Method of manufacturing an oriented film from alloyed thermoplastic polymers, apparatus for such manufacture resulting products
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B32B-027/04
B29C-049/08
B29C-067/24
B29C-047/00
B29C-047/06
B29C-047/14
B29C-047/70
B29C-055/00
B29C-055/06
B29C-047/12
B29C-047/88
B29K-023/00
B29K-067/00
B29K-077/00
B29K-105/00
출원번호
US-0554119
(2004-04-26)
등록번호
US-9346220
(2016-05-24)
우선권정보
GB-0309315.0 (2003-04-24)
국제출원번호
PCT/EP2004/004687
(2004-04-26)
§371/§102 date
20061018
(20061018)
국제공개번호
WO2004/094129
(2004-11-04)
발명자
/ 주소
Rasmussen, Ole-Bendt
출원인 / 주소
Rasmussen, Ole-Bendt
대리인 / 주소
Strozier, Robert W
인용정보
피인용 횟수 :
0인용 특허 :
43
초록▼
A blend of two partly incompatible polymers is extruded to form a film under conditions such that the alloy in the blend comprises fibrils extending mainly in one direction, the width and thickness of each fibril having a mean lower than 5 μm, the fibrils being formed of the polymer component having
A blend of two partly incompatible polymers is extruded to form a film under conditions such that the alloy in the blend comprises fibrils extending mainly in one direction, the width and thickness of each fibril having a mean lower than 5 μm, the fibrils being formed of the polymer component having a higher melting point, and the fibrils being surrounded by a matrix of the second polymer, which has a lower coefficient of elasticity. The special morphology is achieved by providing grids in a grid chamber upstream of the exit orifice of the extrusion die, and by sequential hot stretching at a temperature at which the higher melting polymer is at least partly crystalline, and cold stretching, at which both polymers are substantially solid. The second, cold stretching step, is carried out under conditions to give an elongation at break at 20° C. of at least 25%. The films are of particular value for forming crosslaminates having high shock resistance. Preferably the polymer forming fibrils is polypropylene and the polymer forming the matrix is an ethylene polymer, preferably LLDPE.
대표청구항▼
1. A film comprising: a layer comprising a polymer alloy composition comprising: a first polymer phase comprising microscopic fine fibrils of a first polymer P1, anda second polymer phase comprising a matrix of a second polymer P2 in which the fibrils of the first polymer P1 are dispersed and alloye
1. A film comprising: a layer comprising a polymer alloy composition comprising: a first polymer phase comprising microscopic fine fibrils of a first polymer P1, anda second polymer phase comprising a matrix of a second polymer P2 in which the fibrils of the first polymer P1 are dispersed and alloyed, andat least 4 die lines are substantially parallel with main surfaces of the film,where:the polymers P1 and P2 are at least partly crystalline at temperatures less than 100° C.,the polymer P2, in its unoriented state at 20° C., exhibits a coefficient of elasticity (E1), while the polymer P1, in its unoriented state at 20° C., exhibits a coefficient of elasticity (E2) that is at least 15% lower than E1,the polymers P1 and P2 are compatible or compatibilized during extrusion and have a compatibility of the two polymers P1 and P2 is sufficient to prevent internal voids from forming in the film upon repeated flexing, andeach fibril extends substantially in one direction, has a mean width less than or equal to about 5 μm, has a mean thickness less than or equal to about 5 μm, are flat, and is substantially parallel to main surfaces of the film. 2. The film according to claim 1, further comprising a minor coextruded surface layer on at least one side of the layer to enhance bonding properties and/or modify frictional properties of the film. 3. The film according to claim 2, wherein the polymer P1 comprises polypropylene, polyamide or polyethylene terephthalate, and the polymer P2 comprises a propylene copolymer, or polyethylene. 4. The film according to claim 3, wherein the polypropylene comprises a crystalline copolymer of propylene. 5. The film according to claim 3, wherein the polyethylene comprises a copolymer of ethylene. 6. The film according to claim 1, wherein the film is in the form of a crosslaminate. 7. The film according to claim 1, wherein the film is in the form of a rope, twine or woven-tape product. 8. A film comprising: a layer comprising a polymer alloy composition comprising:a first polymer phase comprising microscopic fine fibrils of a first polymer P1,a second polymer phase comprising a matrix of a second polymer P2 in which the fibrils the first polymer P1 are dispersed and alloyed, andat least 4 die lines are substantiallyparallel to main surfaces of the film making an angle of about 1 o or less relative to the main surfaces,where:the polymers P 1 and P2 are at least partly crystalline at temperatures less than 100° C.,the polymer P2, in its unoriented state at 20° C., exhibits a coefficient of elasticity (E 1), whilethe polymer P 1, in its unoriented state at 20° C., exhibits a coefficient of elasticity (E2) that is at least 15% lower than E1,the polymers P1 and P2 are compatible or compatibilized during extrusion and have a compatibility of the two polymers P 1 and P2 is sufficient to prevent internal voids from forming in the film upon repeated flexing,each fibril extends substantially in one direction, is flat, is substantially parallel with the main surfaces of the film, has a thicknesses less than or equal to about 0.5 μm, has a width at least 5 times the thickness, and has a mean of the width and the thickness less than or equal to about 5 pm. 9. The film according to claim 8, further comprising a minor coextruded surface layer on at least one side of the layer to enhance bonding properties and/or modify frictional properties. 