Method and apparatus for forming a laminate

[Detailed Description of the Invention]

The present invention relates to the method of forming the laminated piece containing the film of at least two sheets of a polymer substance, and its device. The various methods of pasting up a plurality of films and forming a laminated piece are known. When making a film by extrusion, usually a pressure sensitive adhesive is attached on one side of the surface where a film faces each other so that it may paste up only by applying pressure between films, or both. If a pressure sensitive adhesive is used, the following faults will arise. Namely, welding from one end of a laminated piece to the other becomes impossible, and a pressure sensitive adhesive must be applied in the form of solution, and, for this reason, that method of adding becomes complicated. It is required to use the high temperature that handling of a film becomes difficult to use the pressure sensitive adhesive which can carry out a co-extrusion and can weld a laminated piece. It is difficult for the pressure-sensitive film by which a co-extrusion is carried out to be adhesive, and to roll such a film in the shape of a roll. It is because pressure is applied to a film during volume work. The method of the present invention is in the state which opened generally a plurality of separate films formed by polymer in which those [ at least one ] thermoplastic for Arrangement are possible, While maintaining a sandwiches state in which it was made to move forward certainly under tension, and sandwiches of a separate film were formed in, contacting the surface where a film of an adjoining each set adjoins directly in a field and a field, and the above of a separate film became it tense, It lets between a pair of movement rollers which counter film sandwiches at a temperature quite lower than normal temperature or the melting point pass, and is mechanical pressure, a position of a large number which set a mostly near interval prolonged in parallel to a forward direction -- Along -- it is made to bend certainly and the surface of each roller has a slot and a summit-of-the-mountain part projected alternately in that case, and an above-mentioned summit-of-the-mountain part and a slot to project are circular, or a screw type. It has entered mutually to sufficient depth for the summit-of-the-mountain part of one roller to produce the slot of the roller of another side, and bending of the above-mentioned size, The above-mentioned positive bending arises in the direction perpendicular by turns to the opposed face in a mutual position, and it is to the above-mentioned sandwiches, It is horizontally zigzag temporary almost equally, namely, a ring or To attached in Facial is given, and it is such a size of bending, Process a contact surface of Mutually of a pair of adjoining sandwiches-like film into a Along machinery target in the above-mentioned position, and this gives eternal transverse direction extension, and it appears in making into the above-mentioned bending position a film plane which contacts mutually simultaneously, and carrying out cold welding combination to Along 1 clue mostly, enough, and is characterized by a certain thing. If pressing work and extension work are combined, the improved surprising junction effect will be acquired as compared with the junction effect acquired only by press. It is the room temperature from which the junction effect which can be especially accepted only by press is not acquired, and it is a surprising thing that can acquire the improved junction effect. Thus, if pressing work and extension work are combined, the junction effect improved at a temperature lower than the melting temperature of a surface coat will be acquired. Thus, it can remove supplying adhesion polymer independently, and/or heating and raising temperature by using the method of the present invention. The present invention also contains the device for enforcing this method again. Wide is in a Ivy state almost level about at least two separate films of polymer in which those thermoplastic for Arrangement of this device are possible, The means for contacting the surface where the film of the adjoining each set adjoins in a direct side and a field, making it move forward certainly and forming the sandwiches of at least a pair of separate films under tension, In the direction perpendicular to the plane by turns from the above-mentioned even state, it is about the film sandwiches which move forward in this way, the position which has extended in parallel to the forward direction, which approached mostly and kept the interval and which carries out alternation -- Along -- making it contact mechanically and making it bend certainly -- the above-mentioned film sandwiches -- temporary -- about 1 -- having a means for giving the ring or To attached in ZIG ZAG or Facial -- the size of the above-mentioned bending, [ like ] Process the field in contact with both the films of the adjoining each set into a Along machinery target in the above-mentioned position, and this gives eternal transverse direction extension, and it consists of a device which comes out of the film plane which contacts Mutually intratemporally to the above-mentioned bending position enough by carrying out cold welding combination mostly at Along 1 clue, and is characterized by a certain thing. It is desirable to carry out extension continuously. In order to extend, it may let two or Nip of a