Patent Description:
Plastic containers have been increasingly used in packaging applications, such as food packaging. A typical plastic container often used for bulk packaging of food (e.g. powdery food, coffee, cocoa, nuts) is called FIBC (=flexible intermediate bulk container). This type of container often is a woven polyethylene or polypropylene.

In the inside or outside of the woven material, another plastic liner is often used. This liner is made of a monolayer or multilayer film which comprises polymer materials. There are different types of adherence of this liner to the outer woven liner as seen in the prior art documents e.g. <CIT>.

In the case of multilayer film, the different layers offer different advantages to the final applications. The inside layer (=the layer coming into direct contact with the food packed) is often formulated to allow very good sealing, thus protecting the existence of leakers that would be detrimental for the packed product. Other layers may comprise abuse resistant polymers to increase the mechanical strength of the material.

In case of oxygen sensitive food materials, at least one layer of the multilayer construction comprises material which is impermeable to oxygen. As well known in the art, such materials are often polyamides, PVDC or EVOH.

It is very often the case that the multilayer film is in "gusseted tube" configuration. The reason is that this configuration is more practical for bulk filling, transport and unloading versus a simple tube. Gussets are produced in line with the process by the use of two "pleating constructions" (often wooden, plastic or metal) which the film follows during on line processing. As these multilayer tube materials are often produced with the "hot blown film" method which often involves rotation of the collapsing frame and of the gusset equipment, a common problem is that the creases are not present continuously but periodically following the rotation and this increases the scrap and lowers the efficiency of the operation. There are cases where the creases are so often that the tube cannot be made into a gusset efficiently.

It is generally known in the art that less stiff polymers e.g. LDPE have better gussetability versus stiffer ones like HDPE. It is believed that the material must be softer and more pliable in order to form efficiently a gusset during the production process. High barrier materials such as EVOH or polyamide are generally considered to make the gusseting process even more difficult as they are usually stiffer than polyolefins.

There is a need to improve the "gussetability" of the plastic structure i.e. to find materials pliable enough and with enough bubble stability to produce gussets with no creases in the commonly used thickness range of <NUM>-<NUM> microns without sacrificing the oxygen barrier properties of the plastic film.

Another common requirement of the film used as interior film for FIBC bulk container is the need for excellent "flex crack resistance". As explained in <CIT>, flex cracking may occur during shipping and handling of liners where flowable materials are packed. As further explained in the above reference, the Gelbo flex testing is used for the evaluation of flex crack. However, this reference does not refer to oxygen barrier polymers which in general have much worse flex crack properties than polyolefins.

There has been in the prior art efforts to improve the flex crack of films. For example <CIT> teaches a proper film construction to improve flex cracking of barrier polymers such as EVOH.

<CIT> relates to gusseted plastic film with a thickness of <NUM> to <NUM> microns, comprising a polyolefin homopolymer or copolymer, a polyether copolymer and a layer comprising oxygen barrier polymer. <CIT> does not describe a multilayer film comprises an outer layer comprising a blend of two or more polyamides and an outer layer further comprising polyamide-based slip and/or anti-block additives.

<CIT> relates to the use of composite foils based on polyvinyl alcohols as packaging material for polymers susceptible to oxidation. <CIT> does neither disclose a film with an outer layer comprising a blend of two or more polyamides nor the use of slip and/or anti-block additives in the outer layer or an inner layer comprising a blend of an ethylene alpha-olefin copolymer and a polyether copolymer.

<CIT> and <CIT> relate to flexible liners for use in bulk containers such as those used in flexible intermediate bulk container ("FIBC") systems or bag-in-box container systems, and disclose a nylon coextruded or laminated to a polyethylene or polypropylene layer. <CIT> and <CIT> do neither disclose a film with an outer layer comprising a blend of two or more polyamides nor the use of slip and/or anti-block additives in the outer layer or an inner layer comprising a blend of an ethylene alpha-olefin copolymer and a polyether copolymer.

<CIT> relates to packages for moisture containing products, such as cheese, including a polyamide layer, an ethylene vinyl alcohol (EVOH) layer, a sealant layer, and a moisture barrier layer located between the sealant layer and the polyamide and EVOH layers. <CIT> does not disclose the use of a polyamide-based slip/anti-block additive in the outer layer nor an inner layer comprising a blend of ethylene alpha-olefin copolymer and polyether copolymer.

However, there is still a need in the market to improve further the gussetability and the flex crack of films that are used as FIBC liners.

In the market films with the structure
Polyolefin (outer layer) / tie layer / Polyamide / EVOH / tie layer / Polyolefin / Polyolefin (inner layer)
are sometimes used.

