POLYETHYLENE/METAL LAMINATES AND METHODS OF MAKING SAME

Abstract: A structure in which polyethylene is bonded to a metal substrate is made by a method comprising the steps of engaging a surface (3a) of a film (3) of linear low density polyethylene with a surface (2a) of a sheet metal or foil (2); heating at least the sheet metal (2); and applying pressure to opposed free surfaces (3b), (4b) of the film and sheet metal to engage the film with the metal. The laminated article may be folded to a pouch or alternatively deformed by press tools to make trays or hollow articles. The polyethylene is essentially a linear low density polythylene having a density in the range of from 0.91 to 0.94 g.ml<s-1>s produced by low pressure polymerisation of ethylene and but-1-ene.

Description: POLYETHYLENEMETALLAMINATESANDMETHODSOFMAKINGSAME This invention relates to structures comprising an element of polyethylene bonded to a surface of a metal substrate and to methods of making such structures. More particularly, but not exclusively, the invention relates to structures in the form of a laminate of polyethylene film and metal in the form of sheet or foil which may be formed into an article. British Patent Specification No. 1,295,132 describes a method of forming a laminate of polyethylene and various metal substrates. In one example given, a low density polyethylene film v/as pretreated by corona dis¬ charge and then applied to preheated tinplate by means of a rubber coated roller. The laminate was allowed to nol whereon the peel -strength of the bond between the pretreated . polyethylene and the tinplate was 33 lb. per linear inch (150N/linear inch). " When the method v/as repeated using an untreated polyethylene the coating could readily be stripped off the tinplate. Unexpectedly we have found that a particular range of the now available polyethylenes called "linear low density polyethylenes" can be bonded directly to various metal substrates by the influence of heat and pressure. The term "linear low density polyethylene" is becoming widely used in the plastics industry. (See for example "Modem Plastics International" March 1SS0 p. 35; European Plastics News" March 1980 p. 8; and "Modem Flastics International" 1979 p. 26, p. 76). In this specification the term "linear lev; densi y polyethylene" is used to denote a group of co-polymeric materials of low to medium densitry, produced by lew pressure co-polymerisation of ethylene and an alpha olefin co-monomer, using an appropriate catalyst. The molecular arrangement is believed to consist of a r.egular linear main-chain backbone with a number of short side chains. Where the co-monomer is but-1-ene, the side chains are formed by ethyl groups. The poly¬ mers show different behaviour from conventional low density polyethylenes made by the high pressure process, in particular by having a higher melt temperature. According to the invention, a structure including an element of polyethylene bonded to a surface of a metal substrate is characterised in that the polyethylene is a linear low density polyethylene having a density in the range from 0.91 to 0.94 g. l ""1 , produced by low pressure co-polymerisation of ethylene and but-1-ene. The metal substrate may be chosen from various metals such as steel; steel having a coating of tin or chromium or chromium/chromium oxide or zinc; aluminium; aluminium alloy; nickel; zinc or copper. The metal substrate may, if desired have a conversion coating thereon such as the pas¬ sivation coating on tinplate or oxide on aluminium. In one embodiment of the structure, the polyethylene element is in the form of a ilm bonded to a metal sheet or foil. In another embodiment, polyethylene elements are bonded to opposed surfaces of the sheet metal or foil to form a laminate comprising polyethylene/metal/ polyethylene. If desired, the laminates may be made with sheet metal or foil bonded to opposed surfaces of the polyethylene film. The polyethylene preferably has a melt flow index (MFI) less than 3.0 g/10 in. , a preferred range being between 0.2 and 2.0 g/10 min. As indicated above, the density of the pol * -ethylene must be in the range 0.91 to 0. ^ g.ml , this density reflecting the appropriate number of If desired the polyethylene may contain fillers or pigments such as titanium dioxide. The invention