CA2617135A1 - Method of thermoforming - Google Patents

Method of thermoforming Download PDF

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Publication number
CA2617135A1
CA2617135A1 CA 2617135 CA2617135A CA2617135A1 CA 2617135 A1 CA2617135 A1 CA 2617135A1 CA 2617135 CA2617135 CA 2617135 CA 2617135 A CA2617135 A CA 2617135A CA 2617135 A1 CA2617135 A1 CA 2617135A1
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CA
Canada
Prior art keywords
layer
weight
polyamide
melting point
film
Prior art date
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Granted
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CA 2617135
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French (fr)
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CA2617135C (en
Inventor
Frank M. Hofmeister
Bobby Ayers
Nathanael R. Miranda
Cindy T. Price
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Cryovac LLC
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Individual
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/02—Physical, chemical or physicochemical properties
    • B32B7/027—Thermal properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/04—Polymers of ethylene
    • B29K2023/08—Copolymers of ethylene
    • B29K2023/086—EVOH, i.e. ethylene vinyl alcohol copolymer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2077/00—Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/05—5 or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/24—All layers being polymeric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/02—Temperature
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31725—Of polyamide
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31725—Of polyamide
    • Y10T428/31739—Nylon type
    • Y10T428/31743—Next to addition polymer from unsaturated monomer[s]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31725—Of polyamide
    • Y10T428/31739—Nylon type
    • Y10T428/31743—Next to addition polymer from unsaturated monomer[s]
    • Y10T428/31746—Polymer of monoethylenically unsaturated hydrocarbon
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31725—Of polyamide
    • Y10T428/3175—Next to addition polymer from unsaturated monomer[s]

Abstract

A method of thermoforming comprises the steps of providing a film, heating the film, and forming the heated film onto a mold. The film comprises a propylene/ethylene copolymer skin layer having a melting point of from about 130~C to about 150~C and an interior polyamide layer having a melting point of from about 125~C to about 230~C.

Claims (69)