The present inventor experienced that such films are quite difficult to produce stably due to poor gussetability and poor flex crack properties. However, the present inventor unexpectedly found out that if the outer layer comprises polyamide, gussetability and flex crack resistance improve substantially.

According to the invention a very suitable film for the FIBC liner has a thickness of <NUM> to <NUM> microns and comprises.

Optionally the film comprises another layer comprising an oxygen barrier polymer.

In this application the following definitions are used:
Unless otherwise indicated all percentages used herein refer to percentage by weight.

The term "gusset" is interpreted as well known in the art. That is a plastic tubular film having a partial <NUM> fold configuration.

The term "film" refers to a flat or tubular flexible structure of thermoplastic material.

The term "FIBC liner" refers to a plastic film slit, sealed and cut to the proper dimensions and used inside a "flexible intermediate bulk container" (FIBC) for extra protection of the bulk cargo.

The term "heat shrinkable" refers to a film that shrinks at least <NUM>% in at least one of the longitudinal and transverse directions when heated at <NUM> for <NUM> seconds. The shrinkability is measured according to ASTM <NUM>.

The phrase "longitudinal direction" or "machine direction" herein abbreviated "MD" refers to a direction along the length of the film.

The phrase "outer layer" refers to the film layer which comes in immediate contact with the outside environment (atmosphere). In the FIBC application, the outer layer is in contact with the outside woven construction of PP or PE.

The phrase "inner layer" refers to the film layer that comes in direct contact with the product packed. This is also called "sealing layer" as this layer must be hermetically sealed in order to protect the product from ingress of air.

The phrase "intermediate layer" refers to any layer of the film that is neither outer nor inner layer. A film may comprise more than one intermediate layers.

As used herein, the term "homopolymer" refers to a polymer resulting from polymerization of a single monomer.

As used herein, the term "copolymer" refers to a polymer resulting from polymerization of at least two different polymers.

As used herein, the term "polymer" includes both above types.

As used herein, the term "polyolefin" includes all the polymers produced by polymerization of olefins. Polyethylene, polypropylene, polybutylene and other products are included in this general category.

As used herein the term "polyethylene" identifies polymers consisting essentially of the ethylene repeating unit. The ones that have a density more than <NUM> are called high density polyethylene (HDPE), the ones that are have less than <NUM> are low density polyethylene (LDPE).

As used herein the phrase "ethylene alpha olefin copolymer" refers to polymers like linear low density polyethylene (LLDPE), medium density polyethylene (MDPE), very low density polyethylene (VLDPE), ultra-low density polyethylene (ULDPE), metallocene catalyzed polymers and polyethylene plastomers and elastomers.

In these cases the alpha olefin can be propene, butene, hexene, octene etc. as known in the art.

As used herein the term "homogeneous ethylene alpha olefin copolymers" refer to ethylene alpha olefin copolymers having a molecular weight distribution less than <NUM> as measured by GPC. Typical examples of these polymers are AFFINITY from DOW or Exact from Exxon.

As used herein the phrase "styrene polymers" refers to styrene homopolymer such as polystyrene and to styrene copolymers such as styrene-butadiene copolymers, styrene-butadiene-styrene copolymers, styrene-isoprene-styrene copolymers, styrene-ethylene-butadiene-styrene copolymers, ethylene-styrene copolymers and the like.

As used herein the phrase "ethylene methacrylate copolymers" refers to copolymers of ethylene and methacrylate monomer. The monomer content is less than <NUM>% per weight. The abbreviation used is EMA.

As used herein the phrase "ethylene vinyl acetate copolymer" refers to copolymers of ethylene and vinyl acetate. Abbreviation used is EVA.

As used herein the term "barrier polymers" or "oxygen barrier polymers" refer to polymers that have an oxygen permeability less than <NUM><NUM>/m<NUM>*atm*<NUM> per <NUM> microns of polymer. The measurement is made as per ASTM F <NUM> at <NUM>, <NUM>% RH.

As used herein, the term EVOH refers to saponified products of ethylene vinyl ester copolymers. The ethylene content is typically in the range of <NUM> to <NUM>% per mol.

As used herein the term PVDC refers to a vinylidene chloride copolymer wherein a major amount of the copolymer comprises vinylidene chloride and a minor amount of the copolymer comprises one or more monomers such as vinyl chloride and/or alkyl acrylates and methacrylates.

As used herein, the term "polyamides" includes aliphatic homo- or co-polyamides commonly referred to as e.g. polyamide <NUM>, polyamide <NUM>, polyamide <NUM>, polyamide <NUM>, polyamide <NUM>, polyamide <NUM>, polyamide <NUM>/<NUM>, polyamide <NUM>/<NUM>, polyamide <NUM>/<NUM>, modifications thereof and blends thereof. Said term also includes crystalline or partially crystalline, aromatic or partially aromatic, polyamides, such as polyamide 6I/6T or polyamide MXD6. Said term also includes polyamides made of combination of three or more monomers, such as polyamide <NUM>/<NUM>/<NUM>, <NUM>/<NUM>/6I, <NUM>/<NUM>/<NUM> and others. The term also includes polyamide alloys such as Orgalloy from Arkema.