further provides a method of making a structure including an element of polyethylene bonded to a surface of a metal substrate by engaging the poly¬ ethylene element with the surface of the metal sub¬ strate and bonding it thereto by the application of heat and pressure, characterised by the step of select- ing the polyethylene to be a linear lov/ density poly- _, ,* ethylene having a density from 0.91 to 0.9 g.ml produced by low pressure co-polymerisation of ethylene and but-1-ene. In one embodiment of the method the polyethylene element is in the form of a film and the metal substrate is in the form of a sheet or foil. If desired the polyethylen film may be engaged v/ith one side of the sheet metal or to opposed sides of the sheet metal to make a laminate of polyethylene/metal/polyethylene. Conversely sheet metal may be engaged with opposed surfaces of the polyethylene film to make a laminate of metal/ polyethylene/metal. In a first embodiment of the method the polyethylene and metal substrate are heated to a temυerature within the range 200°C to 300°C; sufficient pressure is applied to exclude any risk of bubbles between .the polyethylene and substrate. The pressure is preferably less than 3500 kPa, a particularly preferred range of pressure being between 200 kPa and 2400 kPa. The pressure is preferably applied for a period in the range 0.1 seconds to 5 minutes, the shorter times- eing applicable by pinch rolls and the longer times being applicable by press tools. Preheat may be applied to the polyethylene or to the etal substrate or to both the polyethylene and the metal substrate. If desired the polyethylene may be pretreated by a pretreatment chosen from corona discharge, glow discharge- or flame treatment; however this pre¬ treatment is not essential. The metal substrate may be flame treated before engagement with the polyethy¬ lene. In a second embodiment of the method the polyethylene and metal substrate may be bonded to a relatively low strength at a temperature in the range 140 C to 300 C, after which the structure is heated without applied pressure at a temperature in the range 180°C to 3C0°C to create a stronger bond. Preferably this period of heat without pressure does not exceed 5 minutes. The structure produced by the method may be formed into articles by folding to a pouch or tray cr alter¬ natively drawing between a punch and die to make a hoi- low article. After such mechanical working operations it may be desirable to heat the article in crder to ensure that the polyethylene is bonded ^ to the substrate. " We have found that linear low density polyethylenes of the type defined above mace by the low pressure process, will provide a means to achieve high bond strength between the polyethylene and metal substrate without recourse to adhesives, with less energy input than is required for conventional polyethylenes. Embodiments of the invention will now be further des¬ cribed by way of example and with reference to the accompanying drawings, in which:- r>igure 1 is a sectioned side elevation of a laminated structure ; Figure 2 is a sectioned side view of a press tool during pressing of the laminated structure; Figure 3 is a diagrammatic sketch of a pair of rolls for pressing the laminated structure; Figure 4 is a diagrammatic side view of a punch and die for pressing the laminated structure; and Figure 5 shows in sectioned elevation a hollow article produced by the punch and die of Figure 4. In Figure 1 a structure 1 is shown to comprise a sheet metal substrate 2, a first outer layer 3 of polyethy¬ lene and a second outer layer 4 of polyethylene, the polyethylene being a linear low density polyethylene having a density from 0.91 to 0.94 g.ml , produced by low pressure co-polymerisation of ethylene * and but-1-en Both the first and second layers of polyethylene are firmly engaged with the metal substrate without recours to any further adhesive. The structure of Figure 1 is formed by engaging a surface 3a of the first outer layer 3 with a surface 2a of the metal substrate 2 and a surface 4a. of the second outer layer 4 with a surface 2b of the metal substrate 2, heating at least the metal substrate 2 and applying pressure to the free surfaces 3b and 4b to form the structure. Pressure may be applied by means of press platens as will be described with