Multilayer films made of pvoh

Abstract

The present invention relates to films made of PVOH and phyllosilicates, which are particularly suitable for producing food packaging. The film can be used to produce a layer of a multi-layer packaging. The film can form both a gas barrier and a water barrier and can in particular provide excellent adhesion between layers.

Description

[0001] PVOH multilayer films

[0002] The present invention relates to films that are particularly suitable for the production of food packaging. The film can be used to produce one layer of a multilayer packaging. The film can form both a gas and a water barrier and, in particular, can provide excellent adhesion between layers, which, however, can be easily removed during the recycling process.

[0003] The widespread and important principle of sustainability also applies to packaging materials. There are various approaches. One is the use of biopolymers. Another approach is recycling-friendly design, i.e. a packaging structure that avoids highly complex, energy-intensive and costly treatment processes during recycling, leads to pure, directly reusable raw materials after separation and thus makes the entire process economical and perfectly sustainable – i.e. a circular process. It is important that the materials can be processed as completely as possible into pure secondary raw materials. With multi-layer materials, it is therefore important that the individual raw materials can be separated from one another as cleanly as possible without having to use a lot of energy. It is also advantageous if the desired properties of a packaging can be achieved using as few layers or materials as possible.

[0004] Of course, even with recycling-friendly packaging design, the goal remains to use biopolymers wherever possible instead of fossil-based polymers, so that even if they are not disposed of properly, no microplastics are released into nature. Biopolymers or bio-based polymers are polymers based on renewable resources or polymers that are biodegradable. The most commonly available renewable raw material is cellulose, which is mainly obtained from wood, cotton, and annual plants. However, cellulose has inherent disadvantages that limit its use: poor solubility in common solvents, which makes it difficult to use as a coating, and the lack of thermoplasticity required for direct extrusion. In addition, cellulose is hygroscopic and, depending on the relative humidity, participates in an adsorption-desorption equilibrium with water vapor or carbon dioxide.It absorbs water, which leads to volume swelling upon absorption and volume shrinkage upon release. It therefore has neither a high gas nor an aroma barrier. The latter, in particular, hinders the use of cellulose-based materials in packaging applications for moist foods or humid environments. To overcome these disadvantages, cellulose is combined with barrier layers. They can meet the high requirements (protection against moisture, water, and grease, as well as resistance to oxygen permeability (OTR)) and also fulfill shelf life requirements. However, these layers often pose a problem in the recycling process because they cannot be completely removed from the carrier material, or once removed, are difficult or only with great effort.

[0005] Due to its good barrier properties against oxygen, CO2, and other polar, gaseous / volatile compounds such as flavorings, polyvinyl alcohol (PVOH) is often used as a barrier layer in cellulose-based multilayer systems for food packaging. It dissolves residue-free in the added water during the recycling process (no microplastic formation in the recyclate or wash water). A disadvantage is its lack of a barrier against water vapor in current applications.

[0006] Crosslinking generally improves water resistance. However, depending on the crosslinking density, the barrier effect against gases and the rate of degradation also decrease. To combine good water resistance with a high barrier level, a metal complexing agent can be used as an alternative. However, this leads to reversible network formation. Due to the accumulation of these metal complexing agents in the wash water, this is problematic for ecological reasons and causes significant costs for separation and disposal. Non-polar water vapor barrier layers can also be combined with PVOH layers. However, the non-polar water vapor barrier layers are difficult to apply to polar PVOH. Good adhesion values ​​can be achieved by pretreating the non-polar surfaces with corona (plasma) pretreatment or the use of adhesion promoters.However, this often means more effort and therefore more costs.

[0007] The object of the invention is to provide an improved oxygen barrier for packaging, and in particular food packaging, which at the same time does not interfere with the recycling of the packaging or even improves or facilitates this.

[0008] At least one of these aspects of the task is triggered by a slide that

[0009] 2 - 95 wt.% polyvinyl alcohol

[0010] 3 - 70 wt. % of a layered silicate, a mixture of layered silicates or comparable mineral

[0011] 0-30 wt.% plasticizer and / or other additives, and optionally water. The phyllosilicate or mixture of phyllosilicates is in the form of micro- and nanoparticles. The particles are preferably platelet-shaped. This means they are thin but flat. In other words, the length and width of the particles are greater than their thickness. The film is suitable for a wide variety of packaging applications and is particularly suitable for the production of food packaging.

[0012] One embodiment of the present invention relates to films, in particular for the production of food packaging, comprising

[0013] 30 - 89 wt.% polyvinyl alcohol

[0014] 10 - 50 wt.% of a layered silicate or a mixture of layered silicates 1 - 30 wt.% of a plasticizer characterized in that the layered silicate or the mixture of layered silicates is in the form of microparticles and nanoparticles.

[0015] The films according to the invention can also be in the form of a coating on a carrier material or in the form of a layer of a multilayer material, in particular a multilayer composite material, or a multilayer packaging.

