throbber
(12) United States Patent
`
`
`
`
`Sheppard et al.
`
`
`
`(10) Patent N0.:
`
`
`
`
`
`(45) Date of Patent:
`
`
`
`US 6,455,150 B1
`
`
`
`
`
`*Sep. 24, 2002
`
`
`US006455l50Bl
`
`
`
`............. .. 428/349
`9/1987 Keung et al.
`4,692,379 A
`
`
`
`
`
`. . . .. 428/216
`1/1988 Crass et al.
`. . . . . .
`4,720,420 A
`
`
`
`
`
`
`: 212:: 6‘ 1,1111111111A 2:22;
`:‘:ZZ1‘€:Z:
`amanoe a.
`,
`,
`
`
`
`
`
`
`
`
`E/I".H°m ettali ““““““
`2
`
`
`
`
`
`
`4,961,992 A * 10/1990 Ballzlldrrlii) :t
`........ 5 428/332
`
`
`
`
`
`4,966,933 A * 10/1990 Kawakami et 51:55.22... 524/310
`
`
`
`
`
`
`5,057,177 A
`10/1991 Ballonietal.
`....... .. 156/244.11
`
`
`
`
`
`5,110,671 A *
`5/1992 Balloni et al.
`............ .. 428/218
`
`
`
`
`
`
`
`5,169,714 A * 12/1992 Kondo et al.
`............. .. 428/331
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`E13
`
`
`W0
`
`
`
`FOREIGN PATENT DOCUMENTS
`0 242 055
`10/1937
`
`
`
`
`
`
`
`W0 95/15256
`6/1995
`
`
`OTHER PUBLICATIONS
`
`
`
`
`
`
`Schmitz, Peter et al., “Films.” Ullmann’s Encyclopedia of
`
`
`
`
`
`
`
`
`
`Industrial Chemistry, 5th Ed., Vol. A11, pp. 85-110, Jan.,
`1988.*
`
`
`
`
`
`
`* cited by examiner
`
`
`.
`.
`.
`.
`
`
`
`
`
`
`
`.
`.
`.
`.
`Przmary Exam;/1er—ViVian. Chen
`(74) Attorney, Agent, or Fzrm—Dennis P. Santini; Rick F.
`
`
`
`
`
`
`
`James
`
`ABSTRACT
`(57)
`
`(*9 a“ “PP”
`A hemealable multilayer. film ‘’°mP‘iSi“g:
`
`
`
`
`
`
`
`
`heat-sealable layer comprising (I) an ethylene polymer,
`
`
`
`
`
`t
`1. k d
`t.
`1
`t
`1
`d
`1
`
`
`
`
`
`
`
`
`
`f1°§‘r’0Z$:r’legugggfufefier0j‘“Sik:(a:ep§:;f;1 aaiilggissalfiicfle
`
`
`
`
`
`P Y
`P
`g
`.
`Y
`Y
`size of from about 0.5 pm to about 20.0 /tm, as a combined
`
`
`
`
`
`
`
`
`slip agent and antiblocking agent: (b) an intermediate core
`
`
`
`
`
`
`
`
`
`layer comprising a propylene polymer; and (c) a lower
`
`
`
`
`
`
`
`heat_Sea1ab1e layer Consisting essentially of
`an ethylene
`
`
`
`
`
`
`
`
`
`
`
`
`
`polymer copolymer or
`terpolymer
`(ii) a particulate
`crosslinkied hydrocarbyl-substituted polysiloxane having ei
`
`
`
`
`mean particle size of from about 0.5 pm to about 20.0 /tm
`
`
`
`
`
`
`
`
`
`
`as a combined slip agent and antiblocking agent; and (iii)
`
`
`
`
`
`
`
`
`
`from about 0.15 wt% to about 1.5 wt% of a liquid,
`
`
`
`
`
`
`
`
`hydrocarbyl-substituted polysiloxane. The upper heat-
`
`
`
`
`
`1'
`'d
`I bl
`l bl
`l
`d
`t
`t
`'
`
`
`
`
`
`
`
`;::y:,,,:,;:’,:,;,;g,:;,:§:,,,::;,,;:;;,g1;,,;,,,;:1;;,
`
`
`
`
`
`
`
`transferred from the lower heat-sealable la er
`
`
`
`
`
`
`‘
`5’
`
`17 Claims, N0 Drawings
`
`
`
`
`
`(54) MULTI-LAYER ORIENTED HEAT
`
`
`
`
`SEALABLE FILM STRUCTURE OF
`
`
`
`
`
`
`
`
`(76)
`
`
`
`
`
`
`Inventors: Karen A. Sheppard, 67 Edendery Cir.,
`
`
`
`
`Fairpert’ NY (US) 14450’ Jay Ki“
`
`
`
`
`
`
`K°““g> 6011 A119“ Padgham Rd->
`
`
`
`
`
`MaC€d0H>NY(US)14502;FF311°iS
`
`Tran The-Dzuy, 1349 Ayrau1tRd.,
`
`
`
`
`
`Fairport, NY (US) 14450; Joseph E.
`
`
`
`
`
`Brew, 801 East AVe., Newark, NY (US)
`
`
`
`
`
`
`
`
`
`
`14513; Benoit Ambroise, Rue de la
`Barriere, 50, B-6792 Halanzy (BE)
`
`
`
`
`
`This patent issued on a continued pros-
`
`
`
`
`
`
`
`
`
`
`
`
`ecution application filed under 37 CFR
`
`
`
`
`
`
`155(d)’ and is Subjeet to the twenty year
`
`
`
`
`
`
`term provlslons of 35 U'S'C'
`patent
`154(a)(2)~
`
`
`(*) Notice:
`
`
`
`
`Subject to any disclaimer, the term of this
`
`
`
`
`
`
`patent is extended or adjusted under 35
`
`
`
`
`
`
`
`
`USC. 154(b) by 0 days.
`
`(21) Appl. No.: 08/164,598
`
`
`
`
`(22)
`Filed:
`Dec. 9, 1993
`
`
`
`
`Int. Cl.7 ....................... .. B32B 27/08, B32B 27/18,
`(51)
`
`
`
`
`
`
`
`
`.
`
`
`
`
`B32B 27/32, B32B 31/30
`
`
`
`
`(52) U.s. Cl.
`..................... .. 428/327, 428/323, 428/343,
`
`
`428/346, 428/347, 428/349; 428/354, 428/355 EN;
`
`
`
`
`
`428/515; 428/516; 428/523; 156/24411;
`
`
`
`
`
`_
`264/17316
`
`
`
`
`
`Fleld Of Search ............................... ..
`
`
`
`
`
`
`
`
`
`
`
`
`
`428/527’ 405’ 515’ 516’ 525’ 557’ 545’
`546’ 547’ 549’ 554’ 555 EN’ 156/24411’
`
`
`
`
`
`
`
`264/17516
`
`
`
`
`
`
`
`(56)
`
`
`
`,
`
`References Clted
`
`
`Us. PATENT DOCUMENTS
`
`
`
`8/1985 Gust ., ,1.
`..................
`4,533,509 A
`
`
`
`
`
`
`428/215
`6/1986 Crass ct 41‘
`4’595’625 A *
`
`
`10/1986 Doyen ...................... .. 428/213
`4,618,527 A
`3/1987 Crass et al.
`............... .. 428/337
`4,652,489 A
`
`
`
`
`
`
`4/1987 Balloni et al.
`............ .. 428/213
`4,659,612 A
`
`
`
`
`
`
`
`
`
`PAGE 1 OF 8
`
`BOREALIS EXHIBIT 1008
`
`BOREALIS EXHIBIT 1008
`
`PAGE 1 OF 8
`
`

