Multilayer films of FDCA-based polyesters

• US 9,969,150 B2
• Filed: 12/18/2013
• Issued: 05/15/2018
• Est. Priority Date: 12/20/2012
• Status: Active Grant

• Current Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Original Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Inventors: Bhattacharjee, Debkumar, Jenkins, Steven R., Sehanobish, Kalyan
• Primary Examiner(s): Khatri, Prashant J
• Application Number:
  US14/653,753
• Publication Number:
  US 20150343746A1
• Time in Patent Office: 1,609 Days
• CPC Class Codes: B32B 15/08 of synthetic resin
• CPC Class Codes: B32B 2255/10 on synthetic resin layer or on natural or synthetic rubber layer
• CPC Class Codes: B32B 2255/205 Metallic coating
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2307/518 bi-axially
• CPC Class Codes: B32B 2307/7242 Non-permeable
• CPC Class Codes: B32B 2307/7244 Oxygen barrier
• CPC Class Codes: B32B 2307/7246 Water vapor barrier
• CPC Class Codes: B32B 2439/70 Food packaging
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/28 comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
• CPC Class Codes: B32B 27/304 comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/306 comprising vinyl acetate or vinyl alcohol (co)polymers
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/34 comprising polyamides
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: B32B 7/027 Thermal properties
• CPC Class Codes: C08G 63/181 Acids containing aromatic rings
• CPC Class Codes: Y10T 428/24942 including components having same physical characteristic in differing degree
• CPC Class Codes: Y10T 428/31678 Of metal
• CPC Class Codes: Y10T 428/31739 : Nylon type
• CPC Class Codes: Y10T 428/31786 : Of polyester [e.g., alkyd, etc.]
• CPC Class Codes: Y10T 428/3192 : Next to vinyl or vinylidene chloride polymer
• CPC Class Codes: Y10T 428/31938 : Polymer of monoethylenically unsaturated hydrocarbon

Abstract

A multilayer film comprising (a) a biaxially-oriented polyethylene furanoate (BO-PEF) polymer layer, (b) an optional ink layer, (c) a bonding layer, and (d) a sealant layer, wherein the BO-PEF polymer has an O₂ gas permeability of less than 0.25 cc-mil/100 in.² 24 hrs atm at 80% relative humidity, or a moisture permeability of less than 0.5 g-mil/100 in.² 24 hrs atm at 38° C., or both. The film may be formed from microlayers of BO-PEF-based polymer and polymer with a melting point of at least 5° C. greater than the melting point of the BO-PEF-based polymer.

Claims

1. A multilayer film comprising (a) a biaxially-oriented polyethylene furanoate (BO-PEF) polymer layer, (b) an optional ink layer, (c) a bonding layer, and (d) a sealant layer, wherein the BO-PEF polymer layer has (i) an O2 gas permeability of 0.25 cc-mil/100 in.2 24 hrs atm (5 cc 20 μ

m/m2 24 hrs atm) at 80% relative humidity (ASTM D-3985) or less, or (ii) a moisture permeability of 0.5 g-mil/100 in.2 24 hrs atm (9.8 g 20 μ

m/m2 24 hrs atm) at 38°

C. (ASTM F-1249) or less, or (iii) both, and

wherein the BO-PEF polymer layer comprises a microlayer sequence comprising a number, n, of repeating units, each repeating unit comprising at least two microlayers, (a) and (b),

wherein (a) is a first polymer with a melting point of at least 5°

C. greater than the melting point of second polymer (b); and

wherein second polymer (b) is a BO-PEF polymer formed from one or more diacid or diester monomers selected from the group consisting of 2,5-furan dicarboxylic acid (FDCA) and C₁ to C₁₀ alkyl diesters thereof, wherein said monomers comprise at least 35 mole % of the BO-PEF polymer,

said microlayer sequence being characterized by the absence of any tie layer between microlayers (a) and (b),

such that the resulting structure has the formula {(a)(b)(c)}n, where (c) represents one or more optional additional layers which may be the same or different from layers a and b, but which layer(s) (c) are not tie layers.

2. The multilayer film of claim 1 wherein the BO-PEF polymer has (a) a weight average molecular weight of 20,000 to 100,000 and (b) a polydispersity index of less than 4.

3. The multilayer film of claim 1, wherein 100 mole % of diacid or diester monomers used to form the BO-PEF polymer are selected from the group consisting of FDCA and C₁ to C₁₀ alkyl diesters thereof.

4. The multilayer film of claim 1, wherein the diacid or diester monomers used to form the BO-PEF polymer further comprises up to 65 mole % of 2,6-naphthalene dicarboxylic acid (NDCA), one or more C₁ to C₁₀ alkyl diester thereof, glycolide, or combinations thereof.

5. The multilayer film of claim 1 wherein the BO-PEF layer is coated with a layer of polyvinylidene chloride (PVDC) polymer.

6. The multilayer film of claim 1 wherein the sealant layer comprises one or more layers of polyethylene (PE) polymer.

7. The multilayer film of claim 6 wherein the sealant layer comprises one or more polymers selected from the group consisting of low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), very low-density polyethylene (VLDPE), ethylene vinyl acetate (EVA), and polypropylene (PP).

8. The multilayer film of claim 1 further comprising one or more layers of ethylene vinyl alcohol (EVOH).

9. The multilayer film of claim 8 wherein the film comprises tie layers between adjacent layers of sealant layer and EVOH layers.

10. The multilayer film of claim 1 further comprising an abuse layer formed from a polymer selected from the groups consisting of a polyolefin, polyethylene terephthalate and nylon.

11. The multilayer film of claim 1 further comprising a foil or metalized layer.

12. The multilayer film of claim 1 which does not contain a foil or metalized layer.