[0016] Depending on which of the film's positive properties are most important, the amounts of polyvinyl alcohol and phyllosilicate can be varied. Higher amounts of polyvinyl alcohol, especially in combination with suitable plasticizers (including water), increase adhesiveness and elasticity, but reduce the barrier effect of the mineral additives. Due to their chemical composition with many surface-existing OH functions, phyllosilicates generally have a positive influence on adhesion to polar substrates. The film can therefore contain 2-95 wt.% polyvinyl alcohol, preferably 20-80 wt.% polyvinyl alcohol, preferably 30-70 wt.% polyvinyl alcohol, and more preferably 40-65 wt.% polyvinyl alcohol.

[0017] Polyvinyl alcohol (PVOH) is a synthetic polymer of vinyl alcohol, which does not exist as a free monomer and is therefore produced by more or less complete hydrolysis of polyvinyl esters. Characteristic of polyvinyl alcohols is the vinyl alcohol unit [CH2CH(OH)] nPolyvinyl alcohol is generally slightly branched and has a degree of polymerization of approximately 500 to 2500. Polyvinyl alcohols are usually produced by replacing the acetate groups of polyvinyl acetate with hydroxyl groups, e.g. by hydrolysis or alcoholysis. The percentage of acetate groups replaced by hydroxyl groups is the degree of hydrolysis of the PVOH produced and indicates the percentage of hydroxyl groups present in the PVOH out of the total possible hydroxyl groups. The present invention encompasses, inter alia, films whose PVOH has a degree of hydrolysis of 60 to 98 mol%, and preferably of 70 to 95 mol%, more preferably of 75 to 90 mol%, and even more preferably of 80 to 90 mol%. A PVOH with a degree of hydrolysis of 86 to 89 mol% is particularly preferred.

[0018] The present invention also encompasses films and materials whose PVOH has a molecular weight of 13,000 to 80,000, and preferably of 15,000 to 60,000, and more preferably of 30,000 to 50,000. The PVOH used preferably has good solubility at low water temperatures. It is preferred if the PVOH of the present invention can be prepared at least at 20°C as a 4% solution in water. By adding the micro- and nanoparticles of the layered silicate, the lower water barrier of a cold-soluble PVOH (with the aforementioned advantages) can be compensated for, with absolute impermeability to most gases. Thus, a good barrier function is combined with good solubility in cold water.

[0019] Depending on the degree of hydrolysis, PVOH is a water-soluble and biodegradable plastic in an aqueous environment. PVOH plastics are characterized by high tear strength and elasticity. These properties depend on the air humidity, as the plastic absorbs water. Depending on their composition, they have a controllable water dissolution temperature of 5–90°C. It is preferred if the PVOH of the present invention can be produced at 20°C as a solution in water containing at least 4%. One possible embodiment of the film of the present invention is soluble in water at a maximum temperature of 40°C, preferably 20°C. In one embodiment, the PVOH portion of the film can dissolve completely in water. In dissolved form, it can be processed and recovered for reuse or, alternatively, completely degraded into water (H2O) and carbon dioxide (CO2) by the action of microorganisms and bacteria.Due to their chemical composition, no toxic intermediate compounds are formed. In contrast to non-degradable polymers, whether fossil-based or bio-based, water-soluble PVOH granules and products, once dissolved, do not produce microplastics. Layered silicates (also known as sheet silicates or phyllosilicates) are silicates whose silicate anions consist of layers of corner-sharing SiCh tetrahedra. These layers or bilayers are not linked to one another via further Si-O bonds to form frameworks. Possible layered silicates for the film according to the invention are bentonite, montmorillonite, hectonite, pyrophyllite Al2[(OH)2|Si40io], apophyllite, muscovite, phlogopite, and talc, with talc being preferred due to its ready availability. Montmorillonite is also suitable.

[0020] One embodiment relates to films in which the layered silicate is present in the form of micro- and nanoparticles as a mixture of talc and a related similar layered silicate, such as montmorillonite. The microparticles may consist of talc and the nanoparticles of another layered silicate, such as montmorillonite. Another embodiment relates to films in which the layered silicate in the form of micro- and nanoparticles consists solely of talc.

[0021] The mineral talc, also known as talc in powdered form, has the chemical composition Mg3[(OH)2|Si40io] and is therefore chemically a magnesium silicate hydrate.

[0022] Talc microparticle and nanoparticle synthesis can be carried out using physical and chemical methods. Physical methods involve creating particles by reducing the size of the starting material, e.g., by grinding it after mining (top-down approach). However, talc can also be produced synthetically (bottom-up approach). It has proven advantageous to use chemically synthesized nanoparticles, as a more uniform size distribution and better layering can be achieved.

[0023] To specifically influence the film's properties, the amounts of the components can be adjusted. Due to its hydrophilic nature, polyvinyl alcohol is well suited as a barrier against greases and mineral oils. The hydrogen bonds between the polymer chains, combined with its crystalline structure, make polyvinyl alcohol an excellent barrier against oxygen, nitrogen, carbon dioxide, and organic solvents. Using layered silicates in a PVOH solution allows for higher overall solids contents. This enables greater layer thicknesses, and the coating production process, which uses less water, saves energy. Furthermore, significantly higher oxygen barrier values ​​can be achieved with comparable layer thicknesses than with pure PVOH. Furthermore, the addition of bio-based plasticizers and natural minerals significantly reduces the oil-based portion of the overall mixture.

