Vinylidene chloride composition and film made therefrom

Abstract: A film with properties such as good thermal stability, enhanced extrudability, improved oxygen barrier properties, and reduced stickiness to metal surfaces is made by the use of a vinylidene chloride composition with small amounts of a plasticizer, such as epoxidized oil or epoxidized alpha olefin, and with acrylate/styrene polymer, such as methyl methacrylate/butyl acrylate/styrene polymer, butyl acrylate/butyl methacrylate/methyl methacrylate polymer, or poly (alpha-methylstyrene).

Description: This invention relates to a multi-layer polymeric film, specifically packaging film having a plasticized layer of a vinylidene chloride copolymer film having lowered oxygen transition and stickiness and enhanced thermostability and extrusion rate. Thermoplastic packaging films made of vinylidene chloride copolymer, hereinafter referred to generally as "saran", have been used for a long number of years to package food products which include cheese, fresh and processed meats, and a wide variety of other food and non-food items. (Saran is a trademark registered to Dow in many countries; however, in the United States, saran has become generic for vinylidene chloride polymers and vinylidene chloride copolymers.) Saran films are known to be good barriers to the transmission of oxygen, i.e. have a very low oxygen permeability. Examples of such films are disclosed in U.S. Patent No. 2,919,059 which issued in December 1959 to Arthur F. Sporka. This patent discloses laminate films of cellophane-saran-polyethylene and polyethylene-saran-polyethylene which are made by treating the polyethylene film surface to enhance its cling sheer strength so that a laminate or multi-layer film can be made by using the inherent attractive forces in the face-to-face surfaces of adjoining plies of preformed film A later and more satisfactory method of producing a multi-layer film having a layer of saran is disclosed in U.S. Patent No. 4,112,181 which issued on September 5, 1978 to William G. Baird, Jr. et al. In this patent a method of coextruding a tubular film is described wherein the walls of the tube have at least three layers, a center layer being a saran layer. The tubular film is subsequently biaxially oriented by the trapped bubble technique. Another satisfactory method of producing a multi-layer saran film is disclosed in U.S. Patent No. 3,741,253 which issued on June 26, 1973 to Harri J. Brax et al., which specifically discloses a multi-layer, biaxially oriented film having a saran barrier layer. This film is made by an extrusion coating process in which a substrate of polyethylene or ethylene vinyl acetate copolymer is coextruded in the form of a tube, cross-linked by irradiation, inflated into a tubing, a layer of saran extrusion coated onto the inflated tubing, and then another layer of ethylene-vinyl acetate copolymer is coated onto the saran. After cooling, this multi-layer tubular structure is flattened and rolled up. At a later time, the tube is inflated, sent through a hot water bath where it is heated to its orientation temperature, and as it is drawn out of the bath, it is inflated into a bubble thereby biaxially orienting tie film. The bubble is rapidly cooled to set the orientation. This process produces a shrinkable barrier film with low oxygen permeability. Also, the advantages of a cross-linked film are provided without subjecting the saran layer to irradiation which tends to degrade saran. The barrier layer in the laboratory examples of the above mentioned patent to Brax et al. is a plasticized copolymer of vinylidene chloride and vinyl chloride. The copolymer is a mixture of 10% suspension polymerized and 90% emulsion polymerized copolymer. The emulsion polymerized copolymer comprises about 70% vinylidene chloride and 30% vinyl chloride and the suspension polymerized copolymer comprises about 80% vinylidene chloride and 20% vinyl chloride. Such copolymers are obtainable from the Dow Chemical Company of Midland, Michigan. Vinylidene chloride copolymers are also available from Solvay. In order to be successfully extruded at commercial rates the foregoing described mixture of vinylidene chloride copolymers must be stabilized and plasticized. A successful stabilizer-plasticizer combination is epichlorohydrin/bisphenol A, and epoxy resin sold as EPON resin 828 by the Shell Chemical Company, and 2-ethyl hexyl diphenyl phosphate sold as Santicizer-141 by Monsanto Chemical Co. Other known stabilizers include epoxidized linseed oil and epoxidized soybean oil and citrates. A quite successful and satisfactory plasticizer package is made using approximately 4% of the EPON 828 and approximately 2% of