`
`
`
`US 6,455,150 B1
`
`2
`
`slip characteristics without the adverse appearance, wetting
`
`
`
`
`
`
`
`and adhesion effects typically experienced with amide-
`
`
`
`
`
`
`
`modified films. However, when laminated to other films,
`
`
`
`
`
`
`
`such structures exhibit significantly higher coefficient of
`
`
`
`
`
`
`
`friction values and cannot be used in conventional form, fill
`
`
`
`
`
`
`
`
`and seal machines.
`
`
`
`U.S. Pat. No. 4,618,527, discloses a biaxially oriented
`
`
`
`
`
`
`
`film structure comprising (I) a comparatively thick base
`
`
`
`
`
`
`
`layer of a thermoplastic resin containing: an antistatic com-
`
`
`
`
`
`
`
`bination of (a) a compound of the formula RN(R1)2 wherein
`
`
`
`
`
`
`
`R is a C5—C24 alkyl group R1 is H(OCH2CH2)n; n=1—25; and
`
`
`
`
`
`
`
`(b) a monoester of an aliphatic C2—C24 fatty acid; and a slip
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`improving proportion of (c) a C12—C24 fatty amide; and (II)
`a comparatively thin surface layer on at least one surface of
`
`
`
`
`
`
`
`
`(I), the surface layer comprising a thermoplastic resin con-
`
`
`
`
`
`
`
`
`taining an anti-block and COF reducing proportion of a
`
`
`
`
`
`
`
`
`finely divided inorganic material. This structure can be
`
`
`
`
`
`
`
`
`laminated to another film such as a polymeric film or a paper
`
`
`
`
`
`
`
`film.
`
`In U.S. Pat. No. 4,652,489, a sealable, opaque poly-
`
`
`
`
`
`
`
`olefinic multilayer film composed of a polypropylene base
`
`
`
`
`
`
`layer, a non-sealable surface layer, and a sealable surface
`
`
`
`
`
`
`
`layer, is disclosed. The. sealable surface layer has a low
`
`
`
`
`
`
`
`
`
`minimum sealing temperature and is made from a copoly-
`
`
`
`
`
`
`
`mer of propylene and ethylene or butene-1 units and/or a
`
`
`
`
`
`
`
`
`terpolymer of ethylene, propylene and butene-1 units. The
`
`
`
`
`
`
`
`non-sealable layer
`is a combination of a propylene
`
`
`
`
`
`
`
`homopolymer and a slip agent. The base layer contains an
`
`
`
`
`
`
`
`
`additive which is incompatible with polypropylene. The
`
`
`
`
`
`
`process includes stretching of the film, and during the
`
`
`
`
`
`
`
`
`
`stretching step, the polymer matrix is torn open around the
`
`
`
`
`
`
`
`
`
`additive particles to form vacuoles which give the base layer
`
`
`
`
`
`
`
`
`
`a degree of opacity
`
`
`
`U.S. Pat. No. 4,659,612 discloses an oriented, polymer
`
`
`
`
`
`
`
`
`film laminate possessing a low coefficient of friction, good
`
`
`
`
`
`
`
`receptivity for water-based coatings and good optical char-
`
`
`
`
`
`
`
`
`acteristics.
`
`U.S. Pat. No. 4,692,379 discloses an oriented, heat seal-
`
`
`
`
`
`
`
`
`
`able polymer film laminate possessing a low coefficient of
`
`
`
`
`
`
`
`friction, good receptivity for water-based coatings and good
`
`
`
`
`
`
`
`
`optical clarity and a method for manufacturing such a
`
`
`
`
`
`
`
`laminate.
`
`U.S. Pat. No. 4,720,420 discloses a sealable, transparent
`
`
`
`
`
`
`
`polyolefinic multilayer film composed of a polypropylene
`
`
`
`
`
`base layer, a non-sealable surface layer, and a sealable
`
`
`
`
`
`
`
`surface layer. The sealable surface layer has a low minimum
`
`
`
`
`
`
`
`
`
`sealing temperature and is made from a copolymer of
`
`
`
`
`
`
`
`propylene and ethylene or butene-1 units and/or a terpoly-
`
`
`
`
`
`
`
`mer of ethylene, propylene and butene-1 units. The non-
`
`
`
`
`
`
`
`
`sealable layer
`is a combination of
`a propylene
`
`
`
`
`
`
`
`homopolymer, a slip agent, and an anti-blocking agent. The
`
`
`
`
`
`
`
`process provided includes coextruding the three layers,
`
`
`
`
`
`
`
`biaxially stretching the coextruded film, and subjecting the
`
`
`
`
`
`
`
`
`non-sealable layer to a corona-discharge treatment.
`
`
`
`
`U.S. Pat. No. 4,734,317 relates to a polyolefin film having
`
`
`
`
`
`
`
`
`a base layer composed essentially of propylene polymers
`
`
`
`
`
`
`
`
`and having sealing layers present on both sides, composed
`
`
`
`
`
`
`
`
`essentially of sealable olefin polymers. Polydialkylsiloxane
`
`
`
`
`
`is incorporated in a first of the two sealing layers, and this
`
`
`
`
`
`
`
`
`
`
`layer is not subjected to corona treatment. The second
`
`
`
`
`
`
`
`
`
`sealing layer is subjected to corona treatment and has
`
`
`
`
`
`
`
`
`
`polydialkylsiloxane, not
`incorporated, but present on its
`
`
`
`
`
`
`
`the polydialkylsiloxane having been trans-
`outer surface,
`
`
`
`
`
`
`
`ferred to this layer by contact with the sealing layer in which
`
`
`
`
`
`
`
`
`
`polydialkylsiloxane is incorporated. The relative polydi-
`
`
`
`
`
`alkylsiloxane occupancy on the second layer, which is
