U.S. patent application number 13/115292 was filed with the patent office on 2011-09-15 for low conductivity balloons and methods of producing same.
This patent application is currently assigned to ANAGRAM INTERNATIONAL, INC.. Invention is credited to Paul Ansolabehere, Dean Borchardt, Jeffrey J. Cernohous, Gianfranco Chicarella, Michael Fatica, Todd Sarnstrom, Andrew Swanson.
Application Number | 20110223828 13/115292 |
Document ID | / |
Family ID | 42104599 |
Filed Date | 2011-09-15 |
United States Patent
Application |
20110223828 |
Kind Code |
A1 |
Sarnstrom; Todd ; et
al. |
September 15, 2011 |
LOW CONDUCTIVITY BALLOONS AND METHODS OF PRODUCING SAME
Abstract
The present invention relates to articles and methods for
producing non-latex balloons with low surface electrical
conductivities and an extended product life. In a preferred
embodiment, a multilayer composite film having an exposed
metallized layer is coated with an elastomeric sealant layer that
increases electrical resistivity of the balloon product to greater
than 1.0.sup.8 Ohms/sq. The invention relates to articles and
methods for producing needed bonds and seal strength required to
manufacture non latex balloons. The balloons of this invention have
an extended product life because they are more resistant to common
defects like pin holing and stress cracks than conventional balloon
systems.
Inventors: |
Sarnstrom; Todd; (Ellsworth,
WI) ; Ansolabehere; Paul; (Minnetonka, MN) ;
Borchardt; Dean; (River Falls, WI) ; Swanson;
Andrew; (Bayport, MN) ; Cernohous; Jeffrey J.;
(Hudson, WI) ; Fatica; Michael; (North Kingstown,
RI) ; Chicarella; Gianfranco; (North Providence,
RI) |
Assignee: |
ANAGRAM INTERNATIONAL, INC.
EDEN PRAIRIE
MN
|
Family ID: |
42104599 |
Appl. No.: |
13/115292 |
Filed: |
May 25, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12317595 |
Dec 22, 2008 |
7972193 |
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13115292 |
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Current U.S.
Class: |
446/220 ;
156/250 |
Current CPC
Class: |
B32B 2255/205 20130101;
B32B 2307/20 20130101; B32B 2307/702 20130101; A63H 27/10 20130101;
B32B 27/36 20130101; Y10T 156/1052 20150115; B32B 2250/05 20130101;
B64B 1/40 20130101; B32B 15/08 20130101; A63H 2027/1025 20130101;
B32B 7/02 20130101; B32B 2255/10 20130101; B32B 27/32 20130101;
B32B 2307/72 20130101; B32B 27/08 20130101; B64B 1/14 20130101;
B32B 27/34 20130101 |
Class at
Publication: |
446/220 ;
156/250 |
International
Class: |
A63H 3/06 20060101
A63H003/06; B32B 37/02 20060101 B32B037/02; B32B 37/14 20060101
B32B037/14; B32B 38/10 20060101 B32B038/10 |
Claims
1. A non-latex balloon product comprising, in combination: a. a
polymeric film layer; b. a metalized layer overlaying one side of
the polymeric film, where the metalized layer has an exposed side;
and c. an elastomeric sealant layer overlaying the exposed side of
the metalized layer, wherein the balloon product has a surface
electrical resistivity of greater than 1.0.sup.8 Ohms/sq.
2. The balloon product of claim 1 characterized in that the
polymeric film comprises polyester.
3. The balloon product of claim 1 wherein the elastomeric sealant
layer comprises a melt processable polyolefin.
4. The balloon product of claim 1 wherein the dry bonding strength
between the base polymeric film and the metalized layer is greater
than 300 g/in.
5. The elastomeric sealant layer of claim 3 wherein the polyolefin
is a melt processable polyolefin that has seal strength to itself
that is greater than 2000 g/in.
6. The elastomeric sealant layer of claim 3 wherein the polyolefin
is a melt processable polyolefin that has bond strength to the
metalized layer that is greater than 200 g/in.
7. The balloon product of claim 1 wherein the elastomeric sealant
layer is extrusion coated directly onto the exposed side of the
metalized layer.
8. The balloon product of claim 1 wherein a primer layer is between
the elastomeric sealant layer and the exposed side of the metalized
layer.
9. The balloon product of claim 1 wherein the primer layer is a
silane or polyethyleneimine based primer that is solution coated
directly onto the exposed side of the metalized layer prior to
adding the elastomeric sealant layer.
