POLYMERIC MATERIAL AND ITS USE IN MULTILAYER PRODUCTS

Abstract: The invention relates to a multilayer product for the production of packaging, the product comprising a carrier web (1), on one face of which there is disposed a tight multilayer coating (2) which includes a moisture-proof layer (b) and a gas-tight layer (a). The gas-tight layer is made up of a blend of an ethylene/vinyl alcohol copolymer and a polar ethylene polymer. The moisture-proof layer is polyolefin, preferably a blend of polyethylene and a polar ethylene polymer.

Description: Polymeric material and its use in multilayer products The invention relates to a packaging material which has good barrier properties vis-a-vis gases and moisture. The invention further relates to a polymeric material which is used as a gastight layer in such packages, and further to multilayer products in which said polymer is used. Liquid foodstuffs, such as juices, which are sensitive to oxidation, are in general packaged in sales packages made from laminated paperboard. Through selection of the packaging material, efforts are made to provide good chemical and mechanical protection for the product, and the material has to be sufficiently firm in shape to be easy to handle. There is in general use a packaging material the structural part of which consists of paperboard or paper which is sufficiently firm but, nevertheless, flexible so that a package of a desired shape can be formed therefrom. To protect the structural material from liquid and other moisture, it is coated with plastic, usually polyethylene. However, the oxygen permeability of polyethylene and paperboard is high, and therefore the product would spoil very rapidly if a gas-tight layer were not also added to the package. The gas-tight layer conventionally used has been aluminum foil bonded to the paperboard. Another alternative has been a gas barrier polymer such as ethylene/vinyl alcohol copolymer (EVOH). The purpose of the gas-tight layer is to prevent the access of oxygen into the product and thus, for example, to maintain high the level of vitamin C in the product. For some time, attempts have been made to eliminate the aluminum foil, for example for reasons of environmental protection, but also because of its poor handlability. Furthermo¬ re, the aluminum layer is easily broken. Finnish Patent FI89567 discloses a barrier structure in which ethylene/vinyl alcohol copolymer is used. Such structures, in the same way as when aluminum is used, usually contain, in addition to the carrier web (polyethylene + paperboard), at least five layers: polyethylene/paperboard/polyethylene/adhesion plastic/gas-tight EVOH polymer/adhesion plastic/polyethylene. The multilayer structure, of course, also increases the price of the package and renders its manufacture complicated. Furthermore, the gas-tight polymer in itself is expensive. EP patent 423511 sought a solution in which lower amounts of EVOH would suffice. Therein a blend of EVOH and polyethylene is used, in which the amount of polyethylene is at maximum 80 %, but preferably at maximum 40 %. The EVOH/PE layer on the inside of the package mainly serves as an aroma-proof layer and, if good gas-tightness (oxygen-tightness) is also desired, a second EVOH/PE layer or some other oxygen-tight layer is added, with adhesion plastic layers on its both sides. In this case the number of layers is four in addition to the carrier web. An object of the present invention is to provide a multilayer product by means of which the disadvantages of the prior art can be eliminated. When polymers according to the invention are used, the number of layers can be reduced from the conventional number, which is usually five in addition to the carrier web, since a separate adhesion plastic layer is not needed. It has been observed, surprisingly, that, if a blend of a commonly known gas-tight polymer, i.e. ethylene/vinyl alcohol copolymer (EVOH), and of a polar ethylene polymer is used in the gas-tight layer, this layer having good adhesion properties and being heat-sealable, the use of the adhesion plastic layer can be abandoned. In the system according to the invention, the gas-tight layer contains a polar ethylene polymer in an amount of 5-60 %, preferably 15-40 %. The polar polymer may be a copolymer of ethylene and acrylic ester, such as ethylene/ethyl acrylate copolymer (E/EA), ethylene/butyl acrylate copolymer (E/BA), ethylene/methyl acrylate copolymer (E/MA), ethylene/vinyl acetate copolymer (E/VA), or a copolymer of ethylene and (met)acrylic acid (E/EA, E/MAA). The polar polymer may also be an anhydride- or acid- modified polyolefin, in which case the acid (anhydride) used may be, for example, maleic, fumaric or itaconic acid (anhydride). Furthermore, the polar polymer may also be a terpolymer, such as a terpolymer of ethylene, methyl acrylic acid and butyl acrylic acid (E/MAA/BA) or a copolymer of ethylene, acrylic ester and maleic anhydride. The basis weight of gas-tight polymer is typically 1-20 g/m 2 , preferably 