Recyclable packaging materials and their preparation methods

Abstract

The present disclosure provides a recyclable article comprising: 50 wt% to 90 wt% of at least one polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 wherein the article exhibits a Young's modulus of less than 700 MPa; and a haze value of less than or equal to 50%. The present disclosure also provides a film or laminate comprising the recyclable article. The present disclosure also provides a blown film extrusion process for preparing the article.

Description

Technical Field

[0001] The subject matter disclosed herein relates to the field of packaging materials, and particularly to recyclable packaging materials for manufacturing packaging products. Background Art

[0002] With the rapid growth in demand for quality products, the packaging industry has become one of the fastest-growing industries in the world economy. According to research done by Smithers, by 2028, the global packaging market is expected to expand by approximately 3% per year, exceeding $1.2 trillion (The Future of Packaging: Long-Term Strategic Forecast to 2028).

[0003] There are various packaging materials available in the market, such as glass, cardboard, paper, and metal, but one of the most commonly used plastic and polyethylene packaging materials occupies a large market share. Polyethylene (PE) derived from petroleum sources is highly advantageous in terms of being the most durable, extremely lightweight, and low-cost compared to other plastics. However, like other synthetic plastics, PE is non-biodegradable and thus accumulates as plastic debris in landfills, posing a serious threat to environmental health and safety.

[0004] Many types of polyethylene are known, such as low-density polyethylene (LDPE), medium-density polyethylene (MDPE), high-density polyethylene (HDPE), etc., which are used for packaging various food products, cosmetics, and other daily necessities. HDPE has the benefit of high tensile strength but lacks transparency. Thus, it is applied to packaging products that are opaque but have considerable stiffness, such as industrial chemicals and water pipes. On the other hand, LDPE is more popular in manufacturing flexible caps, bottles, and plastic bags and films due to its flexibility and relative transparency. CN1760087A discloses a packaging film material of a multilayer composite material prepared by coextrusion of 5 film layers, wherein each of the 5 film layers contains 2 to 3 of low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), polyvinylidene chloride (PVDC), ethylene vinyl acetate (EVA), and metallocene polyethylene.

[0005] Aluminum barrier laminated tubes (ABL) and polymer barrier laminated (PBL) tubes are also used for packaging oral, pharmaceutical, cosmetic, and home care formulations. With the increasing use of these tubes, concerns about recyclability are also on the rise. Due to the disadvantages of ABL tubes such as non-recyclability and lack of transparency, we are seeing a trend towards switching from ABL to PBL to improve recyclability and transparency. In traditional PBL tubes, the polymer blend is made of LDPE, LLDPE, MDPE, and HDPE rather than a barrier layer and pigments. However, with the trend towards single materials, attempts are being made to maximize the use of polymers such as polypropylene and HDPE and minimize the barrier layer throughout the formulation to facilitate the recyclability of the tube in the corresponding stream (e.g., the HDPE stream) and also improve the transparency of the tube while maintaining the required stiffness and recyclability. Therefore, there is an urgent need in the prior art to develop a packaging film that meets the above aspects. Summary of the Invention

[0006] In a first aspect of the present disclosure, there is provided a recyclable article comprising: 50 wt% to 90 wt% of at least one polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 wherein the article exhibits a Young's modulus of less than 700 MPa; and a haze value of less than or equal to 50%.

[0007] In a second aspect of the present disclosure, there is provided a method for preparing a recyclable article as a film as described herein, the method comprising: (a) melting at least one polyethylene to obtain a polyethylene melt stream; (b) extruding the polyethylene melt as a downward flow from an annular die to obtain an extruded material; (c) inflating the extruded material to obtain a blown film bubble; and (d) quenching the blown film bubble with cold water to obtain a recyclable article as a film.

[0008] In a third aspect of the present disclosure, there is provided a method for preparing a recyclable article as a laminate as described herein, the method comprising: (a) obtaining at least one film by a method comprising: (1) melting at least one polyethylene to obtain a polyethylene melt stream; (2) extruding the polyethylene melt as a downward flow from an annular die to obtain an extruded material; (3) inflating the extruded material to obtain a blown film bubble; and (4) quenching the blown film bubble with cold water to obtain a recyclable article as a film; (b) obtaining at least one extruded laminate layer or adhesive laminate layer; and (c) laminating at least two films with at least one extruded laminate layer / adhesive laminate layer to obtain a recyclable article as a laminate.

[0009] In a fourth aspect of the present disclosure, there is provided the use of an article as described herein for a packaging material, wherein the packaging material is a lamitube, a shoulder barrier liner, or an inner barrier liner.

[0010] These and other features, aspects, and advantages of the subject matter will be better understood with reference to the following description. This summary is provided to introduce a series of concepts in a simplified form. This summary is not intended to identify key features or essential features of the claimed subject matter. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The detailed description is described with reference to the accompanying drawings. In the drawings, the leftmost digit of a reference numeral indicates the drawing in which the reference numeral first appears. The same numbers are used throughout the drawings to indicate like features and components.

[0012] Figure 1 A cross-section of a seven-layer barrier film-1 and barrier film-2 (100) according to an embodiment of the present disclosure is shown.

[0013] Figure 2 A cross-section of a seven-layer normal film-1 (200) according to an embodiment of the present disclosure is shown. DETAILED DESCRIPTION

[0014] Those skilled in the art will recognize that the present disclosure is subject to variations and modifications other than those specifically described. It is to be understood that the present disclosure includes all such variations and modifications. The present disclosure also includes all such steps, features, compositions, and compounds individually or jointly referred to or indicated in this specification, and any and all combinations of any or more of such steps or features.

[0015] DEFINITIONS

[0016] For convenience, certain terms and examples used in the specification are described herein before further describing the present disclosure. These definitions should be read in light of the remainder of the present disclosure and will be understood by those skilled in the art. The terms used herein have meanings recognized and known to those skilled in the art; however, for convenience and completeness, specific terms and their meanings are set forth below.

[0017] An object without a quantifier is used to refer to one or more (i.e., at least one) objects.

[0018] The terms "comprising" and "including" are used in an inclusive, open sense, meaning that additional elements may be included. It is not intended to be construed as "consisting only of...".

[0019] Throughout the specification, unless the context requires otherwise, the word "comprising" and variations such as "comprises" and "comprising" will be understood to imply the inclusion of the stated element or step or group of elements or steps but not the exclusion of any other element or step or group of elements or steps.

[0020] The term "comprising" is used to mean "including but not limited to". "Comprising" and "including but not limited to" are used interchangeably.

[0021] As used herein, the term "at least one" means one or more, and thus includes individual components as well as mixtures / combinations.

[0022] As used herein, the phrase "at least one polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 " means any polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 wherein the polyethylene may further include modified polyethylene such as metal-modified polyethylene, chemically modified polyethylene, fiber-modified polyethylene, etc.

[0023] As used herein, the phrases "high density polyethylene", "medium density polyethylene", "low density polyethylene" and "linear low density polyethylene" refer to polyethylene having a density known to those skilled in the art.