1. A method of thermoforming comprising the steps of:
providing a film comprising:
a skin layer forming an outer surface of the film, wherein:
the skin layer has a melting point of at least about 130°C and at most about 150°C; and the skin layer comprises one or more propylene/ethylene copolymers; and a first polyamide layer forming an interior layer of the film, wherein:
the first polyamide layer has a melting point of at least about 125°C and at most about 230°C; and the first polyamide layer comprises one or more polyamides;
heating the film; and forming the heated film onto a mold.
2. The method of claim 1 wherein the skin layer has a melting point of at most about 145°C.
3. The method of claim 1 wherein the skin layer has a melting point of at most about 140°C.
4. The method of claim 1 wherein the skin layer comprises at least about 50 %, by weight of the layer, of propylene/ethylene copolymer having an ethylene comonomer content of at least about 1 wt % and at most about 10 wt %.
5. The method of claim 1 wherein the skin layer comprises at least about 50 %, by weight of the layer, of propylene/ethylene copolymer having an ethylene comonomer content of at least about 3 wt % and at most about 8 wt %.
6. The method of claim 1 wherein the skin layer comprises at least about 50 %, by weight of the layer, of propylene/ethylene copolymer having a melting point of at least about 130°C and at most about 145°C.
7. The method of claim 1 wherein the one or more propylene/ethylene copolymers comprise one or more homogeneous propylene/ethylene copolymers.
8. The method of claim 1 wherein the one or more propylene/ethylene copolymers comprise one or more random propylene/ethylene copolymers.
9. The method of claim 1 wherein the thickness of the skin layer is at least about 5 %
and at most about 25 % of the total thickness of the film of the providing step.
10. The method of claim 1 wherein the first polyamide layer has a melting point of at most about 210°C.
11. The method of claim 1 wherein the first polyamide layer has a melting point of at most about 200°C.
12. The method of claim 1 wherein the first polyamide layer has a melting point of at least about 170°C.
13. The method of claim 1 wherein the first polyamide layer comprises at least about 20 %, by weight of the layer, of nylon-6/6,6.
14. The method of claim 1 wherein the first polyamide layer comprises at least about 90 %, by weight of the layer, of nylon-6/6,6.
15. The method of claim 1 wherein the first polyamide layer comprises at least about 30 %, by weight of the layer, of nylon-6/6,6 having a melting point of at least about 180°C and at most about 195°C.
16. The method of claim 1 wherein the first polyamide layer comprises at least about 50 %, by weight of the layer, of nylon-6/6,6 having a caprolactam comonomer content range selected from: 1) at least about 30 mole % to at most about 35 mole % and 2) at least about 85 mole % to at most about 90 mole %.
17. The method of claim 1 wherein the first polyamide layer comprises from about 1 to about 80 %, by weight of the layer, of one or more amorphous polyamides.
18. The method of claim 1 wherein the first polyamide layer comprises at most about 5 %, by weight of the layer, of amorphous polyamide.
19. The method of claim 1 wherein the first polyamide layer is substantially free of amorphous polyamide.
20. The method of claim 1 wherein the thickness of the first polyamide layer is at least about 5% and at most about 25% of the total thickness of the film of the providing step.
21. The method of claim 1 wherein the film further comprises a barrier layer comprising ethylene/vinyl alcohol copolymer.
22. The method of claim 1 wherein the film further comprises a barrier layer directly adjacent the first polyamide layer, wherein the barrier layer comprises ethylene/vinyl alcohol copolymer.
23. The method of claim 22 wherein the barrier layer comprises at least about 80 %, by weight of the layer, of ethylene/vinyl alcohol copolymer.
24. The method of claim 22 wherein the barrier layer has a thickness that is at least about % and at most about 20% of the total thickness of the film of the providing step.
25. The method of claim 22 wherein the film further comprises a second polyamide layer directly adjacent the barrier layer.
26. The method of claim 25 wherein the second polyamide layer has a melting point of at most about 210°C.
27. The method of claim 25 wherein the second polyamide layer has a melting point of at most about 200°C.
28. The method of claim 25 wherein the second polyamide layer has a melting point of at least about 170°C.
29. The method of claim 25 wherein the second polyamide layer comprises at least about 20 %, by weight of the layer, of nylon-6/6,6.
30. The method of claim 25 wherein the second polyamide layer comprises at least about 90 %, by weight of the layer, of nylon-6/6,6.
31. The method of claim 25 wherein the second polyamide layer comprises at least about 50 %, by weight of the layer, of nylon-6/6,6 having a melting point of at least about 180°C
and at most about 195°C.
32. The method of claim 25 wherein the second polyamide layer comprises at least about 50 %, by weight of the layer, of nylon-6/6,6 having a nylon-6 comonomer content range selected from: 1) at least about 30 mole % to at most about 35 mole % and 2) at least about 85 mole % to at most about 90 mole %.
33. The method of claim 25 wherein the second polyamide layer comprises from about 1 to about 80 %, by weight of the layer, of one or more amorphous polyamides.
34. The method of claim 25 wherein the second polyamide layer comprises at most about %, by weight of the layer, of amorphous polyamide.
35. The method of claim 25 wherein the second polyamide layer is substantially free of amorphous polyamide.
36. The method of claim 25 wherein the thickness of the second polyamide layer is at least about 10 % and at most about 20 % of the total thickness of the film of the providing step.
37. The method of claim 25 wherein:
the first polyamide layer comprises at least about 50 %, by weight of the layer, of nylon-6/6,6; and the second polyamide layer comprises at least about 50 %, by weight of the layer, of nylon-6/6,6.
38. The method of claim 37 wherein the nylon-6/6,6 of the first and second polyamide layers are substantially the same.
39. The method of claim 1 wherein the film further comprises an intermediate layer between the skin layer and the first polyamide layer, wherein the intermediate layer:
has a melting point of at least about 105°C and at most about 150°C; and comprises one or more propylene/ethylene copolymers.
40. The method of claim 39 wherein the intermediate layer is directly adjacent the skin layer.
41. The method of claim 40 wherein the intermediate layer has a melting point of at most about 130°C.
42. The method of claim 40 wherein the intermediate layer has a melting point of at most about 120°C.
43. The method of claim 40 wherein the intermediate layer has a melting point of at most about 115°C.
44. The method of claim 40 wherein the intermediate layer comprises at least about 50 %, by weight of the layer, of propylene/ethylene copolymer having an ethylene content of at least about 1 wt % and at most about 10 wt %.
45. The method of claim 40 wherein the intermediate layer comprises at least about 50 %, by weight of the layer, of propylene/ethylene copolymer having an ethylene content of at least about 3 wt % and at most about 8 wt %.
46. The method of claim 40 wherein the intermediate layer comprises at least about 50 %, by weight of the layer, of propylene/ethylene copolymer having a melting point of at least about 105°C and at most about 130°C.
47. The method of claim 40 wherein the intermediate layer comprises at least about 50 %, by weight of the layer, of propylene/ethylene copolymer having a melting point of at least about 105°C and at most about 120°C.
48. The method of claim 40 wherein the intermediate layer comprises one or more homogenous propylene/ethylene copolymers.
49. The method of claim 40 wherein the intermediate layer comprises one or more random propylene/ethylene copolymers.
50. The method of claim 40 wherein the intermediate layer comprises:
at least about 40 %, by weight of the layer, of a first propylene/ethylene copolymer having a melting point of at least about 110°C; and at least about 10 %, by weight of the layer, of a second propylene/ethylene copolymer having a melting point of at most about 110°C.
51. The method of claim 50 wherein the first propylene/ethylene copolymer has a melting point of at least about 115°C and the second propylene/ethylene copolymer has a melting point of at most about 100°C.
52. The method of claim 50 wherein at least one of the first and second propylene/ethylene copolymers is a homogeneous propylene/ethylene copolymer.
53. The method of claim 39 wherein the intermediate layer comprises at least about 50 weight %, by weight of the intermediate layer, of PEC having a density of at least about 0.860 and at most about 0.905.
54. The method of claim 1 wherein the film of the providing step has not been oriented and the film has a thickness of at most about 10 mils.
55. The method of claim 1 wherein the film of the providing step has not been oriented and the film has a thickness of at most about 6 mils.
56. The method of claim 1 wherein the film is substantially free of polyester.
57. The method of claim 1 wherein the film of the providing step has a Young's modulus of at most about 120,000 psi at 50°C, measured according to ASTM D882.
58. The method of claim 1 wherein the total luminous transmittance of the film of the providing step is at least about 95%, measured according to ASTM D1003.
59. The method of claim 1 wherein the heating step heats the film to a temperature of at least about 45°C.
60. The method of claim 1 wherein the heating step heats the film to a temperature of at most about 105°C.
61. The method of claim 1 wherein the heating step heats the film to a temperature of at most about 60°C.
62. The method of claim 1 wherein the forming step comprises vacuum forming.
63. The method of claim 1 wherein the forming step comprises plug assist vacuum forming.
64. The method of claim 1 wherein the forming step comprises air assist vacuum forming.
65. The method of claim 1 wherein the film is substantially devoid of ethylene/vinyl alcohol copolymer.
66. The method of claim 1 wherein:
the film of the providing step is non-oriented and has a thickness of at most about 12 mils;
the skin layer comprises at least about 50 %, by weight of the layer, of one or more propylene/ethylene copolymers having a melting point of at least about 130°C and at most about 150°C; and the first polyamide layer comprises at least about 50 %, by weight of the layer, of one or more polyamides having a melting point of at least about 125°C and at most about 230°C;
and wherein the film further comprises:
an intermediate layer directly adjacent the skin layer, wherein the intermediate layer comprises at least about 50 %, by weight of the layer, of one or more propylene/ethylene copolymers having a melting point of at least about 105°C and at most about 150°C;
a barrier layer directly adjacent the first polyamide layer, wherein the barrier layer comprises ethylene/vinyl alcohol copolymer; and a second polyamide layer directly adjacent the barrier layer wherein the second polyamide layer comprises at least about 50 %, by weight of the layer, of one or more polyamides having a melting point of at least about 125°C and at most about 230°C; and wherein:
the heating step heats the film to a temperature of at least about 45°C
and at most about 105°C.
67. The method of claim 66 wherein the first polyamide layer comprises at least about 50 %, by weight of the layer, of nylon-6/6,6 and the second polyamide layer comprises at least about 50 %, by weight of the layer, of nylon-6/6,6.
68. The method of claim 66 wherein the film further comprises a tie layer directly adjacent to both the intermediate layer and the first polyamide layer, wherein the tie layer comprises at least about 50 %, by weight of the layer, of a modified polyethylene polymer.
69. A thermoformable film comprising:
a skin layer comprising at least about 50 %, by weight of the layer, of one or more propylene/ethylene copolymers having a melting point of at least about 130°C and at most about 150°C;
a first polyamide layer comprises at least about 50 %, by weight of the layer, of one or more polyamides having a melting point of at least about 125°C and at most about 230°C;
an intermediate layer between the skin layer and the first polyamide layer and directly adjacent the skin layer, wherein the intermediate layer comprises at least about 50 %, by weight of the layer, of one or more homogenous propylene/ethylene copolymers having a melting point of at least about 105°C and at most about 150°C;
a barrier layer directly adjacent the first polyamide layer, wherein the barrier layer comprises ethylene/vinyl alcohol copolymer; and a second polyamide layer directly adjacent the barrier layer wherein the second polyamide layer comprises at least about 50 %, by weight of the layer, of one or more polyamides having a melting point of at least about 125°C and at most about 230°C.
CA 2617135 2005-08-01 2006-07-17 Method of thermoforming Active CA2617135C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US11/194,303 US7935301B2 (en) 2005-08-01 2005-08-01 Method of thermoforming
US11/194,303 2005-08-01
PCT/US2006/027590 WO2007015789A2 (en) 2005-08-01 2006-07-17 Method of thermoforming

