The present invention provides a polyester film useable to provide a tamper-evident, resealable lidding component for packaging. Resealable packaging has become popular especially in the area of foodstuffs for its advantages of providing to the consumer a product container eliminating the need to transfer leftovers to another storage receptacle.
Multilayer films used in the peelable and/or resealable packaging field are known, for example, in US 2018/0215522, assigned to BOSTIK SA, and in U.S. Pat. No. 7,413,800, assigned to Terphane, Inc. Resealable packagings are used in the food-processing industry and mass marketing for packaging perishable foods, in particular fresh products. These packagings generally comprise a container (or receptacle) and a seal forming a lid, which are hermetically attached to one another by welding. After the seal has been opened for the first time and a portion of the food product contained in the receptacle has been consumed, the user can reposition the seal on the receptacle, so as to reseal the packaging substantially hermetically, and to consequently, as appropriate, after placing it in a refrigerator, store the remaining portion of the product. A sequence of reopenings and resealings is also possible.
Multilayer films used in resealable packaging systems should allow an easy first opening and satisfactory reclosing/reopening cycles. For example, easy first opening can be achieved by an initial peel strength measured as the application of a force of less than or equal to 15 N/cm, preferably 7 N/cm or less, and with a propagation force, once the package has been opened, of preferably about 3 to 11 N/cm, more preferably 4 to 11 N/cm. The film also preferably enables an easy self-adhering reclosure of the packages, that is to say easy manual repositioning of the two parts of the film after a series of closing/reopening operations, with reopening forces of greater than 1 N/cm, preferably greater than or equal to 2 N/cm, more preferably 2-4 N/cm.
Many current resealable lidding structures or films employ either a peelable label adhered to a non-removable lid or, where it is desired to allow removal of a larger portion of the product cover, die-cutting an opening. These films are typically produced by laminating a heat sealable biaxially oriented polyethylene terephthalate (BOPET) film to a printable BOPET web with a water-based pressure sensitive adhesive (PSA) coating. The heat sealable layer is then laser scored or die cut to provide an opening into the container. Due to the technologies required to produce this structure, multiple conversion steps are typically required for production. This results in long lead times and an expensive packaging cost typically passed along to consumers. Moreover, water-based PSAs have low moisture resistance which may result in package failures. The laser scoring leaves a ribbon of film around the edge of the tray rim limiting access to the foodstuff inside.
It would accordingly be preferable to have packaging where the entire lid functioned as a peelable opening, allowing greater access to the container, and allowing avoidance of the additional cost and process steps of die-cutting.
In addition, few current resealable lids offer tamper evidence. If it is desired to have resealable packaging which is tamper-evident, it may be necessary to affix an additional label closure which is broken or not resealable once removed, to serve notice that the package has been opened, requiring additional steps and cost.
The present invention provides a multilayer film that can be used to form resealable packaging. The film can be used to form an entire lid of a tray, for example, avoiding the necessity for having just a peelable label, and further avoiding the need for die-cutting of an opening. In addition, the film provides a tamper-evident feature allowing consumers to know if the package has been opened.
The invention provides a film comprising (a) a biaxially-oriented polyethylene terephthalate (BOPET) layer, (b) a pressure sensitive (PSA) layer, (c) a layer of dispersed polyurethane particles, and (d) a BOPET layer. BOPET layer (a) is optionally printable, so that product information can be provided to a consumer. Layers (a) to (d) are in the above order, and typically adjacent to each other, preferably without additional internal layers.
