Multi-layer high moisture barrier polylactic acid film

• US 9,221,213 B2
• Filed: 02/18/2011
• Issued: 12/29/2015
• Est. Priority Date: 09/25/2009
• Status: Active Grant

• Current Assignee: Toray Plastics (America), Inc. (Toray Industries Incorporated)
• Original Assignee: Toray Plastics (America), Inc. (Toray Industries Incorporated)
• Inventors: Dou, Shichen, Paolilli, Tracy A., Fitch, John J., Brandmeier, Michael F., Chang, Keunsuk P.
• Primary Examiner(s): Chen, Vivian
• Application Number:
  US13/030,392
• Publication Number:
  US 20110171489A1
• Time in Patent Office: 1,775 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: B29C 55/023 using multilayered plates or sheets
• CPC Class Codes: B29C 55/143 firstly parallel to the direction of feed and then transversely thereto
• CPC Class Codes: B29K 2029/04 PVOH, i.e. polyvinyl alcohol B29K2031/04 takes precedence
• CPC Class Codes: B29K 2067/046 PLA, i.e. polylactic acid or polylactide
• CPC Class Codes: B29K 2995/006 Bio-degradable, e.g. bioabsorbable, bioresorbable or bioerodible
• CPC Class Codes: B29K 2995/0067 non-permeable
• CPC Class Codes: B32B 15/08 of synthetic resin
• CPC Class Codes: B32B 15/082 comprising vinyl resins; comprising acrylic resins
• CPC Class Codes: B32B 15/20 comprising aluminium or copper B32B15/016 and B32B15/017 take precedence
• CPC Class Codes: B32B 2250/03 3 layers
• 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 2272/00 Resin or rubber layer comprising scrap, waste or recycling material
• CPC Class Codes: B32B 2307/31 Heat sealable
• CPC Class Codes: B32B 2307/408 Matt, dull surface
• CPC Class Codes: B32B 2307/412 Transparent
• CPC Class Codes: B32B 2307/50 having particular mechanical properties
• CPC Class Codes: B32B 2307/518 bi-axially
• CPC Class Codes: B32B 2307/702 Amorphous
• CPC Class Codes: B32B 2307/704 Crystalline
• CPC Class Codes: B32B 2307/7163 : Biodegradable
• CPC Class Codes: B32B 2307/7242 : Non-permeable
• CPC Class Codes: B32B 2307/7246 : Water vapor barrier
• CPC Class Codes: B32B 2307/7265 : Non-permeable
• CPC Class Codes: B32B 2307/746 : Slipping, anti-blocking, low friction
• CPC Class Codes: B32B 2307/75 : Printability
• CPC Class Codes: B32B 2439/46 : Bags
• CPC Class Codes: B32B 2451/00 : Decorative or ornamental articles wall paper B32B2607/02
• CPC Class Codes: B32B 2519/00 : Labels, badges
• CPC Class Codes: B32B 2553/00 : Packaging equipment or accessories not otherwise provided for
• CPC Class Codes: B32B 27/08 : of synthetic resin
• CPC Class Codes: B32B 27/18 : characterised by the use of special additives
• CPC Class Codes: B32B 27/30 : comprising vinyl (co)polymers; comprising acrylic (co)polymers
• 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 27/36 : comprising polyesters
• CPC Class Codes: B32B 37/153 : at least one layer is extruded and immediately laminated while in semi-molten state
• CPC Class Codes: B32B 5/16 : characterised by features of a layer formed of particles, e.g. chips, powder or granules layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: C08K 2201/018 : Additives for biodegradable polymeric composition
• CPC Class Codes: C08K 3/012 : Additives activating the degradation of the macromolecular compounds
• CPC Class Codes: C08K 5/0033 : Additives activating the degradation of the macromolecular compound
• CPC Class Codes: C08L 23/0861 : Saponified vinylacetate
• CPC Class Codes: C08L 29/04 : Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
• CPC Class Codes: C09D 123/0861 : Saponified vinylacetate
• CPC Class Codes: C09D 129/04 : Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
• CPC Class Codes: C23C 14/14 : Metallic material, boron or silicon
• CPC Class Codes: Y10T 428/12549 : Adjacent to each other
• CPC Class Codes: Y10T 428/1338 : Elemental metal containing
• CPC Class Codes: Y10T 428/1341 : Contains vapor or gas barrier, polymer derived from vinyl chloride or vinylidene chloride, or polymer containing a vinyl alcohol unit
• CPC Class Codes: Y10T 428/1355 : Elemental metal containing [e.g., substrate, foil, film, coating, etc.]
• CPC Class Codes: Y10T 428/1359 : Three or more layers [continuous layer]
• CPC Class Codes: Y10T 428/1379 : Contains vapor or gas barrier, polymer derived from vinyl chloride or vinylidene chloride, or polymer containing a vinyl alcohol unit
• CPC Class Codes: Y10T 428/24851 : Intermediate layer is discontinuous or differential
• CPC Class Codes: Y10T 428/24917 : including metal layer
• CPC Class Codes: Y10T 428/24975 : No layer or component greater than 5 mils thick
• CPC Class Codes: Y10T 428/265 : 1 mil or less
• CPC Class Codes: Y10T 428/266 : of base or substrate
• CPC Class Codes: Y10T 428/269 : including synthetic resin or polymer layer or component
• CPC Class Codes: Y10T 428/31692 : Next to addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31797 : Next to addition polymer from unsaturated monomers