`
`
`
`
`
`
`
`
`
`
`1
`
`MULTI-LAYER ORIENTED HEAT
`
`
`
`SEALABLE FILM STRUCTURE OF
`
`
`
`IMPROVED MACHINABILITY
`
`
`FIELD OF THE INVENTION
`
`
`
`
`This invention relates to the field of composite polymer
`
`
`
`
`
`
`
`films of reduced surface frictional characteristics and to a
`
`
`
`
`
`
`method of making such films. It more particularly refers to
`
`
`
`
`
`
`
`a biaxially oriented composite film structure having
`
`
`
`
`
`
`
`
`
`
`
`
`
`improved properties,
`including heat sealability, good
`machinability and reduced coefficient of friction.
`
`
`
`
`
`BACKGROUND OF THE INVENTION
`
`
`
`In the packaging of certain types of foods, such as snack
`
`
`
`
`
`
`
`
`foods including candies, potato chips, cookies and the like,
`
`
`
`
`
`
`
`
`
`it is common practice to employ a multi-layer film. Polypro-
`
`
`
`
`
`
`
`
`pylene films are widely used in the packaging industry due
`
`
`
`
`
`
`
`
`to their superior physical properties, such as, transparency,
`
`
`
`
`
`
`
`
`stiffness, moisture barrier characteristics and others. Despite
`
`
`
`
`
`
`
`
`
`
`
`
`
`these highly desirable properties, unmodified polypropylene
`film has the disadvantageous property of having a high
`
`
`
`
`
`
`
`
`inherent coefficient of friction and film-to-film destructive
`
`
`
`
`
`
`
`blocking on storage. This high film-to-film coefficient of
`
`
`
`
`
`
`
`
`friction makes polypropylene films difficult to be success-
`
`
`
`
`
`
`
`
`
`
`
`
`
`fully employed in automatic packaging equipment in their
`unmodified form.
`
`
`In the past, coefficient of friction characteristics of
`
`
`
`
`
`
`
`
`polypropylene and other thermoplastic films have been
`
`
`
`
`
`
`
`beneficially modified by the inclusion in the polymer of fatty
`
`
`
`
`
`
`acid amides, such as, erucamide and oleamide. The effec-
`
`
`
`
`
`
`
`
`
`tiveness of this type of material depends upon its ability to
`
`
`
`
`
`
`
`migrate to the surface of the film in order to reduce the
`
`
`
`
`
`
`
`
`
`coefficient of friction. Both of the aforementioned amides
`
`
`
`
`
`
`
`are commonly used for reducing coefficient of friction. The
`
`
`
`
`
`
`
`
`development of the desired low coefficient of friction value
`
`
`
`
`
`
`
`is strongly dependent upon the type and amounts of amides,
`
`
`
`
`
`
`
`
`and time and temperature aging effects. Even the heat
`
`
`
`
`
`
`
`
`
`history of the film while in storage and shipping and during
`
`
`
`
`
`
`
`
`
`subsequent converter processes, significantly affects the
`
`
`
`
`
`
`coefficient of friction. In addition,
`the presence of these
`
`
`
`
`
`
`
`
`
`types of fatty acid amides on the film surface results in
`
`
`
`
`
`
`
`
`
`
`
`visible adverse appearance effects, manifested by an
`
`
`
`
`
`
`
`increase in haze, a decrease in gloss and the presence of
`
`
`
`
`
`
`
`
`
`streaks. These materials also adversely effect the wettability
`
`
`
`
`
`
`
`
`and adhesion of solvent and water-based inks, coatings and
`
`
`
`
`
`
`
`
`adhesives.
`
`In the case of oriented polypropylene films which are
`
`
`
`
`
`
`
`
`
`widely used in the food packaging industry, it is common to
`
`
`
`
`
`
`
`
`laminate this film with itself or with other thermoplastic
`
`
`
`
`
`
`
`
`
`films or with paper films. When oleamide or erucamide are
`
`
`
`
`
`
`
`
`used in the polypropylene films a significant increase in
`
`
`
`
`
`
`
`coefficient of friction has been observed after lamination to
`
`
`
`
`
`
`
`such films. It
`is theorized that this is due either to the
`
`
`
`
`
`
`
`
`
`
`
`migration of the amide back into the polypropylene film or
`
`
`
`
`
`
`
`
`to the loss of the additive layer at the film surface. Therefore,
`
`
`
`
`
`
`
`
`
`
`these types of oriented laminated polypropylene films have
`
`
`
`
`
`
`
`limited usage for particular converting processes. Attempts
`
`
`
`
`
`
`
`to replace these amides to provide a consistent coefficient of
`
`
`
`
`
`
`
`friction have not been successful.
`
`
`
`
`
`In U.S. Pat. No. 4,533,509, there is described a multi-
`
`
`
`
`
`
`
`
`layer structure comprising a comparatively thick base layer
`
`
`
`
`
`
`
`of an optically clear thermoplastic resin and a comparatively
`
`
`
`
`
`
`
`thin surface layer containing a finely divided inorganic
`
`
`
`
`
`
`
`material in a proportion sufficient to thereby impart anti-
`
`
`
`
`
`
`block characteristics and decrease film-to-film coefficient of
`
`
`
`
`
`
`friction. The resulting film has non-blocking and improved
`
`
`
`
`
`
`
`
`
`10
`
`15
`
`
`
`20
`
`25
`
`30
`
`35
`
`
`
`40
`
`45
`
`
`
`50
`
`55
`
`
`
`60
`
`65
`
`
`
`PAGE 2 OF 8
`
`PAGE 2 OF 8
`
`