roller with a slot which gears to a pair of Mutually beyond it suitably pass, and makes two or a plurality of films the slot on the roller extend in the longitudinal direction of a sheet substantially at this time. Thus, although it is Facial, it is formed during horizontal extension, and adhesion (bonding) takes place. Before passing along the following above-mentioned pair Fold formed by passing along a set of above-mentioned pairs, that of To equalize is level desirable partially at least. At least one of the rollers with a slot may be heated, and adhesion may be improved. However, as mentioned above, all extensions under pressure are carried out at room temperature, or it carries out at the temperature near room temperature in many cases. It is desirable to combine the method of the present invention with one or more longitudinal direction pulling processes, and to extend a laminated piece in the direction of 2 axis as a result. After ending transverse direction extension substantially, it is desirable to perform longitudinal direction extension. The purpose of carrying out longitudinal direction extension following on transverse direction extension is to avoid the line of the film extended severely formed when a roller with a slot or the same device acts on the film by which for Arrangement was carried out to the longitudinal direction. It is desirable to extend especially, by machines which allow considerable transverse direction contraction, when Desire [ high Tearing-proof propagation nature and blowout-proof nature ], or when a comparatively low breakdown point can be permitted. Still higher growth is obtained by this until it fractures. Longitudinal direction extension - it is usually wanted -- as - in order to allow contraction at the same time it carries out in the narrow range, it is desirable to attach very thin longitudinal direction Fold to a laminated piece like what was indicated by U.S. Pat. No. 3233029. When it is thin Facial formed in the sheet [ being graceful ] of the process of the last of transverse direction extension when a longitudinal direction extension field is fed with a sheet in relation to this, but maintained, usually a suitable result is obtained. It is usually desirable for at least one opposite surface of the film which it is going to weld to have the melting point lower than the remaining films. The surface where both counter may contain such a layer. The strip of low melting point polymer or the shape of a spot may be sufficient as the layer. The one opposite surface contains low melting point polymer, and another side may contain the spot of release (release) polymer, or the layer of the strip, namely, it may decrease the strength of adhesion. Although making by extrusion of a fusion polymer substance is desirable as for a film, when it solidifies, it is most desirable to be based on extrusion of the blend of polymer which is nonmiscible as a blend contains the distributed thing of one polymer in the mother's body. In order to use fibrous grain structure of distorting polymer of each class and having those superior of after-solidification division nature for Arrangement, it is desirable to carry out thinning, fusing each class of the polymer blend pushed out before extrusion, during extrusion, or after extrusion. The suitable method of performing this extrusion is written with sufficient statement about a use To cut off substance as low melting point polymer in 50 to Japanese-Patent-Application-No. 82361 specification of original application as the statement about the end products made by that method, and a polymer blend. Hereinafter, an attached chart explains the present invention about an example. In Drawing 1, classification Q is a portion of a line by which transverse direction extension and lamination are carried out at sheet 79. Classification R is a longitudinal direction extension line. Although sheet 79 contains a pair of films which were supplied separately and mixed, finally it is not pasted up as a laminated piece before the 1st roll 72. The system of the roller of classification Q consists of driven Nip― roller 71, play roller 73, and roller 74 that has a cross section similar to a banana. Banana roller 74 after each process is useful to extend Fold made by transverse direction extension. Over play roller 75, sheet 79 goes into the longitudinal direction extension line of classification R, and pulls there through bathing 76 which is useful to remove the heat which generated the sheet by extension and to maintain to a suitable extension temperature, for example, 20 *~40-degreeC. Finally, a sheet is rolled on bobbin 77. Arrow 78 shows the direction of machinery. A pair of rollers 72 with a driven slot are shown in Drawing 2 in detail, and sheet 79 is pressed and extended between teeth 80 of roller 72. In Drawing 3, the relative length of an arrow with the line of sheet 79 shows the relative amount for Arrangement attained by the biaxial direction extension method shown in Drawing 1 and Drawing 2. In Drawings 4 and 3, a number shows the changing width and lines A and B which have unequal character on the whole. furthermore -- as opposed to middle class 83 with thin outside layers 81 and 82 of sheet 79 -- also Absolutely(ing) -- it must be cautious of it not being symmetrical. This non-symmetry is useful to further tear and to make a fork. The next is some examples of the present invention and all the percents in it are based on weight. Example 