Publications (2)

Publication Number Publication Date
CA2617135A1 true CA2617135A1 (en) 2007-02-08
CA2617135C CA2617135C (en) 2011-09-20

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ID=37564195

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CA 2617135 Active CA2617135C (en) 2005-08-01 2006-07-17 Method of thermoforming

Country Status (9)

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US (1) US7935301B2 (en)
EP (1) EP1919707B1 (en)
AR (1) AR057482A1 (en)
AU (1) AU2006276211B2 (en)
BR (1) BRPI0614258B1 (en)
CA (1) CA2617135C (en)
MX (1) MX2008001459A (en)
NZ (1) NZ565332A (en)
WO (1) WO2007015789A2 (en)

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US20070026250A1 (en) 2007-02-01
EP1919707B1 (en) 2015-10-07
BRPI0614258A2 (en) 2011-03-15
AU2006276211B2 (en) 2011-11-24
WO2007015789A2 (en) 2007-02-08
EP1919707A2 (en) 2008-05-14
AR057482A1 (en) 2007-12-05
NZ565332A (en) 2011-06-30
WO2007015789A3 (en) 2007-04-19
MX2008001459A (en) 2008-04-02
BRPI0614258B1 (en) 2018-02-06
CA2617135C (en) 2011-09-20
US7935301B2 (en) 2011-05-03

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