[0024] Adhesion to other materials, especially similarly modified non-polar materials, is also significantly improved by blending PVOH with the phyllosilicates. During film production, greater process stability is achieved (due to significantly reduced foam formation) and fewer defects are formed. A more stable mixture can also be achieved, meaning that with high phyllosilicate contents, no segregation or settling of the solid components occurs.

[0025] To maximize adhesion promoter properties, moisture barrier, and gas barrier, it has proven advantageous for the film to contain 25-70 wt.% polyvinyl alcohol, preferably 30-65 wt.% polyvinyl alcohol, and more preferably 35-55 wt.% polyvinyl alcohol. The amount of phyllosilicate(s) (micro- and nanoparticles in total) can be between 3 and 70 wt.%, preferably 10-50 wt.%, preferably 15-40 wt.%, and more preferably 18-30 wt.%.

[0026] With regard to all embodiments described here, it is preferred if the microparticles have a diameter of 0.3 - 5 pm and the nanoparticles have at least one dimension that is less than 100 nanometers. One embodiment of the invention relates to films wherein the microparticles have a maximum diameter of 0.3 - 10 pm, preferably 0.3 - 5 pm and more preferably 0.5 - 4 pm. The microparticles can be characterized more precisely by the maximum and the mean (median) particle size. Here, it is preferred if the microparticles have a maximum particle size (d98%) of less than 15 pm, preferably less than 12 pm and more preferably less than 10 pm. The median particle size (d50%) can be in the range from 0.5 pm to 5 pm, preferably between 1 pm and 2.5 pm. The microparticles can be regular, irregular, laminar particles or have a flat or platelet shape.If the microparticles are irregularly shaped, the ranges given above refer to equivalent diameters determined by comparing physical properties, such as the settling speed in a liquid, of the particle with a sphere of the corresponding diameter.

[0027] The term "nanoparticles" herein refers to particles that have at least one dimension that is less than 100 nanometers. The term "nanoparticles" encompasses materials that consist of particles in the solid state that occur either independently or as components of aggregates or agglomerates. One embodiment of the invention relates to films wherein the nanoparticles have a maximum diameter of 1-100 nm, preferably 2-80 nm, and more preferably 5-50 nm. The nanoparticles can be characterized more precisely by their maximum and median particle size. Here, it is preferred if the microparticles have a maximum particle size (d98%) of less than 100 nm. The median particle size (d50%) can be in the range from 2 to 50 nm.

[0028] The nanoparticles can have a platelet-like shape, with one or two external dimensions being less than 100 nm and another external dimension being in the range of 2 to 50 nm. This smaller external dimension is preferably the thickness or height of the nanoparticles, which is thus in the range of 2 to 50 nm, preferably 8-25 nm, and more preferably 10-20 nm. It is preferred that the nanoparticles have a thickness in a range of 5 to 50 nm, and the length ratio of the longest external dimension to the thickness is in a range of 20,000 to 5, preferably 5,000 to 20, and ideally 500 to 50. This refers to individual, non-agglomerated nanoparticles.

[0029] The ratio in weight percent of microparticles to nanoparticles in the film according to the invention or in individual layers of the film or a multilayer material can be between 60:40 and 95:5. A range of 70:30 and 90:10 or 75:25 and 85:15 is preferred.

[0030] Plasticizers are substances that make the film or layers, and the materials made from them, softer, more flexible, and more pliable. They increase plasticity and reduce viscosity.

[0031] Plasticizers within the meaning of this invention can be selected from a group consisting of glycerin, glycerol esters, sorbitol, propylene glycol, triethyl citrate, and 2-methyl-1,3-propanediol. Glycerin is preferred. Plasticizers whose action is based on intermolecular interactions are preferred over plasticizers that act via copolymerization. Therefore, any residual (equilibrium) water contained in the product also acts as a plasticizer.

[0032] In addition to the components mentioned above (PVOH, phyllosilicate, and plasticizer), the film according to the invention can also contain a solvent, preferably water, and other additives. The addition of water prior to melt processing can be used specifically for the production of foam films at processing temperatures well above 100°C by evaporation due to pressure loss at the die.

[0033] The solvent can make up to 90% by weight of the composition from which the film is produced. The film according to the invention can contain up to 15% by weight of water, preferably up to 5% by weight, and more preferably up to 2% by weight, or have a water content of 1-15% by weight, and more preferably 2-10% by weight.

[0034] The additional additives can make up to 2 percent by weight of the film according to the invention. Films containing less than 1 percent by weight of additives not explicitly mentioned, or with an additive content of 0.1 to 1 percent by weight, and more preferably of 0.01 to 0.5 percent by weight, are preferred. Possible additives include other polymers, stabilizers such as light stabilizers, pigments, and dyes. However, since the purity of recyclates is also important for optimizing recycling processes, it can also be advantageous if no additional additives are present and the films consist only of PVOH, phyllosilicate(s), and a plasticizer.