1 The cylindrical film of three layers which has the following composition is pushed out. Middle class (70% of the whole): The blend with the gaseous phase type iso Tactical polypropylene ("Novo Wren") and the 15% ethylene vinyl acetate copolymer (16% vinyl acetate) which have a high atactic content. The surface coat of both sides (one side is 10% of the whole, and another side is 20% of the whole): Serve as an ethylene vinyl acetate copolymer (16% vinyl acetate)-low melting point layer. The polypropylene has melt index 0.3~0.6 by ASTMD1238 conditions L, and although an ethylene vinyl acetate copolymer is the same ASTM, it has melt index 2.5 by conditions E. A cylindrical film is pushed out by 180 degrees C~230 degreeC from a 1-mm width slot, and it pulls to 0.130 mm by a molten state. A blow ratio is kept very low and is usually kept at 1.2:1. Then, it is made the even film which cuts it spirally and has 45 * grain angle. Such two films cut spirally are sent through 7 sets of rollers with a slot by 20 degreeC, as grain becomes perpendicular to Mutually and the thin surface coat faces Mutually - (refer to Drawing 1 and the 2nd figure) The width of each slot is 1 mm and the width of each upheaval is 0.5 mm. Engagement (difference of the level between the top part) of mutual upheaval is 2 mm. While passing along a set of rollers with a slot, respectively, it is made Masanao although it is Facial formed in the laminated piece. Since the mechanical operation between rollers with a slot and a low melting point copolymer layer exist, it is between the colds at Cleavage value in which two films are comparatively low. - Welded exfoliation strength 10 gr/cm of which - measurement was done - And it is simultaneously pulled in the intersection direction. After letting 7 sets pass by 20 degreeC, it lets a set of same rollers with a slot heated by 120 degreeC in the laminated piece although it had the same size and mutual engagement once pass. Thereby, a powerful adhesion line is formed. Finally, for Arrangement is carried out to a longitudinal direction by pulling a laminated piece (intersection-contraction is made into the minimum like) to a three-stage by about 1-cm extension Hook. Extension of this last is adjusted so that the whole - extension-ratio between the transverse direction colds and the whole - extension-ratio between the longitudinal direction colds may become equal. An area-extension-ratio is 2.4:1. As compared with the low density polyethylene film of the powerful bag which has square rice weight high 85% for the test result of this product, and has melt index 0.3 by the same ASTM condition E.Gauge, it is 100 gr/m with this laminated piece.²Come out, and it is and is 185 gr/m with a polyethylene film.²Was. Shock strength (it measures by fall of the ball of 61 mm in diameter and weight 320gr) is 100 gr/m.²With a Stacking film, they are 5.5 m and 180 gr/m.²With a of polyethylene film, they are 2 m, Tongue split resistance: (total sample 5 cm in width, and break 10 cm in length which are torn at the speed of 100 mm/m), and 100 gr/m.²With a Stacking film, they are 6.8 kg and 180 gr/m to 5.9 kg and a transverse direction in the direction of machinery.²About a of polyethylene film, it is 1.3kgr and Elemendorf ripping resistance (shock - tearing): (this examination is change of the standard aiming at much more symmetrical Tear). Result: 100 gr/m²With a Stacking film, it is 441 Kgcm/m to a longitudinal direction.²It is 344 Kgcm/cm to a transverse direction.²180 gr/m²With a of polypropylene film, it is 167kg/cm to a longitudinal direction.²It is 172 Kgcm/cm to a transverse direction.²When it is made to exfoliate by removing one piece of sheet and the structure is investigated under a microscope, that of ing with outstanding Fibrous tissue in which the main layers have a zigzag grain direction can be seen. Example 2 The procedure of Example 1 is changed as follows and repeated. The film of three layers by which the co-extrusion was carried out has the following composition. Middle class (70% of the whole): The blend of 85% Tactical [ iso ] polypropylene (the same model as Example 1), and 15% ethylene propylene rubber (the almost same melt index as polypropylene). The surface coat of both sides (15% each of the whole): Fuse much more powerfully an ethylene vinyl acetate copolymer (the same model as Example 1), and a film after coming out of Di. - Thinning was carried out. From 1-mm thickness to namely, 0.065 mm (60 gr/m)²up to -- tensile Ivy. When it inspects by a polarization line, under [ those for fusion-Arrangement which arose are equivalent to - extension between / about 35% of / the 1 axis colds ]. Two after cutting and in this film are spirally pasted up with the 3rd film, and it is Made about 3 ―Bly laminated piece. The 3rd layer arranged in the middle had a grain direction of the longitudinal direction obtained by cutting the same film to a longitudinal direction. Although lamination and Tension were performed by the machines of Example 1, all the processes were carried out by 20 degreeC, and the device was adjusted so that the whole surface product-extension ratio of 2.5:1 might be produced. The last film laminated piece thickness is 72 gr/m by this.²Became. The exfoliation strength of adhesion between layers is 10 gr/m.²until measurement was carried out. When it investigates under a microscope, it is the same structure as Example 1, and is Oh. The following test results were obtained.

