High-Strength Laminate

The present invention relates to a method of manufacturing a laminated high-strength sheet. Cross-laminates of uniaxially oriented films from crystalline polymers are known to exhibit a generally highly advantageous combination of different strength properties of which the most surprising has been the tear propagation strength (cf. U.S. Pat. No. 3,322,613) especially when a relatively poor bonding is effectuated between the layers. During the tearing from an incision, the layers will then delaminate around the notch while they split or flow in different directions--the tear "forks"--whereby the notch effect is smoothed out. Sheets of this kind are particularly useful for various heavy duty applications such as tarpauline substitutes, cover sheets, heavy duty bags, and heavy duty wrapping film.

The most expedient method of producing a sheet of the above kind is described in British Patent Specification No. 816,607, and involves strongly orienting the molecules of a tubular film in its longitudinal direction, helically cutting i.e., at an angle to the orientation direction, and unfolding the oriented film to a flat film with the orientation extending obliquely (e.g. 45.degree. C.), and subsequently continuously laminating this film with a similarly produced flat film, while the respective directions of orientation are arranged in criss-crossing relationship.

It is known that, for a given thickness, the tear propagation resistance is pronouncedly increased by use of 3 layers with 3 different directions of orientation, e.g. obtained by laminating 1 longitudinally oriented film with 2 films which are oriented obliquely as described above.

One drawback of the process described above (and the resultant product) is that it is practically impossible to produce really thin film, whereby the economical advantage of increased strength per unit weight is limited. It has proven that the technically economical lower limit possible with the carrying out of the spiral-cutting and the laminating processes is, generally speaking, about 30 gr per sq.m. Thus for a 2-layers laminate, the lower limit is about 60 gr per sq.m while for a 3-layers laminate (which as mentioned above is necessary for optimum utilization of the tear-stopping effects) it is about 90 gr per sq.m.

A second draw-back is the practical limitation in width caused by the rotation of heavy machine-parts and bobbins in connection with the spiral cutting. As a very general statement, it can be said that the width is hereby limited to about 11/2-2 m.

A third draw-back relates to certain energy-absorption values for the cross-laminates so produced. Relatively low energy-absorption has been found with regard to high-speed tearing (Elmendorf tear test) and for low and high speed tensile testing (TEA strength and Elmendorf impact strength). In this connection it appears that the very anisotropic character of the layers is disadvantageous. If for instance a 2-ply cross-laminate of this kind is drawn parallel to the direction of orientation in one of the layers, then the yield point and the elongation at break are in essence determined by the layer.

My earlier work to overcome the above mentioned drawbacks, and to provide for a cheaper production process for a product with similar or analogous properties, is described in British patent specification No. 1,261,397. In that specification a process is disclosed which produces a criss-crossing structure through a die with rotating parts, while forming in the same die a soft and weaker middle zone by coextrusion. The method consists in coextruding several concentrical or almost concentrical layers of crystalline polymer alternating with layers of a softer polymer, and dividing such concentric layers inside the die by means of teeth arranged in rows and fixed to the cylindrical die walls pointing from the concave outer wall surface inwardly, and from the convex inner wall surface outwardly. The die-parts with their rows of teeth are rotated in opposite directions and thereby the layers are divided according to the left hand helices adjacent one sheet surface and right-hand helices adjacent the other sheet surface. It is specified that the dividing or combing can either be carried through to the middle of the film or be limited to portions near the surfaces. The coextrusion of polymers upstream of the combing zone is adapted to provide for a soft and weak middle-zone.

The film extruded by this method consists, in all essence, of unoriented material. However, the system of alternating stiff layers of a "first polymer" and soft layers of a "second polymer" divided into filaments or streams in a linear pattern by the teeth, produces in each half-part of the sheet a tendency to split or flow in one direction, and since the linear patterns at the two surfaces criss-cross each other and a tendency to deliminate is provided by the soft zone, there is obtained a certain tear-stopping effect which is analogous to the "forking" effect in a true cross-laminate.

The above specification further proposes to biaxially stretch the so produced laminate under such conditions that instead of yielding biaxially oriented layers, the molecular orientation will become generally uniaxial in each layer, with the direction of orientation in different layers criss-crossing each other. In order to obtain such uniaxial orientation, the second material must be very prone to yield, e.g. because it is still molten or semi-molten while the first material is solid, and the filaments of the first material must be kept straightened out by biaxial strain.

Although the above method would on principle solve the problems of obtaining a lower thickness and higher width in cross laminated products there were found some essential difficulties during later technical developments. It was confirmed that the extrusion method was commercially feasible for manufacture of unoriented film with high tear propagation strength, but with a low impact strength due to the lack of orientation. However, essential drawbacks were found in connection with a subsequent biaxial stretching. As also indicated in the specification, one must use a relatively large number of rows of the teeth in the extrusion die in order to obtain the fibre fineness which is necessary for the stretching system.

This, however, made the maintenance of the die difficult and caused frequent "hang-up" of polymer lumps between the teeth. Further, the interaction between the teeth in one half-part of the die and those in the other half-part made it necessary either to use excessive amounts of soft middle layer material, or to limit the combing to two relatively thin surface zones of the sheet. Further, it was very difficult to establish and maintain the biaxial stretching conditions necessary for obtaining a generally uniaxial molecular orientation as described.

The present invention is based on the discovery that even a strongly biaxially oriented film, with the same orientation in two directions perpendicularly to each other, can exhibit a pronounced direction of splitability, provided the film is extruded from a polymer blend and is melt-attenuated in connection with the extrusion. Due to the melt attenuation there is formed a unidirectional fibrous morphology which can be observed in an ordinary microscope. There is also produced a uniaxial orientation by the melt attenuation, although this orientation is generally very weak. When the film (which can e.g. consist of about 50% polypropylene and 50% polyethylene) is drawn at an angle to the grain direction, e.g. perpendicularly thereto, then the fibre portions, as seen on a micro-scale, will deflect and branch out; but it is still possible to follow the zig-zagging path of the fibre grain from branch-point to branch-point, and when following different paths in this manner it will be found that, on a macro-scale there is still a generalized unidirectional grain. This micro-structure is very different from the filament structure described in the above Brit. Pat. No. 1,261,397.