the Santicizer-141 in the foregoing described mixture of vinylidene chloride copolymers. In Canadian Patent No. 968,689, which was issued on June 5, 1975 to Mario Gillio-tos et al., the effect of plasticizers on the barrier properties of a saran barrier layer in a multi-layer thermoplastic packaging film is described. First, the Gillio-tos et al. patent discloses that homopolymers of vinylidene chloride cannot be converted into film by conventional extrusion techniques because they decompose very rapidly at the temperature of extrusion. Second, by copolymerizing vinylidene chloride with minor amounts of one or more other monomers such as vinyl chloride, methyl acrylate, etc. it is possible to produce copolymers which, when mixed with suitable plasticizers, can be extruded into films which can be oriented by stretching to give shrinkable film. The oriented films are heat shrinkable and are widely used for packaging purposes, particularly for packaging food. As stated, vinylidene chloride copolymers need to be plasticized so that they can be satisfactorily extruded and stretched into oriented films. The greater the proportion of plasticizer the easier the polymer is to extrude and orient and the better the abuse resistance of the final product. On the other hand, the oxygen permeability of the final product also increases with increasing plasticizer content and for many purposes, especially packaging food, it is vital that the oxygen permeability should be low. In recent years, the requirements of the packaging industry have become more and more demanding and for current commercial practices permeability below 20 cc/24 hours/m 2 /atmoshere per mil thickness is expected and a permeability below 10 is highly desirable. U.S. Patent No. 4,686,148, which issued on August 11, 1987 to Marvin R. Havens, and U.S. Patent No. 4,698,111 which issued on October 6, 1987 to the same inventor, disclose the addition of glycerin and a plasticizer such as epoxidized soybean oil to a vinylidene chloride polymeric composition, in order to enhance thermal stability of a film having a plasticized layer of vinylidene chloride copolymer. DE-A-2 260 937 discloses a modifying agent for vinylidene chloride resins, which resins can be used for the manufacture of packaging films. JP-A-53-16753 discloses a vinylidene resin composition having high barrier properties which comprises a plasticizer, a styrene/methyl methacrylate copolymer, a vinylidene chloride polymer and a rubber-like elastomer. The resin composition can be used for the manufacture of food packaging materials. It is an object of the present invention to provide a multi-layer polymeric film which has lower oxygen transmission rate. Still another object of the present invention is to improve the thermal stability of the multi-layer polymeric film so that there is less tendency to degrade while being extruded so that the extrusion rate can be increased and the stickiness with respect to metal surfaces in contact with the material during its processing, such as screw flights, channels, and die surfaces can be reduced and thereby longer processing times and less disruptions for purging or cleaning the extrusion system can be obtained. By lowering the oxygen transmission rate, the thickness of barrier layers and, hence, the quantity of saran required for a barrier film is reduced. Also since the thickness of saran layers can be reduced, it is another object of the present invention to provide a film wherein the saran layer is thick enough to be an effective gas barrier but thin enough so that it is not adversely affected to any significant extent by irradiation used to cross-link layers which are cross-linkable and adjacent to the saran layer in a multi-layer film. It has been discovered that the addition of a polymer comprising mer units derived from butyl acrylate, butyl methacrylate and methyl methacrylate to a blend of plasticizers and vinylidene chloride copolymer provides several improvements to extrusion of this material and films produced thereby. Enhanced external lubrication allows reduction of conventional plasticizers, the reduction of which improves oxygen barrier properties (i.e. reduces oxygen transmission rates). Furthermore, the improved lubrication results in generation of less shear heat during processing which leads to less polymer degradation. This allows reduction or modification to the additives normally required to prevent heat-induced degradation which, in turn, can lead to further oxygen barrier improvements. The sum of these effects permits higher extrusion speeds and orientation rates are maintained with improvements in oxygen barrier properties. In a similar manner, extrusion speed and