[0024] As used herein, the term "extrusion lamination" refers to a process in which two or more packaging films are joined together by a molten resin extruded in the form of a film placed between the two packaging films. The molten resin thus serves as a binder and may be selected from high density polyethylene, low density polyethylene, linear low density polyethylene, medium density polyethylene, modified polyethylene such as maleated polyethylene, or combinations thereof.

[0025] As used herein, the term "adhesive lamination" refers to a process in which two or more packaging films are joined together using an adhesive such as polyurethane.

[0026] As used herein, the term "laminated tube" refers to a laminated tube widely used for packaging cosmetic materials, toothpaste and other viscous food products.

[0027] As used herein, the term "film" refers to a single or multi-layered wall between the product to be packaged and the surrounding environment, wherein the layer comprises at least one polyethylene selected from high density polyethylene, medium density polyethylene or combinations thereof.

[0028] As used herein, the term "laminate" refers to a wall between the product to be packaged and the surrounding environment, the wall comprising at least two films with or without an extrusion lamination layer / adhesive lamination layer.

[0029] As used herein, the term "UV blocker" refers to a chemical compound that can block or absorb UV radiation.

[0030] As used herein, the term "pigment" refers to a colored substance.

[0031] As used herein, the term "functional masterbatch" refers to an additive used to impart special properties or functions to plastics.

[0032] As used herein, the term "sealant" refers to a layer that is usually present on the inner side of a packaging film to thermally seal and moisture-seal the contents of the product being packaged.

[0033] As used herein, the term "blocked" refers to the adhesion of a blown film bubble during the bubble collapse stage in a blown film extrusion process without an extruded laminate layer or an adhesive laminate layer therebetween, thereby forming a film with twice the thickness of the bubble film layer.

[0034] As used herein, the term "printable layer" refers to a layer that can be printed, may or may not be in contact with the surrounding environment, and there is no restriction on its positioning on the inner (inner layer) or outer (outer layer) side of the recyclable product produced therefrom. The printable layer can also be regarded as a sealant layer in contact with the material being packaged.

[0035] As used herein, the term "sealant layer" refers to a layer that is in contact with the material being packaged and there is no restriction on its positioning on the inner (inner layer) or outer (outer layer) side of the recyclable product produced therefrom. The sealant layer can also be regarded as a printable layer in contact with the surrounding environment.

[0036] As used herein, the term "Young's modulus" refers to a measure of the stiffness or resistance to elastic deformation of a solid under load. It relates stress (force per unit area) to strain (proportional deformation) along an axis or line. In the present disclosure, the Young's modulus of a packaging material such as a film, laminate, or article made therefrom is measured and found to be less than 700 MPa (Z-score < 2). The Young's modulus is measured in the machine direction (MD) and the transverse direction (TD).

[0037] As used herein, the term "haze value" refers to a measure of the turbidity of a sample and is described as the amount of scattered light (large-scale deflection) relative to the amount of transmitted light. The lower the haze measurement value, the higher the transparency of the sample, indicating better visibility. Haze is the percentage of light passing through with an average deviation from the incident beam greater than 2.5 degrees. The haze value is calculated using the formula Td / Tt (scattered light greater than 2.5 degrees (Td) / total transmitted light (Tt)). In the present disclosure, the haze value of a film, laminate, or article is less than 50%, indicating a relatively high transparency of the material.

[0038] Ratios, concentrations, amounts, and other numerical data may be presented herein in a range format. It should be understood that the use of such a range format is merely for convenience and brevity and should be interpreted flexibly as including not only the values explicitly recited as the limits of the range, but also all the individual values or sub-ranges included within that range as if each value and sub-range were explicitly recited. For example, a thickness range of 50 μm to 520 μm should be interpreted as including not only the explicitly recited limits of 50 μm to 520 μm, but also sub-ranges within the specified range, such as 65 μm to 450 μm, 85 μm to 360 μm, etc., and individual amounts within the specified range, including amounts with decimals, such as 90 μm, 140 μm, and 250 μm.

[0039] As discussed in the background, high-density polyethylene has high strength and rigidity, but due to its high crystallinity compared to other PE types, it lacks transparency and softness, which are highly desirable for attracting consumers to the product by improving the aesthetics and feel of the packaging. Although HDPE can achieve downgauging to some extent, the packaging tubes made of HDPE are very hard and inconvenient to use. Generally, the upward blown film extrusion process is used to manufacture single-layer and multi-layer films. Alternative methods available for manufacturing films include cast films and thermally quenched films by the downward extrusion method.

[0040] Depending on ductility, polyethylene can be pressed, cast, or extruded into various shapes. The extrusion process is one of the most widely used processes for forming polyethylene into films, bottles, and tubes. To manufacture a film, the blown film process is used, which begins by feeding the plastic material from a hopper into an extruder, where the plastic material is heated to form a melt. This melt form of the plastic is forced through a circular die, resulting in a semi-solid tube whose diameter is expanded by blowing air through the die. The film is cooled using air or water to cause it to crystallize. Additionally, several nip rolls flatten it to form a roll of sheet. Films can be extruded in an upward direction, a downward direction, and a horizontal direction, and the rates of extrusion and blow molding can be controlled to achieve the desired strength, gloss, and haze of the extruded film. The upward blown film process is commonly used to manufacture transparent films for transparent thermoformed web applications. Since the current application goal is to obtain very high transparency, polyethylene is restricted to low-density polyethylene with a small amount of HDPE blend. However, the increased LDPE content makes the HDPE film non-recyclable in the HDPE recycling stream and poses several challenges during recycling.

[0041] In view of the above, the object of the present disclosure is to provide an environmentally friendly packaging material mainly composed of high-density polyethylene or medium-density polyethylene. It solves the need to improve the transparency of the tube by replacing the traditional upward blown film extrusion with a downward blown film extrusion process and switching to an HDPE / MDPE-based film, which improves the transparency of the product and also meets the recycling requirements of specific regulations without loss of transparency. At the same time, compared with products made with the popular upward blown film technology, most products made of HDPE / MDPE by downward extrusion will also be softer. This will improve the feel of the packaging.

[0042] Accordingly, the present disclosure provides a recyclable packaging product comprising from 50 wt% to 90 wt% of at least one polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 The polyethylene is mainly high-density polyethylene, and the resulting product can be a laminate or film, exhibiting a Young's modulus of less than 700 MPa. Thus, products having a film or laminate containing HDPE / MDPE exhibit good tensile properties, stiffness, and at the same time are elastic and soft in nature. In addition, since HDPE, MDPE, and their combinations can be recycled in established bottle-grade recycling streams and other recyclable streams, increasing their content in packaging helps reduce environmental damage. A barrier layer reduction of ≤10% also ensures that the packaging material is recyclable in the corresponding recycling stream. The products of the present disclosure made by the downward extrusion process are transparent, with a haze of ≤50%, making them potential candidates to replace commercially used upward blown films with lower transparency. In addition, in view of several existing environmental problems, packaging materials made of the environmentally friendly recyclable products of the present disclosure have strong market potential in the long run.