After a certain elongation, e.g. about 40% perpendicularly to the grain, examination of the film in polarized light (or more exactly by x-ray diffraction) shows that the orientation is equal in all directions. After further drawing in the same direction, there is still a pronounced splitability along the grain direction, until at a certain point, e.g. about 80% total elongation, the splittability is equal in all directions. On further drawing, the main direction of splitability will coincide with the main direction of orientation. The film can e.g. be elongated 100% in this direction, and thereafter drawn in the original grain direction till the point where it has equal orientation in all directions. At this point there is again a marked splitability in the original grain direction, and by microscopial examination it will be possible, although difficult, to follow the zig-zagging course of the grain and see that on a macro-scale, the grain direction still in essence coincides with the direction of splittability.

Following this discovery, the method according to the present invention comprises the steps of attenuating while extruding each of at least two layers of at least one molten polymer blend to impart to the polymer thereof a unidirectional grain with a pronounced direction of splittability when solidified, before or after their solidification uniting the layers into a common sheet with the grain direction or adjacent layers therein extending in criss-crossing relationship, while forming a generally weak bond between said layers, solidifying if not already solid, and finally biaxially orienting the solid laminated sheet thus obtained in several steps which each are generally substantially uniaxial at a temperature sufficiently low for maintaining a significant splittability in each layer.

The product produced hereby is a high-strength laminate comprising generally weakly adhered biaxially oriented films, each formed of a blend which exhibits a distinct fibrous morphology with the fibres forming a distinct generalized unidirectional grain when measured on a macro-scale but with the fibre-portions strongly deflected in substantially zig-zag fashion from this direction as seen on a micro-scale and with the unidirectional grain in at least two of the films criss-crossing each other.

It has been found that the structure so formed is particularly suitable for almost any high-strength application where energy absorption is essential, no matter whether the energy absorption occurs during tear propagation, puncturing, or impact. The splittability of the layers in connection with the weak bonding between the layers produces a "forking effect" similar to that taking place in cross-laminates of uniaxially oriented film, but the energy absorption during fast tearing (Elmendorf tear test) is essentially higher. Further, most impact properties, in particular Elmendorf impact strength, are improved, and so will usually be the energy-absorption during fast puncturing (Beach-strength). These improvements are considered to be partly a result of the biaxial character of the orientation in each layer, and partly of the distinctive fibrous morphology. The biaxial orientation has the further advantage that the laminate according to the invention has "shrinkfilm" properties, which cross-laminates of uniaxially oriented films do not have.

It has been mentioned above that the process for producing cross-lamination of uniaxially oriented films, under practical conditions gives a rather high limit for sheet thickness (about 90 gr per sq.m for a 3-ply) and a rather low limit for sheet width. In both these respects the present method is greatly advantageous due to the fact that the sheet is strongly stretched in two or more directions after lamination. Thus, it is technically and economically feasible to achieve about 10 gr per sq.m weight for each of the films in the laminate, i.e. about 30 gr per sq.m for a 3-ply laminate. This greatly broadens the fields of use.

While blends of very compatible polymers, e.g. different polyamides, will usually not form a grain as described, blends of semicompatible or incompatible coextrudible thermoplastic polymers will always do so, provided the contents of one polymer is not too predominant. To be on the safe side, there should not be more than 85% of any polymer in the blend. If the polymers are really incompatible, there should preferably be added an "alloying agent".

The best properties will be obtained if the grain is formed of crystalline threads "cemented" together by small amounts of a surrounding elastomer. By small amounts is meant about 5.20% of the total.

In order to keep the content of elastomer low and still obtain a distinctive fibrous morphology with the elastomer tending to surround the other material, the elastomer is preferably used as an "alloying agent" for two other polymers. Thus a preferable composition is two crystalline incompatible polyolefins--e.g. iso- or syndiotactic polypropylene and high- or low density polyethylene--with addition of a sticky polymer which bonds to both--e.g. atactic polypropylene, ethylene-propylene-rubber (preferably a sticky type with relatively high contents of propylene), and polyisobutylene of a mol weight as commonly used for pressure sensitive adhesives.

The attenuation, by which the uniaxial grain is formed, can be carried out in different ways. It can e.g. be by gradual reduction of the spacing of the exit chamber in the extrusion die, or by passage of the molten material between a row of closely spaced partitions or the like in the die, or by stretching in molten state after the exit of the die, or by combinations of such steps.

The direction of splittability and the splittability in the layers is determined by measuring the tear propagation resistance by the tongue tear method in different directions. The direction of splittability is understood as the direction which exhibits the lowest tear propagation strength, while the splittability is understood as the ratio between the highest tear propagation resistance and the lowest tear propagation resistance. The splittability in the layers after the biaxial orientation should preferably be bigger than 2:1, however 1.5:1 can be tolerated.

In order to allow a local delamination during tearing, and thereby make the tear "fork", it is essential to form a generally weak bond in the lamination of the layers. If the bond formed is an even or uniform bond, and the thickness of each layer is 20 gr per sq.m, a peel strength between about 5 gr per cm and 500 gr per cm is generally suitable. Since there is a "competition" between rupturing forces and delaminating forces during tearing, the upper limit depends on the layer thickness and is generally proportional to the latter.

As it will appear from the description of various embodiments, there exist different means to establish and control the strength of the bonding, of which the most practical involve at some step a coextrusion of a special layer of adhesive component of "release component".

As regards the biaxial orientation, it has been found essential to carry it out in several steps which each are generally substantially uniaxial. It was hereby found that simultaneous stretching in two directions destroyed the grain so that no "forking effect" was achieved. There is also a tendency to destroy the grain by stretching near the melting point of the major components of the sheet. I believe that recrystallization and other physical phase-rearrangement phenomena play a role in this connection. In any case the best properties have been found by stretching below the recrystallization temperature which e.g. for polypropylene is about 70.degree.-80.degree. C., and even lower temperatures are preferable. For stretching at such low temperatures special stretching methods are necessary which will be dealt with later in this specification.