As used herein the term "ionomer" refers to ethylene-acid copolymers which have been neutralized by metals such as sodium, zinc, lithium or others.

The acid used is usually methacrylic or acrylic acid.

As used herein, the term "ethylene acid copolymer" refers to copolymers of ethylene with acid, most usually methacrylic or acrylic acid.

As used herein, the term "polyester" includes crystalline polymers, amorphous polymers and polyester elastomers. Common polyesters are crystalline PET (polyethylene terephthalate), amorphous PET, PETG (glycol modified polyethylene terephthalate), PBT (polybutylene terephthalate), PTT (polytrimethylene terephthalate), PBN (polybutylene naphthalate), PEN (polyethylene naphthalate). Other polyester materials are also included in the above definition.

As used herein the term "polybutylene" refers to butene-<NUM> homopolymers and copolymers. Useful copolymers comprise ethylene mer units. Ethylene content should be generally less than <NUM>%per weight.

Preferably the film comprises <NUM> to <NUM> layers, more preferably <NUM> to <NUM> layers.

A typical example of the film construction in <NUM> layer mode is:.

A typical example of the film construction in <NUM> layer mode is.

The film in a preferable version contains high oxygen barrier materials so that it protects the components of the pack from the detrimental effect of oxygen ingress. EVOH is a preferred option but also polyamide and PVDC are viable alternatives. The EVOH is preferably <NUM> to <NUM>% ethylene per mol, more preferably <NUM> to <NUM>% ethylene per mol.

In another preferred version of the invention, the barrier polymer is polyamide. Most suitable polyamides are polyamide <NUM> and copolymer <NUM>/<NUM> or <NUM>/<NUM>.

Preferably, the intermediate layers comprise different polyolefins. Preferred polyolefins are ethylene alpha olefin copolymers, where alpha olefin is preferably butene, hexene or octene.

In a preferred version the ethylene alpha olefin copolymers are random copolymers with densities from <NUM>/cm<NUM> up to <NUM>/cm<NUM>. In a further preferred version the molecular weight distribution of the ethylene alpha olefin copolymers are less than <NUM>, preferably less than <NUM>, preferably less than <NUM>.

As well known in the art, there is no natural adhesion between polyolefins and oxygen barrier polymers such as EVOH.

Suitable materials for the tie layer process include maleic anhydride modified EVA, maleic anhydride modified polyethylene, maleic anhydride modified EMA, maleic anhydride modified elastomer, partially saponified EVA copolymer and polyurethane elastomer.

In the tie layers also polyamides can be used, given the strong natural adhesion between polyamide and EVOH. Preferred polyamides are polyamide <NUM>, polyamide <NUM>/<NUM> and polyamide <NUM>/<NUM>.

The outer layer of the film comprises polyamide. Polyamide <NUM> and polyamide <NUM>/<NUM> are preferred.

The outer layer comprises a blend of two or more different polyamides. In a preferred version, the outer layer comprises an amorphous polyamide.

The outer layer further comprises polyamide based slip and/or polyamide based antiblock additives.

In a preferred version of the invention, the outer layer comprises at least <NUM> ppm (parts per million) per mass of an amide lubricant such as oleamide, erucamide, stearamide, oleyl palmitamide and so on. Preferable amide is strearamide.

The outer layer may also comprise antistatic additives or polymers. These can offer either "permanent" antistatic performance, where there is no deterioration of the antistatic properties for at least <NUM> months or "temporary" antistatic performance. In a preferred version of the invention, the outer layer comprises a "permanent" antistatic.

The inner layer of the film would be able to seal the film to itself to secure that no leakers and oxygen influx is allowed. This could be detrimental to the product packed.

Suitable materials for the inner layer include different polyolefins, preferable ethylene alpha olefin copolymers, low density polyethylene, polypropylene or polyether copolymers.

The inner layer comprises a blend of ethylene alpha olefin copolymers and polyether copolymers. Preferred polyether copolymers are materials such as polyamide-polyether copolymers, polyolefin-polyether copolymers, polyester-polyether copolymers and the like. Typical materials are Irgastat from BASF, Pebax from Arkema, Pelestat from Sanyo and the like.

In general, the above layers may comprise further well known in the art additives such as antiblock, slip, antifog, polymer processing enhancers and others.

From a commercial hot blown film line the following film was produced.