Abstract

A laminate film including a first polylactic acid layer; a second metal-receiving layer including PVOH, EVOH, or a blend thereof on a side of the first polylactic acid layer; and a metal layer deposited on a side of the metal-receiving layer opposite the polylactic acid layer. The metal-receiving layer may be coextruded with the polylactic acid first layer or may be a coating applied to one side of the polylactic acid first layer. This laminate film exhibits excellent gas and moisture barrier properties, appearance, and metal adhesion. It may also include a heat sealable or winding improving layer on the side opposite the metal receiving-layer of the first polylactic acid layer.

Claims

1. A laminate film comprising:

a biaxially oriented first layer comprising polylactic acid (PLA), wherein the thickness of the first layer is 15-25 μ

m;

a metal receiving second layer comprising uncrosslinked ethylene vinyl alcohol (EVOH) and a pro-degradant, wherein the second layer is co-extruded on a side of the first layer, wherein the thickness of the second layer is 1-2 μ

m; and

a metal barrier layer on a side of the second layer opposite the PLA-containing layer;

wherein the laminate film has a single barrier layer, wherein the metal barrier layer is the single barrier layer, and a moisture vapor transmission rate equal to or less than 0.37 g/m²/day.

2. The laminate film of claim 1, wherein the metal layer is vapor deposited on the side of the second layer.

3. The laminate film of claim 1, wherein the metal layer comprises aluminum.

4. The laminate film of claim 1, wherein the metal layer has an optical density of 1.5-5.0.

5. The laminate film of claim 1, further comprising a non-contiguous primer metal layer between the second layer and the metal layer.

6. The laminate film of claim 5, wherein the non-contiguous primer metal layer comprises copper or titanium.

7. The laminate film of claim 1, wherein the first layer or the second layer further comprises a tie-resin.

8. The laminate film of claim 7, wherein the tie-resin comprises 0.5-10 wt. % of the first layer or the second layer.

9. A laminate film comprising:

a biaxially oriented first layer comprising PLA, wherein the thickness of the first layer is 15-25 μ

m;

a metal receiving second layer comprising;

(i) a polymer chosen from the group consisting of uncrosslinked EVOH, uncrosslinked PVOH, and combinations of uncrosslinked EVOH and uncrosslinked PVOH; and

(ii) a tie-resin, wherein the second layer is co-extruded on a side of the first layer, and wherein the thickness of the second layer is 1-2 μ

m; and

a metal barrier layer on a side of the second layer opposite the PLA-containing layer;

wherein the laminate film has a single barrier layer, wherein the metal barrier layer is the single barrier layer, and a moisture vapor transmission rate equal to or less than 0.37 g/m²/day.

10. The laminate film of claim 9, wherein the second layer comprises EVOH and PVOH.

11. The laminate film of claim 9, wherein the second layer consists of a blend of EVOH and PVOH.

12. The laminate film of claim 9, wherein the metal layer is vapor deposited on the side of the second layer.

13. The laminate film of claim 9, wherein the metal layer comprises aluminum.

14. The laminate film of claim 9, wherein the metal layer has an optical density of 1.5-5.0.

15. The laminate film of claim 9, further comprising a non-contiguous primer metal layer between the second layer and the metal layer.

16. The laminate film of claim 15, wherein the non-contiguous primer metal layer comprises copper or titanium.

17. The laminate film of claim 9, wherein the first layer further comprises a tie-resin.

18. The laminate film of claim 17, wherein the tie-resin comprises 0.5-10 wt. % of the first layer.

19. The laminate film of claim 9, wherein the tie-resin comprises 0.5-10 wt. % of the second layer.