orientation rates can be improved while the required oxygen barrier is provided by a thinner layer of vinylidene chloride copolymer. Common methods for determining overall thermal stability for extrusion of vinylidene chloride copolymer blends with plasticizers and stabilizers involve working the blend between a pair of heated rollers or inside a heated mixing chamber. The time required for shear and temperature-induced degradation to produce a noticeably blackened polymer is a measure of effectiveness of a plasticizer/stabilizer combination in promoting heat stability. Commercially acceptable vinylidene chloride copolymer plasticizer/stabilizer combinations should show thermal stability times of 10-15 minutes in a mixing chamber such as a Brabender (trademark) blender running at 148.88°C (300°F) and 63 revolutions per minute. Likewise, when working the blend between a pair of heated rollers, the time for degradation may be used to show thermal stability. There are 4 conditions of degradation for which the time is observed with a heated two-roll mill. One is time to plate out. Plating out means the blend, which is on the front roller, begins to separate into its components, and small transfers will begin onto the back roller of bits of the separated components. The second is time to varnish. Varnish is the noticeably blackened polymer discussed in the paragraph above. The third is time to stickiness. Stickiness means the material has begun to stick on the metal rolls, which is an indication of its sticking on the metal components (screw flights, channels, die, etc.) of an extruder. Fourth is time to pick off. Pick-off means part of the melted blend transfers from the front roll to the back roll. For each of these four, commercially acceptable vinylidene chloride copolymer plasticizer/ stabilizer combinations should show thermal stability on a two-roll heated mill of 10 to 15 minutes when the mill is running at 168.33°C (335°F) and 25 revolutions (front roll) per minutes and 22 revolutions (back roll) per minute. Of course, times longer than 10-15 minutes mean performance even better than what is already commercially acceptable, which means longer extrusion runs due to less down time, as discussed above. It has been found that the addition of approximately 2% by weight of a polymer comprising mer units derived from butyl acrylate, butyl methacrylate and methyl methacrylate to a blend of 2% by weight of epoxidized oil and 96% vinylidene chloride copolymer will in most cases maintain or improve the thermal stability of the composition (all weight percents herein are weight percents of the final blended composition), compared with a composition of 4% by weight of epoxidized oil and 96% vinylidene chloride copolymer. Thus, the subject-matter of the present invention, is the multi-layer polymeric film of claim 1. Preferred polymers of this kind are butyl acrylate/butyl methacrylate/methyl methacrylate polymers, and mixtures thereof. Preferred epoxidized oils are epoxidized linseed oil and epoxidized soybean oil. The plasticizer may be selected from the group consisting of epoxidized linseed oil, epoxidized soybean oil, epoxidized alpha olefin, epoxidized ester, tetraethylene, glycol di(2-ethylhexoate), epoxidized plasticizers, epoxy plasitcizers, and combinations thereof. Still other aspects of the present invention include irradiation of the above multi-layer film employing said polymer in the saran layer as specified above to cross-link the cross-linkable layers. Such cross-linkable layers may be surface layers or internal layers in addition to the saran layer and are preferably selected from the group consisting of ethylene-vinyl acetate copolymers, branched polyethylene, linear low density and very low density polyethylene, and blends thereof. DEFINITIONS As used herein, the following terms are understood to have the meaning set forth below. By the term polymer comprising mer units derived from butyl acrylate, butyl methacrylate and methyl methacrylate, it is intended to mean additives for vinylidene chloride copolymer, which additives are polymers such as butyl acrylate/butyl methacrylate/methyl methacrylate polymers. Blends of these are also included. "Polymer" means the product of polymerization and includes but is not limited to copolymers, interpolymers, terpolymers, block copolymers, graft copolymers, alternating copolymers, and addition copolymers. "Plasticizer" means a substance or material incorporated in a film or film layer to increase the flexibility, workability, or extrudability of the film. These substances include both monomeric plasticizers and polymeric plasticizers and are generally those material which function by reducing the normal