`
`
`
`US 6,455,150 B1
`
`
`3
`determined by means of ESCA spectroscopy, is not more
`
`
`
`
`
`
`than 15. The three-layer polyolefin film is prepared by a
`
`
`
`
`
`
`
`
`coextrusion process. It is particularly suitable for use as a
`
`
`
`
`
`
`
`packaging film on high-speed packaging machines.
`
`
`
`
`
`U.S. Pat. No. 4,764,425 discloses an oriented, heat-
`
`
`
`
`
`
`
`
`sealable polypropylene film which possesses a low coeffi-
`
`
`
`
`
`
`
`cient of friction, excellent anti-static behavior and good
`
`
`
`
`
`
`
`
`
`
`optical clarity.
`U.S. Pat. No. 4,961,992 relates to a polymer film laminate
`
`
`
`
`
`
`
`
`having improved machinability on modern high speed belt
`
`
`
`
`
`
`
`drive machines, particularly when these machines are set up
`
`
`
`
`
`
`
`
`to form lap seals. Amethod of assembling such a film is also
`
`
`
`
`
`
`
`
`
`provided. The film includes an outside web having-an upper
`
`
`
`
`
`
`
`
`surface layer containing a silicone oil. This laminating web
`
`
`
`
`
`
`
`
`can be used with virtually any co-laminate, metallized or
`
`
`
`
`
`
`
`
`not, which is bonded thereto with an adhesive. Upon wind-
`
`
`
`
`
`
`
`
`ing the composite film laminate upon a core, silicone oil is
`
`
`
`
`
`
`
`
`
`transferred to the inside surface of the laminates thus pro-
`
`
`
`
`
`
`
`
`viding an inside coefficient friction which is about equal to
`
`
`
`
`
`
`
`or less than the outside coefficient of friction. Hot slip
`
`
`
`
`
`
`
`
`
`
`properties are also improved upon such transfer. The outside
`
`
`
`
`
`
`
`
`
`and inside webs are independently formed, which allows the
`
`
`
`
`
`
`
`
`inside web to include coatings or film layers which are not
`
`
`
`
`
`
`
`
`
`ordinarily usable in a silicone oil-containing film.
`
`
`
`
`
`U.S. Pat. No. 5,110,671 discloses an oriented, multi-layer
`
`
`
`
`
`
`
`polymer
`film laminate having a core of isotactic
`
`
`
`
`
`
`
`polypropylene, an outside skin layer of isotactic polypropy-
`
`
`
`
`
`
`lene containing an anti-blocking agent and an inside heat
`
`
`
`
`
`
`
`
`sealable skin layer containing an anti-blocking agent and a
`
`
`
`
`
`
`
`coefficient of friction reducing amount of a silicone oil.
`
`
`
`
`
`
`Despite these advances in the art, a need still exists for a
`
`
`
`
`
`
`
`
`
`film structure of improved machinability which also pro-
`
`
`
`
`
`
`
`
`vides excellent sealability, strength and stiffness.
`
`
`
`
`
`
`SUMMARY OF THE INVENTION
`
`
`
`In accordance with the present invention, there is pro-
`
`
`
`
`
`
`
`
`vided a film structure which includes at least one layer of an
`
`
`
`
`
`
`
`
`olefin homo-, co- or ter-polymer having a surface-treated
`
`
`
`
`
`
`
`external surface which is printable, sealable and machinable,
`
`
`
`
`
`
`
`the layer containing, as combined slip agent and antiblock,
`
`
`
`
`
`
`
`
`a particulate cross-linked hydrocarbyl-substituted polysilox-
`
`
`
`
`
`ane. Particularly preferred particulate cross-linked
`
`
`
`
`
`hydrocarbyl-substituted polysiloxane include the poly-
`
`
`
`
`
`
`monoalkylsiloxanes.
`Also, a heat sealable multilayer film structure of improved
`
`
`
`
`
`
`
`machinability is provided. The film structure comprises an
`
`
`
`
`
`
`upper heat sealable layer comprising an olefinic homopoly-
`
`
`
`
`
`
`
`mer copolymer or terpolymer having a surface-treated exter-
`
`
`
`
`
`
`nal surface which is printable, sealable and machinable, the
`
`
`
`
`
`
`
`
`layer containing, as combined slip agent and antiblock, a
`
`
`
`
`
`
`
`
`
`
`
`particulate cross-linked hydrocarbyl-substituted
`polysiloxane, an intermediate layer comprising an olefinic
`
`
`
`
`
`
`polymer, and a lower heat sealable layer comprising an
`
`
`
`
`
`
`
`
`olefinic homopolymer, copolymer or terpolymer having an
`
`
`
`
`
`external surface which is sealable and machinable, the layer
`
`
`
`
`
`
`
`
`containing, as combined slip agent and antiblock, a particu-
`
`
`
`
`
`
`
`late cross-linked hydrocarbyl-substituted polysiloxane.
`
`
`
`
`A method of producing a-heat sealable multilayer film
`
`
`
`
`
`
`
`structure of improved machinability is also provided. The
`
`
`
`
`
`
`
`method includes the-step of coextruding a film structure, the
`
`
`
`
`
`
`
`film structure including an upper heat sealable layer com-
`
`
`
`
`
`
`
`
`
`prising an olefinic homopolymer, copolymer or terpolymer
`
`
`
`
`
`
`having a surface-treated external surface which is printable,
`
`
`
`
`
`
`sealable and machinable, the layer containing, as combined
`
`
`
`
`
`
`
`slip agent and antiblock,
`a particulate cross-linked
`
`
`
`