Preferably the biaxial orientation produced by the stretching below the melting point should in any direction have a component at least equal to the orientation produced by the melt-attenuation, and generally it is preferable to make the biaxial orientation much stronger. Degree of orientation should in this connection be measured by x-ray defraction, but for quick and approximate examination of relative values, observations of interference colors between crossed polaroid filters are also suitable.

As explained above it is essential that the bonding between the grainy layers is generally weak, in order to enable a local delmination to take place during tear propagation. This, however, does not necessarily mean that the bonding must be weak all over the surface, but on the contrary great advantage for tear strength is generally achieved by employing a pattern of strongly bonded regions with the remaining region being weakly bonded or unbonded. Hereby, the necessarily local delamination is easily strated, but thereafter is stopped or will proceed only under great resistance. At the same time the strongly bonded portions prevent a delamination of the laminate in or adjacent to a glued or welded seam under tension, which otherwise can easily occur.

By a suitable choice of the bonding pattern, the different bonding strengths, and the type of rupture in the weak-bond or no-bond areas, i.e. whether brittle or more fluid, the tearing properties can be "tailor-made" for different purposes.

This technique is particularly useful in connection with relatively thin layers. It has already been mentioned that there is a "competition" between rupturing and delaminating forces during tear propagation, which means that an easier start or initiation or delamination is required as the layers are made thinner. As a practical rule, it will almost always be advisable to apply the strong/weak bond technique if the layers are thinner than about 40-50 gr per sq.m.

The use of strong-bond/weak-bond or strong-bond/no-bond patterns are in fact well known in connection with cross-laminates of films which are uniaxially oriented or are biaxially oriented in a very unbalanced manner, cf. the specifications of U.S. Pat. Nos. 3,496,056 and 3,342,657 and Brit. Pat. No. 1,316,640 and Danish Pat. No. 119733. However, the layers of such known laminates, when tested individually, exhibit extremely low impact and puncture resistance (except in case of special and expensive polymers such as e.g. nylon 6), whereas it has been found that the individual layers according to the present invention exhibit pronouncedly and surprisingly higher impact and puncture resistance. Therefore, a weaker adhesion (or no adhesion) in the relevant areas and/or a larger extension of these areas is allowable without any significant loss of impact or puncture strength.

A preferred way of forming or improving the effect of the generally weak bond between adjacent layers is by means of a release or adhesive substance.

By release substance is here meant a substance, preferably a polymer material, with either a low cohesive strength in itself or with a low adhesion to the adjacent polymer layer.

Whether a release or an adhesive substance is to be chosen depends on whether and to what extent the polymer blends are compatible with each other and of the uniting method, e.g. the temperature used during lamination.

In any case, by means of the added release or adhesive substance, it is possible to better control the magnitude of the bonding force.

A preferred way of effectuating the bond is by the application of the pattern of the release or adhesive substance to the midlayer of a laminate formed of at least three layers whereby one obtains the advantage that during tearing, the free or weakly bonded parts of the midlayer will elongate because of the stretching forces applied, and will absorbe some energy thus further stopping the notch effect.

Although there are several operational advantages obtained when the layers are formed and united inside an extrusion die, it is preferable with respect to the properties obtained to form the layers separately and then unite them into a common sheet, since this enables the formation of the most pronounced uniaxial grain in each layer.

In one embodiment of the latter approach a solid, preproduced film layer may be placed around a mandrel that extends through the centre of a rotating extrusion die. The solid film can be forwarded along the mandrel and when passing the exit slot of the extrusion die, catching and forwarding and thus attenuating the rotated, still fluid polymer layer which in that way is wound around the solid film forming an outer film with a helically running grain.

As already mentioned, the tear propagation strength for a given total laminate thickness is significantly better in a 3-layered laminate than in a 2-layered laminate. Therefore it is also preferable to extrude two or more films successively out of two or more mutually contrarotating extension slots onto the same solid film in the manner mentioned above.

Further advantages of the latter method are the possibility of producing fully uniaxial grain during the individual oblique haul-off, the possibility of chockcooling the polymer on the mandrel, thereby achieving a finer grain and less tendency to age by recrystallization, as well as higher working speed, and the possibility of allowing the use of more difficult polymers, e.g. polymers of particular high molecular weight because of the supporting and conveying effect of the film on the mandrel, which can be very close to the circular exit slot of the extrusion die.

In the above description, the rotating fluid tubular layer is drawn inwardly from the rotating extrusion die onto the solid conveying film. This feature will generally be advantageous because the elastic tensions produced by the die rotation tend to reduce the diameter of the tubular fluid film, thus promoting the catching of the fluid film by, and its sticking to, the forwarded, solid film.

However, it is also possible to arrange the solid, forwarded film in a generally tubular shape with a diameter greater than that of the rotating die exit slot, and by blowing or by other means expand the extruded fluid, rotating, tubular film outwardly onto the surrounding solid film.

It should be mentioned that the solid film may be forwarded and rotated while the extrusion die is fixed instead of the opposite.

It should be noted that by "machine direction" is here meant the forwarding direction of the solid preproduced film.

In a preferred embodiment the different process steps, viz. extruding the several layers from the same die in relatively rotating circular streams, attenuating, uniting with the grain of adjacent layers in criss-crossing relationship and biaxial stretching can be carried out by an in line system. Preferably the sheet consists of three layers with the grain of the midlayer extending longitudinally as will be further described layer in connection with the description of the drawings.

Compared to depositing an extruded second layer onto a preformed first layer, the in line embodiment has the operational advantage that all layers are extruded from the same die, but this is achieved at the expense of the conveying effect contributed by the preformed solid layer.

By solidifying each grainy layer before they are united to a common sheet simpler or more conventional equipment can be used. In a preferred embodiment of this method the film is subjected to lateral tentering while above its melting point. This will give the possibility of producing rather wide layers. The lateral tentering can be carried out by means of a tenter frame preferably in an oven with circulating air which is kept at a temperature slightly above the melting point.