10. A non-latex balloon product comprising, in combination: a. a
core polyester layer having first and second sides; b. an amorphous
polyester layer adhered to the first side of the core polyester
layer film; c. a metalized layer adhered to the second side of the
polyester film where the metalized layer has an exposed side; d. a
primer layer coating the exposed side of the metalized layer; and
e. a elastomeric sealant layer overlaying the primer coated exposed
side of the metalized layer, wherein the balloon product has a
surface electrical resistivity of greater than 1.0.sup.8
Ohms/sq.
11. The balloon product of claim 10 characterized in that the core
polyester layer comprises polyethylene terephthalate (PET).
12. The balloon product of claim 10 wherein the elastomeric sealant
layer comprises a melt processable polyolefin.
13. The balloon product of claim 10 wherein the dry bonding
strength between the base polymeric film and the metalized layer is
greater than 300 g/in.
14. The elastomeric sealant layer of claim 12 wherein the
polyolefin is a melt processable polyolefin that has seal strength
to itself that is greater than 2000 g/in.
15. The elastomeric sealant layer of claim 12 wherein the
polyolefin is a melt processable polyolefin that has bond strength
to the metalized layer that is greater than 200 g/in.
16. The balloon product of claim 10 wherein the primer layer is a
silane or polyethyleneimine based primer that is solution coated
directly onto the exposed side of the metallized layer prior to
adding the elastomeric sealant layer.
17. A non-latex balloon product comprising, in combination: a. a
core polyester layer having first and second sides; b. an amorphous
polyester layer adhered to the first side of the core polyester
layer; c. a metalized layer overlaying on the amorphous polyester
layer where the metalized layer has an exposed side; d. a primer
layer coating the exposed side of the metalized layer: and e. an
elastomeric sealant layer overlaying the exposed side of the
metalized layer, wherein the balloon product has a surface
electrical resistivity of greater than 1.0.sup.8 Ohms/sq.
18. The balloon product of claim 17 wherein the elastomeric sealant
layer comprises a melt processable polyolefin.
19. The elastomeric sealant layer of claim 18 wherein the
polyolefin is a melt processable polyolefin that has seal strength
to itself that is greater than 2000 g/in.
20. The elastomeric sealant layer of claim 18 wherein the
polyolefin is a melt processable polyolefin that has bond strength
to the metalized layer that is greater than 200 g/in.
21. The balloon product of claim 17 wherein the primer layer is a
silane or polyethyleneimine based primer that is solution coated
directly onto the exposed side of the metalized layer prior to
adding the elastomeric sealant layer.
22. A method of manufacturing a balloon product comprising, in
combination, a. providing a polymeric film having first and second
sides; b. applying a metallized layer overlaying the second side of
the multilayered composite film, where the metalized layer has an
exposed side; c. extrusion coating an elastomeric sealant layer
over the exposed side of the metallized layer sealant layer to form
a laminate; and d. thermally die cutting and welding the laminate
using a mechanically driven process to form a balloon product,
wherein the balloon product has a surface electrical resistivity of
greater than 1.0.sup.8 Ohms/sq.
23. The method of claim 22 wherein a coating of primer is applied
to the exposed side of the metallized layer prior to the extrusion
coating of the elastomeric sealant layer
24. The method of claim 23 wherein the primed metallized layer is
dried prior to extrusion coating the elastomeric sealant layer.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. patent
application Ser. No. 12/317,595 filed on Dec. 22, 2008, the entire
contents of which are incorporated herein by reference.
SUMMARY OF THE INVENTION
[0002] The present invention relates to non-latex balloons having
low electrical conductivity and to methods for producing such
balloons, where at least one metalized layer is encapsulated with
an elastomeric film layer. The low electrical conductivity is
achieved by providing a balloon construction wherein a metalized
layer is sandwiched between an elastomeric sealant layer and a film
layer. Alternatively, our invention incorporates a primer that
improves the adhesion between the elastomeric sealant and metalized
layers. The balloons of these embodiments have low electrical
conductivity, increased float life, improved scuff resistance and
the needed bonds and seal strength required to manufacture non
latex balloons.
[0003] For the purpose of this invention electrical conductivity is
a measure of how well the surface of the balloon accommodates the
movement of an electric charge. Electrical resistivity is the
reciprocal of conductivity. It is the opposition to the flow of
electrical current on the surface of a balloon. The unit of measure
for electrical resistivity is the ohm. Materials with low
resistivity are good conductors of electricity and materials with
high resistivity are good insulators. In this invention resistivity
was tested as the indicator for conductivity.
