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Novel Barrier Film Technology
Bruce FosterPolyKnows LLC
AIMCAL WCHC &
SPE/FlexPackCon 2016
Presented October 12, 2016
Consider
The following examples of perfectfood packaging structures…
Problem:
Solution:
Removed from Nature’s Package, food quickly spoils
Man-made BARRIER PACKAGING
Objective
Clear, chlorine-free printable & heat seal-able barrier film
Outline
• Approach with this study• Brief review of some barrier packaging film
technologies• Experimental conditions• Results• Conclusions• Next Steps
Barrier Film Technologies
• Barrier to what?– Oxygen, moisture, fragrance, oils, spices,
solvents….
• This work: oxygen & moisture
• The films:biaxially oriented polypropylene (BOPP)biaxially oriented polyester (BOPET, PET)
Measures of Barrier
• Oxygen Transmission Rate (@equilibrium)
- OTR, cc/m2/day (@ 1 atmosphere)– Test temperature & relative humidity (RH) specified– ASTM D-3985
• Moisture Vapor Transmission Rate (@equilibrium)
– MVTR, g/m2/day (@ 1 atmosphere)– Test temperature & RH specified– ASTM F-1249
Barrier Film Coatings
• Aluminum Vacuum Metallization• Aluminum Oxide (AlOx) & Silicon Oxide (SiOx)• Polyvinylidine dichloride (PVdC)• Polyvinyl alcohol (PVOH, PVA)• Ex-foliated nano-clays• Ethylene vinyl alcohol (EVOH)
“Novel” Approach – Multiple Water-Based Coatings
BOPPprimerCoating - 1Coating - 2
Multiple Water-Based Coatings
BOPPPrimer-1Coating-1
Coating-2Primer-2
Possibility for Interfacial Effects
Primer-2
Primer-1
Barriercoating Interfacial effects
BOPP
Coating-2Coating-1
Table 1Some Multi-Layer Clear Barrier Films
Base Film Coatings (1/2/3…) WVTRg/m2/day
OTRcc/m2/day
Ref. #
BOPET PVdC (HB) / PVdC (HS) – one or both sides (solvent-based)
(“IPV”)<1g/m2/hr Not given 1
BOPET PVdC / PVOH / PVdC – one or both sides (solvent-based) ~2
<0.03 @0%RH0.03 @50%RH1-2 @100%RH
2
BOPP Primer / PVOH1 / PVOH2Not
given
0.02 @0%RH0.1 @50%RH54 @100%RH
3
BOPP Primer / PVOH / Acrylic Notgiven
0.86 @0%RH2.1 @75%RH 4
Experimental
• Base film: 25-um BOPP (co-polymer skin)• Water-based Coatings:
– Primer (X-linking PEI)– Modified PVOH– Self cross-linking acrylic
• Pilot coating line:1. Corona-treat 2. Prime (reverse-gravure) / dry (~65oC film temp)3. Coat (rev-gravure) / dry (~65oC film temp)4. Repeat steps 2 & 3 (some day!)
Table 2Experimental Results
Coatings: PVOH1 Acrylic1 PVOH2 Acrylic2 OTR1 WVTR2
Sample# Thickness (t), microns cc/m2/day g/m2/day
Control - - - - ~2000 ~5
1 0.5 - - - 81 5.4
2 1.0 - - - 20* -
3 1.5 - - - 7* -
4 0.5 0.9 - - 95 -
5 0.5 0.9 0.5 0.9 TBD TBD
1. 23oC, 0%RH 2. 38oC, 90%RH *Calculated (Graph 1)
Graph 1. Experimental vs. Theoretical
y = -2.064x + 1.2533R² = 0.9951
y = -2.0245x + 1.0145R² = 0.9999
0.5
0.7
0.9
1.1
1.3
1.5
1.7
1.9
2.1
2.3
2.5
-0.6 -0.5 -0.4 -0.3 -0.2 -0.1 0 0.1 0.2
Log(
OTR
)
Log(t)
Experimental
Theoretical
Experimental Results – Clear!
• Haze – 2.4• 45o Gloss – 90.4
Conclusions
• Clear, chlorine-free coated film with moderate oxygen & moisture barrier
• Interfacial effects not observed
Next Steps
• Prepare & test sample #5 (Table 2)• Alter chemistry of primers & coatings to
induce interlayer effects
References
1. US Patent #3,959,526 dated May 25, 19762. US Patents #5,102,699 dated April 7, 1993 &
#5,225,288 dated July 6, 1993 3. US Patent #5,330,831 dated July 19, 1994 4. US Patent #5,508,113 A dated April 16, 1996
Acknowledgements
Chiripal Poly Films Ltd. &
Mr. Piyush Jha
Thank You for Your Attention
Questions?
AIMCAL WCHC &
SPE FlexPackCon 2016
Presented October 12, 2016