[Table]

Hereinafter, the embodiments of the present invention are enumerated. (1) A method of the application for patent which extends at room temperature substantially given in the 1st paragraph of the range. (2) A way of an application for patent given in the 1st paragraph of the range the slot has extended in the longitudinal direction of the film substantially in the method given in the preceding clause carried out by letting Nip of a roller with a slot which gears two or the film beyond it pass. (3) A way given [ above-mentioned ] in 2 paragraphs the distance to the center of the slot which adjoins from the center of one slot with the same roller is about 1.5 mm, and the engagement depth is about 2 mm. (4) The 2nd above-mentioned paragraph that there is a roller with a slot of a plurality of pairs which gets into gear, and let Nip of each set pass for the film in series, or a method given in 3 paragraphs. (5) A method given [ above-mentioned ] in 4 paragraphs which extended level [ before letting the following above-mentioned pair pass ] Fold formed by letting the one above-mentioned pair pass. (6) The method of one of any statements to the 2nd above-mentioned paragraph that heats at least one roller and improved adhesion thru/or the 5th paragraph. (7) The method of one of any statements to the 2nd above-mentioned paragraph that carries out extension under pressure at room temperature mostly thru/or the 5th paragraph. (8) The method of one of any statements to the 2nd above-mentioned paragraph that extended the laminated piece to one or more stages to the longitudinal direction thru/or the 7th paragraph. (9) A method given [ above-mentioned ] in 8 paragraphs it was made to essentially before the start of longitudinal direction extension terminate transverse direction extension. (10) Preceding clause 8 or a method given in 9 paragraphs of having allowed transverse direction contraction equivalent to under longitudinal direction extension. (11) The method of one of any statements to the 1st above-mentioned paragraph of a claim in which at least one of the surfaces where the film which it is going to paste up counters contains the layer of polymer in which the melting point is lower than the remainder of the film, or the 1 thru/or 10 above-mentioned paragraph. (12) A way given [ above-mentioned ] in 10 paragraphs the layer of low melting point polymer is carrying out the form of Sushi or a point. (13) when it solidifies, the blend of polymer contains the distributed thing of one polymer in the polymer mother's body -- as By pushing out the blend of polymer which is nonmiscible, while to the 1st paragraph of the range of the application for patent in which each film was formed or the 1st above-mentioned paragraph thru/or the 12th paragraph, it is the method of any one statement. (14) A device of an application for patent given in the 2nd paragraph of the range with which the slot has extended in the longitudinal direction of the film mostly including the means for the means for applying pressure and extending a film to let Nip of these rollers pass for a pair of rollers with a slot which get into gear, and a film. (15) A device given [ provided with the roller with a slot of a plurality of pairs which gets into gear, and the means for letting each Nip of these rollers pass for a film in series / above-mentioned ] in 14 paragraphs. (16) The 14th above-mentioned paragraph provided with the means for heating at least one roller with a slot, or a device given in 15 paragraphs. (17) A device of one of any statements to the 2nd paragraph of the range of the application for patent furthermore provided with the means for extending a laminated piece to a longitudinal direction or the 14th above-mentioned paragraph thru/or the 16th paragraph. (18) A device given [ above-mentioned ] in 17 paragraphs located so that a laminated piece might be extended after extending a laminated piece for all the means for extending a laminated piece to a longitudinal direction horizontally.

[Brief Description of the Drawings]

Drawing 2 whose Drawing 1 is a process line which shows law on the other hand is a detail view of "a roller with a slot" which performs transverse direction extension of the unequal field called "Sushi", Although the pattern of Sushi of the film in which intersection extension of Drawing 3 was carried out by the process line of Drawing 1, the expansion schematic diagram for the Arrangement, and Drawing 4 are expansion transverse cross sections of the film of Drawing 3 actually observed by Speculum, in order to make them clear, the measure of being twice many as the measure of width has shown thickness. 71 ... driven nip roller, 72 ... roller with a slot, 73 ... play roller, 74 ... banana roller, 75 ... play roller, 76 ... bathing, 77 ... bobbin, 79 ... sheet, 80 ... tooth.