BACKGROUND
[0004] Non-latex balloons, often referred to as metalized balloons,
have been popular for many years. See, e.g., U.S. Pat. Nos.
4,077,588; 4,290,763 and 4,917,646, the teachings of which are
incorporated herein by reference. Typically one or more sheets of
the non-latex balloon is printed with a colorful decoration, such
as a character, design, message, or combination thereof. More
recently, toy products have developed which include a combination
of balloons or a combination of balloons and other structures, such
as appendages. See, e.g., U.S. Pat. Nos. 5,338,243; 4,778,431 and
5,108,339, the teachings of which are also incorporated herein.
[0005] Films constructed of multiple layers are known in the art as
a viable strategy to combine the characteristics of each film layer
into an overall film construction. For example, it is well known in
the art that metalizing polymeric films improves the barrier
properties of that film towards water and gases such as carbon
dioxide, oxygen and also lighter-than-air gas, such as helium. In
the case of the latter, metalized polymeric films have found wide
application for producing helium filled balloons. For example,
metalized polyamides (e.g., Nylon 6) have been widely used in this
application. However, the difference in mechanical properties
between the Nylon layer and metalized layer can be problematic in
this application. Upon inflation of a balloon, the Nylon layer
stretches and can cause microscopic cracks in the metalized layer
because the metalized layer does not have the same elastic
properties as the Nylon. This unfortunately reduces the barrier
properties of the film and subsequently the inflated life of the
balloon. One strategy to alleviate this problem is to utilize a
higher modulus, more stretch resistant polymeric film. Polyethylene
terephthalate (PET) is an example. However, when a more stretch
resistant film is utilized in a helium balloon construction this
often results in greater instances in seam failure and film
cracking because the force that was being dissipated by the film is
now more highly concentrated at other areas of the balloon.
[0006] It is also known to construct buoyant helium balloons that
comprise a sealant layer, a film layer and a metal barrier layer.
Additionally, it is known in the art to use a primer to provide the
desired level of adhesion between the seal and film layers that is
required to produce a functional and robust balloon. The metal
layer has been the focus of unsupported claims that buoyant
metalized helium balloons have become entangled in power lines
leading to nuisance power outages. The suspected cause of these
incidents is attributed to the high electrical conductivity of the
outer metal layer of these types of metalized balloons. To the
extent such problems actually exist, our invention eliminates this
concern by encapsulating the metal layer between insulating
elastomeric polymer film layer such that the electrical
conductivity of the finished balloon is reduced by at least 5
magnitudes (10.sup.5).
BRIEF DESCRIPTION OF THE INVENTION
[0007] Our invention can be summarized as a non-latex balloon
product comprising, in combination, a film, where a metalized layer
is adhered to one side of the polymeric film. An elastomeric
sealant layer is layered over the exposed side of the metalized
layer such that the finished balloon product will have a surface
electrical resistivity of greater than 1.0.sup.11 Ohms/sq. This
defines the highly dissipative film as virtually non-conductive. In
some instances it is preferable to add a primer to the exposed side
of the metalized layer prior to adhering the elastomeric sealant
layer.
[0008] Our invention also covers a non-latex balloon product
comprising, in combination, a polyethylene terephthalate (PET) film
having first and second sides, an amorphous layer adhered to the
first side of the core polyester layer, where a metalized layer is
adhered to the second side of the core polyester layer or to the
amorphous layer. An elastomeric sealant layer is applied to either
a non-primer or primer coated exposed side of the metalized layer
resulting in a balloon product that has a surface electrical
resistivity of greater than 1.0.sup.11 Ohms/sq.
BRIEF DESCRIPTION OF THE FIGURES
[0009] FIG. 1 is schematic side view of one embodiment of the
multi-layered film composite of the non-latex balloon product of
our invention.
DETAILED DESCRIPTION
[0010] As mentioned, multilayer films are known in the art as a
viable strategy to combine the characteristics of each film layer
into an overall film construction. For example, it is well known in
the art that metalized polymeric films improves the barrier
properties of that film towards water and gases such as carbon
dioxide, oxygen and also helium. In the case of the latter,
metalized polymeric films have found wide application for producing
balloons that are filled with lighter than air gases, such as
helium. However, the difference in mechanical properties between
the polymer film layer and metalized layer can be problematic in
this application. Upon inflation of a balloon, the film layer
stretches and can cause microscopic cracks in the metalized layer
because it does not have the same elastic properties. This reduces
the barrier properties of the film and subsequently the inflated
life of the balloon. Although the art has used a higher modulus,
more stretch resistant polymeric film, this often results in
greater instances in seam failure and film cracking because the
forces that were being dissipated by the film are now more
localized at seams and other stress areas of the balloon. Although
the use of a multilayer polyester construction can provide
outstanding resistance to cracking while providing an improved
barrier to helium upon inflation, these constructions still have
high electrical conductivity as a result of the metalized layer
being on the exposed exterior of the balloon construction. Our
invention coats or encapsulates the metal layer with the addition
of an elastomeric polymer layer directly over the metalized layer.