In principle, any BOPET film can function as layer (a). BOPET films are well known as disclosed in, e.g., U.S. Pat. Nos. 2,823,421 and 2,884,663. Layer (a) may receive a corona and/or a coex treatment to improve adhesion of inks and adhesives. The corona treatment can be a pretreatment of the film layer (a) prior to supplying the film to the lamination apparatus or can be a “bump” corona treatment where a corona treater is present on the production line and effects treatment prior to application of adhesive and lamination. Corona treatment can also be a combination of pretreatment and bump treatment. Preferred BOPET films are surface-treated to increase adhesion. Representative surface-treated films are disclosed in, e.g., U.S. Pat. Nos. 4,476,189 and 5,985,437. Surface-treated BOPET films suitable as layer (a) are also commercially available, for example, from Terphane LLC, and include Terphane 10.21 (one side COEX treated), 10.25 (one side COEX, one side corona treated) and 10.15 (one side corona treated). Layer (a) may have a thickness of 2-100 μm, or 5-50 μm, or 10-40 μm, for example.
Preferred pressure sensitive adhesives include styrene block copolymers obtained from styrene monomers and from at least one other comonomer, such as ethylene, propylene, isoprene, butadiene and butylene. The copolymers can possess a linear, radial or star-shaped, diblock, triblock or multiblock structure, with an intermediate block of at least one of the above comonomers. These PSAs further contain a tackifier such as an aliphatic resin enhancing compatibility between the styrene and non-styrene blocks of the block copolymer. Such resins include polyterpenes, polymers from C5 cuts, optionally modified by C9 cuts, polymers from partially or completely hydrogenated C9 cuts optionally modified by aliphatic cuts. The PSA typically contains 45 to 85%, preferably 55 to 70%, by weight of copolymer or a blend of copolymers and 15 to 60%, preferably 30 to 45%, by weight of tackifying resin or a blend of tackifying resins. The adhesive may also contain a small fraction of a plasticizer, a stabilizer or a filler, these being additives conventionally used in hot-melt adhesives. Thus, typical PSAs contain a blend of at least one styrene block copolymer and at least one compatible tackifying resin.
Preferably, such a blend has, at between −20 and +40° C., an elastic modulus G′<5×105 Pa (Dahlquist criterion), a viscosity n (measured according to the ISO 11443 standard), at a temperature of at least 130° C.
Particularly preferred pressure sensitive adhesives are those comprising a blend of:
In particular, the PSA has the following properties:
Thickness of the PSA layer is preferably 5-35 μm, more preferably 5-22 μm.
In an embodiment prior to extrusion, the adhesive is in the form of pellets or granules at room temperature.
Suitable pressure sensitive adhesives are disclosed in U.S. Pat. No. 7,622,176.
Layer (c) is applied as a dispersion of elastic polyurethane particles and then dried or cured. Such dispersions are known as haptic coatings, used on the outer surface of films, to provide a soft-touch sensation. Such coatings are disclosed, for example, in U.S. Pat. No. 10,428,237, and are also commercially available, e.g., NeoRez® R-1030 from DSM Coating Resins B.V., Purkote™ 23593 from Ashland Inc. and 191230PX® from Michelman Inc. Thickness of the polyurethane layer may vary over a wide range, and typically is 0.1-5 μm, preferably 0.1-3 μm. Layer (c) may be referred to herein as an elastic polyurethane dispersion.
Layer (d) is preferably a “specialty” BOPET, comprising a multi-layer film of biaxially-stretched polyethylene terephthalate having an A:B:A:C structure, in which:
In the preferred BOPET of layer (d), the content of layers (A) is preferably 10 to 15% based on total thickness of layer (d), more preferably about 13%, and each layer (A) preferably contains 200 to 300 ppm of antiblocking agent; the content of layer (B) is preferably 61 to 78% based on total thickness of layer (d), more preferably about 69%, and preferably contains 90-215 ppm antiblocking agent; the content of layer (C) is preferably 12 to 24% of total thickness of layer (d), more preferably about 18%, and preferably contains 150 to 250 ppm of antiblocking agent. Layers (A) and (B) preferably have a combined thickness of 2-100 μm. Layer (C) preferably has a thickness of 0.1 to 10 μm. Layer (d) preferably has an overall combined thickness of layers (A), (B) and (C) of 2-110 μm, preferably from 4-15 μm, more preferably from 6-10 μm, preferably 8 μm.
