imprinted on the visible side. In the case of a transparent base layer 12 in the carrier layer 18, the layer adjoining the base layer 12 may also be imprinted.
(36) Such a film laminate 16 is used to produce packaging for foodstuffs, animal feed or hygiene articles, for example in the form of bags 1 or as membrane-like closures (lid 21) of receptacles (
(37) In many applications, such as FFS machines, care must be taken that, according to the invention, the predominant surface area proportion is provided with the surface structures 14, since otherwise smooth sliding against the steel surface of the machines is not ensured. However, it is possible to have individual unembossed regions, for example for the configuration of customer logos.
(38) The surface structures 14, however, also yield improved compressibility of the film laminate 16, whereby the sealing process is also supported on overlapping regions of multiple sealed seams 2, 3 (as is described by way of example in
(39) Since such embossed films of the sealing layer 11, made of PE, for example, can also be produced by way of flat film extrusion, for which presently only smooth films made of PP are used, it is also possible to use PE raw materials having a higher melt flow index (MFI). Due to the improved flowability of the film material 16, closing of the air channels during sealing and the prevention of leaks on the sealed seam can be additionally supported.
(40) The effect of the sealing film 10 according to the invention in a film laminate 16 during sealing will be described based on an example in the form of bags 1. For this purpose, bags, as shown in
(41) Film laminate A is a conventional laminate comprising a base layer 12 made of BOPET having a layer thickness of 12 m, and a sealing layer 11 bonded thereto, comprising a conventional smooth PE film, which was produced by way of blown film extrusion and is primarily made of LDPE and which has a layer thickness of 60 m, a basis weight of 55 g/m.sup.2 and a melting temperature of 113 C. The sealing film 10 of the sealing layer 11 provided with 400 ppm ESA as a slip additive (S-value of 24,000) and 2000 ppm antiblock agent has a COF (static/dynamic) of 0.34/0.27 against itself and of 0.20/0.16 against steel. The static COF relates to the COF when relative movement is absent, and the dynamic COF relates to the COF when relative movement is present.
(42) Film laminate B is a laminate comprising a base layer 12 made of BOPET having a layer thickness of 12 m, and an embossed sealing layer 11 according to the invention bonded thereto, which has surface structures 14 and is commercially available as a film for medical and hygiene applications. The surface structures 14 are implemented as embossed structures here in the form of hexagonal structures protruding from the surface (Table 1, sealing film no. 4). The sealing layer 11 used is a sealing film in the form of a PE film made primarily of less expensive LLDPE butene C4, having a mean layer thickness of 51.31 m, a basis weight of 50 g/m.sup.2 and a melting temperature of 121 C. Due to the surface structures 14, this sealing layer 11 has a COF (static/dynamic) of 0.38/0.35 against itself and of 0.20/0.18 against steel, even without any slip additives such as ESA and antiblock additives. The COF of the film laminate according to the invention is thus exactly in the desired range for further processing such films on common packaging machines. Even during the subsequent experiments regarding processing on a packaging machine in the form of a vertical form-fill-seal (vFFS) machine, it was confirmed that no problems in this regard during processing were observed.
(43) The result is shown in Table 3.
(44) TABLE-US-00003 TABLE 3 Film laminate A Film laminate (comparison) B (invention) Tightness of Tightness of t.sub.s [s] t.sub.z [s] A t.sub.Q [ C.] pack. pack. 0.30 0.55 109 150 C. 60% 83% 0.25 0.5 120 160 C. 90% 97% 0.20 0.45 133 165 C. 23% 97% 0.25 0.5 120 165 C. 100% 100% 0.20 0.45 133 170 C. 23% 97%
(45) As is apparent from Table 3, the sealing time t.sub.s can be shortened when using a film laminate B according to the invention, which directly impacts the number A of bags that can be produced per minute. This is achieved with an inexpensive raw material and a lower amount of material. This is all the more remarkable as the film formulation of the sealing layer 11 has not yet been optimized in any way. The effect is only due to the improved compressibility achieved by the surface structures 14 in the sealing layer 11.