intermolecular forces in a resin thus permitting the macromolecules to slide over one another more freely. Other known plasticizers with epoxy groups attached such as, epichlorohydrin/bisphenol A epoxy, epoxidized linseed oil, and epoxidized soybean oil also function as plasticizers by reducing intermolecular forces and, as well, act as scavengers for HCl. Hydrogen chloride is a by-product of the degradation of saran. "Oriented" or "Orientation" refer to the process of stretching a hot plastic article followed by cooling to realign a molecular configuration thus improving mechanical properties. Stretching in one direction is called uniaxial orientation and in two directions is called biaxial orientation. In thermoplastic films which have been oriented there is an internal stress remaining in the plastic sheet which can be relieved by reheating the sheet to a temperature above that at which it was oriented. The material will then tend to shrink back to the original dimensions it had before it was stretch oriented. "Vinylidene chloride polymer" or "vinylidene chloride copolymer" or "saran" means vinylidene chloride copolymerized with at least one other monomer. This includes, but is not limited to vinylidene chloride vinyl chloride copolymer, vinylidene chloride acrylonitrile copolymer, vinylidene chloride methyl acrylate copolymer, vinylidene chloride butyl acrylate copolymer, other vinylidene chloride alkyl acrylate copolymers, and mixtures thereof. Thus, included are blends of vinylidene chloride methyl acrylate copolymer and vinylidene chloride vinyl chloride copolymer. Vinylidene chloride methyl acrylate copolymer is designated by the abbreviation PVDC-MA and vinylidene chloride vinyl chloride copolymer is designated by the abbreviation PVDC-VCl. "Barrier" refers to a property in thermoplastic materials which indicates that the particular material has a very low permeability to gases. The principal barrier materials referred to herein are the vinylidene chloride copolymers designated as "saran" Hydrolyzed ethylene-vinyl acetate copolymers designated (also known as ethylene vinyl alcohol copolymers) by the abbreveations: "HEVA" (of "EVOH"), and acrylonitrile styrene copolymers such as those sold under the tradename Barex 210 or Barex 218 by BP Chemicals. DETAILED DESCRIPTION One significant result of the present invention is that the barrier properties of films made in accordance with the present invention are improved while the thermal statility of these same films is usually maintained and in some cases improved as well. This is demonstrated in Tables 2 and 3 below wich tabulates various barrier (saran) layer resin compositions with the resulting thermal stability and/or oxygen transmission rate for the film samples. The film structure in each example of Tables 2 and 3 was: sealant layer/core layer/barrier layer/abuse layer where: sealant layer = 10% linear low density polyethylene (density 0.920) + 90% ethylene vinyl acetate copolymer (6% VA); core layer = ethylene vinyl acetate copolymer (19% VA); barrier layer = (to be defined below); and abuse layer = ethylene vinyl acetate copolymer (9% VA). In the above film structures for the defined barrier layer the amounts were measured as parts per hundred (pph) of vinylidene chloride copolymer. The materials used in the different barrier layer compositions are identified in Table 1 below, with "S" indicating vinylidene chloride copolymer; "O" indicating epoxidized oil; "A" indicating acrylate/styrene copolymer; "A-BMA" indicating butyl acrylate/butyl methacrylate/methyl methacrylate polymer; and "P" indicating alternative plasticizers. Material Name Description Source S-1 MA 134 Vinylidene Chloride/ Methyl Acrylate Copolymer (8.5 wt% MA) Dow S-2 WV 323 Vinylidene Chloride/Vinyl Chloride Copolymer (26.8 wt% VC) Solvay S-5 PV 325 Vinylidene Chloride/Vinyl Chloride Copolymer (26.5 wt% VC) Solvay O-2 Plas-Chek 775 Epoxidized Soybean Oil Ferro A-1 Metablen P 710 Methyl Methacrylate/Butyl Acrylate/Styrene Polymer Atochem A-BMA Metablen L1000 Butyl Acrylate/Butyl Methacrylate/Methyl Methacrylate Polymer Atochem CR Calcium Ricinoleate Caschem P-1 Vikoflex 5075 Epoxidized Propylene Glycol Dioleate Viking P-2 Vikoflex 16 Epoxidized alpha olefin Viking 629A Oxidized Polyethylene Allied Signal Note: Metablen P710 is by weight 44% methyl methacrylate, 30% butyl acrylate, and 26% styrene, with an error of 10%. Its weight average molecular weight is 102,700, with a standard deviation of 2000. Metablen L1000 is by weight 19% butyl acrylate, 29% butyl methacrylate, and 53% methyl methacrylate, with an error of 10%. Its weight average molecular weight is 223,000, with a standard deviation of 4000. Ex. Composition (pph) Thermal Stability (Minutes) on 2-Roll Heated Mill Ease of Cleaning at End of Test Sticking Plating Pick Off Varnish 1. 