reference to Figure 2 or by means of a pair of rolls as will be described with reference to Figure 3. However in Figure 3 a structure having only one plastics layer is described to show that the invention is not limited to metal substrates having a plastics coating on both sides. Figure 2 shows the structure 1 while being pressed in a simple press as may be used in a laboratory to produce samples about 12 cm wide by 20 cm long from which test pieces may be cut. The samples are also big eno g ÷.r. r -O- provide a blank for further forming into a hollow article by processes such as are used for folding, stamping, drawing or wall ironing. The press tools comprise an upper platen 5 and a lower platen 6 5 mounted in a press (not shown) so that the tools may be opened to permit entry of the sheet metal and polyethylene and closable to apply pressure to form the structure. The press platens 5 and β are heated and on closing the platens the pressure arising from • 10 platen 5 is delivered through an upper copper plate 7 and an upper sheet 8 of polytetrafluoroethylene (PTFΞ) into the layer 3 of polyethylene, and the pressure arising from the plate 6 is delivered through a lower copper plate 9 and a lov/er sheet 10 of PTFΞ on to the 15 layer 4 of polyethylene. The purpose of the copper plates 7 and 9 is to spread the heat from the platens 5 , β evenly across the structure. The purpose of the PTFΞ sheets 8, 10 is 20 to prevent the polyethylene sticking to the copper sheets 7, 9. The use of the press tools will now be explained by an example: A blank 12 cm wide by 20 cm long was cut 25 from a larger sheet of chromium/chromium oxide coated steel known in the trade as TFS. The blank was 0.21 mm thick, temper 2, type D steel. Two copper plates each 25 cm long x 25 cm wide were wiped clean with a soft rag. A strip of PTFΞ film 13 cm wide by 22 cm long 30 was placed on each copper plate to act as non-stick linings. A strip of linear low density polyethylene (LL FΞ) film 100 thick measuring 12 cm wide x 20 cm long was placed on each non-stick lining (the LIDPΞ film used was one provided under the the number LPX2 5 by Esso Co.). The TFS blank was cleaned with alcohol and then sandwiched between the PTFΞ/L-LDPE covered copper plates in the stacking order depicted in Figure 2. The stack of steel, Oolyethylene and cccoer ^_ _^_=~ was then placed between the platens of the press which were at 200°C. The press platens were closed and a load of about 10 tonnes was maintained for 30 seconds. There¬ after the platens were opened and the structure v/as removed from the press to cool in air before testing. Th purpose of the applied pressure is to effect bonding bet¬ ween the sheet metal and the polyethylene films and also to exclude bubbles between the films and the sheet metal. Figure 3 shows a pair of rolls 11, 12 set apart a distance to compress a single polyethylene film 13 on to a preheated strip of sheet metal 14. Such an arrangement has the advantage that bubbles will.be driven out as the polyethylene film engages the strip of sheet metal. As the rolls impose a pinch pressure along a line of contact parallel to the axis- of the rolls it is difficult to give a quantitative estimate of the pressure imposed to produce the structure. Whilst the strip of sheet metal, could be heated by a gas burner the source of heat shown is an induction heater denoted 15. The polyethylene may if desired be pretreated by a pre- treatment chosen from corona discharge, glow discharge or flame treatment as is commonly used in the art. Various linear low density polyethylene films, having a density of 0.91 to 0.94 g.ml —1 and formed from ethy¬ lene and but-1-ene, and various types of sheet metal may be used and in Table 1 several examples are given together with the peel strengths of the structure measured on testing in a 90° peel strength test per 2.5 cm of width laminate: The results obtained with linear lew density polyethylene film (11DFE) may be compared with the results obtained with lev/ density polyethylene (L PΞ) and high density polyethylene (HDPΞ) shown in the first two scrouos of the Table: TABLE 1 Comparison of bond 'strengths arising bstween various metal substrates and various polyethylenes. Polymer: Type .o, Metal 90"Peel Bond strength 5 Strength arising from per 2.5 cm 30 seconds at width 200°C ICI ALK 11/01 LDPE TFS No bond to TFS ICI ALK 11/01 LDPE TINPLATE No bond to tinplate 10 ICI ALK 11/01 LDPE BLACKPLATE No bond to blackplate ICI ALK 11/01 LDPE ALUMINIUM No bond to aluminium BP RIGIDEX 50 IIDPE TFS - Weak Bond BP RIGIDEX 50 HDPE TINPLATE - Weak Bond BP RIGIDEX 50 IIDlΕ " BLACKPLATE - Weak Bond 15 BP RIGIDEX 50 HDPE ALUMINIUM - Weak Bond ESSO LPX2 LLDPE TFS 2500 g :Strong Bond: 25N/2.5cm ESSO LPX2 LLDPE TINPLATE /»800 gm:Strong Bond: 7N/2.5cm ESSO LPX2 LLDPE BLACKPLATE 5600 gm:Strong Bond: 55N/ . cm ESSO LPX2 LLDPE ALUMINIUM 3330 gm:Strong Bond: 32N/2. cm ?