This elastomeric layer results in balloon constructions that have
very low electrical conductivity. Compared to existing metalized
balloons, conductivity reductions of up to 5 magnitudes (10.sup.5)
are achieved by incorporating an internal metalized layer. The
balloons of our invention also offer exceptional metal integrity
and outstanding bonds and seal strengths.
[0011] Electrical conductivity of the balloon can be determined by
measuring the surface and volume resistivity of the balloon,
utilizing methods such as ASTM D257 or ANSI/ESD STM11.12-2007.
[0012] The balloon product of our invention comprises at least a
base polymeric film layer, a metalized layer and an elastomeric
sealant layer. As used in this application the term "elastomeric
polyolefin" has a specific definition. Various definitions have
been employed to define elastomers in the past. Generally, an
elastomer is defined as a substance that has the properties of a
rubber such that it stretches under tension, generally has a high
tensile strength, retracts rapidly, and generally recovers its
original dimensions upon being released after stretching. An
elastomer will typically have plastic-type traits in processing and
rubber-type traits in functionality. Such polyolefins, when formed
into various substrates, will be extensible in at least one
direction when a biasing force is applied, and will return to some
portion of its original dimensions after the biasing force is
removed. Elastomeric compositions, when formed into a meltblown
web, will generally, but not always, have the capability of being
stretched to an elongation of at least about 25% of its original
relaxed length, and upon release of the stretching force will
recover at least about 40% of the elongation, i.e., will, in the
case of 25% elongation, contract to an elongation of not more than
about 15%. (For example, a 4 inch length of material will be deemed
to be an elastomeric if it can be stretched to a length of at least
about 5 inches and if, upon release of the stretching force, it
contracts, in the case of being stretched to 5 inches, to a length
of not more than about 4.6 inches.)
[0013] Elastomeric properties are a function of temperature and
rate of elongation. For the purpose of the examples in FIG. 2, room
temperature and normal balloon expansion rates were used. The
elastomeric sealant layer used in our invention has a recovery of
elongation preferably 40 to 100%, more preferably 60 to 100% and
most preferably 75 to 100%.
TABLE-US-00001 FIG. 2. Elastomeric Properties of Sealant Layer
Conducted at Room Temperature Average Elastomeric Recovery of
Sealant Elongation Elongation Elongation Layer % Rate % A 25% 1
inch/min 82% A 25% 5 inch/min 85% A 25% 10 inch/min 87% A 25% 15
inch/min 90% B 25% 1 inch/min 86% B 25% 5 inch/min 87% B 25% 10
inch/min 89% B 25% 15 inch/min 91% C 25% 1 inch/min 85% C 25% 5
inch/min 85% C 25% 10 inch/min 86% C 25% 15 inch/min 86%
[0014] Where:
[0015] "A" is a low density, linear low density polyethylene
blend.
[0016] "B" is a low density, linear low density polyethylene and
ethylene alpha olefin blend.
[0017] "C" is a 4% EVA copolymer resin, high impact, high clarity
LDPE.
[0018] In contrast to the specific "elastomeric polyolefin" defined
above for use in our invention, a "non-elastomer" or
"non-elastomeric polyolefin" is defined for purposes of the present
invention as being a polyolefin that when formed into a meltblown
web, will, but not always, fail to meet the stretch characteristics
for an elastomeric web set forth above. Examples of non-elastomeric
polymer films used in balloon manufacture are disclosed in U.S.
Pat. No. 4,077,588, where it is suggested that such non-elastomeric
polymer films polymers can be used to coat a metal film. As
described in the examples below, using a non-elastomeric polyolefin
as taught in the '588 patent to coat a metalized layer results in a
balloon that has no ability to be inflated more than at or about
one atmosphere of pressure with air or lighter than air gas. In
contrast, our invention requires the use of an elastomeric
polyolefin sealant applied to the metalized layer, preferably
linear low density polyethylene, which results in a balloon that
has the ability to be inflated greater than one atmosphere of
pressure with air or lighter than air gas.