Biaxial orientation of BOPET layer (d) can be achieved subsequent to coextrusion of the layer by high temperature stretching of the film, e.g., at 226-238° C., preferably at 238° C. The film is stretched in the transverse direction/machine direction (TD/MD) 300-400%, preferably 350%.
In an embodiment, BOPET layer (a) and/or heat sealable BOPET layer (d) may also be coated with a barrier coating in order to reduce permeability of the film to gases such as oxygen, nitrogen, and other gases, a mixture of gases, moisture vapor, and/or odors. Representative barrier coatings may be found in the group of organic barrier polymers and filled polymers, which include vinylidene chloride polymers and copolymers, such as PVDC, PVOH or EVOH based coatings (such as described in U.S. Pat. No. 10,392,527 and US 2017/0210867), polyurethane coatings, or other water-based, solvent-based, or UV/EB cured coatings. The barrier coating may be reinforced with nanosized additives, such as mica, vermiculite, nanofibers, or others, in order to enhance its barrier properties, such as described in U.S. Pat. No. 8,080,297. The barrier coating may be prepared from dispersions, or solutions, and then coated onto the film surface, and sequentially dried using any known coating method, including but not limited to gravure, flexo, offset, spray, and dipcoating. Other barrier coatings may result from metallic, ceramic or organic deposition, such as aluminum, aluminum oxide, silicon oxide, melamine, among others. Such coatings may be deposited by any known coating method, including but not limited to spraying, thermal evaporation, sputtering, chemical vapor deposition, and atomic layer deposition. See also U.S. Pat. No. 7,413,800, discussing barrier coatings at col. 4, lines 18-24.
The multilayer film of the invention can be produced by coextrusion of the layer (d) BOPET, separate coextrusion of layer (a) BOPET, gravure coating of the layer (c) polyurethane dispersion on layer (d) BOPET, and extrusion laminating layer (d) BOPET to layer (a) BOPET with layer (b) PSA as the adhesive. In extrusion lamination, as shown in
The films of the invention provide the advantage of being capable of forming a resealable lidding for a container, which lidding can comprise the entire surface closure of the container, without the need for die-cutting. Moreover, the presence of the internal polyurethane layer (c), rather than functioning as a haptic or “soft touch” coating intended to modify the surface feel of the film, provides a tamper-evident feature, as when the lid is opened for the first time, the film transitions from clear to cloudy. Layer (c) may further include a dye to enhance this effect.
A container in accordance with the invention is represented by
Without further elaboration, it is believed that one skilled in the art can, using the preceding description, utilize the present invention to its fullest extent. The preceding preferred specific embodiments are, therefore, to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever.
The entire disclosures of all applications, patents and publications, cited herein are incorporated by reference herein.
Unless explicitly noted otherwise, all percentage data for mixtures denote percent by weight, and relate to the corresponding mixture as a whole, comprising all solid or liquid components, without solvents. Furthermore, unless explicitly noted otherwise, all temperatures are indicated in in degrees Celsius (° C.). The following examples are intended to explain the invention without limiting it.
A series of film samples were created to test the suitability of the resulting film having this structure
for a resealable lidding film for packaging containers.
Film A: 92 gauge (23.3 μm) multilayer biaxially oriented PET film with a Corona treated surface on one side (“Corona Side”) and a coextruded copolyester on the opposite side (“COEX Side”).
PSA: Extrudable pressure sensitive adhesive.
Film B: 50 gauge (12.7 μm) multilayer biaxially oriented PET film with a coextruded copolyester heat sealable layer that includes a slip package on one side (“Heat Seal Side with Slip”) and a Corona treated surface on the opposite side (“Corona Side”).
Film C: 52 gauge (13.2 μm) multilayer biaxially oriented PET film with a haptic (“soft touch”) matte coating on one side (“Soft Touch Side”) and a coextruded copolyester heat sealable layer on the opposite side (“Coex Side”).