`
`
`hydrocarbyl-substituted polysiloxane, an intermediate layer
`
`
`
`
`
`10
`
`
`
`15
`
`
`
`20
`
`25
`
`
`
`30
`
`35
`
`
`
`40
`
`45
`
`
`
`50
`
`55
`
`
`
`60
`
`65
`
`
`
`PAGE 3 OF 8
`
`4
`
`comprising an olefinic polymer, and a lower heat sealable
`
`
`
`
`
`
`
`layer comprising an olefinic homopolymer, copolymer or
`
`
`
`
`
`
`terpolymer having an external surface which is sealable and
`
`
`
`
`
`
`
`machinable, the layer containing, as combined slip agent and
`
`
`
`
`
`
`
`
`antiblock, a particulate cross-linked hydrocarbyl-substituted
`
`
`
`
`polysiloxane.
`In practicing the method of the present
`
`
`
`
`
`
`
`
`is particularly preferred to employ as the
`it
`invention,
`
`
`
`
`
`
`
`
`
`
`
`particulate dross-linked hydrocarbyl-substituted polysilox-
`ane a polymonoalkylsiloxane.
`
`
`By improved machinability is meant that the film exhibits
`
`
`
`
`
`
`
`a consistently low coefficient of friction and has improved
`
`
`
`
`
`
`
`
`
`
`
`anti-slip and non-blocking characteristics.
`Accordingly, it is an object of the present invention to
`
`
`
`
`
`
`
`
`provide a film structure of excellent sealability.
`
`
`
`
`
`
`It is another object of the present invention to provide a
`
`
`
`
`
`
`
`
`film structure with improved machinability.
`
`
`
`
`
`It is a further object of the present invention to provide a
`
`
`
`
`
`
`
`
`film structure having an improved range of process oper-
`
`
`
`
`
`
`
`
`
`ability.
`It is yet another object of the present invention to provide
`
`
`
`
`
`
`
`
`a film which may be bonded to a wide variety of substrates
`
`
`
`
`
`
`
`
`and coatings.
`
`
`It is a yet further object of the present invention to provide
`
`
`
`
`
`
`
`a film .structure in which a conventional treatment testing
`
`
`
`
`
`
`
`method can be used.
`
`
`
`Other and additional objects, and the several advantages
`
`
`
`
`
`
`
`
`of the present invention, will become apparent to those of
`
`
`
`
`
`
`
`
`
`ordinary skill in this art upon a reading of the specification
`
`
`
`
`
`
`
`
`
`and the claims appended thereto.
`
`
`
`
`
`DETAILED DESCRIPTION OF THE
`
`
`INVENTION
`
`
`
`
`
`
`
`
`
`
`In general, the present invention can be practiced with any
`
`
`
`
`
`
`
`
`
`thermoplastic film, for example, the polyolefins in general,
`
`
`
`
`
`
`
`and specifically, polymers, copolymers and blends of
`
`
`
`
`
`
`
`ethylene, propylene, butylene, etc., polyesters, such as,
`
`
`
`
`
`
`
`
`
`
`
`
`
`polyethylene terephthalate acrylic polymers and copolymers
`and the like. The basic film structures of the present inven-
`
`
`
`
`
`
`
`
`
`
`tion find utility when supported or laminated to another film
`
`
`
`
`
`
`
`
`in order to accommodate a particular end use. Thus, polymer
`
`
`
`
`
`
`
`
`film layers different from the intermediate layer can be
`
`
`
`
`
`
`
`
`
`laminated to the intermediate layer of the structure for
`
`
`
`
`
`
`
`
`particular purposes. Such polymeric films include any ther-
`
`
`
`
`
`
`
`
`moplastic film different from the intermediate layer of the
`
`
`
`
`
`
`
`
`
`film.
`
`Particularly preferred polymers employed as the interme-
`
`
`
`
`
`
`diate layer of the film herein are the polypropylenes which
`
`
`
`
`
`
`
`
`
`are highly isotactic. The preferred polypropylenes are well
`
`
`
`
`
`
`
`
`known in the art and are formed by polymerizing propylene
`
`
`
`
`
`
`
`
`in the presence of stereospecific catalysts system. They can
`
`
`
`
`
`
`
`
`have a melt index at 230° C. ranging from about 0.1—25. The
`
`
`
`
`
`
`
`
`
`crystalline melting point
`is about 160° C. The number
`
`
`
`
`
`
`
`
`
`average molecular weight ranges from about 25,000 to
`
`
`
`
`
`
`
`100,000. The density ranges from about 0.90-0.91.
`
`
`
`
`
`
`
`For descriptive purpose only, the film structures of the
`
`
`
`
`
`
`
`
`
`present invention will be described as having an upper skin
`
`
`
`
`
`
`
`layer (a), an intermediate layer (b) and a lower skin layer
`
`
`
`
`
`
`
`
`
`
`As may be appreciated by those skilled in the art, the use of
`
`
`
`
`
`
`
`
`
`the terms upper and lower to refer to particular skin layers
`
`
`
`
`
`
`
`
`
`is merely relative. Moreover, although referred to as skin
`
`
`
`
`
`
`
`
`layers,
`the upper and lower layers may have additional
`
`
`
`
`
`
`
`
`
`structures bonded thereto, based on the functional require-
`
`
`
`
`
`
`
`ments of the overall structure.
`
`
`
`
`The polymer materials which are contemplated as the
`
`
`
`
`
`
`material for use in forming skin layers (a) and (c) are
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`PAGE 3 OF 8
`
`