[0019] The overall thickness of the multilayer balloon film is
preferably between 5 and 70 microns, more preferably between 5 and
50 microns and most preferably between 5 and 35 microns. In this
multilayer construction, the base composite film layer thickness is
preferably 30 to 95% of the overall thickness, more preferably 40
to 80% of the overall thickness and most preferably 50 to 75% of
the overall layer thickness. The elastomeric sealant layer of this
construction is preferably 5 to 75% of the overall thickness, more
preferably 5 to 60% and most preferably 5 to 40% of the overall
thickness. The metalized layer is preferably 0.0001 to 1% of the
overall thickness, more preferably 0.001 to 0.1% and most
preferably 0.005 to 0.05% of the overall thickness. This
construction is subsequently thermally welded and die cut to form a
balloon article.
[0020] FIG. 1 illustrates schematically the cross section of one
embodiment of the multilayered film 1 that is used to manufacture
the non-latex balloon products of the present invention. The base
polymeric film layer of this invention can be produced from any
thermoplastic material commonly utilized for helium balloon films.
Non-limiting examples of thermoplastic materials useful for the
base polymeric film layer of our invention include polyamides,
polyesters and polyolefins. Preferably the base polymeric film
layer comprises a polyethylene terephthalate (PET) layer 3 and a
amorphous polyester layer 2. The amorphous polyester layer 2 is
preferably co-extruded with the core layer 3 to increase the
bonding between the core polyester layer 3 and the amorphous layer
2.
[0021] To this base polymeric film is added a metalized layer 4,
for example, direct lamination of a thin metal foil or vapor
deposition or sputtering. In a preferred method, the metalized
layer is applied to the exposed polymeric layer in thicknesses
measured by optical density. A preferred method is vacuum
deposition, which is capable of applying a metal layer of about 1.8
to about 3.2 optical density. Adhesion between the metalized
barrier layer 4 and the polymeric layer is also important factor
because the damage or removal of the metalized layer 4 during the
processes of balloon fabrication and un-expected handling at the
end consumers would degrade the barrier property of the film no
matter how the newly produced film showed good barrier property.
Especially for this invention, because the metalized layer 4 needs
to be buried in between the base composite film and the sealant
layer 6, the metalized layer 4 needs to remain adhering to the base
polymeric film with sufficient strength not to cause de-lamination
in the structure. The dry bonding strength between the base
polymeric film and the metalized layer 4 may be more than 300 g/in,
preferably more than 600 g/in.
[0022] Especially when the metalized layer 4 would be exposed to
the wet process, such as applying any water base primer on the
metalized layer 4 to enhance the lamination and sealing strength of
the laminate and balloon, the bonding strength at wet condition
between the base polymeric film and the metalized layer 4 would be
important. The bonding strength between the base polymeric film and
the gas barrier layer 4 in wet conditions is preferably more than
30 g/in, more preferably more than 100 g/in, most preferably more
than 600 g/in.
[0023] To achieve such bond strength values, an electrical
treatment such as plasma/corona treatment on the polyester film
would be used before the gas barrier layer is applied on the
polyester film. To achieve higher bond strength value, additional
deposition anchorage layer, such as Cu seeding, Ni seeding are
preferably applied before the main metal barrier layer is
deposited. Instead of or in addition to such deposition anchorage
layer, amorphous layer 2 mentioned above and/or additional coating
layer on the base composite film would be preferable.
[0024] The metalized layer 4, PET layer 3 and amorphous polyester
layer 2 represent one of many preferred starting multilayered films
that are used to manufacture the balloon products of our
invention.
[0025] In contrast to prior used balloon films, an elastomeric
sealant layer 6 is added directly to the metalized layer 4,
preferably using an extrusion coating process that is known to
those skilled in the art of manufacturing multilayered balloon
films. In a preferred embodiment, the metalized side of the film is
first coated with an optional priming layer 5. The priming layer is
utilized to improve interfacial adhesion between the elastomeric
sealant layer and the exposed metalized layer. Many primers are
known in the art for improving the adhesion between such materials
and can be applied using conventional melt or solution coating
techniques. In this instance, a preferred embodiment of this
invention utilizes some grades of copolyethylenes, for example
ethyleneacrylicacid (EAA), or polyethylenimine and its derivatives,
as well as silane coupling agents. Silane coupling agent would be
selected from a number of molecules containing two or more
functional groups, one being the silane and another functional
group having reactivity with the resin. The silane functional group
can form covalent bonds to itself and to the oxide surface of
polymers and minerals and the other functional group is selected to
react with the resin. In the case of amino-silanes, the amino group
can form a chemical bond with the oxidized sealant layer. A wide
range of other functional groups are available that can react with
the sealant resin through various chemistries of the sealant
polymer. Combinations of various functional groups with the silane
group are referred to as organosilanes and well known as coupling
agents and primers in their use to increase adhesion between
different materials. The amino functional group has the advantage
that when one or more are combined with the silane functional
group, the result is an amino-silane molecule that can easily be
diluted and applied from water with unusually stable dilute aqueous
mixtures which are free from rapid gel formation, preferably, such
as amino aloxy silane, aminopropylsilane (APS),
aminotriethoxysilane or combinations thereof. Preferred silanes
useful in this invention include, but are not limited to:
alkoxysilanes, functional alkoxysilanes, amino alkoxysilanes, alkyl
alkoxysilanes and vinyl alkoxysilanes or combinations thereof.