Film D: 48 gauge (12.2 μm) multilayer biaxially oriented PET film with a coextruded matte surface on one side (“Matte Side”) and a Corona treated surface on the opposite side (“Corona Side”).
Film E: 48 gauge (12.2 μm) multilayer biaxially oriented PET film that has been chemically treated on one side (“Chemically Treaded Side”) and a coextruded copolyester on the opposite side (“Coex Side”).
Film F: 48 gauge (12.2 μm) multilayer biaxially oriented PET film with a very smooth, high coefficient of friction surface on one side (“Smooth Side”) and a coextruded copolyester on the opposite side (“Coex Side”).
Film G: 53 gauge (13.5 μm) multilayer biaxially oriented PET film with a coextruded copolyester heat sealable layer on one side (“Heat Seal Side”) and a soft touch (haptic) matte coating on one side (“Soft Touch Side”).
Film H: 37 gauge (9.4 μm) multilayer biaxially oriented PET film with a coextruded copolyester heat sealable layer on one side (“Heat Seal Side”) and a Corona treated surface on the opposite side (“Corona Side”) with multidirectional ‘easy tear’ property.
Film I: 72 gauge (18.3 μm) multilayer biaxially oriented PET film that has a dead-fold property with a Corona treated surface on one side (“Corona Side”) and an untreated plain PET surface on the opposite side (“Plain Side”).
Film J: 56 gauge (14.2 μm) multilayer biaxially oriented PET film with multidirectional ‘easy-tear’ property as described in U.S. Pat. No. 7,943,230.
Film A was used for the Top Film Layer for all Samples, with the Corona Side of Film A oriented towards the Middle Layer at Interface 1 for the first eight (8) Samples and the COEX Side oriented towards the Middle Layer at Interface 1 for the next seventeen (17) Samples.
The same PSA was used for the Middle Layer, but with different thicknesses.
Films B-J were used for the Bottom Film Layer with different sides oriented towards the Middle Layer at Interface 2.
For each Sample, the Film for the Top Film Layer and the Film for the Bottom Film Layer were fed to a nip into which the PSA for the Middle Layer was extruded as illustrated in
Table I summarizes the combinations of films, film orientations, and middle layer thicknesses that were used to create the Samples.
Samples 1-14 were evaluated as to suitability for a resealable film (on container) application, as determined by Peel Strength, Haze, and Clarity. The tamper evident feature (changing from clear to cloudy when peeled and resealed for the first time) is provided by Samples 3, 4, 12 and 13 (those with the Soft Touch Coating at Interface 2). The Soft Touch Coating listed in Table 1 is a coating of layer (c), namely from an elastic polyurethane dispersion.
Samples 15-20 show the effect of the amount of PSA used in the middle layer on Peel Strength, Haze and Clarity.
Samples 21 and 23 show the effect of Film l's dead-fold property due to lack of biaxial orientation (only partially oriented to make it ‘twistable’) on the tear-ability of the bottom film layer.
Sample 22 shows the effect of Film J's tear-ability on the structure's performance as it is desirable for the bottom film layer to break cleanly upon the first opening.
Samples 24 and 25 show the effect of BOPET layer (d) as the bottom film layer, but without the haptic (soft touch) coating of layer (c).
The Peel Strength testing results are summarized in Table II below.
It is desirable for the 1st Peel Strength to be greater than 1140 gf/in for adhesive failure and for the 2nd Peel Strength to be greater than 285 gf/in for adhesive failure.
The Samples were also tested for Haze and Clarity. Haze was tested using a BYK Gardner haze-gard plus following ASTM method D 1003. The same device was used to measure Clarity. The Haze and Clarity testing results are summarized in Table III below.
It is desirable to have a Haze value of ≤13.0% and a Clarity value of ≥88.2%
This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Patent Application No. 63/010,418, filed on Apr. 15, 2020.
Filing Document | Filing Date | Country | Kind |
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PCT/US2021/027172 | 4/14/2021 | WO |
Number | Date | Country | |
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63010418 | Apr 2020 | US |