10. The film according to claim 8, wherein the polymer P1 comprises EVOH, vinylidene chloride polymers or polyamide. 11. The film according to claim 8, wherein the film is uniaxially or biaxially oriented and is laminated to another oriented film, whereby the main directions of orientation cross each other. 12. A cellular expanded film comprising: a layer comprising a polymer alloy composition comprising: a first polymer phase comprising microscopic fine fibrils of a first polymer P1, a second polymer phase comprising a matrix of a second polymer P2 in which the fibrils are dispersed and alloyed,at least 4 die lines are substantially parallel to main surfaces of the film making an angle of about 1° or less relative to the main surfaces, anda volatile expansion agent that is soluble in the polymer P2 and insoluble in the polymer P1,where:the polymers P1 and P2 are at least partly crystalline at temperatures less than 100° C.,the polymer P2, in its unoriented state at 20° C., exhibits a coefficient of elasticity (El), whilethe polymer P1, in its unoriented state at 20° C., exhibits a coefficient of elasticity (E2) that is at least 15% lower than E1,the polymers P1 and P2 are compatible or compatibilized during extrusion and have a compatibility of the two polymers P1 and P2 is sufficient to prevent internal voids from forming in the film upon repeated flexing,the volatile expansion agent expands to form a fine cellular expanded structure in the film, and each fibril extends substantially in one direction, has a mean width less than or equal to about 5 μm, has a mean thickness less than or equal to about 5 μm, are flat, and is substantially parallel to main surfaces of the film. 13. The film according to claim 12, wherein the film is uniaxially or biaxially oriented and is laminated to another film, where the main directions of orientation cross each other. 14. The film according to claim 12, wherein the film is in the form of a rope, a twine or a woven-tape product. 15. The film according to claim 12, wherein the film is in the form of a split fiber product. 16. The film according to claim 12, wherein the polymer P2 in its unoriented state at 20° C. exhibits a coefficient of elasticity (E1) which is at least 15% lower than a coefficient of elasticity (E2) of the polymer P1. 17. The film according to claim 8, wherein the polymer P2 comprises a copolymer of propylene or polyethylene. 18. The film according to claim 8, wherein, in the alloy, a weight proportion of the polymer P1 is in the range 5 to75%. 19. The film according to claim 1, wherein the width of the fibrils is at least 10 times the thickness. 20. An extruded oriented film comprising: a layer including: an extrusion formed polymer alloy comprising: a dispersion of microscopically crystalline or semi-crystalline fine fibrils of a polymer P1 surrounded by a polymer P2,at least 4 die lines are substantially parallel to main surfaces of the film making an angle of about 1° or less relative thereto, andwhere the fibrils extend substantially in one direction, have a thickness less than or equal to about 1 μm, have a width at least 5 times the thickness, have a mean of the width and the thickness less than or equal to about 5μum, are flat, and are substantially parallel with the main surfaces of the film due to extruding the blend through the exit orifice of the extrusion, andwhere the polymer P1 and the polymer P2 are different and are at least partly crystalline at temperatures less than 100° C. and are compatible or compatibilized during extrusion, where the compatibility is sufficient so that the film does not develop internal voids upon repeated flexing of the film, andwhere the polymer P2, in its unoriented state at 20° C., exhibits a coefficient of elasticity (E1) which is at least 15% lower than a coefficient of elasticity (E2) of the polymer P1. 21. The film according to claim 20, wherein the film further comprises a minor coextruded surface layer on at least one side of the alloy layer to enhance bonding properties and/or modify frictional properties of the film. 22. The film according to claim 21, wherein the polymer P1 comprises polypropylene, polyamide or polyethylene terephthalate, and the polymer P2 comprises a propylene copolymer, or polyethylene. 23. The film according to claim 22, wherein the polypropylene comprisess a crystalline copolymer of propylene. 24. The film according to claim 22, wherein the polyethylene comprises a copolymer of ethylene. 25. The film according to claim 20, wherein the film is in the form of a crosslaminate. 