2-10 g/m 2 . Many advantages can be gained by using, instead of ethylene/vinyl alcohol copolymer, a blend thereof and a polar ethylene polymer. The polymer blend also serves as a good oxygen barrier layer when it is inside a coextruded structure, in the same way as does EVOH alone. When the layer made of the polymer blend is on the inside surface of the package structure, a good aroma-proofing is also achieved. As compared with a mere ethylene/vinyl alcohol polymer, a lower blistering tendency and a higher resistance to heat and moisture are achieved. Since one component in the polymer blend is polar, as a consequence better sealability properties, good hot-tack properties, and better adhesion properties are achieved than by using a pure polymer. As a result, the use of a separate adhesion plastic layer can be abandoned. Furthermore, the processibility of the polymer blend is better, and smaller layer thicknesses can be used. Polyolefin, preferably polyethylene, which may be any polyethylene (LD, HD, LLD, VLD, etc.), is used as the moisture-proof layer. Preferably a polar polymer selected from the same group as the polymers in the gas-tight polymer blend is added to the polyethyle¬ ne, in an amount of 2-50 %, preferably 20-30 %. By this addition, good adhesion of the layers to each other is ensured, as is good seal strength at lower sealing temperamres. Furthermore, the blistering tendency is lower. Environmental stress crack resistance (ESCR), water vapor transmission rate (WVTR) and frictions are easier to control. Resist¬ ance to wear is also better, especially if high-density (HD) or linear (LLD) polyethylene is used, and consequently, plastic dust will not be formed on rapid package-manufacturing lines and the blanks will travel smoothly on the lines. The polar polymer can be mixed with the ethylene/vinyl alcohol polymer and, respective¬ ly, with the polyolefin by any conventional mixing technique. Either melt mixing or dry mixing can be used. The carrier web may be any web which can be coated, but a combination of paperboard and polyethylene is highly suitable for packages for liquids. The other layers are typically bonded to the carrier web by coextrusion coating. The number of layers placed on one side of the carrier web, and their mutual order, can be varied according to the application, and in particular according to the requirements set by the product to be packaged. With smaller numbers of layers, the price of the multilayer structure, i.e. the packaging material, will be considerably lower. According to the present invention, 2-layer coextrusion instead of the previous 5-layer coextrusion will well suffice for many applications. Owing to the small number of layers, pulpability will be considerably improved, and blistering tendency in the heat-sealing step is nil. The improved pulpability is due above all to the fact that an EVOH/PE layer bonded directly to paperboard detaches from the paperboard more easily than does an adhesion plastic layer. In consequence to easier pulping, recycling of the material will be simpler. Depending on the application, the gas-tight layer (a) and the moisture-proof layer (b) may be in different orders on the carrier web: a-b, b-a, a-a- a-b-a. The order depends on the product to be packaged, i.e. on whether protection is needed specifically against the permeability of moisture, oxygen, aromatic substances, etc. The invention is described in greater detail with the help of the following examples. Example 1. A gas-tight plastic was prepared by blending an amount of 80 % of ethylene/vinyl alcohol copolymer, EVOH (44 % ethylene), manufacturer Du Pont and trade name Selar OH 4416, with an amount of 20 % of ethylene/ethyl acrylate copolymer, EEA, manufacturer Borealis and trade name NCPE 5860. The mixing was performed in a Berstoff twin screw extruder (© = 40 mm). A carrier web (15 g/m 2 PE-LD and 300 g/m 2 paperboard) was coextrusion coated on a Beloit pilot line with a double-layer coating in which the gas-tight layer consisted of 10 g/m 2 (EVOH + EEA) and the moisture-proof layer consisted of 30 g/m 2 low-density polyethylene, PE-LD, manufacturer Borealis Polymers Oy and trade name NCPE7518. There were thus only two layers in addition to the carrier web. The oxygen permeability of the material was 6 cm 3 /m 2 per 24 h at a temperature of 23 °C and a relative humidity of 50 % . The oxygen permeability of a corresponding conventional 5-layer structure was 4 cm 3 /m 2 per 24 h. The layers of the conventional structure were: carrier web 15 g/m 2 PE-LD and 300 g/m 2 cardboard, and on top of it a 5-layer coextrusion coating consisting of 20 g/m 2 PE-LD, 6 g/m 2 adhesion polymer, 10 g/m 2 EVOH, adhesion plastic 6 g/m 2 , and PE-LD 20 g/m 2 (Figure 1). The adhesion polymer used was polyethylene modified with maleic anhydride, trade name NCPE 0470, manufacturer Borealis Polymers Oy. The saving of material in the structure according to the invention is considerable as compared with traditional structures, and