() UNIFOS B001 LLDPE ZINC COATED Useful Bond 56N/2.5cm STEEL SHOT (Bonded at 220°C for minutes) DIPPED *) From the Table it can be seen that linear low density that the 90° angle of peel varied as did the strength observed so the mean of three maximum values were recorded (see column 6 of Table 2). The results are recorded in Newtons per width of test structure 5 (nominally 2.5 cm). The peel strength observed also varied during peeling apart particularly when test pieces made in the large press were tested. Values of strengths which were 10 exceeded for 256 of the peeling period were noted, an are recorded as means of 3. (See the results in parenthesis in column 8 of Table 2). The results are recorded in Table 2 in which the left 15 hand column (1) indicates the subgroups of polymer tested, LLDPE denoting linear low density polyethylene; LDPE denotes low density polyethylene; and HDPE denotes high density polyethylene; 20 column (2) records the polymer tested by trade- name or code; column (3) records the melt flow index in gm/ 0 min; column (4) records the density of polymer in gm/ml; column (5) records the number of branches per 1000 back- 25 bone carbon atoms as estimated by nuclear magnetic resonance; It is not possible to compare fairly the results of columns β and 7 with 8 because of the differing type of test piece. Column (5) records the number of side branches per 1000 backbone carbon atoms. As these side branches are not easily incorporated into the crystalline lattice, they lead to an increase in the amorphous content of the polymer and thence a lowering in density. The relationship between number of side branches (column (5)) and density (column (4)) is apparent. We believe that polyethylenes having a significant number of ethyl side branches (more than the 4 side branches per 1000 carbon atoms of SCLAIR 1βA) which is reflected in a density of less than 0.94 g.ml , give rise to satisfactory bonding to metals. Study of column 6 shows that the ' LLDPE polyethylenes having a significant number of ethyl sidechains (but-1-ene copolymers denoted Group A in column 1 with density between 0.91 and 0.94) give much higher bond ; strengths than the LLDPE polyethylenes having hexyl sidechains (Group 3 in column 1). For example "Unifos 8001" in Group A had a peel strength of 120N/2.5cm when bonded to TFS at 260°C for 10 seconds in contrast to "D0W61 00/35" which had a peel strength of 26 N/2.5cm when bonded under the same conditions to TFS. It must be pointed out that the results given for SCLAIR .16A are low because this grade of linear low density polyethylene has a high density and an in¬ sufficient number cf. ethyl side chains. 'The low density polyethylenes of Group C and the high density polyethylenes of Groups D and Ξ also gave much weaker bonds than the Group A linear low density polyethylenes with density between 0.91 and 0.94. Although the polyethylenes of Groups 3, C, D and Ξ did achieve increased bond strengths at high te - peratures of 275°C and 295°C they never match the Group A polymers. It is therefore concluded that linear low density polyethylenes having ethyl side- chains and with density from 0.91 to 0.94 g.ml require less energy to achieve a strong bond than do the other polyethylenes tested. Column 7 confirms this conclusion at a lower period of pressing of 5 seconds. Column 8 serves to show that the results are repro- ducible on large scale samples. Again the linear low density polyethylenes (of Group A) having ethyl side chains show the greatest bond strengths (see TTΛTT * PCS 8001 ). However it must be observed that while the HDPE R002/47 gave a peel strength of 2 5N/2.5cm, this prolonged treatment is not commercially attractive, The laminates of LLDPE with TFS were