[0035] One embodiment therefore relates to films, in particular for the production of food packaging, containing or consisting of

[0036] 30 - 70 wt.% polyvinyl alcohol

[0037] 15 - 40 wt. % of a layered silicate or a mixture of layered silicates

[0038] 5 - 30 wt. % plasticizer

[0039] 0 - 2 wt. % additives, characterized in that the layered silicate or the mixture of layered silicates is in the form of microparticles and nanoparticles.

[0040] A further embodiment relates to films, in particular for the production of food packaging, containing or consisting of

[0041] 30 - 70 wt.% polyvinyl alcohol

[0042] 15 - 30 wt. % of a layered silicate or a mixture of layered silicates

[0043] 5 - 30 wt. % plasticizer

[0044] 0 - 20 wt.% solvent, preferably water, characterized in that the layered silicate or the mixture of layered silicates is in the form of microparticles and nanoparticles.

[0045] A further embodiment relates to films, in particular for the production of food packaging, containing or consisting of

[0046] 30 - 80 wt. % polyvinyl alcohol 20 - 50 wt. % of a layered silicate or a mixture of layered silicates

[0047] 5 - 30 wt. % plasticizer

[0048] 0 - 1 wt.% additives, and

[0049] 0 - 5 wt.% solvent, preferably water, characterized in that the layered silicate or the mixture of layered silicates is in the form of microparticles and nanoparticles.

[0050] An additional embodiment relates to films, in particular for the production of food packaging, containing or consisting of

[0051] 30 - 70 wt. %, preferably 55 - 65 wt. % polyvinyl alcohol

[0052] 15 - 30 wt. %, preferably 18 - 25 wt. % of a layered silicate or a mixture of layered silicates

[0053] 5 - 30 wt%, preferably 15 - 25 wt% plasticizer, and

[0054] 0-10 wt% solvent, preferably water, characterized in that the layered silicate or the mixture of layered silicates is in the form of microparticles and nanoparticles. This film contains no further additives other than unavoidable impurities, which amount to less than 0.1 wt% and preferably less than 0.01 wt%.

[0055] One embodiment of the invention comprises a film made of

[0056] 4 - 40 wt.% polyvinyl alcohol, preferably 2 wt.% PVOH

[0057] 20 - 80 wt.% of a layered silicate, preferably 8 wt.% with a ratio of 3:1 of nanoparticles to microparticles and preferably nanoparticles to microparticles of talc, and

[0058] 0 - 8 wt.% plasticizer. This film can be made from a composition of

[0059] 1 - 10 wt.% polyvinyl alcohol, preferably 2 wt.% PVOH

[0060] 5 - 20 wt.% of a layered silicate, preferably 8 wt.% with a ratio of 3:1 of nanoparticles to microparticles and preferably nanoparticles to microparticles of talc, 0 - 2 wt.% plasticizer, and

[0061] 80 - 90 wt.% water.

[0062] These films can be manufactured very thin and have a very good oxygen barrier or, in general, a very good gas barrier. However, they are difficult to apply as a homogeneous coating and tend to be brittle after drying, especially with very high phyllosilicate content. This can be improved with a small amount of plasticizer.

[0063] One embodiment of the invention comprises a film made of

[0064] 30 - 50 wt.% polyvinyl alcohol,

[0065] 40 - 50 wt. % of a layered silicate or a mixture of layered silicates, with a ratio of 3: 1 of nanoparticles to microparticles and

[0066] 0 - 10 wt.% plasticizer.

[0067] This film can be made from a composition of

[0068] 1 - 40 wt.% polyvinyl alcohol, preferably 15 -20 wt.% PVOH

[0069] 5 - 40 wt.% of a layered silicate, preferably 20 - 30 wt.% with a ratio of 3:1 of nanoparticles to microparticles and preferably nanoparticles to microparticles of talc,

[0070] 0 - 10 wt. % plasticizer, and

[0071] 50 - 90 wt.% water. A further embodiment of the invention comprises a film made of

[0072] 30 - 60 wt.% polyvinyl alcohol,

[0073] 40-75 wt.% of a layered silicate or a mixture of layered silicates made up of nanoparticles and microparticles and

[0074] 6 - 18 wt.% plasticizer.

[0075] An alternative embodiment of the invention comprises a film made of

[0076] 50 - 75 wt.% polyvinyl alcohol, preferably 60 - 65 wt.%

[0077] 15-25 wt.% of a layered silicate or a mixture of layered silicates, preferably 18-22 wt.% with a ratio of 1:3 to 1:20 of nanoparticles to microparticles

[0078] 10 - 25 wt. % plasticizer preferably glycerin and

[0079] 0 - 5 wt.% water.

[0080] It is preferred if the solids ratio in these films is 4:3:1 = PVOH / plasticizer microparticles layered silicate(s) nanoparticles layered silicate(s).

[0081] These films have been shown to be cost-effective, multifunctional barrier layers. Furthermore, when applied as a solution or dispersion, they are also suitable as adhesion-promoting layers for multilayer materials. These layers adhere well to various substrates such as paper, PET films, or PE / PP films.