In order to simplify the lamination of separately extruded and solidified films, and thereby also make lamination of thinner films possible, at least the first phase of the uniting process may be combined with at least the first phase of the lateral stretching process. This essentially helps to prevent the formation of pleats during lamination. If the desirable stretching temperature is lower than the temperature necessary for sticking the films together, the first e.g. 10-20% of the stretching can take place at a higher temperature without any niticeable harm.

In order to facilitate the uniting when a layer is extruded around a preformed solid layer wound on a mandrel, a lower melting adhesive polymer may be coextruded on at least one surface of at least one of such layers.

If the lower melting adhesive polymer is sufficiently sticky, it has the practical advantage of avoiding controlled heating means, whereby the apparatus becomes particularly cheaper. In this connection, it has been found that the simultaneous stretching of two films while they are pressed together has a surprisingly high tendency to cold-weld the films together, so that only a small degree of stickiness is required. E.G. surface layers of polyethylene with 16% vinylacetate copolymerized have been found to weld at room temperature in this manner, yielding a peel-strength of 10 gr per cm. The bonding strength can subsequently be increased by passage over or between heated rollers.

The adhesive polymer may be coextruded in stripes. It is hereby possible to expediently obtain the strong-bond/weak-bond or strong-bond/no-bond pattern explained above.

Another method of expediently obtaining a bonding pattern of the said kind consists in coextruding on one of adjacent surfaces of two layers a continuous play of an adhesive polymer, and further to provide stripewise or spotwise the other of said surfaces with a release layer.

Still another method to obtain the bonding pattern is to coextrude the adhesive polymer so that the zones of no-bond regions form a dotted configuration.

As previously mentioned, the stretching process is preferably carried out at a relatively low temperature, e.g. room temperature, and use in the normal way of a tenter frame under those circumstances will almost inevitably give an uneven "necking-down" with a laterally varied tear-propagation strength. A generally even application of stretching forces is thus more preferred.

It is known to produce lateral stretching under even application of the stretching forces, see French Pat. No. 1.331.095 and Brit. Pat. No. 1,078,732. Both make use of 2 rubber conveyor belts which are expanded laterally at the same time as they are firmly pressed together, thereby gripping and drawing the film. However, for purposes the present invention simpler methods have proven more convenient. In this connection it should be noted that a strictly even distribution of the stretching forces are not necessary, but--on the contrary--a certain uneveness on a fine scale will be advantageous as far as tear propagation strength is concerned. It has in particular been found advantageous for the tear propagation strength to let the state of orientation vary across the film according to a pattern of striations--see FIGS. 8 and 9--in such manner that in one set of striations the biaxial orientation is unbalanced and is strongest parallel or nearly parallel to the striations, while in the intervening striations, it is also unbalanced but is strongest perpendicularly or nearly perpendicularly to the striations.

When especially high tear propagation and puncture resistance are desirable, and relativly low yield point is allowable, the stretching is carried out with the laminate in longitudinally pleated condition. There is hereby obtained a higher elongation at break. In order to allow the contraction at the same time as the longitudinal stretching is carried out in a narrow zone, the laminate is preferably supplied with very fine, longitudinal pleats--in analogy to what is disclosed in U.S. Pat. No. 3,233,029. In this connection, a suitable result is usually obtained when the fine pleats formed by the last step of the lateral stretching are maintained in the sheet when the latter is fed into the longitudinal stretching zone.

Although it is stated above that there are advantages in producing in the film a striated pattern of orientation and thickness variations, especially with a view to the tear propagation resistance, this effect should normally not be exaggerated since this would have an adverse effect on printability as well as on resistance to puncture by sharp items.

The object of stretching the film while in pleated condition therefore is to avoid an exaggerated tendency to distinct formation of the linear stretching zones, which usually would occur if the sheet were longitudinally oriented in any significant degree.

With regard to the attenuation and the uniting of the layers, another preferred embodiment of the invention involves extruding, attenuating and uniting the several layers in a common extrusion die. Hereby one loses some of the advantages achieved by the method using a solid, preformed layer since it is hereby impossible to obtain truly uniaxial directions of grain--but gains the operational advantage of handling only one common sheet outside the extrusion die.

It is simple to construct the extrusion die-parts for extruding three or more layers, which as previously mentioned has several advantages.

It is preferable when the layers are extruded by a common die to coextrude a polymer for controlling the adhesive strength of the layers.

Due to the fibrous morphology, the stretching process will normally produce internal but usually not trespassing voids in the grainy layers. This effect is particularly significant when the stretching takes place at a relatively low temperature, and more or less opaqueness is produced hereby. This effect can be utilized as a substitute for white pigmentation, but can also be abolished by subsequent pressure rolling.

The invention will now be described in more detail with reference to the drawings, of which

FIG. 1 shows a section through an extrusion-die for manufacturing of a sheet material according to the invention.

FIG. 2 in perspective view with displaced sections shows the principle of an extrusion die with two counter-rotating exit slots and means to extrude two layers through each slot.

FIG. 3 in similar view shows the principle of an extrusion die with two counter-rotating and one fixed slot and with interjacent exit slots for air streams.

FIG. 4 in perspective view and partly in section shows the principle of a rotating, ring formed extrusion die with a mandrel extending through its centre.

FIG. 5 is a flow-sheet of the process regarding a preferred embodiment of the method according to the invention.

FIG. 6 is a process-line of a preferred cold stretching method.

FIG. 7 is a detail of the "grooved rollers" which perform the lateral stretching in uneven zones, called "striations".

FIG. 8 is a schematical sketch, on an enlarged scale, of the pattern of the striations and the orientation therein, of a film cross-stretched according to the process-line of FIG. 6.

FIG. 9 is an enlarged cross-section of the film of FIG. 8 as actually observed by microscopy, however for the sake of clarity, the thickness is shown on a scale twice that of the width.