[0026] The elastomeric sealant layer 6 of this invention is chosen
such that it has adequate adhesion to itself when thermally welded
and die cut to act as a robust balloon seam. The preferred
elastomeric sealant layer 6 of this invention is a polyolefin
having seal strength greater than 2000 g/in. More specifically, a
preferred embodiment utilizes linear low density polyethylene
(LLDPE) as a sealant layer having a seal strength greater than 3500
g/in allowing the balloon to be inflated greater than one
atmosphere of pressure with air or lighter than air gas. The
elastomeric sealant layer thickness is preferably between 5 and 50
microns, more preferably between 5 and 30 microns and most
preferably between 5 and 25 microns. It has been found that
extrusion coating of the sealant layer onto the metalized layer of
this invention provides an excellent construction for balloon
applications that is resistant to common defects (e.g., pinholes,
cracking) seen in balloons known in the art. In a preferred
embodiment, the bond strength between the sealant layer and the
metalized layer is greater than 200 g/in, more preferably it is
greater than 350 g/in and most preferably it is greater than 500
g/in. The sealant layer is applied in a quantity such that the
electrical conductivity of the final multi layered film or finished
balloon product is lower when compared to balloons having exterior
metalized layers. Preferably, the surface electrical resistivity is
greater than 1.times.10.sup.8 Ohms/sq, more preferably greater than
1.times.10.sup.9 Ohms/sq and most preferably greater than
1.times.10.sup.10 Ohms/sq. This resistivity is in contrast to
existing balloons with exterior metalized surfaces that have
resistivity of less than 1.times.10.sup.3 Ohms.
[0027] The elastomeric sealant material of this invention is chosen
such that it is melt processable. Melt-processing typically is
performed at a temperature from 120.degree. to 330.degree. C.;
although optimum operating temperatures are selected depending upon
the melting point, melt viscosity, and thermal stability of the
sealant layer chosen. Different types of melt processing equipment,
such as extruders, may be used to process the melt processable
compositions of this invention. Extruders suitable for use with the
present invention are described, for example, by Rauwendaal, C.,
"Polymer Extrusion," Hansen Publishers, p. 23-48, 1986.
[0028] Upon coating the metalized layer with the sealant layer, the
film construction is registered before thermal die cutting and
welding to the desired shape and size. Careful selection of the
temperatures and pressures for the die cutting and welding
processes are always important for providing a balloon with a
robust seam. Mechanical heat seal and die cutting allows for more
precise control of exerted pressures than hydraulic die cutting
processes, because of the ease of adjusting the pressures exerted,
mechanical heat seal and die cutting processes are preferred for
the films of this invention. It has also been found that thick seam
constructions ( 1/32'' to 1/2'') offer greater resistance to
defects with the non-latex balloon film composite of this
invention. Regardless of whether hydraulic or mechanical die
cutting is used, it well known to use die cutting on multi-layered
films to prepare appropriate balloon shapes. In practice, because
of the flexibility of the polymeric film construction, the balloons
shape may be any that is desired such as round, square, triangular,
curved, and the like. The shape may be that of famous novelty
characters such as dinosaurs, the insignia of athletic teams and
the like. After aligning the desired shapes of the film composite
they are joined or adhered to each other, leaving an opening so
that the material may be later inflated. Adhesion or joining of the
cut shapes can be accomplished using means well known in the art.
If desired, a valve can be inserted into the opening and the layers
abutting the valve adhered to form a complete structure. The use of
a valve is considered optional. For use as a balloon, the seamed
film composite is inflated by inserting a lighter than air gas into
the opening, sealing the opening after the material has been fully
inflated or through a valve, if present. In practice, the materials
of the present invention are capable of retaining the
lighter-than-air gas, preferably helium for at least seven days,
more preferably more than 14 days and most preferably more than one
month and one year being possible. As a result, the resulting
materials are considered excellent candidates for premium quality
balloons.