[0082] Another aspect of the present invention is a process for producing the film according to the invention, comprising the steps:

[0083] Producing a composition from a dispersion of nanoparticles of a layered silicate or a mixture of layered silicates, a dispersion of microparticles of the layered silicate(s) and a solution of polyvinyl alcohol and a plasticizer by mixing the solution of polyvinyl alcohol and a plasticizer with the dispersion of microparticles and adding the dispersion of nanoparticles and

[0084] Extrusion of a film from the composition.

[0085] The preparation of the composition for the production of the film can include the following steps:

[0086] Providing a dispersion of nanoparticles of a layered silicate or a mixture of layered silicates

[0087] Providing a dispersion of microparticles of the layered silicate or a mixture of layered silicates

[0088] Providing a solution of polyvinyl alcohol and a plasticizer

[0089] Mixing the solution of polyvinyl alcohol and a plasticizer with the dispersion of microparticles

[0090] Adding the dispersion of nanoparticles.

[0091] Both the dispersion of nanoparticles, the dispersion of microparticles and the solution of polyvinyl alcohol with the plasticizer preferentially use water as a solvent.

[0092] The use of a high-speed mixer in the preparation of the nanoparticle dispersion and the microparticle dispersion, as well as in the mixing of these dispersions with the solution of polyvinyl alcohol and plasticizers, has proven particularly suitable. Alternatively, the composition can also be prepared by the following steps: Providing a dispersion of nanoparticles of a layered silicate or a mixture of layered silicates

[0093] Provision of the microparticles of the layered silicate or the mixture of layered silicates in the form of a powder

[0094] Providing a solution of polyvinyl alcohol and a plasticizer

[0095] Mixing the solution of polyvinyl alcohol and a plasticizer with the powdered microparticles while stirring

[0096] Adding the dispersion of nanoparticles.

[0097] With the described processes, it is possible to add a sufficient amount of layered silicates and achieve a homogeneous distribution of the particles, which leads to higher oxygen barrier values ​​of the produced products (films).

[0098] Alternative manufacturing processes utilize the principle of melt mixing (= compounding), in which micro- and nanoparticles are directly incorporated into a PVOH melt including plasticizer. The resulting uniform and thus easily metered granules can be used for all common melt processing methods, such as multilayer cast or blown film, co-extrusion coatings, and injection molding.

[0099] The film can also be produced by thermoforming, injection molding, or blow molding. When producing a multilayer composite material, film can be produced as a coating on one of the adjacent layers (e.g., paper or polymer). When using an aqueous solution to form a layer or film, the still-moist layer can also be used as an adhesive for another adjacent layer. The films according to the invention can also be produced by coextrusion with another layer.

[0100] It can be advantageous to completely or largely avoid water during film production, as this eliminates a complex and energy-intensive drying step. If the films are produced from a water-free composition, they can be directly manufactured using a melt process, applied to a substrate, or incorporated directly into a multilayer film as a barrier interlayer by coextrusion. They can be applied as a coating using a slot die, for example. This allows, for example, a precise thickness of the film or layer to be precisely adjusted.

[0101] In the production of a multilayer composite material, the film according to the invention can be applied as a coating directly to various existing carrier layers (e.g., paper or polymer) or to previously applied (e.g., aqueously applied) pre-barrier layers. When using an aqueous solution to form the layer or film, the still-moist layer can also be used as an adhesive for one or more additional, supplied web-like materials (paper, film, aluminum foil, or composite materials).

[0102] A further aspect of the invention is a multilayer material, wherein at least one layer of the multilayer material consists of a film according to the invention. The film can form one or more layers of the material.

[0103] The films according to the invention, as an intermediate layer in a multi-layer material, generally enable a clean separation of adjacent layers. This is possible because the film dissolves in cold water after the packaging material has been shredded. This means that the different raw materials previously used for the multi-layer or composite materials, e.g., different polymers or paper, can first be cleanly and homogeneously separated from one another and, after separation (e.g., by flotation according to density), processed, i.e., granulated or dispersed depending on the raw material. The soluble PVOH, including plasticizer and contained materials, can also be purified by filtration, concentrated, and recycled. Since washing steps with cold water are part of most established recycling processes, these require little or no modification.The additional layers that may be present in the multilayer material of the invention alongside the film according to the invention may consist of paper, a polymer, or a polymer blend. Other additives may also be present. However, it is preferred if these layers consist of at least 95% by weight, preferably 99% by weight, paper, or at least 95% by weight, preferably 99% by weight, a polymer. The polymers may be biopolymers or bio-based polymers. The polymers may be selected from the group comprising polyolefins, such as PE (polyethylene), polypropylene (PP), EEA (ethylene ethyl acrylate copolymer or ethylene acrylic acid copolymer), polybutylene succinate, polyhydroxyalkanoates in the form of homo- and copolymers, such as polyhydroxybutyric acid, polyhydroxyvaleric acid, and mixtures thereof, a mixture of polylactide and polyhydroxyalkanoates, or a mixture of poly(butylene adipate-co-terephthalate) and polylactide.