[0043] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present disclosure, the preferred methods and materials are now described. All publications mentioned herein are incorporated herein by reference.

[0044] The scope of the present disclosure is not limited by the specific embodiments described herein, which are intended for illustrative purposes only. As described herein, products, compositions, and methods that are functionally equivalent are clearly within the scope of the present disclosure.

[0045] In one embodiment of the present disclosure, there is provided a recyclable product comprising: from 50 wt% to 90 wt% of at least one polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm3 at least one polyethylene having a density in the range, wherein the article exhibits a Young's modulus of less than 700 MPa; and a haze value of less than or equal to 50%.

[0046] In one embodiment of the present disclosure, there is provided a recyclable article comprising: 50 wt% to 90 wt% of at least one polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 range, wherein the article exhibits a Young's modulus of less than 500 MPa; and a haze value of less than or equal to 50%.

[0047] In one embodiment of the present disclosure, the article exhibits a haze value of less than 40%. In another embodiment of the present disclosure, the article exhibits a haze value of less than 35%. In yet another embodiment of the present disclosure, the article exhibits a haze value of less than 30%. In yet another embodiment of the present disclosure, the article exhibits a haze value of less than 26%.

[0048] In one embodiment of the present disclosure, there is provided a recyclable article comprising: 50 wt% to 90 wt% of at least one polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 range, wherein the article exhibits a Young's modulus of less than 700 MPa; and a haze value of less than or equal to 40%. In another embodiment of the present disclosure, wherein the article exhibits a Young's modulus of less than 700 MPa; and a haze value of less than or equal to 35%. In yet another embodiment of the present disclosure, wherein the article exhibits a Young's modulus of less than 700 MPa; and a haze value of less than or equal to 30%. In a further embodiment of the present disclosure, wherein the article exhibits a Young's modulus of less than 700 MPa; and a haze value of less than or equal to 26%.

[0049] In one embodiment of the present disclosure, there is provided a recyclable article comprising: 50 wt% to 90 wt% of at least one polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3At least one polyethylene having a density within the range, wherein the article exhibits a Young's modulus of less than 500 MPa; and a haze value of less than or equal to 40%. In another embodiment of the present disclosure, wherein the article exhibits a Young's modulus of less than 500 MPa; and a haze value of less than or equal to 35%. In yet another embodiment of the present disclosure, wherein the article exhibits a Young's modulus of less than 500 MPa; and a haze value of less than or equal to 30%. In a further embodiment of the present disclosure, wherein the article exhibits a Young's modulus of less than 500 MPa; and a haze value of less than or equal to 26%.

[0050] In one embodiment of the present disclosure, there is provided a recyclable article as described herein, wherein the article is a film or a laminate. In another embodiment of the present disclosure, wherein the article is a film. In yet another embodiment of the present disclosure, wherein the article is a laminate.

[0051] In one embodiment of the present disclosure, there is provided a recyclable article as described herein, wherein the article is a multilayer film having 3 to 11 layers. In another embodiment of the present disclosure, the article is a multilayer film having 4 to 8 layers. In yet another embodiment of the present disclosure, the article is a multilayer film having 5 to 7 layers.

[0052] In one embodiment of the present disclosure, there is provided a recyclable article as described herein, wherein at least one polyethylene is selected from high density polyethylene, medium density polyethylene, or a combination thereof. In another embodiment of the present disclosure, wherein at least one polyethylene is high density polyethylene. In yet another embodiment of the present disclosure, wherein at least one polyethylene is medium density polyethylene.

[0053] In one embodiment of the present disclosure, there is provided a recyclable article as described herein, wherein the article further comprises one or more components selected from high density polyethylene, low density polyethylene, linear low density polyethylene, and medium density polyethylene.

[0054] In one embodiment of the present disclosure, there is provided a recyclable article as described herein, wherein the article optionally comprises a UV blocker, a pigment, a functional masterbatch, or a combination thereof.

[0055] In one embodiment of the present disclosure, there is provided a recyclable article comprising: 50 wt% to 90 wt% of at least one polyethylene selected from high density polyethylene, medium density polyethylene or a combination thereof, wherein the article exhibits a Young's modulus of less than 700 MPa and a haze value of less than or equal to 50%, the article further comprises one or more components selected from high density polyethylene, low density polyethylene, linear low density polyethylene, medium density polyethylene, and optionally, a UV blocker, a pigment, a functional masterbatch, or a combination thereof.

[0056] In one embodiment of the present disclosure, a recyclable article is provided, comprising: at least one polyethylene selected from high-density polyethylene, medium-density polyethylene, or a combination thereof, in an amount of 50 wt% to 90 wt%, wherein the article exhibits a Young's modulus of less than 500 MPa and a haze value of less than or equal to 50%, and the article further comprises one or more components selected from high-density polyethylene, low-density polyethylene, linear low-density polyethylene, and medium-density polyethylene, and optionally, a UV blocker, a pigment, a functional masterbatch, or a combination thereof.

[0057] In one embodiment of the present disclosure, a recyclable article as described herein is provided, wherein the article comprises 60 wt% to 70 wt% of at least one polyethylene.

[0058] In one embodiment of the present disclosure, a recyclable article as described herein is provided, wherein the article comprises 60 wt% to 70 wt% of at least one polyethylene selected from high-density polyethylene, medium-density polyethylene, or a combination thereof.

[0059] In one embodiment of the present disclosure, a recyclable article as described herein is provided, wherein the thickness of the article is in the range of 50 μm to 520 μm. In another embodiment of the present disclosure, the thickness of the article is in the range of 90 μm to 450 μm. In yet another embodiment of the present disclosure, the thickness of the article is in the range of 90 μm to 350 μm.

[0060] In one embodiment of the present disclosure, a recyclable article as described herein is provided, wherein the thickness of the article is in the range of 200 μm to 350 μm.

[0061] In one embodiment of the present disclosure, a recyclable article is provided, comprising: at least one polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 in an amount of 50 wt% to 90 wt%, wherein the article exhibits a Young's modulus of less than 700 MPa and a haze value of less than or equal to 50%; and the thickness of the article is in the range of 50 μm to 520 μm.

[0062] In one embodiment of the present disclosure, a recyclable article is provided, comprising: at least one polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 in an amount of 50 wt% to 90 wt%, wherein the article exhibits a Young's modulus of less than 700 MPa and a haze value of less than or equal to 50%; and the thickness of the article is in the range of 90 μm to 350 μm.

[0063] In one embodiment of the present disclosure, a recyclable article is provided, comprising: 50 wt% to 90 wt% of at least one polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 wherein the article exhibits a Young's modulus of less than 700 MPa and a haze value of less than or equal to 50%; and the thickness of the article is in the range of 200 μm to 350 μm.