`
`
`
`US 6,455,150 B1
`
`5
`
`
`
`
`
`
`suitably exemplified by polyolefinic homopolymers, copoly-
`mers and terpolymers. Where homopolymers are to be used,
`
`
`
`
`
`
`they may be formed by polymerizing the respective mono-
`
`
`
`
`
`
`
`mer. This can be accomplished in a conventional manner by
`
`
`
`
`
`
`bulk or solution polymerization, as those of ordinary skill in
`
`
`
`
`
`
`this art will plainly understand. The copolymers are exem-
`
`
`
`
`
`
`
`
`
`plified by and include block copolymers, for example of
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`ethylene and propylene, random copolymers, for example of
`
`
`
`
`
`
`
`ethylene and propylene, and other ethylene homopolymers,
`copolymers, terpolymers, or blends thereof.
`
`
`
`
`Preferred for use in forming upper skin layer (a) and lower
`
`
`
`
`
`
`
`
`
`
`skin layer (c) are heat sealable polymeric materials selected
`
`
`
`
`
`
`
`
`
`from the group consisting of ethylene-propylene-butene-1
`
`
`
`
`
`
`
`
`
`
`
`
`(EPB)
`terpolymer, ethylene -propylene (EP)
`random
`
`
`
`
`
`
`
`copolymer, linear low density polyethylene (LLDPE), low
`
`
`
`
`
`
`density polyethylene (LDPE), medium density polyethylene
`
`
`
`
`
`
`(MDPE), high density polyethylene (HDPE) or blends
`thereof.
`
`Suitable EPB terpolymers are those obtained from the
`
`
`
`
`
`
`
`
`random inter-polymerization of from about 1 to about 8
`
`
`
`
`
`
`
`weight percent ethylene, preferably from about 3 to about 6
`
`
`
`
`
`
`
`weight percent ethylene with from about 65 to about 95
`
`
`
`
`
`
`
`
`
`weight percent propylene, preferably from about 86 to about
`
`
`
`
`
`
`
`93 weight percent propylene, butene-1 representing the
`
`
`
`
`
`
`
`balance. The foregoing EPB terpolymers are for the most
`
`
`
`
`
`
`
`
`
`part characterized by a melt index at 230° C. of from about
`
`
`
`
`
`
`
`2 to about 16 and advantageously from about 3 to about 7,
`
`
`
`
`
`
`
`a crystalline melting point of from about 100° C. to about
`
`
`
`
`
`
`
`
`140° C., an average molecular weight of from about 25,000
`
`
`
`
`
`
`
`
`to about 100,000 and a density within the range of from
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`about 0.89 to about 0.92 gm/cm3.
`The EP random copolymers generally contain from about
`
`
`
`
`
`
`
`2 to about 7 weight percent ethylene, the balance being made
`
`
`
`
`
`
`
`
`
`up of propylene. The copolymers can have a melt index at
`
`
`
`
`
`
`
`
`230° C. generally ranging from about 2 to about 15 and
`
`
`
`
`
`
`
`
`preferably from about 3 to about 8. The crystalline melting
`
`
`
`
`
`
`
`point is usually from about 125° C. to about 150° C. and the
`
`
`
`
`
`
`
`
`
`number average molecular weight range is from about
`
`
`
`
`
`
`
`25,000 to 100,000. The density will usually range from
`
`
`
`
`
`
`
`
`about 0.89 to about 0.92 gm/cm3.
`
`
`
`
`
`In general, where blends of EPB terpolymer and EP
`
`
`
`
`
`
`
`
`
`random copolymer are used, such blends will contain from
`
`
`
`
`
`
`
`
`
`about 10 to about 90 weight percent EPB terpolymer and
`
`
`
`
`
`
`
`
`preferably from about 40 to about 60 weight percent EPB
`
`
`
`
`
`
`
`terpolymer,
`the balance being made up of EP random
`
`
`
`
`
`
`
`
`
`
`copolymer.
`Heat sealable blends of homopolymer which can be
`
`
`
`
`
`
`
`
`utilized in providing layers (a) and/or (c) include about 1 to
`
`
`
`
`
`
`
`
`
`about 99 weight percent polypropylene homopolymer, e.g.
`
`
`
`
`
`one which is the same as, or different from, the polypropy-
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`lene homopolymer constituting intermediate layer (a)
`blended with about 99 to about 1 weight percent of a linear
`
`
`
`
`
`
`
`
`
`
`
`low density polyethylene (LDPE).
`Prior to extrusion,
`in accordance with the present
`
`
`
`
`
`
`
`
`invention, one or both skin layers (a) and/or (c) is com-
`
`
`
`
`
`
`
`
`
`
`pounded with an effective amount of a combined antiblock-
`
`
`
`
`
`
`ing and slip agent. Preferred combined antiblocking and slip
`
`
`
`
`
`
`
`
`
`agents are selected from the group of particulate cross-
`
`
`
`
`
`
`
`
`
`
`
`
`
`linked hydrocarbyl-substituted polysiloxanes. Particularly
`preferred are the particulate cross-linked polymonoalkylsi-
`
`
`
`
`
`
`loxanes. Most particularly preferred are non-meltable poly-
`
`
`
`
`
`
`
`monoalkylsiloxanes characterized as having a mean particle
`
`
`
`
`
`size of about 0.5 to about 20.0 um and a three dimensional
`
`
`
`
`
`
`
`
`structure of siloxane linkages. Such materials are commer-
`
`
`
`
`
`
`
`
`cially available from Toshiba Silicone Co., Ltd., worldwide,
`
`
`
`
`
`
`
`
`and in the United States from General Electric Co., and are
`
`
`
`
`
`
`
`
`
`
`
`10
`
`
`
`15
`
`
`
`20
`
`
`
`25
`
`
`
`30
`
`
`
`35
`
`
`
`40
`
`
`
`45
`
`
`
`50
`
`
`
`55
`
`
`
`60
`
`
`
`65
`
`
`
`PAGE 4 OF 8
`
`
`6
`marketed under the tradename Tospearl. Other commercial
`
`
`
`
`