The extrusion die shown in FIG. 1 is an example of how to carry out the method, in which two polymer-in-polymer dispersions are extruded into a common collecting chamber through two rows of partitions, which are rotating in opposite directions. The two dispersion streams 1 and 2 are fed through inlet channels in the lower part of the die to annular channels 4 and 5 respectively in the two walls in the track 6, in which the two rings 7 and 8 are moved in opposite directions by driving means, e.g. by teeth and toothed wheels (not shown). The two rings 7 and 8 are supplied with rows of partitions 9 and 10 respectively, by which two rows of openings 11 and 12 are formed, through which the two dispersions are extruded into the collecting chamber 15, formed by the two parts 13 and 14, and terminating in the exit slot 16. For the sake of simplicity, the partisions 9 and 10 are shown as radially extending, but in real fact they are placed at an angle to the radial direction to prevent the formation of die-lines in the extruded sheet. By the extrusion through the two rotating rings 7 and 8 the two dispersions will each become attenuated and will hereby acquire a fibrillar morphology. The two arrays of attenuated streams will thereafter unite in the collecting chamber 15 and form a laminate with criss crossing fibrous morphology. The thickness of this laminate is reduced by the passage through the exit slot 16 and further by a normal draw-down and blow process. Hereafter the film is stretched both in the longitudinal and the transverse direction at a relatively low temperature. Due to the two different fiber directions the two half-parts of the film will exhibit tendencies to split in different directions during tearing. The materials, from which the two half-parts are formed, are so selected that they adhere poorly to each other. The material will thereby delaminate in a small area around any incision, from which tearing takes place, and this will smooth out the notch effect.

The die shown in FIG. 2 consists of four main parts, viz a fixed inlet part (17) for circular distribution of the polymers as explained below, a fixed bearing part (18), and supported here by the two rotating parts (19) and (20) which form one exit orifice (21). The polymers (A) and (B) are fed to the inlet part (17) where they are distributed in concentrical circular streams. (A) is extruded through the annular conduits (22) and (23), for which either one or two extrudes may be used. (B) is extruded through the annular conduit (24). For even distribution, (22), (23) and (24) are supplied with distribution baffles or other distribution means (not shown).

For the sake of clarity, the bearings and sealings between the bearing part (18), the rotating part (19), and the rotating part (20), are not shown, neither are the drives for (19) and (20).

From the three annular conduits (22), (23) and (24) the polymer streams pass the bearing part (18) through three circular arrays of channels (25), (26) and (27), each communicating with an annular chamber (28), (29) and (30) respectively.

The two rotating parts (19) and (20) are preferably rotated at almost equal velocity, but in different directions, as indicated by the arrows (31) and (32). Each rotary part in itself is a coextrusion die for two layers, one consisting of (A) and one of (B). For the sake of clarity, reference figures for explanation of the flow are shown only on part (20), but the flow through part (19) is similar. From the chamber (29) polymer (A) passes into the rotating part through channels (33), while polymer (B) from chamber (30) passes into the rotating part through channels (34). Inside the rotating part are two annular conduits (35) and (36) in communication with, respectively the channels (33) and (34), and separated from each other by a thin circular wall (37).

Having passed the edge of the wall (37), (A) and (B) merge together in an annular collecting chamber (38), which terminates in the exit orifice (21). By the passage through the collecting chamber (38) and into the exit orifice (21), the thickness of the fluid sheet is strongly reduced whereby the material is attenuated.

The partitions between adjacent channels (33) and (34) respectively ought to be streamlined, as shown. For the sake of clarity they appear to extend radially in the drawing, but in real fact they should be forming an angle with this direction to reduce the tendency of the forming of die-lines.

"Polymer A" is a blend of two incompatible or semi-compatible polymers, while "Polymer B" is adapted to give the sheet a suitable tendency to delaminate. It may therefore, e.g. consist of an elastomer which is a poor adhesive for the two layers of A, and may be extruded in stripes. However, if the channels 22 and 23 are fed with two different polymer blends, that are mutual incompatible, the polymer B may be an adhesive with a relative strong bond to the two polymer blends, and it must in that case be extruded in stripes or otherwise interrupted fashion.

The device shown in FIG. 3 consists of essentially similar main parts (39), (40), (41) and (42), but there is one exit slot (53) and (54) respectively in each of the rotating parts (41) and (42), and there is further a fixed exit slot (43) which is formed by the bearing part (40). From the three sets of annular conduits (44), (45) and (46) the polymer streams (C) and (D) pass the bearing part (40) through channels (47) and (48), respectively, and into the three annular chambers (49) and (50), of which the latter continues in the fixed exit slot (43). Each of the chambers (49) is formed of a fixed part (40) and a rotating part (41) or (42). Through channels (51) in (41) and (42) each of the chambers (49) communicate with the corresponding one of the two annular chambers (52) in the rotating parts, and each chamber (52) terminates in an exit slot (53) and (54), respectively.

Arrows (55) and (56) show the direction of rotations.

Having left the die, the three tubular films are fused together at the same time as the two films formed of (C) are subjected to torsion due to the rotations of (41) and (42).

From the outside and inside of the part (40), air is led through channels (55) ending in orifices (56). For the sake of clarity, the channels (55) from the outside of the part (40) are not shown. Through other channels (57) in the parts (41) and (42), the air is led through exit slots (58) and (59) between the fixed part (40) and the rotating parts (41) and (42) respectively. The channels (57) in the part (42) are not shown, for the sake of clarity. The ringformed pockets of air thus created between adjacent layers, prevent the rotating outer and inner polymer films from pleating against the midlayer immediately outside the exit slots.

Preferably the extruded film is blown, and both internal and external air-cooling is applied.

The arrangement shown in FIG. 2 is usually simpler to operate than that shown in FIG. 3, while the latter offers some special possibilities. One is to use expanded polymer for the middle layer, and another is to achieve a longitudinal grain in this layer, so that there will be 3 grains in the sheet. The presence of 3 instead of 2 directions in connection with the preferably tendency to delaminate, will significantly increase the tear propagation strength. Besides the attenuation process is more definitely finished before the lamination, which as previously mentioned is advantageous.