[0029] Test Methods
[0030] Dry bonding strength of the metalized layer to the polymeric
film substrate was measured by heat-sealing of an Dow PRIMACOR 3300
film to the metal surface on a Sentinel heat sealer. On the back
side of the film, adhesive tape (3M 610) is applied to keep the
film from breaking during the test. Heat seal conditions are
220.degree. F. temperature, 20 seconds dwell time, and 40 psi jaw
pressure, 1 heated jaw. Prior to peeling the sealed materials are
cut so that each web can be gripped in a separate jaw of the
tensile tester and one square inch section of sealed material can
be peeled. The peel is initiated by hand and then the two webs are
peeled apart on an Instron tensile tester in a 180 degree
configuration toward the PRIMACOR film. If the metal is separated
from the substrate and remains attached to the PRIMACOR film then
the mean force of the peel is reported as the metal bond
strength.
[0031] Wet bonding strength of the metalized layer was measured by
the same procedure as dry bonding strength, with the exception that
a cotton swab soaked with water is used to apply water to the
interface of the sealed area as it is being peeled.
[0032] Sealing strength of the elastomeric coating was measured per
the following: The seal layer is sealed to itself using a Pack Rite
heat sealer with 15''.times.3/8'' jaw. The heat seal conditions are
405 degrees F. temperature, 2 seconds dwell time, and 90 psi jaw
pressure, 1 heated jaw. Prior to peeling the sealed materials are
cut such that each web can be gripped in a separate jaw of the
tensile tester and the sealed material can be peeled. The two webs
are peeled apart on an Instron tensile tester in an unsupported
90.degree. configuration known as a T-peel. A peel speed of
6''/minute with a jaw separation of 4'' is used until the load
drops by 20%, signaling failure. The maximum recorded load prior to
failure is reported as the seal strength.
[0033] The bond strength of the elastomeric coating to the
metalized surface requires the use of a separate sheet dropped onto
the film web before the extrudate application during the extrusion
process. The sheet subsequently shields the film under the sheet
from extrusion coating and thus provides a means of separating the
extrudate from the extruded film. The interfacial bond strength
between the extrudate and the film is measured during an
unsupported 90.degree. peel test of the test sample. The test
samples are configured such that the unsupported portion of the
test sample is the extruded film and the peel portions of the test
sample are the uncoated film and the extruded sheet. A peel speed
of 6''/minute with a jaw separation of 11/4'' is used and the
maximum recorded load during a 1/2'' distance is reported as the
bond strength.
[0034] Surface resistivity of the film was measured using an ACL
Staticide Model 800 Megohmmeter with concentric ring electrodes,
following the ANSI/ESD STM11.11-2006 test method.
[0035] Floating time of the balloon is determined by inflating it
with helium gas and measuring the number of days that the balloon
remains fully inflated. A balloon is filled from a helium source
using a pressure regulated nozzle designed for "foil" balloons,
such as the Conwin Precision Plus balloon inflation regulator and
nozzle. The pressure should be regulated to 16 inches of water
column pressure with an auto shut off. The balloon should be filled
with helium in ambient conditions of about 70 degrees F.
temperature until the internal pressure of the balloon reaches 16
inches of water column and the regulator shuts off. The balloon
should be tethered below the balloon's valve access hole to avoid
distorting or damaging the valve thus creating slow leaks of helium
gas through the valve. During the testing the balloon should be
kept in stable environment close the ambient conditions stated.
Changes in temperature and barometric pressure should be recorded
to interpret float time results, as any major fluctuations can
invalidate the test. The balloon is observed over the course of the
test for the appearance of fullness. One judgment criteria used is
when the appearance of the balloon changes so that the wrinkles
running through the heat seal seam area become deeper and longer,
extending into the front face of the balloon; and the cross-section
of seam becomes a v-shape, as opposed to the rounded shape that
characterizes a fully inflated balloon. At this time the balloon
will still physically float, but will no longer have an
aesthetically pleasing appearance. The number of days between
initial inflation and the loss of aesthetic appearance described
above is reported as the floating time of the balloon.