further tested by thermal processing in water in a pressure cooker at 100 kPa and at 120°C for 1 hour; no dela ination was observed. The laminates of LLDPE with TFS were also drawn into cup shaped articles and no delamination occurred. Figure 4 shows a tool set comprising a punch 16, and die 17 through which the punch 16 is moved as indicated by arrow "A", and a blank holder 18 which is moved as indicated by arrows 3 to co-operate with the top face 17A of the die 17 to restrain a blank from wrinkling as the punch 16 pushes the blank through the die 17 to draw a hollow body. In Figure 4 the tool set is depicted during the drawing of a circular blank 19 cut ; from the laminated articώsa-t)-- * -* of Figures 1, 2 or 3 so that, as the punch 16 pushes the central portion of the blank through die 17, the blank holder 18 co-operates with the top face 17A of the die 17 to prevent wrinkling of the peripheral margin of the blank. Figure 5 shows the hollow body 20 drawn by the tool set of Figure 4. Although this body 20 has been * drawn from a blank having linear low density polyethy- lene film on both sides, a blank having a film on one side only may be used if for example a drawn can having an internal film is desired. The laminated article may also be shaped by a punch and die such as are used to make shallow articles such as trays and mats. When the metal substrate is a foil such as ' aluminium foil the laminated article may be used for making bags and the like. When rolls are used to pinch the linear lov; density polyethylene film into engagement with the sheet metal or foil, the sheet metal or foil and film may be fed from coils such as are supplied by the manufacturers of the metal and film. During the folding or drawing of the structure to form an article, the polyethylene to metal bond may be weakened. However this possible weakening may be repaired by heating the article to a temperature preferably in the range 200°C to 295°C, to re-establish the bond between the linear low density polyethylene and the metal substrate. TABU! 2 Bond Strength Measurements Values are maximum bond strength correct to the nearest integer in N/2.5cm (nominal). Values in parenthesis in column 8 are mean values in the same units of strengths exceeded f 59<) of the peeling action. (1) (2) (3) w (5) (6) (7) (8) Subgroup Polymer MFI Density No. of Large 10 (Trade (g/10 (g.ml "" ) branches Small Press Press per 1000 name) mins) backbone 10 sees 5 sees 4 min carbon atoms 2 0°C 260°C 275°C 295°C 295°C 235°C A LLDPE Unifos 8001 1.0 0.919 20 47 120 112 107 106 305 (27 . ethyl sidechain Esso LPX1 1.0 ' 0.918 20 106 107 114 125 174 (15 (but-1-ene Esso LPX2 2.0 0.920 21 4 28 70 74 63 198 (16 copolymcr) Sclair 16A 0.25 0.946 0 1 16 84 11 37 (23 D LLDPE Dow 20/ * 5 1.0 0.920 19 0 16 29 26 14 66 (40 20 hexyl Dow 61500/356.0 0.919 24 4 26 30 27 12 5 (3) πi oohain Dow 2553 40.0 0.935 10 0 6 2 3 3 (1) C LDPE ALK 36 0.2 0.936 12 33 52 55 37 149 (13 ALK 11/01 2.0 0.918 30 0 2 19 34 26 84 (74 SHELL 30 TABLE 2 continued (1) (8) Subgroup Polymer MFI Density No. of Large (Trade (g/10 (g.ml "1 ) branches Small Press Press pep 1000 10 sees name) mins) backbone 5 sees 4 mins carbon atoms 240°C 260°C 275 C 295 C 295 C 235°C D HDPE R002/47 0.2 0.947 0 10 42 72 39 215 (18 10 copolymer R002/ 0.2 0.953 0 28 41 106 26 171 (13 R'lO 4.0 0.949 0 4 13 19 17 102 (87 E HDPE R00 6/60 0.6 0.960 0 12 27 85 23 177 (16 homopolyriier R50 5.0 0.962 1 15 21 29 22 85 (65 15 R180/60 18.0 0.965 0 10 24 31 22 54 (23

Claims: AMENDED CLAIMS (received by the International Bureau on 4 December 1981 (04.12.81)) . A structure including an element of polyethylene bonded to a surface of a metal substrate, characterised in that the polyethylene is a linear low density poly¬ ethylene having a density in the range from 0.91 to 0.94 g.ml and a melt flow index in the range 0.2 to 2.0 g/10 min, produced by low pressure co-polymerisation of ethylene and but-1-ene. 2. A structure according to claim 1 characterised in that the polyethylene element is in the form of a film and the metal substrate is a sheet or foil. 3. A structure according to claim 1 or 2 characterised in that the polyethylene contains a pigment or filler. 