[0064] In one embodiment of the present disclosure, a recyclable article is provided, comprising: 50 wt% to 90 wt% of at least one polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 wherein the article exhibits a Young's modulus of less than 500 MPa and a haze value of less than or equal to 50%; and the thickness of the article is in the range of 50 μm to 520 μm.

[0065] In one embodiment of the present disclosure, a recyclable article is provided, comprising: 50 wt% to 90 wt% of at least one polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 wherein the article exhibits a Young's modulus of less than 500 MPa and a haze value of less than or equal to 50%; and the thickness of the article is in the range of 90 μm to 350 μm.

[0066] In one embodiment of the present disclosure, a recyclable article is provided, comprising: 50 wt% to 90 wt% of at least one polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 wherein the article exhibits a Young's modulus of less than 500 MPa and a haze value of less than or equal to 50%; and the thickness of the article is in the range of 200 μm to 350 μm.

[0067] In one embodiment of the present disclosure, a recyclable article is provided, comprising: 50 wt% to 90 wt% of at least one polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 wherein the article exhibits a Young's modulus of less than 700 MPa and a haze value of less than or equal to 35%; and the thickness of the article is in the range of 50 μm to 520 μm.

[0068] In one embodiment of the present disclosure, a recyclable article is provided, comprising: 50 wt% to 90 wt% of at least one polyethylene having a density in the range of 0.94 g / cm 3from 0.94 g / cm to 0.97 g / cm 3 at least one polyethylene having a density in the range of from 0.94 g / cm to 0.97 g / cm, wherein the article exhibits a Young's modulus of less than 700 MPa and a haze value of less than or equal to 35%; and the thickness of the article is in the range of from 90 μm to 350 μm.

[0069] In one embodiment of the present disclosure, there is provided a recyclable article comprising: 50 wt% to 90 wt% of at least one polyethylene having a density in the range of from 0.94 g / cm 3 to 0.97 g / cm 3 at least one polyethylene having a density in the range of from 0.94 g / cm to 0.97 g / cm, wherein the article exhibits a Young's modulus of less than 700 MPa and a haze value of less than or equal to 35%; and the thickness of the article is in the range of from 200 μm to 350 μm.

[0070] In one embodiment of the present disclosure, there is provided a recyclable article comprising: 50 wt% to 90 wt% of at least one polyethylene having a density in the range of from 0.94 g / cm 3 to 0.97 g / cm 3 at least one polyethylene having a density in the range of from 0.94 g / cm to 0.97 g / cm, wherein the article exhibits a Young's modulus of less than 500 MPa and a haze value of less than or equal to 35%; and the thickness of the article is in the range of from 50 μm to 520 μm.

[0071] In one embodiment of the present disclosure, there is provided a recyclable article comprising: 50 wt% to 90 wt% of at least one polyethylene having a density in the range of from 0.94 g / cm 3 to 0.97 g / cm 3 at least one polyethylene having a density in the range of from 0.94 g / cm to 0.97 g / cm, wherein the article exhibits a Young's modulus of less than 500 MPa and a haze value of less than or equal to 35%; and the thickness of the article is in the range of from 90 μm to 350 μm.

[0072] In one embodiment of the present disclosure, there is provided a recyclable article comprising: 50 wt% to 90 wt% of at least one polyethylene having a density in the range of from 0.94 g / cm 3 to 0.97 g / cm 3 at least one polyethylene having a density in the range of from 0.94 g / cm to 0.97 g / cm, wherein the article exhibits a Young's modulus of less than 500 MPa and a haze value of less than or equal to 35%; and the thickness of the article is in the range of from 200 μm to 350 μm.

[0073] In one embodiment of the present disclosure, there is provided a recyclable article as described herein, wherein the article is a film made by a blown film extrusion process.

[0074] In one embodiment of the present disclosure, there is provided a recyclable article as described herein, wherein the article is a film made by a downward blown film extrusion process.

[0075] In one embodiment of the present disclosure, there is provided a recyclable article as described herein, wherein the article is a film made by a downward extrusion blown film extrusion process, the film comprising at least one polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 and wherein the article exhibits a Young's modulus of less than 700 MPa; and a haze value of less than or equal to 50%.

[0076] In one embodiment of the present disclosure, there is provided a recyclable article as described herein, wherein the article is a film made by a downward extrusion blown film extrusion process, the film comprising at least one polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 and wherein the article exhibits a Young's modulus of less than 500 MPa; and a haze value of less than or equal to 50%.

[0077] In one embodiment of the present disclosure, there is provided a recyclable article as described herein, wherein the article is a film having 5 to 7 layers made by a downward extrusion blown film process, the film comprising at least one polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 and wherein the article exhibits a Young's modulus of less than 700 MPa; and a haze value of less than or equal to 50%.

[0078] In one embodiment of the present disclosure, there is provided a recyclable article as described herein, wherein the article is a film, the film comprising: at least one printable layer; at least one first tie layer; at least one barrier layer; at least one second tie layer; and at least one sealant layer, and wherein the article exhibits a Young's modulus of less than 700 MPa; and a haze value in the range of 10% to 50%.

[0079] In one embodiment of the present disclosure, there is provided a recyclable article as described herein, wherein the article is a film, the film comprising: at least one printable layer; at least one first tie layer; at least one barrier layer; at least one second tie layer; and at least one sealant layer, and wherein the article exhibits a Young's modulus of less than 500 MPa; and a haze value in the range of 10% to 50%.

[0080] In one embodiment of the present disclosure, there is provided a recyclable article as described herein, wherein the article is a film, the film comprising: at least one printable layer; at least one first bonding layer; at least one barrier layer; at least one second bonding layer; and at least one sealant layer, wherein the article exhibits a Young's modulus of less than 700 MPa, and wherein the printable layer is the outer layer and the sealant layer is the inner layer. In another embodiment of the present disclosure, the printable layer is the inner layer and the sealant layer is the outer layer.

[0081] In one embodiment of the present disclosure, there is provided a recyclable article, wherein the article is a film as described herein, and the article exhibits a haze value in the range of 10% to 50%.

[0082] In one embodiment of the present disclosure, there is provided a recyclable article, wherein the article is a film as described herein, and at least one printable layer and at least one sealant layer are selected from high density polyethylene, low density polyethylene, linear low density polyethylene, medium density polyethylene, or combinations thereof.

[0083] In one embodiment of the present disclosure, there is provided a recyclable article, wherein the article is a film as described herein, and at least one barrier layer is less than 10 wt% of the total film, preferably less than 5 wt% of the total film.

[0084] In one embodiment of the present disclosure, there is provided a recyclable article, wherein the article is a film as described herein, and at least one barrier layer is selected from ethylene vinyl alcohol copolymer, polyamide, polyethylene terephthalate, or combinations thereof. In another embodiment of the present disclosure, at least one barrier layer is ethylene vinyl alcohol copolymer.