EXAMPLES
[0036] Several tests were performed to evaluate balloons made using
the methods and films of this invention. The first test involved a
side by side experiment comparing control balloon products to
balloon products made with the film of this invention. The
following balloon compositions were tested: [0037] 1) Control--a
film comprising a metalized layer/a PET layer/an amorphous PET
layer/a primer layer/an extrusion coated sealant layer [0038] 2)
Hurst '588 patent--a film comprising a non-elastomeric sealant
layer/a metalized layer/non-elastomeric polyester layer (col. 6,
lines 34-45). [0039] 3) Present Invention--a film comprising a PET
layer/an amorphous PET layer/a metalized layer/an extrusion coated
elastomeric sealant layer. [0040] 4) Present Invention--a film
comprising a PET layer/an amorphous PET layer/a metalized layer/a
primer layer/an extrusion coated elastomeric sealant layer. [0041]
5) Present Invention--a film comprising an amorphous PET layer/a
PET layer/a metalized layer/an extrusion coated elastomeric sealant
layer. [0042] 6) Present Invention--a film comprising an amorphous
PET layer/a PET layer/metalized layer/a primer layer/an extrusion
coated elastomeric sealant layer.
[0043] These films were then mechanically die cut to form multiple
balloon products of a standard size and shape. Multiple balloons of
each example were filled with the same amount of helium and were
buoyancy tested side by side at the same ambient conditions by
tethering the balloons to a fixed support. Each of the balloons was
measured for surface and volume electrical conductivity. The
results are presented in the table below.
TABLE-US-00002 Metal Elastomeric Surface Bond to Coating Bond Seal
Resistivity, Film to Metal Strength Example Sample ohms/sq (g/in)
(g/in) (g/in) #1-Control 1 <1000 n/a 505 4627 a film comprising
a metalized layer/a PET 2 <1000 n/a 525 3981 layer/an amorphous
PET layer/a primer 3 <1000 n/a 514 4258 layer/an extrusion
coated elastomeric sealant Average <1000 n/a 514.67 4288.67
layer Std Dev n/a n/a 10.02 324.09 #2-Hurst '588 patent 1 4.97E+11
98 35 982 a film comprising a non-elastomeric sealant 2 2.39E+11
124 61 1024 layer/a metalized layer/non-elastomeric 3 2.49E+11 109
28 857 polyester layer (col. 6, lines 34-45). Average 3.28E+11
110.33 41.33 954.33 Std Dev 1.46E+11 13.05 17.39 86.87 #3-Present
Invention 1 2.42E+11 865 507 4522 a film comprising a PET layer/an
amorphous 2 3.32E+11 752 585 4411 PET layer/a metalized layer/an
extrusion 3 2.78E+11 816 467 4115 coated elastomeric sealant layer
Average 2.84E+11 811.00 519.67 4349.33 Std Dev 4.53E+10 56.67 60.01
210.39 #4-Present Invention Preferred Embodiment 1 2.84E+11 947 532
3762 a film comprising a PET layer/an amourphous 2 3.18E+11 883 535
4404 PET layer/a metalized layer/a primer layer/an 3 2.84E+11 865
572 4141 extrusion coated elastomeric sealant layer Average
2.95E+11 898.33 546.33 4407.00 Std Dev 1.96E+10 43.10 22.28 322.74
#5-Present Invention 1 1.36E+11 839 547 4235 a film comprising an
amorphous PET layer/a 2 1.33E+11 795 575 4632 PET layer/a metalized
layer/an extrusion coated 3 1.44E+11 826 549 4168 elastomeric
sealant layer Average 1.38E+11 820.00 557.00 4345.00 Std Dev
5.69E+09 22.61 15.62 250.80 #6-Present Invention Preferred
Embodiment 1 1.35E+11 992 555 4084 a film comprising an amorphous
PET layer/a 2 1.41E+11 894 559 3899 PET layer/metalized layer/a
primer layer/an 3 1.44E+11 965 564 4149 extrusion coated
elastomeric sealant layer Average 1.40E+11 950.33 559.33 4360.00
Std Dev 4.58E+09 50.62 4.51 129.71
[0044] This represents a decrease of 8 magnitudes (10.sup.8) in
electrical conductivity for the balloons made according to our
invention.
[0045] The balloons were also monitored each day for the appearance
of fullness, which is a direct indication of loss of helium. The
float life for the control balloons averaged 12 days, whereas the
balloons made following the Hurst '588 patent were unable to be
inflated above atmospheric pressure or failed within 2 hours. Float
life for balloons made according to our invention averaged 24 days;
thus representing a 2 fold increase in the life of the balloon.
[0046] From the above disclosure of the general principles of the
present invention and the various embodiments described, those
skilled in this art will readily comprehend the various
modifications to which the present invention is susceptible. Such
changes and modifications may be made to the invention without
departing from the true scope and spirit of the invention.
Therefore, the scope of the invention should be limited only by the
following claims and equivalents thereof.
* * * * *