The density of ethylene hexene copolymer was <NUM> while MFI was <NUM> under <NUM>/<NUM> kilos.

The maleic anhydride modified LLDPE was Bynel 41E710 from Dow.

Tie layers <NUM> and <NUM> were maleic anhydride LLDPE based copolymer (Admer from Mitsui). EVOH <NUM>% is EVOH with <NUM>% ethylene per mol.

Intermediate layer comprised a blend of <NUM>% octene based LLDPE + <NUM>% LDPE + <NUM>% polyethylene based slip and antiblock masterbatch. The octene based LLDPE had a density of <NUM>/cm<NUM> and an MFI of <NUM> measured at <NUM>, <NUM>. The LDPE had a density of <NUM>/cm<NUM> and an MFI of <NUM> measured at <NUM>, <NUM>.

Inner layer was a blend of
<NUM>% metallocene LLDPE + <NUM>% LDPE + <NUM>% slip antiblock masterbatch Metallocene LLDPE had a density of <NUM> while MFI was <NUM> under <NUM>/<NUM>.

LDPE was the same as the LDPE used in the intermediate layer as above.

In the case of example <NUM> the polyamide <NUM> used in the outer layer was replaced by a polyamide <NUM>/<NUM> of same viscosity (Ultramid C40L from BASF).

In this example, the EVOH <NUM>% (<NUM>% ethylene per mol) was replaced by EVOH <NUM>% (<NUM>% ethylene per mol) which is stiffer and thought to be more difficult to form gusset.

Further, the Tie layer <NUM> of this example is <NUM>% polyamide <NUM>/<NUM> (Ultramid C40L from BASF).

The comparative example was produced according to the structure already used in the market of
Polyolefin (outer layer) / tie layer / Polyamide / EVOH / tie layer / Polyolefin / Polyolefin (inner layer)
Therefore, the following film was produced.

Outer layer was a blend of
<NUM>% of octene based LLDPE + <NUM>% LDPE + <NUM>% polyethylene based slip/antiblock masterbatch.

The octene based LLDPE had a density of <NUM>/cm<NUM> and an MFI of <NUM> measured at <NUM>, <NUM>.

The LDPE had a density of <NUM>/cm<NUM> and an MFI of <NUM>.

Tie layer <NUM> was <NUM>% polyamide <NUM> + <NUM>% polyamide based slip masterbatch + <NUM>% polyamide based antiblock masterbatch, where the polyamide <NUM> was Ultramid B40LN from BASF.

Tie layer <NUM> was maleic anhydride LLDPE based copolymer same as in example <NUM>.

EVOH <NUM>% is EVOH with <NUM>% ethylene per mol.

Intermediate layer comprised a blend of <NUM>% octene based LLDPE + <NUM>% LDPE + <NUM>% polyethylene based slip and antiblock masterbatch. The octene based LLDPE had a density of <NUM>/cm<NUM> and an MFI of <NUM> measured at <NUM>, <NUM>. The LDPE had a density of <NUM>/cm<NUM> and an MFI of <NUM> measured at <NUM>, <NUM>. The structure of this layer is same as in example <NUM>.

LDPE was the same as the LDPE used in the intermediate layer as above. The structure of this layer is same as in example <NUM>.

On the tower of the blown film line two gusset boards were mounted as known in the art. Each example structure ran in production for <NUM> hours and the number of creases was monitored. As the creases tend to come along in timely intervals, "creasing instances" were recorded, meaning any incident was recorded when more than <NUM> creases passed from the nip section of the blown film line.

The rotation speed was kept constant during the experiment.

Reference Example <NUM> (not forming part of the invention) presented <NUM> creasing incident during the two hours production.

Reference Example <NUM> (not forming part of the invention) presented <NUM> creasing incidents.

Reference Example <NUM> (not forming part of the invention) presented <NUM> incidents.

The comparative example presented <NUM> incidents during the two hours production.

The flex crack resistance was measured according to MIL-B-<NUM> D using Gelbo Flex Tester.

The flexing action consists of a twisting motion at a speed of <NUM> cycles per minute. The sample is flexed for <NUM> minutes and then flex failure is determined by measuring the number of pinholes formed in the film. The results are averages of testing of <NUM> specimens of each film.

The higher the number of pinholes the less flex crack resistant the film is. Examples <NUM>-<NUM> are Reference Examples <NUM>-<NUM>, not forming part of the invention.

Claim 1:
A multilayer film having thickness of <NUM>-<NUM> microns, where the film comprises a polyolefin polymer, an outer layer comprising polyamide and an inner layer comprising a blend of ethylene alpha olefin copolymers and polyether copolymers, where the outer layer comprises a blend of two or more polyamides and the outer layer further comprises polyamide based slip and/or polyamide based antiblock additives.