[0085] In one embodiment of the present disclosure, there is provided a recyclable article, wherein the article is a film as described herein, and at least one first bonding layer and at least one second bonding layer independently comprise a polymer adhesive selected from the group consisting of: maleated polyethylene, anhydride grafted ethylene / 1-butene copolymer, anhydride grafted ethylene / 1-hexene copolymer, propylene ethylene copolymer, ethylene vinyl acetate copolymer, ethylene methyl acrylate copolymer, anhydride grafted ethylene / 1-octene copolymer, modified polypropylene, maleated polypropylene, and combinations thereof.

[0086] In one embodiment of the present disclosure, a recyclable article is provided, wherein the article is a film as described herein, and the film has at least 5 layers, having a printable layer, a barrier layer, a sealant layer, and a tie layer, wherein at least one first tie layer is located between at least one printable layer and at least one barrier layer; at least one second tie layer is located between at least one sealant layer and at least one barrier layer, and the thickness of the film is in the range of 50 μm to 260 μm. In another embodiment of the present disclosure, the thickness of the film is in the range of 90 μm to 250 μm.

[0087] In one embodiment of the present disclosure, a recyclable article is provided, wherein the article is a film as described herein, and the film has at least 5 layers, having a printable layer, a barrier layer, a sealant layer, and a tie layer, wherein at least one first tie layer is located between at least one printable layer and at least one barrier layer; at least one second tie layer is located between at least one sealant layer and at least one barrier layer, and the thickness of the film is in the range of 90 μm to 350 μm. For the purposes of this embodiment, the first tie layer and the second tie layer are maleated polyethylene, the printable layer and the sealant layer are a combination of high-density polyethylene, medium-density polyethylene, and low-density polyethylene, and the barrier layer is ethylene vinyl alcohol copolymer.

[0088] In one embodiment of the present disclosure, a recyclable article is provided, wherein the article is a film as described herein, and the film can adhere during a blown film extrusion process and has a thickness in the range of 100 μm to 520 μm.

[0089] In one embodiment of the present disclosure, a recyclable article as described herein is provided, wherein the article is a film comprising the following layers: at least one printable layer selected from high-density polyethylene, medium-density polyethylene, low-density polyethylene, or a combination thereof; at least one first tie layer that is maleated polyethylene; at least one barrier layer that is ethylene vinyl alcohol copolymer; at least one second tie layer that is maleated polyethylene; and at least one sealant layer selected from high-density polyethylene, medium-density polyethylene, low-density polyethylene, or a combination thereof, and the article exhibits a Young's modulus of less than 700 MPa.

[0090] In one embodiment of the present disclosure, a recyclable article as described herein is provided, wherein the article is a film comprising the following layers: at least one printable layer selected from medium-density polyethylene, low-density polyethylene, or a combination thereof; at least one first tie layer that is maleated polyethylene; at least one barrier layer that is ethylene vinyl alcohol copolymer; at least one second tie layer that is maleated polyethylene; and at least one sealant layer selected from medium-density polyethylene, low-density polyethylene, or a combination thereof, and the article exhibits a Young's modulus of less than 500 MPa.

[0091] In one embodiment of the present disclosure, there is provided a recyclable article as described herein, wherein the article is a laminate comprising at least two films.

[0092] In one embodiment of the present disclosure, there is provided a recyclable article as described herein, wherein the article is a laminate made by extrusion laminating or adhesive laminating at least two films, the films having at least 5 layers, having a printable layer, a barrier layer, a sealant layer, and a tie layer, wherein at least one first tie layer is located between at least one printable layer and at least one barrier layer; at least one second tie layer is located between at least one sealant layer and at least one barrier layer, and the thickness of the films is in the range of 50 μm to 260 μm.

[0093] In one embodiment of the present disclosure, there is provided a recyclable article as described herein, wherein the article is a laminate made by extrusion laminating or adhesive laminating at least two films, the films having 5 to 7 layers, made by a downward blown film process, comprising at least one polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 range.

[0094] In one embodiment of the present disclosure, there is provided a recyclable article as described herein, wherein the article is a film having 7 layers, made by a downward blown film process, comprising at least one polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 range, one or more components selected from linear low density polyethylene and medium density polyethylene, and having a thickness of 90 μm.

[0095] In one embodiment of the present disclosure, there is provided a recyclable article as described herein, wherein the article is a laminate made by extrusion laminating / adhesive laminating at least two films, the films having 7 layers, made by a downward blown film process, comprising high density polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 range.

[0096] In one embodiment of the present disclosure, there is provided an article as described herein, wherein the article is a laminate made by extrusion laminating or adhesive laminating at least two films, wherein the films have at least 5 layers, having a printable layer, a barrier layer, a sealant layer, and a tie layer, wherein at least one first tie layer is located between at least one printable layer and at least one barrier layer; at least one second tie layer is located between at least one sealant layer and at least one barrier layer, and the thickness of the films is in the range of 50 μm to 260 μm.

[0097] In one embodiment of the present disclosure, there is provided an article as described herein, wherein the article is a laminate made by extrusion laminating or adhesive laminating at least two films, wherein the first film has 5 to 7 layers, is made by a downward extrusion blow molding process, and comprises at least one polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 and the second film has at least 5 layers, has a printable layer, a barrier layer, a sealant layer, and a tie layer, wherein at least one first tie layer is located between at least one printable layer and at least one barrier layer; at least one second tie layer is located between at least one sealant layer and at least one barrier layer, and the thickness of the film is in the range of 50 μm to 260 μm.

[0098] In one embodiment of the present disclosure, there is provided an article as described herein, wherein the article is a laminate made by extrusion laminating or adhesive laminating the following films with an extrusion laminating layer or an adhesive laminating layer: a film having 3 to 7 layers with a thickness in the range of 40 μm to 125 μm made by an upward extrusion blow molding process and comprising HDPE, and a film having 5 to 7 layers with a thickness in the range of 50 μm to 250 μm made by a downward extrusion blow molding process and comprising at least one polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3

[0099] In one embodiment of the present disclosure, there is provided an article as described herein, wherein the article is a laminate made by extrusion laminating the following films with an extrusion laminating layer having a thickness in the range of 10 μm to 40 μm: a film having 3 to 7 layers with a thickness in the range of 40 μm to 125 μm made by an upward extrusion blow molding process and comprising HDPE, and a film having 5 to 7 layers with a thickness in the range of 50 μm to 250 μm made by a downward extrusion blow molding process and comprising at least one polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 In another embodiment of the present disclosure, the thickness of the extrusion laminating layer is in the range of 15 μm to 35 μm.

[0100] In one embodiment of the present disclosure, there is provided an article as described herein, wherein the article is a laminate made by adhesive laminating the following films with an adhesive laminating layer having a thickness in the range of 3 μm to 5 μm: a film having 3 to 7 layers with a thickness in the range of 40 μm to 125 μm made by an upward extrusion blow molding process and comprising HDPE, and a film having 5 to 7 layers with a thickness in the range of 50 μm to 250 μm made by a downward extrusion blow molding process and comprising at least one polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm​3 A film having 5 to 7 layers made of at least one polyethylene with a density within a certain range and produced by a downward extrusion blown film process. In another embodiment of the present disclosure, the thickness of the adhesive laminated layer is in the range of 4.5 μm to 5 μm.