[0104] Polybutylene succinate (PBS) belongs to the polyester group. PBS is a biodegradable bioplastic that is produced industrially (synthetically). PBS is created through a synthetic reaction of the starting materials succinic acid and 1,4-blotandiol. These starting materials can be produced in two ways: from fossil fuels and from glucose. While PBS was previously obtained exclusively from fossil fuels, today, depending on the raw material, the bioplastic can be produced from up to 100% biobased sources and is then also biodegradable. The biopolymer polyhydroxybutyric acid (PHB) is a fermentatively produced polyester with properties similar to those of the petrochemically produced plastic polypropylene. It can be produced from sugar and starch, but synthesis is also possible from other nutrients such as glycerin and palm oil. PBAT is a biodegradable and compostable copolymer from the polyester group.Polylactides are synthetic polymers (polyesters) made from lactic acid molecules. A preferred polymer is a blend of PBAT and PLA, particularly the blends of Bayer's ecovio® (PBAT, PLA) family. This compostable and predominantly biobased polymer offers several advantageous properties, such as good adhesion to numerous types of paper and cardboard and temperature resistance up to 100°C.

[0105] There are a variety of paper products that are provided with a liquid-tight or gas-tight coating. One aspect of the present invention therefore also relates to multilayer composite materials comprising a paper layer or paper base layer with a liquid-tight coating, with a film according to the invention being sandwiched between the paper layer and the liquid-tight coating.

[0106] The liquid-tight coating can be made of PE or copolymers of acrylic acid esters with ethylene (ethylene acrylic acid copolymer; EAA), especially copolymers of ethyl acrylate with ethylene (EEA). Barrier coatings based on EAA, in particular, offer very good water vapor barrier properties, but also have the disadvantage of significantly interfering with paper recycling. It is therefore advantageous if the EAA coating can be completely separated from the paper in a very early washing step, so that no residues remain in the waste paper. This can be achieved by applying a film or intermediate layer according to the invention between the paper and the EAA coating.

[0107] The film according to the invention can be dissolved during a cold wash cycle of the recycling process, leaving two completely separate, previously adjacent layers for the subsequent processing. These layers can then be recovered as pure recyclate. "Pure," in this context, means that there is no contamination from residues of the other layer. The film according to the invention also serves as a gas barrier and can provide good adhesion.

[0108] The multilayer material can consist of a paper layer with a film according to the invention as a barrier coating and a liquid-tight coating or, more generally, a sealing layer. This can be produced by applying various polymers. Bio-based or biodegradable polymers are preferred. A preferred multilayer material consists of a first layer of paper, an intermediate layer of the film according to the invention, and a second layer (the liquid-tight coating or sealing layer) made of a mixture of PB AT) and PLA. Alternatively, the second layer can consist of EEA. However, the second layer can also consist of PVOH, e.g., a less water-soluble PVOH.

[0109] This material is suitable for the production of paper- and cardboard-based packaging and disposable tableware, such as cups, paper plates, or wrapping paper. The packaging is particularly suitable for coffee.

[0110] In addition to the possibility of composting for packaging, this material also offers the possibility of paper recycling. The PVOH, and thus the intermediate layer of the inventive film, dissolves completely in a cold water wash. This separates the polymer layer from the paper completely and without residue. The PVOH can be recovered from the water for recycling or completely biodegraded. Talc that is not dissolved in water precipitates. However, residues of the talc do not interfere with the use of the paper fibers.

[0111] One embodiment relates to the multilayer material according to the invention, wherein at least one layer of the multilayer material consists of a film according to the invention and the further layers comprise or consist of a different polymer. These further layers can also comprise, in addition to the polymer, a mixture of microparticles and nanoparticles of a layered silicate or a mixture of layered silicates, in particular the same layered silicate(s) as the film according to the invention. This increases the adhesion between the layers. The layer made of the film according to the invention is preferably a middle layer or intermediate layer of the material, located between further layers. The film according to the invention is particularly suitable as an intermediate layer due to its excellent adhesion to other materials. However, additional adhesion promoter layers, e.g., based on PVOH, can also be present.

[0112] If the film according to the invention contains glycerin, this film can be arranged in a multilayer structure of thin layers adjacent to a film according to the invention without glycerin but with a relatively high proportion of phyllosilicate as a barrier layer. This barrier layer can be applied to one side or both sides of the glycerin-containing film, so that a 4- to 5-layer structure can be created. The phyllosilicate(s) of the thin barrier layer prevent migration of the glycerin into more outer (polymer) layers.

[0113] The process for producing the multilayer material according to the invention preferably comprises coextrusion of the various layers. These layers are thus joined together during production. This has proven particularly good for adhesion, especially when all layers are filled with the corresponding phyllosilicates of different sizes. In this case, intensive compression of the three layers in the viscoelastic melt state is advantageous for achieving good adhesion. However, other production processes can also be used.

[0114] Another preferred multilayer material consists of a first layer made of a polymer or a polymer blend, an intermediate layer made of the film according to the invention, and a second layer made of a polymer or a polymer blend. For the packaging of moist foodstuffs, it is advantageous if the first and second layers form a water barrier and a water vapor barrier, respectively. A preferred multilayer material consists of a first layer made of PE, an intermediate layer made of the film according to the invention, and a second layer made of PE or PP. The PE of the first and second layers can be identical. However, the layers can also comprise different types of PE (HDPE, MDPE, LDPE, LLDPE).