100 S-1 instant instant 5(slight) 17 Very Difficult 2 O-2 11(heavy) (Comparison) 2. 100 S-1 4(slight) 2(very slight) 21(slight) 21.5 Easier than Ex. 1 2 O-2 1 A-BMA 3. 100 S-1 12(slight) none 24(slight) 24 Easy 2 O-2 2 A-BMA 4. 100 S-1 25(slight) none none 25 Very Easy 2 O-2 4 A-BMA 5. 100 S-1 None Thru End of Test at 35 none none none Very Easy 2 O-2 6 A-BMA 6. 100 S-1 None Thru End of Test at 35 none none none Easiest of all 2 O-2 8 A-BMA 7. 100 S-1 5(slight) 3(very slight) 18.5 10 Moderately Difficult 2 O-2 2 A-1 8. 100 S-2 7(slight) 15 13 16 Easy 2 O-2 2 A-BMA 9. 100 S-2 This film was made, but tests were not performed on it. 2 O-2 3 A-BMA Note: Above 3 BA, the melt with S-2 became milky, indicating incompatibility between vinylidene chloride-vinyl chloride and Metablen L1000. By comparing Ex. 3 of Table 2 with Ex. 7 of Table 2 , it can be seen that Metablen L1000 was more effective in vinylidene chloride methyl acrylate than was Metablen P710. Also, by comparing Ex. 3 of Table 2 with Ex. 8 of Table 2 , it can be seen that L1000 was more effective in vinylidene chloride methyl acrylate than in vinylidene chloride vinyl chloride. Ex. Composition (pph) Oxygen Transmission (cc/24 hours/sq meter/atm per 25.4 µm (1 mil) thickness) (ASTM D 3985) 1. 100 S-1 + 5.42 4 O-2 (Comparison) 2. 100 S-1 + 2.40 2 O-2 (Comparison) 3. 100 S-1 + 2.60 2 O-2 + 2 A-1 4. 100 S-1 + 2.56 2 O-2 + 1 A-BMA 5. 100 S-1 + 3.23 2 O-2 + 2 A-BMA 6. 100 S-1 + 4.31 2 O-2 + 4 A-BMA 7. 100 S-5 + 11.8 4 O-2 + (Comparison) 8. 100 S-5 + 5.8 2 O-2 (Comparison) 9. 100 S-5 + 8.8 2 O-2 + 2 A-1 10. 100 S-5 + 6.1 2 O-2 + 1 A-BMA 11. 100 S-5 + 6.9 2 0-2 + 2 A-BMA 12. 100 S-5 + 8.5 2 O-2 + 3 A-BMA With regard to Table 3, it can be seen that the formulations containing P710 or L1000 as the acrylate/styrene copolymer are better barriers to the transmission of oxygen than the formulations with 4% epoxidized soybean oil but no acyrlate/styrene copolymer. Thus improved processability is achieved by incorporating acrylate/styrene copolymer without exceeding the oxygen transmission rate of the formulations containing 4% epoxidized soybean oil but no acrylate/styrene copolymer. It is thus seen that the product of this invention produces superior results. While many details of the invention are specified above such details are by way of examples and are not limiting. The spirit and scope of the invention are limited only as set forth in the following claims.

Claims: A multi-layer polymeric film comprising: a) first and second surface layers; and b) disposed between said surface layers, a polymeric layer consisting essentially of 1) 1 to 4 % by weight of a plasticizer, 2) 1 to 4 % by weight of a polymer comprising mer units derived from butyl acrylate, butyl methacrylate, and methyl methacrylate, and 3) the balance comprising at least one polymer comprising mer units derived from vinylidene chloride. The film of claim 1 wherein said surface layers comprise a polyolefin. The film of claim 2 wherein said polyolefin is selected from the group consisting of ethylene-vinyl acetate copolymers, branched low density polyethylene, linear low density polyethylene, very low density polyethylene. and blends of any of the foregoing. The film of claims 1 to 3 wherein said plasticizer comprises an epoxy group. The film of claim 4 wherein said plasticizer comprising an epoxy group is selected from the class consisting of epoxidized linseed oil, epoxidized soybean oil, epoxidized α-olefin, and epoxidized ester. The film of any of claims 1 to 3 wherein said plasticizer is tetraethylene glycol di(2-ethylhexoate). The film of any of claims 1 to 6 wherein said at least one polymer comprising mer units derived from vinylidene chloride further comprises mer units derived from at least one of vinyl chloride, acrylonitrile, and an alkyl acrylate. The film of any of claims 1 to 7 wherein at least one layer of said film is biaxially oriented. The film of any of claims 1 to 7 wherein said film is cross-linked. The film of any of claims 1 to 9 wherein said polymer comprising mer units derived from butyl acrylate, butyl methacrylate, and methyl methacrylate comprises 19 % by weight of butyl acrylate, 29% by weight of butyl methacrylate, and 53% by weight of methyl methacrylate, with an error of 10%. The film of any of claims 1 and 10 wherein said polymeric layer b) further comprises calcium ricinoleate.

Inventors: BEKELE SOLOMON, BEKELE, SOLOMON
Applicants: CRYOVAC INC, CRYOVAC, INC.
Application year: 1992
Main classification: B32B27
IPC codes: B32B27, C08L25, C08J5, C08L33, C08K5, C08L27, B29C55, B29K27