Transparent gas barrier biaxially oriented polypropylene film, a laminate film, and a production method thereof

• US 6,106,933 A
• Filed: 04/01/1998
• Issued: 08/22/2000
• Est. Priority Date: 04/03/1997
• Status: Expired due to Term

• Current Assignee: Toray Industries Incorporated
• Original Assignee: Toray Industries Incorporated
• Inventors: Tanaka, Shigeru, Nagai, Itsuo, Asakura, Masayoshi
• Primary Examiner(s): Thibodeau, Paul
• Assistant Examiner(s): TARAZANO, DONALD LAWRENCE
• Application Number:
  US09/053,330
• Time in Patent Office: 874 Days
• Field of Search: 428/461, 428/515, 428/516, 428/212, 428/702, 428/409, 428/35.9, 427/255.31
• US Class Current: 428/212
• CPC Class Codes: B32B 2255/10 on synthetic resin layer or on natural or synthetic rubber layer
• CPC Class Codes: B32B 2255/20 Inorganic coating
• CPC Class Codes: B32B 2307/412 Transparent
• CPC Class Codes: B32B 2307/518 bi-axially
• CPC Class Codes: B32B 2307/7242 Non-permeable
• CPC Class Codes: B32B 2323/10 Polypropylene
• CPC Class Codes: B32B 2439/00 Containers; Receptacles
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: C23C 14/0063 characterised by means for introducing or removing gases
• CPC Class Codes: C23C 14/081 of aluminium, magnesium or beryllium
• CPC Class Codes: Y10T 428/24942 including components having same physical characteristic in differing degree
• CPC Class Codes: Y10T 428/31 Surface property or characteristic of web, sheet or block
• CPC Class Codes: Y10T 428/31692 Next to addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31913 Monoolefin polymer

Abstract

A transparent gas barrier biaxially oriented polypropylene film, comprising a base layer mainly composed of a polypropylene polymer, a polyolefin resin layer of 30 to 85 J/g in the heat of fusion formed at least on one side of the base layer, and an imperfectly oxidized alumina layer formed on the polyolefin resin layer, wherein the aluminum metal concentration in the internal portion of the imperfectly oxidized alumina layer is higher than that in the surface of the layer and that in the interface with the polyolefin resin layer, and the aluminum metal content of the imperfectly oxidized alumina layer is kept in a range of 10 to 200% nm. It is a transparent metallized gas barrier biaxially oriented polypropylene film excellent in moisture and oxygen barrier properties and also excellent in the gas barrier properties after elongation.

Claims

1. A transparent gas barrier biaxially oriented polypropylene film, comprising:

1) a base layer comprising a polypropylene polymer

2) a polyolefin resin layer of 30 to 85 J/g in the heat of fusion formed at least on one side of the base layer, and

3) an imperfectly oxidized alumina layer formed on the polyolefin resin layer, wherein the aluminum metal concentration in the internal portion of the imperfectly oxidized alumina layer is higher than that in the surface of the layer and that in the interface with the polyolefin resin layer, and the aluminum metal content in the imperfectly oxidized alumina layer is kept in a range of 10 to 200% nm.

2. The transparent gas barrier biaxially oriented polypropylene film, according to claim 1, wherein the imperfectly oxidized alumina layer contains aluminum metal only in its internal portion.

3. The transparent gas barrier biaxially oriented polypropylene film, according to claim 1, wherein the polyolefin resin layer is 3% or less in the areal rate of surface portions with gradients of 30 degrees or more, on the surface provided with the imperfectly oxidized alumina layer.

4. The transparent gas barrier biaxially oriented polypropylene film, according to claim 1, wherein a heat seal layer is formed on the side opposite to the side with the imperfectly oxidized alumina layer formed.

5. The transparent gas barrier biaxially oriented polypropylene film, according to any one of claims 1 through 4, wherein the moisture vapor transmission rate is 2 g/m² day or less and the oxygen transmission rate is 45 cc/m² day or less.

6. The transparent gas barrier biaxially oriented polypropylene film, according to claim 5, wherein the moisture vapor transmission rate after 2% elongation is 2 g/m² day or less and the oxygen transmission rate after 2 g/m² day or less and the oxygen transmission rate after 2% elongation is 45 cc/m² day or less.

7. The transparent gas barrier biaxially oriented polypropylene film, according to any one of claims 1 through 4, wherein the optical transmittance is 75 to 90%.

8. The laminate film comprising a biaxially oriented polypropylene film composed of a polypropylene polymer, being bonded on the transparent gas barrier biaxially oriented polypropylene film stated in any one of claims 1 through 4, on the imperfectly oxidized alumina layer side, through an adhesive or polyolefin resin.

9. The laminate film according to claim 8, wherein the moisture vapor transmission rate is 1.5 g/m² or less and the oxygen transmission rate is 45 cc/m² day or less.

10. The laminate film according to claim 9, wherein the moisture vapor transmission rate after 2% elongation is 1.5 g/m² day or less and the oxygen transmission rate after 2% elongation is 45 cc/m² day or less.

11. A method for producing a transparent gas barrier biaxially oriented polypropylene film, in which an imperfectly oxidized alumina layer is continuously formed on a polyolefin resin substrate consisting of 1) a base layer comprising a polypropylene polymer and 2) a polyolefin resin layer of 30 to 85 J/g in the heat of fusion formed at least on one side of the base layer, by reactively evaporating metal aluminum with an oxidizing gas, comprising the steps of introducing the oxidizing gas below the substrate with its distance from the substrate kept at 1/4 or less of the distance between the evaporation source and the substrate, from the side where the substrate goes into the area for receiving the evaporated aluminum, with the concentration of the oxidizing gas changed in the progression direction of the substrate, to change the concentration of aluminum metal vapor-deposited in the thickness direction of the vapor-deposited layer;

and exposing the imperfectly oxidized alumina layer to atmospheric air, for aging.