Method and device for laminating foils

Claim 3

The method of claim 1 wherein the foils are treated with specific energy densities in the range of 50 to 1500 mWs/cm 2 .

Claim 4

The method of claim 2 wherein at least one of the foils is a low density polyethylene and the foils are treated with energy densities in the range of 50 to 700 mWs/cm 2 .

Claim 5

The method of claim 2 wherein at least one of the foils is a polypropylene material and the foils are treated with specific energy densities in the range of 200 to 1500 mWs/cm 2 .

Claim 6

The method of claim 2 wherein at least one of the films is a polyamide material and the foils are treated with specific energy densities in the range of 100 to 700 mWs/cm 2 .

Claim 7

The method of claim 2 wherein at least one of the foils is an aluminum material and the foils are treated with specific energy densities in the range of 200 to 1000 mWs/cm 2 .

Claim 8

The method according to claim 1 wherein, subsequent to the activiation of the foils, the third pressure is sub-atmospheric such that the foils are brought into contact in vacuo.

Claim 9

The method according to claim 1 wherein the pressures in the first and second treatment chambers are between 0.01 and 200 mbar.

Claim 10

The method according to claim 1 wherein the pressure in the first treatment chamber is different from the pressure in the second treatment chamber.

Claim 11

The method according to claim 1 wherein the pressure in the laminating chamber is between 200 and 1000 mbar.

Claim 12

The method according to claim 1 wherein the bonding of the foils is carried out by passing them through the nip of a pair of laminating rollers, the rollers pressing against one another at a pressure up to 100 N/cm.

Claim 13

The method according to claim 11 comprising the additional step of heating the laminating rollers to a temperature between 350° K. and 600° K.

Claim 14

The method of claim 1 wherein the first and second foils are treated by passing them between first and second pairs of electrodes, the first pair of electrodes being at a different power level than the second pair of electrodes.

Claim 15

The method of claim 13 comprising the additional step of connecting the first and second pairs of electrodes to first and second high frequency generators, respectively, such that the electrodes have only half the generator output voltage to ground.

Claim 16

The method of claim 1 wherein the first foil is treated by passing it over a first electrode roller and into proximity of first and second counterelectrodes.

Claim 17

The method of claim 15 comprising the additional step of operating the first and second counterelectrodes at different power levels.

Claim 18

The method of claim 15 wherein the second foil is treated by passing it over a second electrode roller and into proximity of third and fourth conterelectrodes.

Claim 19

The method of claim 17 comprising the additional step of operating the third and fourth counterelectrodes at different power levels.

Claim 20

The method of claim 1 comprising the additional steps of introducing a first gas into the first treatment chamber and introducing a second gas into the second treatment chamber, the second gas being different from the first gas.

Claim 21

The method of claim 19 wherein the first gas is selected from the group consisting of air, oxygen, nitrogen, carbon dioxide, hydrogen, argon, ethylene, and acetone.

Claim 22

The method of claim 19 wherein the second gas is selected from the group consisting of air, oxygen, nitrogen, carbon dioxide, hydrogen, argon, ethylene, and acetone.

Claim 23

Apparatus for laminating at least two foils such as plastic foils, metal foils and ribbons, paper or fabric, the foils being treated with an electrical gas discharge comprising; (a) a first treatment chamber; (b) means for passing a first foil into the first treatment chamber; (c) first pressure means connected to the first treatment chamber so as to maintain the interior of the first treatment chamber at a first pressure; (d) a second treatment chamber; (e) means for passing a second foil into the second chamber; (f) second pressure means connected to the second treatment chamber so as to maintain the interior of the second chamber at a second pressure; (g) first and second low energy plasma gas discharge means disposed in the first and second treatment chambers, respectively, to treat the first and second foils with a low energy gas discharge such that the surfaces to be bonded together are activated with an energy density of 10 to 10 4 mWs/cm 2 ; (h) a laminating chamber; (i) means to pass the foils into the laminating chamber; (j) third pressure means connected to the laminating chamber so as to maintain the interior of the laminating chamber at a third pressure; and, (k) bonding means disposed in the laminating chamber to bring the foils into contact with each other under heat and pressure such that they are bonded together.

Claim 24

Apparatus for laminating at least two foils such as plastic foils, metal foils and ribbons, paper or fabric, the foils being treated with an electrical gas discharge comprising; (a) a first treatment chamber; (b) means for passing a first foil into the first treatment chamber; (c) first pressure means connected to the first treatment chamber so as to maintain the interior of the first treatment chamber at a first pressure; (d) a second treatment chamber; (e) means for passing a second foil into the second chamber; (f) second pressure means connected to the second treatment chamber so as to maintain the interior of the second chamber at a second pressure; (g) first and second low energy plasma gas discharge means disposed in the first and second treatment chambers, respectively, to treat the first and second foils with a low energy gas discharge such that the surfaces to be bonded together are activated with an energy density of 10 to 10 4 mWs/cm 2 ; (h) a laminating chamber; (i) means to pass the foils into the laminating chamber; (j) third pressure means connected to the laminating chamber so as to maintain the interior of the laminating chamber at a third pressure; and, (k) bonding means disposed in the laminating chamber to bring the foils into contact with each other under heat and pressure such that they are bonded together.

Claim 25

The apparatus of claim 22 wherein the bonding means comprises a pair of laminating rollers defining a nip therebetween, through which the foils pass, the rollers pressing against one another with a pressure of up to 100 N/cm.

Claim 26

The apparatus of claim 23 further comprising means to heat the laminating rollers to a temperature between 350° K. and 600° K.

Claim 27

The apparatus of claim 22 wherein the first low energy gas discharge means comprises: a first electrode roller around which the first foil passes; first and second counterelectrodes located in close proximity to the surface of the first electrode roller; and, first high frequency generator means connected to the first electrode roller, and the first and second counterelectrodes.

Claim 28

The apparatus of claim 25 wherein the first high frequency generator is connected to the electrode and counterelectrodes such that they have half the generator output voltage to ground.

Claim 29

The apparatus of claim 25 further comprising means to operate the first counterelectrode at a different power level than the second counterelectrode.

Claim 30

The apparatus of claim 25 wherein the second low energy gas discharge means comprises: a second electrode roller around which the second foil passes; third and fourth counterelectrodes located in close proximity to the second electrode roller; and, second high frequency generator means connected to the second electrode roller, and the third and forth counterelectrdoes.

Claim 31

The apparatus of claim 28 wherein the second high frequency generator is connected to the electrode and counterelectrodes such that they have half the generator output voltage to ground.

Claim 32

The apparatus of claim 28 further comprising means to operate the third counterelectrode at a different power level than the fourth counterelectrode.

Claim 33

The apparatus of claim 22 further comprising first means to introduce a first gas into the first treatment chamber adjacent its treatment area, and second means to introduce a second gas into the second treatment chamber adjacent its treatment area.

Claim 34

The apparatus of claim 31 wherein the first gas is different from the second gas.