4. A method of making a structure including an element of polyethylene bonded to a surface of a metal substrate by engaging the polyethylene element» ith the surface of the metal substrate.and bonding it thereto by the application of heat and pressure, characterised by the step of selecting the polyethylene to be a linear low density olyethylene having a density from 0.91 to 0.94 g.ml and a melt flow index in the range 0.2 to 2.0 g/10 min, produced by low pressure co-polymerisation of ethy¬ lene and but-1-ene. 5. A method according to claim 4 characterised in that the polyethylene element is in the form of a film, and said metal substrate is in the form of a sheet or foil, said film being engaged to a surface of the sheet or foil. 6. A method according to claim 4 cr claim 5 characterised in that the polyethylene element and substrate are heated to a temperature within the range 200 to 300°C. •7. A method according to any of claims 4 to 6 charac- terised in that the pressure applied is less than 3500 kPa. 8. A method according to any of claims 4 to 7 - 5 characterised in that the pressure applied is in the range 200 to 2400 kPa. 9. A method according to any of claims 4 to 8 characterised in that the pressure is applied for a 10 period in the range 0.1 seconds to 5 minutes. 10. A method according to any of claims 4 to 9 characterised in that the surface of the metal sub¬ strate is heated before the polyethylene element is 5 engaged therewith. 11. A method according to any of claims 4 to 10 characterised in that the polymer is heated before engagement with the surface of the metal substrate. 0 12. A method according to any of claims 4 to 11 characterised in that the polyethylene element is pretreated by a pretreatment chosen from Corona discharge, glow discharge or flame treatment. 25 13. A method according to any of claims 4 to 12 characterised in that the metal surface is flame treated before the polyethylene element is engaged therewith. 30 14. A method according to any of claims 4 to 13 characterised in that, after initial engagement of the polyethylene and substrate at a temperature in the range 140 C- to 300 C the structure is heated without tressure at a temperature in the range 180°C to 3C0°C. DD' 15. A method according to claim 14 characterised in that the structure is heated within the range 1S0°C to 300 C for a period not exceeding 5 minutes. 16. A method according to any of claims 5 to 15 chracterised in that the polyethylene film is engaged with two opposed surfaces of the metal sheet or foil to form a laminated structure of polyethylene/metal/ polyethylene. 17. A method according to any of claims 5 to 15 characterised in that the metal sheet or foil is engaged with both surfaces of the polyethylene film to form a laminated structure of metal/polyethylene/ metal. 18. A method according to any of claims 5 to 17 characterised in that " the metal substrate is a sheet or foil of a metal chosen from steel; steel coated with tin or chromium or chromium/chromium oxide or zinc; aluminium; aluminium alloy; nickel; zinc or copper. 19. A method according to any of claims 5 to 18 characterised in that the surface of the metal sub¬ strate has a conversion coating applied thereto before the polyethylene is engaged therewith. 20. A method according to any of claims 4 to 17, characterised in that the structure is formed to an article by a process chosen from pressing, stamping, drawing, deep drawing or wall ironing. 21. A method according to claim 20 characterised in that the article is heated to a temperature in the range 200 C to 300 C after forming from the structure. 22. A structure characterised by being made according to the method of any of claims 4 ~o 9. 23. An article characterised by being made according to the method of claim 20 or claim 2 . Editorial Note The claims amended by the applicant under Article 19 (1) of the PCT have not been renumbered in accordance with Section 205 of the Administrative Instructions under the PCT. The following information is given hereafter in order to facilitate the understanding of the amended claims: Correspondence between original and amended claims: Original claims Amended claims 1 1 (amended) 2 2 3 (cancelled) . 4 (cancelled) 5 to 25 3 to 23 (amended)

Inventors: GOSSEDGE G, NELSONASHLEY D
Applicants: GOSSEDGE G, METAL BOX CO LTD, NELSONASHLEY D, METAL BOX LTD
Application year: 1981
Main classification: B32B15
IPC codes: B29C65, B29L9, B32B15, B32B27