[0101] In one embodiment of the present disclosure, there is provided an article as described herein, wherein the article is a laminate formed by extrusion laminating / adhesive laminating the following films with an extrusion laminated layer having a thickness of 20 μm: a 5 - layer film with a thickness of 50 μm made of HDPE and produced by an upward extrusion blown film process, and a film with a thickness of 180 μ that contains at least one polyethylene with a density in the range of 3 0.94 g / cm³ 3 to 0.97 g / cm³

[0102] In one embodiment of the present disclosure, there is provided an article as described herein, wherein the article is a laminate formed by extrusion laminating / adhesive laminating the following films with an adhesive laminated layer having a thickness in the range of 4.5 μm to 5 μm: a 5 - layer film with a thickness of 50 μm made of HDPE and produced by an upward extrusion blown film process, and a film with a thickness of 180 μm that contains at least one polyethylene with a density in the range of 3 0.94 g / cm³ 3 to 0.97 g / cm³

[0103] In one embodiment of the present disclosure, there is provided an article as described herein, wherein the article is a laminate formed by extrusion laminating / adhesive laminating the following films with an extrusion laminated layer / adhesive laminated layer: a film having 3 to 7 layers with a thickness in the range of 40 μm to 125 μm made of HDPE and produced by an upward extrusion blown film process, and a second film having at least 5 layers (with a printable layer, a barrier layer, a sealant layer, and a connecting layer) produced by downward extrusion and having a thickness in the range of 50 μm to 250 μm, wherein at least one first connecting layer is located between at least one printable layer and at least one barrier layer; and at least one second connecting layer is located between at least one sealant layer and at least one barrier layer.

[0104] In one embodiment of the present disclosure, there is provided an article as described herein, wherein the article is a laminate comprising at least two films, and the laminate is made by extruding or adhesively laminating the following films with a first extrusion laminating layer / adhesive laminating layer and a second extrusion laminating layer / adhesive laminating layer: a film containing HDPE with a thickness in the range of 40 μm to 60 μm and having 3 to 7 layers made by an upward extrusion blow molding process; at least two films with a thickness in the range of 50 μm to 260 μm and having at least 5 layers (having a printable layer, a barrier layer, a sealant layer, and a tie layer), wherein at least one first tie layer is located between at least one printable layer and at least one barrier layer; at least one second tie layer is located between at least one sealant layer and at least one barrier layer, and wherein the first film and the second film have a thickness in the range of 60 μm to 115 μm.

[0105] In one embodiment of the present disclosure, there is provided an article as described herein, wherein the article is a laminate comprising at least two films, and the laminate is made by extruding / adhesively laminating the following films with a first extrusion laminating layer / adhesive laminating layer and a second extrusion laminating layer / adhesive laminating layer: a film containing HDPE with a thickness of 50 μm and having 5 layers made by an upward extrusion blow molding process; at least two films with a thickness of 75 μm and having at least 5 layers (having a printable layer, a barrier layer, a sealant layer, and a tie layer), wherein at least one first tie layer is located between at least one printable layer and at least one barrier layer; at least one second tie layer is located between at least one sealant layer and at least one barrier layer.

[0106] In one embodiment of the present disclosure, there is provided an article as described herein, wherein the article is a laminate comprising at least two films, and the laminate is made by extruding / adhesively laminating the following films with a first extrusion laminating layer / adhesive laminating layer and a second extrusion laminating layer / adhesive laminating layer: a film containing HDPE with a thickness in the range of 40 μm to 60 μm and having 3 to 7 layers made by an upward extrusion blow molding process, including at least one printable layer; at least one first tie layer; at least one barrier layer; at least one second tie layer and at least one sealant layer of at least two films, and wherein the article exhibits a Young's modulus of less than 700 MPa; and a haze value in the range of 10% to 50%.

[0107] In one embodiment of the present disclosure, there is provided an article as described herein, wherein the article is a laminate comprising at least two films, and the laminate is made by extrusion laminating / adhesive laminating the following films with a first extrusion laminating / adhesive laminating layer and a second extrusion laminating / adhesive laminating layer: at least two films including a film containing HDPE having a thickness in the range of 40 μm to 60 μm and having 3 to 7 layers made by an upward extrusion blow molding process, including at least one printable layer; at least one first connecting layer; at least one barrier layer; at least one second connecting layer; and at least one sealant layer, and wherein the article exhibits a Young's modulus of less than 500 MPa; and a haze value in the range of 10% to 50%.

[0108] In one embodiment of the present disclosure, there is provided an article as described herein, wherein the article is a laminate comprising at least two films, and the laminate is made by extrusion laminating / adhesive laminating the following films with a first extrusion laminating / adhesive laminating layer and a second extrusion laminating / adhesive laminating layer: at least two films including a film containing HDPE having a thickness of 50 μm and having 5 layers made by an upward extrusion blow molding process, including at least one printable layer; at least one first connecting layer; at least one barrier layer; at least one second connecting layer; and at least one sealant layer, and wherein the article exhibits a Young's modulus of less than 700 MPa.

[0109] In one embodiment of the present disclosure, there is provided a recyclable article as described herein, wherein the article is a laminate including an extrusion laminating / adhesive laminating layer for joining the films together, and the extrusion laminating / adhesive laminating layer comprises high density polyethylene, low density polyethylene, linear low density polyethylene, medium density polyethylene, polyurethane, modified polyethylene, or a combination thereof.

[0110] In one embodiment of the present disclosure, there is provided a method for preparing a recyclable article as described herein as a film, the method comprising: (a) melting at least one polyethylene to obtain a polyethylene melt stream; (b) extruding the polyethylene melt stream downward from an annular die to obtain an extruded material; (c) inflating the extruded material to obtain a blown film bubble; and (d) quenching the blown film bubble with cold water to obtain a recyclable article as a film.

[0111] In one embodiment of the present disclosure, there is provided a method for preparing a recyclable article as described herein as a laminate, the method comprising: (a) obtaining at least one film by the method for preparing a recyclable article as described herein as a film; (b) obtaining at least one extrusion laminating / adhesive laminating layer; and (c) laminating at least two films with at least one extrusion laminating / adhesive laminating layer to obtain a recyclable article as a laminate.

[0112] In one embodiment of the present disclosure, an article is provided, wherein the article is a film as described herein: the film is made by a downward extrusion blown film process and has a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 , a thickness of 200 μm, and wherein the article exhibits a Young's modulus of less than 700 MPa and a haze value of less than or equal to 50%.

[0113] In one embodiment of the present disclosure, an article is provided, wherein the article is a film as described herein: the film is made by a downward extrusion blown film process and has a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 , a thickness of 250 μm, and wherein the article exhibits a Young's modulus of less than 700 MPa and a haze value of less than or equal to 50%.