[0115] Depending on the polymer used in the first and second layers, the stiffness and temperature resistance of the multilayer material can be adjusted. The thickness of the individual layers also plays a role.

[0116] The film according to the invention can have a thickness of 0.5 μm to 2 mm. Thin, particularly adhesion-promoting layers can be 0.5 to 10 μm thick, whereas layers intended primarily or additionally to form a gas barrier have a thickness of 10 μm to 1 mm, preferably 100 μm to 0.5 mm. The paper layers can be 100 μm to 5 mm thick. The other polymer layers can be 10 μm to 2 mm thick.

[0117] The first and second layers surrounding the film according to the invention can be made of PBS and / or PHB and may be relatively thick layers. This multilayer material is temperature-resistant, water-resistant, and has an excellent gas barrier.

[0118] The multilayer material according to the invention or the film according to the invention in general, and in particular the material with PBS or PHB, are also suitable for producing a capsule for a beverage preparation system, wherein the capsule comprises a capsule wall that comprises the multilayer material or film. The capsule is preferably a coffee capsule containing coffee powder. The film according to the invention serves to promote adhesion but also forms an excellent barrier layer that protects the coffee aroma from the ingress of aroma-damaging oxygen. Furthermore, it enables clean separation of the polymers when the adjacent layers are made of different polymers.

[0119] The multilayer materials of this invention are suitable for both single-serve capsules and coffee pouches. In particular, the materials consisting of paper, the film according to the invention as a barrier layer, and a polymeric sealing layer meet the high requirements placed on product protection and coffee brewing in high-pressure coffee machines. If the sealing layer is made of a biodegradable polymer (EEA, ecovio®) or a PVOH-based polymer blend, they are also compostable.

[0120] It has been shown that the inventive films exhibit very good adhesion to layers or films made of aluminum or with a very high aluminum content. Therefore, they are ideally suited as adhesion promoters between aluminum layers and other layers of polymers or paper in a multilayer composite material. The added phyllosilicates improve the adhesion between the individual layers. In addition, there is the already described effect that the individual layers can be separated very cleanly from one another by dissolving the inventive film in water. This is a huge advantage for recycling.

[0121] Another preferred multilayer material therefore comprises a first layer and a second layer made of a foil according to the invention, as well as a further layer consisting of aluminum, with the aluminum layer located between the first and second layers of the foil according to the invention. These three layers can be supplemented by external layers made of different polymers or paper. The layer structure is then, from outside to inside: polymer or paper / foil according to the invention / aluminum / foil according to the invention / polymer.

[0122] Suitable polymers include: polypropylene (also cast polypropylene - CPP, oriented polypropylene - OPP), polyethylene terephthalate (PET), and polyethylene. The innermost layer is preferably made of PE. Possible composite materials can have the following layers (from outside to inside):

[0123] PP / inventive film / aluminum / inventive film / PE

[0124] PET / inventive film / aluminum / inventive film / PE

[0125] Paper / inventive film / aluminum / inventive film / PE

[0126] Paper / inventive film / aluminum / inventive film / PP

[0127] These multilayer materials are ideal for the production of bags for storing roasted coffee. They offer excellent aroma protection for several months. This is coupled with improved recycling, which allows for the separation and reuse of individual components. In principle, the statements made in connection with the film also apply to the manufacturing processes, the multilayer material, and the capsule or coffee bag, where appropriate.

[0128] Examples:

[0129] An aqueous composition comprising 60 wt.% H2O, 16 wt.% PVOH, 4 wt.% glycerin, 15 wt.% talc as microparticles (Finntalc M05SL), and 5 wt.% talc as nanoparticles (Nanoclay) was prepared by mixing a solution of polyvinyl alcohol (Selvol™ 205 - 4 wt.%) in water with an aqueous dispersion of microparticles and adding an aqueous dispersion of nanoparticles to the resulting mixture. A high-speed mixer was used to gradually and homogeneously mix the components with the PVOH plasticizer solution. This solution was applied to various known materials as a coating and dried. The film thus consists of 40 wt.% PVOH, 10 wt.% glycerin, 15 wt.% talc as microparticles (Finntalc M05SL), and 5 wt.% talc (Cloisite®) as nanoparticles. The OTR (oxygen transmission rate) was then measured.The OTR is the steady-state rate at which oxygen gas permeates through the corresponding film (possibly consisting of multiple layers) under specific conditions (temperature and relative humidity). The test conditions were 23°C and 50% humidity.

[0130] The following results were obtained:

[0131] Another film consisting of 60 wt.% PVOH (degree of hydrolysis mol % 87.0-89.0; viscosity (cps) 5.2-6.2 Brookfield according to ISO 2555), 8 wt.% glycerol, 24 wt.% talc as microparticles (Finntalc M05SL), and 8 wt.% talc as nanoparticles was prepared by mixing a solution of polyvinyl alcohol (4 wt.%) in water with an aqueous dispersion of microparticles and adding an aqueous dispersion of nanoparticles to the resulting mixture. A high-speed mixer was used to gradually mix the components with the PVOH plasticizer solution until homogeneous. This solution was coated onto paper (PackPro 7, 80 g from Brigl & Bergmeister) and dried. The OTR (oxygen transmission rate) was then measured as before.