`
`
`sources of similar suitable materials are also known to exist.
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`Although the polymer from which skin layer (a) is formed
`is not compounded with a silicone oil,
`this layer may
`
`
`
`
`
`
`
`
`
`ultimately acquire a machinability-improving and coeffi-
`
`
`
`
`
`cient of friction-reducing amount of silicone oil. Thus, when
`
`
`
`
`
`
`
`the finished film laminate containing silicone oil on the
`
`
`
`
`
`
`
`
`
`exposed surface of skin layer (c) is taken up on a winding
`
`
`
`
`
`
`
`
`coil, some of the silicone oil will be transferred from this
`
`
`
`
`
`
`
`
`
`surface to the exposed surface of skin layer (a), primarily to
`
`
`
`
`
`
`
`
`the exposed surfaces of the combined antiblocking and slip
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`agent particles which protrude from layer (a). However,
`since the interior of layer (a) contains no amount of silicone
`
`
`
`
`
`
`
`
`oil which could interfere with the heat sealing properties of
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`this layer (and ordinarily contains no-silicone oil at all), the
`presence thereon of the transferred silicone oil serves to
`
`
`
`
`
`
`
`
`further enhance the coefficient of friction of the layer,
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`improves its machinability, without significantly impairing
`its heat sealability.
`
`
`
`Either or both layers (a) and (c) can also contain pigments,
`
`
`
`
`
`
`
`
`
`fillers, stabilizers, light protective agents or other suitable
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`modifying ingredients if desired. Further, skin layers (a)
`and/or (c) can optionally contain a minor amount of an
`
`
`
`
`
`
`
`
`additional antiblock material, such as silica, clays,
`talc,
`
`
`
`
`
`
`
`
`glass, and the like. These antiblock materials can be-used
`
`
`
`
`
`
`
`
`
`alone, or different sizes and shapes can be blended to
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`optimize machinability. The major proportion of these
`particles, for example, anywhere from more than half to as
`
`
`
`
`
`
`
`
`
`high as 90 weight percent or more, will be of such a size that
`
`
`
`
`
`
`
`
`a significant portion of their surface area, will extend beyond
`
`
`
`
`
`
`
`
`
`the exposed surface of such skin layer.
`
`
`
`
`
`
`In order to enhance its receptivity for water-based
`
`
`
`
`
`
`
`coatings, the upper skin layer can be advantageously treated
`
`
`
`
`
`
`
`
`
`
`by flame treating.
`Lower skin layer (c) of the film laminate can be of
`
`
`
`
`
`
`
`
`
`
`
`substantially the same composition as that of upper surface
`
`
`
`
`
`
`
`layer (a). In a preferred embodiment, the polymer consti-
`
`
`
`
`
`
`
`
`tuting layer (c) is compounded with a silicone oil. The
`
`
`
`
`
`
`
`
`
`silicone oil advantageously possesses a viscosity of from
`
`
`
`
`
`
`
`about 350 to about 100,000 centistokes with 10,000 to about
`
`
`
`
`
`
`
`
`60,000 centistokes being especially preferred. Examples of
`
`
`
`
`
`
`suitable silicone oils are polydialkylsiloxanes,
`
`
`
`
`
`polyalkylphenylsiloxanes, olefin-modified siloxane oils,
`
`
`
`
`
`
`
`
`polyether-modified silicone oils, olefin/-polyether-modified
`silicone oils, epoxy-modified silicone oils and alcohol modi-
`
`
`
`
`
`
`
`
`fied silicone oils, polydialkylsiloxanes which preferably
`
`
`
`
`
`
`have from about 1 to about 4 carbon atoms in the alkyl
`
`
`
`
`
`
`
`
`
`group,
`in particular polydimethyl-siloxanes. Of the
`
`
`
`
`
`
`foregoing,
`the polydialkylsiloxanes,
`in particular,
`a
`
`
`
`
`
`polydimethylsiloxane, are preferred for use herein.
`
`
`
`
`
`
`The silicone oil is added to layer (c) generally in the form
`
`
`
`
`
`
`
`
`
`of a dispersion or emulsion,
`the silicone being present
`
`
`
`
`
`
`
`
`within, as well as on the exposed surface of this layer as
`
`
`
`
`
`
`
`
`
`
`
`discrete microglobules, frequently of an average size of from
`
`
`
`
`
`
`about 1 to about 2 microns. The silicone oil, which is
`
`
`
`
`
`
`
`
`generally substantially uniformly distributed on the exposed
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`surface of layer (c), is responsible for improving machin-
`ability and imparting a further reduction in the coefficient of
`
`
`
`
`
`
`
`friction to this surface as well as the exposed surface of layer
`
`
`
`
`
`
`
`
`(a) when some of the oil is transferred thereto after these
`
`
`
`
`
`
`
`
`
`
`surfaces have been placed in mutual contact, e.g., as will
`
`
`
`
`
`
`
`
`
`occur when the laminate film has been wound on a winding
`
`
`
`
`
`
`
`
`coil.
`
`Polydimethylsiloxane or other silicone oils can be present
`
`
`
`
`
`at from about 0.15 to about 1.5 weight percent, preferably
`
`
`
`
`
`
`
`
`less than 0.5 weight percent, of lower layer Some of this
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`PAGE 4 OF 8
`
`