26. The film according to claim 20, wherein the film is in the form of a rope, twine or woven-tape product. 27. An extruded oriented film comprising: a layer including: an extrusion formed polymer alloy comprising: a dispersion of microscopically crystalline or semi-crystalline fine fibrils of a polymer P1 surrounded by a polymer P2, andat least 4 die lines are substantially parallel to main surfaces of the film making an angle of about 1° or less relative to the main surfaces,where the fibrils extend substantially in one direction, have a thickness less than or equal to about 1 μm, a width at least 5 times its thickness, and have a mean of the width and the thickness less than or equal to about 5 μm due to extruding the blend through the exit orifice of the extrusion,where the polymer P1 and the polymer P2 are different and are at least partly crystalline at temperatures less than 100° C. and are compatible or compatibilized during extrusion, where the compatibility is sufficient so that the film does not develop internal voids upon repeated flexing of the film, andwhere the polymer P2 in its unoriented state at 20° C. exhibits a coefficient of elasticity (E1) which is at least 15% lower than a coefficient of elasticity (E2) of the polymer P1, andlocations of rupture of the polymer P1 fibrils,where the locations of rupture extend in a substantially linear fashion across the film at an angle to the direction of orientation of the fibrils and comprise the polymer P2. 28. The film according to claim 27, wherein the film further comprises a minor coextruded surface layer on at least one side of the alloy layer to enhance bonding properties and/or modify frictional properties of the film. 29. The film according to claim 28, wherein the polymer P1 comprises polypropylene, polyamide or polyethylene terephthalate, and the polymer P2 comprises a propylene copolymer, or polyethylene. 30. The film according to claim 29, wherein the polypropylene comprises a crystalline copolymer of propylene. 31. The film according to claim 29, wherein the polyethylene comprises a copolymer of ethylene. 32. The film according to claim 27, wherein the film is in the form of a crosslaminate. 33. The film according to claim 27, wherein the film is in the form of a rope, twine or woven-tape product. 34. An extruded oriented film comprising: a layer including: an extrusion formed polymer alloy comprising: a dispersion of microscopically crystalline or semi-crystalline fine fibrils of a polymer P1 surrounded by a polymer P2,at least 4 die lines are substantially parallel to main surfaces of the film making an angle of about 1° or less relative to the main surfaces,where the fibrils extend substantially in one direction, have a thickness less than or equal to about +0.5 μm, a width at least 5 times the thickness, have a mean of the width and the thickness less than or equal to about 5μum, are flat and are substantially parallel with the main surfaces of the film due to extruding the blend through the exit orifice of the extrusion,where the polymer P1 and the polymer P2 are different and are at least partly crystalline at temperatures less than 100° C. and are compatible or compatibilized during extrusion, where the compatibility is sufficient so that the film does not develop internal voids upon repeated flexing of the film, andwhere the polymer P2 in its unoriented state at 20° C. exhibits a coefficient of elasticity (E1) which is at least 15% lower than a coefficient of elasticity (E2) of the polymer P1, andlocations of rupture of the polymer P1 fibrils,where the locations of rupture extend in a substantially linear fashion across the film at an angle to the direction of orientation of the fibrils and comprise the polymer P2. 35. The film according to claim 34, wherein the film further comprises a minor coextruded surface layer on at least one side of the alloy layer to enhance bonding properties and/or modify frictional properties of the film. 36. The film according to claim 35, wherein the polymer P1 comprises polypropylene, polyamide or polyethylene terephthalate, and the polymer P2 comprises a propylene copolymer, or polyethylene. 37. The film according to claim 36, wherein the polypropylene comprises a crystalline copolymer of propylene. 38. The film according to claim 36, wherein the polyethylene comprises a copolymer of ethylene. 39. The film according to claim .34, wherein the film is in the form of a crosslaminate. 40. The film according to claim 34, wherein the film is in the form of a rope, twine or woven-tape product. 41. The film according to claim 1, wherein the fibrils are broken at locations in the film. 42. The film according to claim 8, wherein the fibrils are broken at locations in the film. 43. The film according to claim 12, wherein the fibrils are broken at locations in the film. 44. The film according to claim 20, wherein the fibrils are broken at locations in the film. 45. The film according to claim 27, wherein the fibrils are broken at locations in the film. 46. The film according to claim 34, wherein the fibrils are broken at locations in the film.
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