In FIG. 4, (60) is a rotating ringformed extrusion die. Through a fixed part of the extruder-die (not shown), which is in sealed connection with the rotating part (60), a polymer blend is fed into a circular groove (61) and led to the exit slot (62) through channels (63), that are separated by thin, plateformed partitions (64). For the sake of clarity the partitions (64) are shown as radially extending, but they are in real fact forming an angle with radial plans to avoid die-lines in the resultant sheet. (65) is a mandrel that is fixed by means, not shown, and (66) is a longitudinally attenuated preproduced flat sheet, folded to a tubular shape around the mandrel (65). For the sake of clarity a space is shown between the mandrel (65) and the folded sheet (66), but naturally the sheet is lying tight against the mandrel. The sheet (66) is pulled through the extrusion die over the mandrel as indicated by the arrow (67). When the polymer film (70) while still fluid leaves the rotating exit slot (62) it is caught by the folded sheet (66) because of the elastic retention in the attenuated polymer blend, and thus wound around said folded sheet and forewarded along with it, obtaining a helically running direction of splittability indicated by the arrows (68).

The direction of splitability in the preformed, folded sheet (66) is indicated by the arrows (69).

The bonding strength may be controlled e.g. by co-extruding an adhesive layer with the film (66). When the mandrel has a sufficiently high temperature, lamination of the sheet may be effectuated on it. However, often the film (70) is preferably chock-cooled on the mandrel, in which case the temperature of the mandrel may be insufficient for the welding of the two films (66) and (70) together. The lamination may therefore be completed by hot-or coldwelding after the films have left the mandrel (65).

The words "machine direction", which are used earlier in the description refers to the forewarding direction of the sheet (66).

The flow-sheet of FIG. 5 schematically shows the different steps of a preferred method in which the use of rotating die-parts is avoided. The last two steps can be carried out by the cold-stretching method indicated by the process-line of FIG. 6, in which section "Q" is the cross-stretching line and section "R" is the longitudinal stretching line. The system of rollers in section "Q" consists of driven nip-rollers (71), driven grooved rollers (72), idle rollers (73) and banana rollers (74). The banana rollers (74) after each step serve to draw out the pleats produced by the lateral stretching. Over the idle roller (75), the film (79) enters section "R", the longitudinal stretching line, where it is drawn through a water bath (76) serving to abolish the stretching heat and maintain a suitable stretching temperature e.g. at 20.degree.-40.degree. C. onto a bottin (77).

The arrow (78) indicates the machine direction.

In FIG. 7 a pair of driven grooved rollers (72) are shown in detail with the film (79) pressed and stretched between the teeth (80) of the rollers (72).

In FIG. 8 the relative lengths of the arrows in the striations I and II of the film (79) indicate the relative amounts of orientation achieved by the biaxially stretching method shown in FIG. 6 and FIG. 7.

In FIG. 8 as well as in FIG. 9 the numers I and II indicate the striations, which generally have varying width and uneven character. Furthermore it should be noted, that the outer layers (81) and (82) of the film (79) are not always symmetrical with respect of the thin midlayer (83). This assymmetry further serves to make a tear "fork".

For economical reasons, the present invention is particularly useful in connection with blends which mainly contain crystalline polyolefins. Best are for the most common application blends of polypropylene and high-or low-density-polyethylene. What blending ratio should be applied, and whether high- and low-density polyethylene should be used depends on the desired stiffness, low temperature strength, and in general on which strength properties are particularly wanted. In order to obtain a sufficient cohesive strength in each layer, the polypropylene should either be a copolymer semi-compatible with polyethylene, e.g. polypropylene with 2-5% contents of ethylene, or there should be used a suitable "alloying agent". In this connection it is sufficient to maintain high contents of the atactic modification in the iso-(syndio)-tactic polypropylene during manufacture of this polymer instead of removing this "impurity", as normally done. It is a special object of the invention that polypropylene with high contents of the atactic material can be made highly useful. Other "alloying agents" have been mentioned earlier in the specification.

Economically interesting are also blends of polypropylene and an elastomer--e.g. ethylene-propylene-rubber, ethylene-vinylacetate copolymer, polyisobutylene or a "thermoplastic rubber" based on butadiene/styrene.

When particularly high low-temperature resistance and/or high flexibility is desired, blends of low-density polyethylene and a semi-compatible rubber is preferable. It will be understood that the blend needs not be formed by mechanical blending, but can be formed already in the polymerization process. Thus, polypropylene with extreme high contents of the atactic component can be useful without any further admixture, and the known polymerization processes which aim at making blends of polypropylene, polyethylene, and block polymers herebetween, can also be adapted.

Considering polymers outside the polyolefin, groups, the following combinations for example will be useful for special purposes: (a) Polyester/polyamid or polyuretan, (b) polyester of polyamide/polycarbonate, and (c) vinylidene-copolymers in different combinations.

In addition to the layers with the special morphology as described, there may also be layers with special properties. Thus, it is almost always advantageous to co-extrude thin surface layers of a suitable adhesive component in order to enable sealing of the laminate without ruining of the orientation. As another example it will also often be necessary or advantageous, especially for food packaging, to add one or more special layers to improve barrier properties.

The high-strength laminate according to the invention is believed to be advantageous for use within the following rields:

(1) Food packaging: Heavy duty food bags in general, 100% plastics or combined with paper. Frozen food packaging.

(2) Non-food packaging: Fertilizer bags, cement bags, bags for valuable chemicals, e.g. plastic granules, bags for coarse chemicals (e.g. rock salt, rock pieces) and for other sharp items, wrapping of steel plates, packaging of carpets, baling-wrap, e.g. of cotton, wool, lumber wrap, grocery bags, individual packaging of machine-parts, weapons, etc., sterilization-bags for heavy or sharp objects, miscellaneous; e.g. for textile, apparel, paper, drugs, soaps, toilteries, tobacco.

(3) Film in connection with containers: Shrink wrap and strength wrap for pallets, trash bags, in particular compactor bags, industrial shipping packs.

(4) Non-packaging: Fumigating film, earth cover for erosion control, lining in ponds, water reservoirs and channel construction, road underlay, wind screens, green house film, plant-protection film (agricultural and horticultural), cover over dumps of agricultural and horticultural products, salt etc., weathering protection of animals (animal "coats"), raincoats, tents, inflatable architectural structures, water inflated structures, lighter-than-air-buoyant structures, rib-constructions (architectural, cheap vessels), cushion-pillows as fillers in cargos, railroad car liners, truck covers, weathering protection over building under construction, water barrier over cement constructions so retard drying, insulation of roof under shingles, insulation of refrigeration rooms, "membrane-films" in house construction, ceiling tile, misc building papers (in lamination with paper) cheap swimming-pool constructions, industrial tapes.