`
`
`
`US 6,455,150 B1
`
`7
`
`silicone oil will, of course, be present on the exposed surface
`
`
`
`
`
`
`
`
`of layer
`The amount selected should in any event be
`
`
`
`
`
`
`
`
`
`sufficient to provide a coefficient of friction of layers (a) and
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`(c) (following transfer of silicone oil microglobules to the
`latter) of about 0.4 or less, preferably between about 0.25 to
`
`
`
`
`
`
`
`
`about 0.3 up to at le

This document is available on Docket Alarm but you must sign up to view it.


Or .

Accessing this document will incur an additional charge of $.

After purchase, you can access this document again without charge.

Accept $ Charge
throbber

Still Working On It

This document is taking longer than usual to download. This can happen if we need to contact the court directly to obtain the document and their servers are running slowly.

Give it another minute or two to complete, and then try the refresh button.

throbber

A few More Minutes ... Still Working

It can take up to 5 minutes for us to download a document if the court servers are running slowly.

Thank you for your continued patience.

This document could not be displayed.

We could not find this document within its docket. Please go back to the docket page and check the link. If that does not work, go back to the docket and refresh it to pull the newest information.

Your account does not support viewing this document.

You need a Paid Account to view this document. Click here to change your account type.

Your account does not support viewing this document.

Set your membership status to view this document.

With a Docket Alarm membership, you'll get a whole lot more, including:

  • Up-to-date information for this case.
  • Email alerts whenever there is an update.
  • Full text search for other cases.
  • Get email alerts whenever a new case matches your search.

Become a Member

One Moment Please

The filing “” is large (MB) and is being downloaded.

Please refresh this page in a few minutes to see if the filing has been downloaded. The filing will also be emailed to you when the download completes.

Your document is on its way!

If you do not receive the document in five minutes, contact support at support@docketalarm.com.

Sealed Document

We are unable to display this document, it may be under a court ordered seal.

If you have proper credentials to access the file, you may proceed directly to the court's system using your government issued username and password.


Access Government Site

We are redirecting you
to a mobile optimized page.





Document Unreadable or Corrupt

Refresh this Document
Go to the Docket

We are unable to display this document.

Refresh this Document
Go to the Docket