[0132] The following results were obtained:

[0133] A film composed of 78 wt.% PVOH (degree of hydrolysis mol % 87.0-89.0; molecular weight 30-50,000 D), 2 wt.% water, 5 wt.% glycerol, 10 wt.% talc as microparticles (Finntalc M05SL), and 3 wt.% montmorillonite as nanoparticles was prepared by mixing a solution of polyvinyl alcohol (4 wt.%) in water with an aqueous dispersion of microparticles and adding an aqueous dispersion of nanoparticles to the resulting mixture. A high-speed mixer was used to gradually homogenize the components with the PVOH plasticizer solution. This solution was applied as a coating to PE lamination film (60 μm) and paper (PackPro 7, 80 g from Brigl & Bergmeister) and dried. The OTR (oxygen transmission rate) was then measured as previously described.

[0134] The following results were obtained:

[0135] Another film consisting of 70 wt.% PVOH (degree of hydrolysis mol %: 98), 12 wt.% glycerol, 14 wt.% talc as microparticles (Finntalc M05SL), and 4 wt.% talc as nanoparticles was produced by mixing a solution of polyvinyl alcohol (4 wt.%) in water with an aqueous dispersion of microparticles and adding an aqueous dispersion of nanoparticles to the resulting mixture. A high-speed mixer was used to gradually and homogeneously mix the components with the PVOH plasticizer solution, and the solution was heated to 80°C. It was observed that adding significantly more phyllosilicates was hardly possible or would result in poor bonding and thus a defect-prone coating. The resulting solution was applied to paper (PackPro 7, 80 g from Brigl & Bergmeister) as a coating and dried. The OTR (oxygen transmission rate) was then measured as before.In contrast to the films from the previous examples, this film did not dissolve without leaving residue after 30 minutes in cold water (room temperature).

[0136] The following results were obtained:

Claims

PATENT CLAIMS 1. A film, in particular for the production of food packaging, comprising 30 - 89 wt.% polyvinyl alcohol 10 - 50 wt. % of a layered silicate 1 - 30 wt. % of a plasticizer, characterized in that the layered silicate is in the form of microparticles and nanoparticles, wherein the microparticles have a diameter of 0.3 - 5 pm and the nanoparticles have at least one dimension which is less than 100 nanometers.

2. The film according to claim 1, wherein the layered silicate is talc with the chemical composition Mg3Si40io(OH)2.

3. The film according to claim 1, wherein the polyvinyl alcohol has a degree of hydrolysis of 80 to 90 mol%.

4. The film according to any one of the preceding claims, wherein the film has a thickness of 0.5 pm to 2 mm.

5. A multilayer material, wherein at least one layer of the multilayer material consists of a film according to any one of claims 1 to 4.

6. The multilayer material according to claim 5, wherein at least one layer of the multilayer material consists of a film according to any one of claims 1 to 4 and a further layer or further layers consist of paper or a polymer.

7. The multilayer material according to claim 5 or 6, wherein the film is arranged between the further layers as an intermediate layer.

8. The multilayer material according to any one of claims 5 to 7, wherein the further layers consist of polyethylene, polypropylene, ethylene-acrylic acid copolymer, polybutylene succinate, polyhydroxyalkanoates in the form of homo- and copolymers, such as polyhydroxybutyric acid, polyhydroxyvaleric acid and mixtures thereof, a mixture of polylactide and polyhydroxyalkanoates or a mixture of poly(butylene adipate-co-terephthalate) and polylactide.

9. The multilayer material according to any one of claims 5 to 8, wherein the material additionally contains adhesion promoter layers based on polyvinyl alcohol.

10. The multilayer material according to one of claims 5 to 7, consisting of a paper layer, the film according to one of claims 1 to 4 and at least one further layer made of a polymer or polymer mixture, wherein the film according to one of claims 1 to 4 lies between the paper layer and the further layer made of a polymer or polymer mixture.

11. The multilayer material according to claim 10, wherein the further layer consists of a mixture of poly(butylene adipate-co-terephthalate) and polylactic acid or of ethylene-acrylic acid copolymer.

12. The multilayer material according to any one of claims 5 to 7, wherein a first layer of the multilayer material and a second layer consist of a foil according to any one of claims 1 to 4 and a further layer consists of aluminum, wherein the layer of aluminum lies between the first and the second layer of the foil according to any one of claims 1 to 4.

13. A capsule for a beverage preparation system, the capsule comprising a capsule wall comprising the multilayer material according to any one of claims 5 to 11.

14. A method for producing the film according to any one of claims 1 to 4, comprising the steps: - Producing a composition from a dispersion of nanoparticles of a layered silicate, a dispersion of microparticles of the layered silicate and a solution of polyvinyl alcohol and a plasticizer by mixing the solution of polyvinyl alcohol and a plasticizer with the dispersion of microparticles and then adding the dispersion of nanoparticles and - Extrusion of a film from the composition.

15. A process for producing the multilayer material according to any one of Claims 5 to 11, wherein the layers are joined together by co-extrusion.

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