It will be understood, that the above described new extrusion methods and apparatus which make use of rotating die parts, will also have certain useful applications outside the field of high strength laminates. Thus, they can be used to extrude and laminate film without a "grain" as described, which still are applicable with advantage for certain purposes. Further, the general extrusion system shown in FIG. 4 can e.g. be used to spin a melt-oriented film (with or without a grain as described) around a cold-stretched film.

A three layers tubular film is extruded in the following composition:

Middle layer (70% of total)

85% isotactic polypropylene of gas-phase type ("Novolen") with high atactic contents

15% ethylene-vinylacetate, copolymer (16% vinylacetate)

Both surface layers (one 10% of total, the other one 20% of total):

Ethylene-vinylacetate copolymer (16% vinylacetate)--to serve as adhesive layers.

The polypropylene has melt index 0.3-0.6 according to ASTM D 12 38 condition L, while the ethylene-vinylacetate copolymer has melt index 2.5 according to the same ASTM but condition E. The tubular film is extruded from a 1 mm wide slot at 180.degree. C.-230.degree. C. and drawn to 0.130 mm in molten state. The blow ratio is kept very low, viz. 1.2:1.

Thereafter it is cut helically to a flat film with 45.degree. angle of "grain". Two such helically cut films, with their "grain" perpendicular to each other, and the thinner surface layers facing each other, are fed together at 20.degree. C. through 7 sets of "grooved rollers"--see FIGS. 6 and 7. The width of each groove is 1 mm and the width of each ridge is 0.5 mm. The intermeshing of the ridges with each other (difference of level between the tops) is 2 mm. Between each passage through a set of "grooved rollers" the pleats formed in the laminate are straightened out.

By the mechanical work between the "grooved rollers", and due to the copolymer layers which act as adhesive, the two films are hereby cold-welded together with relatively low bonding strength,--peel strength measured to 10 gr per cm--and is at the same time cross-drawn.

After the 7 passages at 20.degree. C. the film is passed once through a similar set of "grooved rollers" with the same dimensions and intermeshing, but heated to 120.degree. C., whereby there is formed lines of strong bonding.

Finally the laminate is longitudinally oriented in three steps with about 1 cm stretching-gab (so as to minimize the cross-contraction). The last stretching is so adjusted that the total lateral cold-stretch-ratio and the total longitudinal cold-stretch ratio are equal, whereby the product hereof, i.e. the area-stretch-ratio is 2.4:1.

Tests results compared to a heavy-duty bag quality low-density polyethylene film of 85% higher sq.m weight and melt index 0.3 according to same ASTM condition E. Gauge 100 gr per sq.m for the laminate and 185 gr per sq.m for the polyethylene film. Impact strength measured by falling-ball (diameter: 61 mm, weight 320 gr) for the laminated film of 100 gr per sq.m: 5.5 m.

For the polyethylene film of 180 gr per sq.m: 2.0 m

Tongue tear resistance:

Tearing at velocity 100 mm per min, total specimen width 5 cm, incission length 10 cm:

For the laminated film of 100 gr per sq.m: 5.9 kg in the machine direction and 6.8 kg in the transverse direction.

For the polyethylene film of 180 gr per sq.m: 1.3 kg.

Elmendorf tear resistance (shock-tearing):

The test is a modification of standards aiming at a more symmetrical tearing. Results:

For the laminated film of 100 gr per sq.m: in longitudinal direction 441 kg cm per sq.cm, in cross-direction 344 kg cm per sq.cm.

For the polypropylene film of 180 gr per sq.m: in longitudinal direction 167 kg cm, per sq. cm in cross-direction 172 kg cm per sq.cm.

A piece of the sheet is delaminated by peeling and the structure is examined in microscope. The main layers have a pronounced fibrous morphology with zig-zagging grain-directions.

The procedure of example 1 is repeated with the following modifications:

Three three-layers coextruded film had the following composition:

Middle layer (70% of total):

85% isotactic polypropylene (same type as in ex. 1)

15% ethylene-propylene-rubber (ab. same melt index as the polypropylene)

Both surface layers (each 15% of total)

ethylene-vinylacetat copolymer (same type as in ex. 1)

The film was stronger melt-attenuated after the exit from the die, namely by drawing from 1 mm thickness of 0.065 mm (60 gr per sq.m).

Examinations in polarized light showed that the melt-orientation produced hereby corresponded to about 35% uniaxial cold-drawing.

After the spiral-cutting, there was produced a 3-ply laminate. The third layer, which was placed in the middle, was with longitudinal "grain direction" obtained by longitudinal cutting of the same film.

The lamination and drawing took place on the machinery of Example 1, but all steps were carried out at 20.degree. C., and the apparatus were adjusted to hereby produce a total area-stretch ratio of 2.5:1 by which the final laminate thickness became 72 gr per sq.m.

The peel strength of the bonding between the layers was measured to 10 gr per cm. Examinations in microscope showed a similar structure as in Example 1. The following test results were obtained:

A series of sheets on polyolefin basis has been produced by the extrusion die shown in FIG. 2. The diameter of the exit slot (21) of the die was 130 mm and the width of the latter 1 mm. The biggest width of the collecting chamber (38) was 4 mm, which means that the amount of attenuation during the passage through the collecting chamber toward the exit slot has been smaller than preferable. The extrusion temperature was about 240.degree. C.

After the longitudinal cutting of the tubular film, the stretching was first carried out laterally in between 4 and 8 steps and thereafter longitudinally in between 2 and 4 steps in the same machinery as used in examples 1 and 2.

The layer composition, flat tube width (measure of blow ratio), stretching temperature, stretch ratio, and results appear from the table below. "Nov" stands for Novolene, a gas-phase polymerized polypropylene with relatively high contents of the atactic modification, "PE" stands for low density polyethylene, "EPR" stands for ethylene-propylene-rubber, "SA 872" "'7823" and 37 8623" are different types of polypropylene with minor contents of polymerized ethylene.