[0114] In one embodiment of the present disclosure, an article is provided, wherein the article is a film as described herein: the film is made by a downward extrusion blown film process and has a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 , a thickness of 300 μm, and wherein the article exhibits a Young's modulus of less than 700 MPa and a haze value of less than or equal to 50%.

[0115] In one embodiment of the present disclosure, an article is provided, wherein the article is a film as described herein: the film is made by a downward extrusion blown film process and has a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 , a thickness of 350 μm, and wherein the article exhibits a Young's modulus of less than 700 MPa and a haze value of less than or equal to 50%.

[0116] In one embodiment of the present disclosure, the use of the article as described herein for a packaging material is provided, wherein the packaging material is selected from a laminated tube, a shoulder barrier liner, and an inner barrier liner.

[0117] The film or laminate of the present disclosure as described herein can be transparent, translucent, or opaque and has a haze value in the range of 0% to 50%.

[0118] Examples

[0119] The present disclosure will now be illustrated by working examples, which are intended to illustrate the workings of the present disclosure and are not intended to imply any limitation on the scope of the present disclosure in a restrictive sense. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present disclosure pertains. Although methods and materials similar or equivalent to those described herein can be used to practice the disclosed methods and compositions, exemplary methods, devices, and materials are described herein. It should be understood that the present disclosure is not limited to the specific methods and experimental conditions described, as such methods and conditions are subject to variation.

[0120] Abbreviations:

[0121] EVOH: ethylene vinyl alcohol copolymer

[0122] G.S.M: grams per square meter

[0123] MD: machine direction

[0124] TD: transverse direction

[0125] Example 1

[0126] Method for preparing the film of the present disclosure

[0127] A multilayer barrier film was prepared by a downward blown film extrusion process, where all layers were prepared by blown film extrusion and then extrusion laminated to form the multilayer barrier film. The film extrusion process is a well-known process, as discussed in the references [H.F. Guiles Jr., J.R. Wagner Jr., E.M. Mount III, Extrusion The definitive processing guide and handbook, William Andrew Inc, Norwich, NY, (2005), 453–463; and T.I. Butler, G.E. Ealer, S.B. Marks, G.D. Oliver, J. Perdikoulias. (eds) Film extrusion manual, 2nd ed. TAPPI (2005)].

[0128] To prepare the multilayer barrier film, a polyethylene material was first melted to obtain a polyethylene melt stream. This melt stream was forced through an extruder into an annular die to obtain an extruded material, which was then inflated by blowing air to form a balloon-shaped tube. Finally, the blown film bubble was quenched using cold water to obtain a transparent recyclable film. The film can have 3 to 11 layers: made by a downward / upward extrusion blown film process and including at least one high-density polyethylene (HDPE) layer. Figure 1 andFigure 2 A seven-layer structure is described in Figure 2 and is detailed in the following paragraphs. The prepared film exhibits a haze value of less than or equal to 50%, a Young's modulus of less than 700 MPa, and has a thickness in the range of 50 μm to 360 μm.

[0129] Barrier film

[0130] Structure of the seven-layer barrier film-1 (100): printable layer / HDPE / MDPE / first tie layer / barrier layer / second tie layer / sealant layer is made as Figure 1 shown. Table 1 describes the order and thickness of each layer. The printable layer (A) is an outer layer made of a combination of MDPE resin and LDPE resin in a weight ratio of 80:20 and has a thickness of 60 μm. Since the EVOH oxygen barrier layer (E) has difficult recyclability, EVOH with a thickness of 15 μm is present in less than 10 wt% of the total film. The 75-μm-thick sealant layer is an inner layer (G) made of a combination of MDPE resin and LDPE resin in a weight ratio of 80:20. This layer contacts the material to be packaged. The first tie layer (D) and the second tie layer (F), each having a thickness of 25 μm, are made of maleated polyethylene. Two layers B (HDPE) and C (MDPE), each with a thickness of 25 μm, are located between the outer layer (A) and the first tie layer (D). Thus, the total thickness of the film is 250 μm, haze ≤ 50%, and Young's modulus < 700 MPa.

[0131] Table 1

[0132]

[0133] The seven-layer barrier films - 2, 2i, 3, and 3i are prepared as shown in Tables 2a to 2d. Here, the 115-μm barrier film - 2 described in Table 2a is illustrated. The printable layer (A) is an outer layer made of a combination of MDPE resin and LDPE resin in a weight ratio of 80:20 and has a thickness of 25 μm. The EVOH oxygen barrier layer (E) with a thickness of 8 μm is present in less than 10% by width of the total film. The sealant layer is an inner layer (G) made of a combination of MDPE resin and LDPE resin in a weight ratio of 80:20 and has a total thickness of 40 μm. This layer contacts the material to be packaged. The first tie layer (D) and the second tie layer (F), each having a thickness of 10 μm, are made of maleated polyethylene. Two layers B (HDPE) and C (MDPE), each with a thickness of 11 μm, are located between the outer layer (A) and the first tie layer (D). Thus, the total thickness of the film is 115 μm, haze ≤ 50%, and Young's modulus < 700 MPa.

[0134] Similarly, 115 μm barrier film - 2i, 140 μm barrier film - 3, and 140 μm barrier film - 3i were obtained with the structures illustrated in Tables 2b, 2c, and 2d, respectively.

[0135] Table 2a

[0136]

[0137] Table 2b

[0138]

[0139] Table 2c

[0140]

[0141] Table 2d

[0142]

[0143] Normal film

[0144] Seven - layer general film - 1 and 1i(200) were prepared by a downward blown - film extrusion process, as Figure 2 shown. The film is transparent and has the structures in Tables 3a to 3b. The following describes 115 μm general film - 1. The printable layer (A) is an outer layer made of a combination of MDPE resin and LDPE resin in a weight ratio of 80:20 and has a total thickness of 28 μm. The MDPE layers (B, C, D, and E) and the 5HDPE layer F each have a thickness of 12 μm / 11 μm. The sealant layer (G) is made of a combination of MDPE resin and LDPE resin in a weight ratio of 80:20 and has a total thickness of 28 μm. Thus, the total thickness of the general film is 115 μm. Similarly, 115 μm general film - 1i was obtained as described in Table 3b.

[0145] Table 3a

[0146]

[0147] Table 3b

[0148]

[0149] A seven-layer general film - 2 is made by a downcast film extrusion process. The general film - 2 has the structure: printable layer / HDPE + MDPE layer / sealant layer, as shown in Table 4. The printable layer (A) is an outer layer made of a combination of MDPE resin and LLDPE resin, with a thickness of 20 μm. Each of the B, C, D, E, and F layers is made of a combination of HDPE resin and MDPE resin in a weight ratio of 1:1, with a total thickness of 10 μm. The sealant layer (G) is made of a combination of MDPE resin and LLDPE resin, with a thickness of 20 μm. Therefore, the total thickness of the general film is 90 μm.