the gas-tightness is of substantially the same level. The structure according to the invention is shown in Figure 2. Example 2. A gas-tight plastic was prepared by mixing an amount of 80 % of ethylene/vinyl alcohol copolymer, EVOH (38 % ethylene), manufacmrer Kuraray and trade name EVAL 101H, with an amount of 20 % of polyethylene modified with maleic acid, manufacturer Borealis Polymers Oy and trade name NCPE 0470. The mixing was carried out in the same manner as in Example 1. A carrier web was coextrusion coated in the same manner as in Example 1, but the thickness of the gas-tight layer was only 6 g/m 2 . The permeability to oxygen was 3 cm 3 /m 2 per 24 h, 23 °C, 50 % relative humidity. In multilayer packaging materials there has often been a problem of blistering during sealing. The blistering tendency of this product according to Example 2 was 50 % less than that of the control product according to Figure 1. Example 3. To maximize internal adhesion and sealability, modified polyethylene was used also as the polyethylene layer (PE-LD). An amount of 25 % of anhydride-modified polyethylene, NCPE 0470, and an amount of 75 % of PE-LD, NCPE 7518, were mixed. The thicknes¬ ses of the layers were the same as in Example 2. As a consequence, the adhesion to the gas-tight layer and the heat-sealing properties were further improved. Blistering tendency also decreased further. Example 4. In order to achieve maximal aroma-proofing, impermeability and flavor-tightness of ethereal oils, a structure according to Example 4 was prepared, but a surface layer similar to the gas-tight layer was added to it (Figure 3). Such a structure has very good properties but, nevertheless, in addition to the carrier web it has only three layers instead of the traditional five. Example 5. In order to improve further the sealing properties and watertightness of the layer coming against the product, the mixing proportions of the gas-tight layer (a) were optimized. A gas-tight plastic was prepared by mixing an amount of 60 % of ethylene/vinyl alcohol copolymer, manufacturer Du Pont and trade name SELAR OH 4416, and an amount of 40 % of polyethylene modified with maleic acid, manufacturer Borealis Polymers Oy and trade name NCPE 0470. The mixing was carried out as in Example 1. A film 40 μm thick was prepared of the blend. The permeability of the film to oxygen was 1.3 cm 3 /m 2 per 24 h, 23 °C, 50 % relative humidity. The oxygen permeability of a film of the same thickness made of pure ethylene/vinyl alcohol copolymer was 0.3 cm 3 /m 2 per 24 h, 23 °C, 50 % relative humidity. If a gas-tight blend such as this, in which the ratio of the polymers is 60/40, is used in a layered structure a-b-a, i.e. there are two gas- tight layers, good gas-tightness and aroma-proofing properties are achieved, and the processibility of the gas-tight blend is considerably better than that of pure ethylene/vinyl alcohol copolymer. The blistering tendency was very low. Example 6. By the use of polymer blends according to the invention, the melt strength of the gas-tight layer can be improved substantially and the so-called blistering tendency of the structure is reduced. Blistering tendency was measured by using a device specially developed for the purpose, in which hot-air blowing is used. The sample to be tested is attached to a holder, which makes a constant-velocity recipro¬ cal movement under hot-air blowing. The distance from the blower to the sample is 7 mm, and the temperature of the hot air is 350 °C. The blowing causes melting of the plastic. The sample will resist without melting under hot air for a number of reciprocal movements which is the greater the better the resistance of the sample to blistering. The test device clearly correlates with results in practice in packaging machines in which hot air is also used for sealing. Table 1 shows the results of the blistering test for the control material according to Figure 1 and for materials according to Examples 3 and 5. The number indicates the number of reciprocal swings. The blistering tendency of the structures according to the invention is considerably lower than that of the control structure. Table 1. Blistering tests in a hot-air blowing device number of 1 1,5 2 2,5 3 3,5 4 4,5 5 swings Product Control, 5-layered U F F F M M - - - Ex. 3, 2-layered U U U U U V F F M Ex. 5, 3-layered U U U U U u U F F U = unbroken V = very few holes F = few holes M = many holes As can be seen from the above examples, by the use of gas-tight and moisture-proof polymer blends according to the invention, considerable savings of material can be achieved and simpler manufacturing techniques can be used and, nevertheless, the permeability and other properties obtained for the package will be at least as good as those achieved with conventional alternatives. The processibility of the EVOH/PE blend is better than that of pure EVOH, which is due to the better melt strength of the blend. Consequently, a thinner gas-tight layer than conventional will suffice.