The fact that even the best samples of this example generally are inferior to those of example 1 to 2 are explained by a less uniaxial total melt attenuation. A certain biaxial melt-attenuation is inevitable in this embodiment, since the streams are first united inside the die in criss-crossing relationship, and thereafter further melt-attenuated during the passage through the exit and immediately thereafter. On the other hand, this method is particularly simple to operate. cm Mullen Outer Layer Middle Layer Orientation Tube Tongue Tear Dart Impact Burst Beach Puncture Trapezoidal Tear Elmendorf Tear Basis Weight Composition Composition Temp. % Width MD TD (ft - lbs) (psi) MD TD MD TD MD TD (g/m.sup.2) 1 70% 7823, 20% PE, 10% EPR PE--10% Cold 100% 30 3.3 1.8 2.5 20 129 136 6.5 7.1 500-1400 500-1300 73.5 2 80% 7823, 20% EPR PE--10% Cold 100% 30 1.7 1.6 2.5 30 242 228 8.9 6.8 800 500-2500 69 3 80% 7823, 20% EPR PE--20% Cold 100% 30 2.7 2.3 2.5 2.6 295 241 7.8 6.4 300-1100 300-1000 62 4 70% SA 872, 30% PE PE--10% Cold 50% 30 7.1 4.6 2.0 37 86 105 11.6 9.5 1200-2400 400-2000 114 5 " PE--10% Cold 100% 30 5.7 2.1 2.5 27 103 118 11.9 7.7 400-2000 1400-3200 73.3 6 " PE--10% Hot 50% 30 9.0 4.5 2.0 35 66 98 10.2 11.4 100-1700 1500-3200 103.9 7 " PE--10% Hot 100% 30 7.5 3.0 1.5 30 67 98 13.6 12.7 500-1500 2400-3000 86.5 8 " PE--10% Cold 50% 45 6.6 1.4 2.0 20 71 105 8.7 8.8 100-800 1100-2600 79 9 " PE--10% Cold 100% 45 2.6 1.4 2.0 19 69 120 7.8 5.0 200-2900 2200-3200 63.4 10 " PE--10% Hot 50% 45 5.8 2.4 2.0 25 44 52 7.7 8.2 300-1100 1100-3200 79.8 11 " PE--10% Hot 100% 45 6.4 2.3 2.2 20 86 88 9.9 8.7 900-1900 900-3200 61.1 12 100% SA 872 PE--10% Cold 100% 30 1.2 3.3 2.5 21 113 103 6.3 5.4 200-1800 600-2200 54.6 13 " PE--10% Cold 100% 30 2.0 1.1 1.5 22 70 68 7.9 5.8 310 800- 2100 79 14 " 50/50 Cold 100% 30 2.1 1.5 2.5 22 126 140 5.3 7.4 200-3000 1500-3200 70.4EPR/PE--10% 15 " 50/50 Hot 50% 30 3.1 2.1 1.5 26 56 44 9.5 8.1 300-3200 100-300 83.2 EPR/PE--10% 16 " 50/50 Hot 100% 30 1.4 1.4 1.5 29 72 64 10.7 7.8 150-2500 200-3200 71.5EPR/PE--10% 17 " EPR 10% Cold 100% 30 5.6 2.8 2.0 29 83 105 9.8 8.9 700-3200 800-2000 84.5 18 80% 7823, 20% EPR EPR 10% Cold 100% 30 4.4 1.9 4.0 23 327 278 12.5 8.4 700-3000 1400 88.4 19 70% 7823, 20% PE, 10% EPR EPR 10% Cold 100% 30 4.5 2.9 3.0 20 212 187 10.4 9.0 1000-3200 900-1300 71.4 20 70% SA 872, 30% PE EPR 10% Cold 50% 30 6.4 3.0 1.5 23 93 105 10.3 8.9 300-3200 1100-3200 74.8 21 " EPR 10% Cold 100% 30 3.9 2.1 3.0 21 100 115 8.2 7.6 300-3200 700-2100 70 22 " EPR 10% Hot 50% 30 4.9 3.9 1.5 26 55 71 11.5 9.4 600-2400 1200-2500 86.9 23 " EPR 10% Hot 100% 30 5.2 3.4 2.0 20 110 116 8.6 10.2 200-2200 700-1600 64.8 24 " EPR 10% Cold 50% 45 6.0 5.0 1.5 26 67 149 13.2 10.1 1400-3000 800-2000 88.7 25 " EPR 10% Cold 100% 45 5.0 3.2 3.0 23 124 145 11.5 7.9 1100-2500 1000-2300 82.9 26 " EPR 10% Hot 50% 45 5.6 3.9 1.5 23 120 101 9.6 9.3 320-3200 1200-3200 83 27 " EPR 10% Hot 100% 45 5.0 5.4 2.0 21 116 113 5.7 8.9 640-3200 600-2700 76 28 85% 8623, 10% PE, 5% EPR EPR 10% Cold 100% 30 0.63 0.32 2.0 20 105 50 2.4 1.8 350 96 66.3 29 90% 8623, 10% EPR EPR 10% Cold 100% 30 0.45 0.26 2.0 15 66 73 1.8 1.5 240 96 74 30 100% SA 872 50/50 Cold 100% 30 4.4 4.3 3.0 24 99 94 9.0 7.7 800-2000 2600-3200 73.8EPR/PE--20% 31 100% SA 872 50/50 Cold 100% 30 4.5 3.5 2.0 23 74 107 8.6 8.4 1400-3000 700-2700 81.7EPR/PE--5% 32 80% SA 872, 10% PE, 10% EPR 50/50 Cold 100% 30 3.4 6.3 3.0 25 110 117 8.4 9.4 700-2000 2400 70.4EPR/PE--10% 33 34 70% Nov, 30% PE 50/50 Cold 100% 30 4.8 2.4 2.5 23 228 194 7.0 7.9 68EPR/PE--10% 35 70% PE, 30% Nov EPR 10% Cold 100% 30 4.9 4.2 4.0 23 336 343 8.6 6.9 71.2 36