Claims: Claims: 1. A multilayer product for the production of packaging, the product having special tightness properties and comprising a carrier web (1) on one face of which there is disposed a tight multilayer coating (2), characterized in that the coating includes, disposed one on top of the other, a moisture-proof layer (b) and a gas-tight layer (a) made up of a blend of an ethylene/vinyl alcohol copolymer and a polar ethylene polymer. 2. A multilayer product according to Claim 1, characterized in that the polar polymer in the gas-tight layer (a) is a copolymer of ethylene and acrylic ester, a copolymer of ethylene and vinyl acetate, or a copolymer of ethylene and (met)acrylic acid. 3. A polar polymer according to Claim 2, characterized in that the acrylic ester is selected from the group ethyl acrylate, butyl acrylate or methyl acrylate. 4. A multilayer product according to Claim 1, characterized in that the polar polymer in the gas-tight layer is a polyolefin modified with carboxylic acid or carboxylic anhydri¬ de. 5. A polar polymer according to Claim 4, characterized in that it is a polyethylene modified with maleic anhydride. 6. A multilayer product according to Claim 1, characterized in that the polar polymer in the gas-tight layer is a copolymer of ethylene, acrylic ester and carboxylic acid or anhydride, such as ethylene/butyl acrylate/metacrylic acid te olymer. 7. A gas-tight layer according to Claim 1, characterized in that the ethylene content in the ethylene/vinyl alcohol copolymer is 20-50 % . 8. A gas-tight layer (a) according to Claims 1-7, characterized in that the blend contains polar polymer in an amount of 5-60 % . 9. A gas-tight layer (a) according to Claims 1-8, characterized in that the basis weight of the layer is 1-20 g/m 2 , preferably 2-10 g/m 2 . 10. A multilayer product according to Claim 1, characterized in that the moisture-proof layer (b) is polyolefin. 11. A multilayer product according to Claim 10, characterized in that the moisture-proof layer (b) is polyethylene. 12. A multilayer product according to Claim 11, characterized in that the moisture-proof layer (b) is a blend of polyethylene and a polar ethylene polymer. 13. A moisture-proof layer according to Claim 12, characterized in that the polar polymer is in accordance with Claims 2-6. 14. A moisture-proof layer according to Claims 11-13, characterized in that the amount of polar polymer is 2-50 %, preferably 20-30 %. 15. A multilayer product according to Claim 1, characterized in that the layers are on top of the carrier web in the order a-b. 16. A multilayer product according to Claim 1, characterized in that the layers are on top of the carrier web in the order b-a. 17. A multilayer product according to any of the above claims, characterized in that it additionally includes a third surface layer. 18. A multilayer product according to Claim 17, characterized in that the third surface layer is a gas-tight layer (a-b-a). 19. A multilayer product according to any of the above claims, characterized in that the multilayer coating is done by coextrusion coating.

Inventors: KOSKI ELINA, KOSKINIEMI RIITTA, KUUSELA SEPPO, LAIHO ERKKI, PENTTINEN TAPANI, SAINIO MARKKU, SALSTE MATTI, KOSKI, ELINA, KOSKINIEMI, RIITTA, KUUSELA, SEPPO, LAIHO, ERKKI, PENTTINEN, TAPANI, SAINIO, MARKKU, SALSTE, MATTI
Applicants: BOREALIS HOLDING AS, ENSO GUTZEIT OY, KOSKI ELINA, KOSKINIEMI RIITTA, KUUSELA SEPPO, LAIHO ERKKI, PENTTINEN TAPANI, SAINIO MARKKU, SALSTE MATTI, BOREALIS HOLDING A/S, ENSO-GUTZEIT OY, KOSKI, ELINA, KOSKINIEMI, RIITTA, KUUSELA, SEPPO, LAIHO, ERKKI, PENTTINEN, TAPANI, SAINIO, MARKKU, SALSTE, MATTI
Application year: 1995
Main classification: B32B27
IPC codes: B32B27, B65D65