[0150] Table 4

[0151]

[0152] Comparative film

[0153] For comparison purposes, an 85 - μm film as shown in Table 5 is prepared by an upcast film extrusion process. The inner layer C is 17 μm thick and is made of a combination of MDPE resin and HDPE resin present in a weight ratio of 85:15. The middle layer B is 51 μm thick and is made of a combination of MDPE resin and HDPE resin in a weight ratio of 15:85. The outer layer A is 17 μm thick and is made of a combination of LLDPE and HDPE resins in a weight ratio of 90:10. Therefore, the total thickness of this general film is 85 μm. Then, this comparison film is compared with various mechanical properties of the general film - 2.

[0154] Table 5

[0155]

[0156] Example 2

[0157] Test of mechanical properties

[0158] Based on various mechanical properties including haze value, stiffness, tear strength, tensile strength, Young's modulus, and elongation at break %, a comparison is made between the 90 - μ general film - 2 prepared by the downcast film extrusion process and the 85 - μ comparison film prepared by the upcast film extrusion process. The results are presented in Table 6.

[0159] Table 6

[0160]

[0161] From the data shown in Table 6, it can be observed that the 90μ general film - 2 made by the down - blown film process exhibits a much lower haze value of only 35.27% and has a Young's modulus of <700 MPa, specifically <500 MPa; on the other hand, the 85μ comparison film made by the up - blown film process exhibits a very high haze value of 72.34% and a Young's modulus of >950 Mpa. Although thicker, the 90μ general film - 2 exhibits lower stiffness (softness), higher tear strength, and higher elongation at break in both the machine direction and the transverse direction. It also exhibits lower haze than the comparison film, even though both films are mainly made of HDPE resin. Therefore, the results obtained clearly show that the 90μ general film - 2 prepared by the blown - film extrusion process has superiority in terms of improved transparency while maintaining the desired stiffness and elasticity of the film. Although both films have a relatively large percentage of 0.94 + g / cc density material (about 78%), there are significant differences in properties. The down - blown film exhibits better transparency, softness, and at the same time shows recyclability in the HDPE recycle stream.

[0162] Example 3

[0163] Method for preparing the laminate of the present disclosure

[0164] Different types of laminates were prepared including at least two films selected from barrier film - 1, barrier film - 2, general film - 1, or a combination thereof. Such laminates were prepared according to the extrusion lamination or adhesive lamination processes well - known in the art. At least two films obtained by the above processes were combined with or without an extrusion lamination layer / adhesive lamination layer (20μm thick) to obtain the transparent / opaque recyclable laminates of the present disclosure. The extrusion lamination layer / adhesive lamination layer is made of high - density polyethylene, low - density polyethylene, linear low - density polyethylene, medium - density polyethylene, polyurethane, modified polyethylene, or a combination thereof. The prepared laminates exhibit a haze value of ≤50% and have a Young's modulus of <700 MPa. The total thickness of the laminate can vary from 50μm to 520μm.

[0165] The three - layer laminate with an extrusion lamination layer / adhesive lamination layer is made of the following structure:

[0166] Laminate 1: (print side) 115μm general film - 1 / 20μm / 115μm barrier film - 2 (sealant), exhibiting 640 MPa (MD) / 698 MPa (TD); haze value 25.2. Tables 2a and 3a show the barrier film - 2 and general film - 1 used to obtain Laminate 1.

[0167] Laminate 2: 140μm normal film - 3 / 20μm / 140μm barrier film - 3, showing 625MPa (MD) / 712MPa (TD); haze value 28.9. Tables 7 and 2c show the barrier film - 3 and normal film - 3 used to obtain laminate 2.

[0168] Table 7

[0169]

[0170] Laminate 3: 115μm barrier film - 2i / 20μm / 115μm barrier film - 2i, showing 480MPa (MD) / 512MPa (TD); haze value 25.7. Table 2b shows the laminated barrier film - 2i used to obtain laminate 3.

[0171] Laminate 4: 140μm barrier film - 3i / 20μm / 140μm barrier film - 3i, showing 481MPa (MD) / 487MPa (TD); haze value 31.6. Table 2d shows the laminated barrier film - 3i used to obtain laminate 4. The 20μm thick extruded laminate layer / adhesive laminate layer made by the extrusion lamination / adhesive lamination process is used to closely combine the polyethylene barrier film and normal film of the laminate.

[0172] From the above laminates, it can be observed that laminates 1 and 2 show a Young's modulus of less than 700MPa and a haze value of less than 35%, and laminates 3 and 4 show a Young's modulus of less than 500MPa and a haze value of less than 35%. Laminates 1 and 2 are made of a barrier film and a normal film, which contain a combination of HDPE and MDPE and have at least one HDPE layer. Laminates 3 and 4 are made of a barrier film and a normal film, which mainly contain MDPE. Therefore, the combination of polyethylene and its thickness plays a crucial role in obtaining products with improved mechanical properties, recyclability, and transparency.

[0173] Another three - layer laminate is made of the following structure, including an outer normal upward blown film (200) reduced from 115μm to 50μm, a 20μm extruded laminate layer / adhesive laminate layer, and an inner barrier film - 1 (100) of 180μm. The barrier film can be a 3 - to 11 - layer film prepared by a downward blown film extrusion process. This laminate shows a haze value of ≤50% and has a Young's modulus of <700MPa.

[0174] Normal film - 1 (50μm) / 20μm / Barrier film - 1 (180μm)

[0175] A five - layer laminate is made of the following structure:

[0176] Normal film - 1 (50μm) / 20μm / Barrier film - 1 (75μm) / 20μm / Barrier film - 1 (75μm)

[0177] The normal film - 1 (50μm) is a transparent outer layer. The first barrier film - 1 is located between two extruded laminate / adhesive laminate layers (20μm thick), and the second barrier film - 1 is located on the inner side of the laminate in contact with the material to be packaged. Both barrier films are 75μm thick and are prepared by the down - blown film process. The resulting laminate exhibits a haze value of ≤50% and has a Young's modulus of ≤500 MPa.

[0178] The adhered barrier blown film can also be formed during the blown film extrusion process, where the two extruded barrier films or normal films prepared as above can adhere to each other without an extruded laminate / adhesive laminate layer therebetween. This results in the formation of an adhered barrier blown film that is twice the thickness of the extruded barrier film / normal film. Thus, an adhered barrier film with a thickness in the range of 100μm to 520μm is formed.

[0179] Advantages of the present disclosure

[0180] The above - described embodiments and their equivalents as described in this subject matter have many advantages, including those advantages described.

[0181] As can be seen from the above embodiments carried out according to the embodiments of the present disclosure, replacing the LDPE - based packaging film with a film mostly made of HDPE or MDPE prepared by the down - blown film extrusion process provides enhanced transparency, i.e., a haze value of ≤50%. The reduction of the Young's modulus in the prepared articles from 700 MPa to 1200 MPa for HDPE / MDPE to less than 700 MPa indicates the desired flexibility and elasticity. Thus, the transparent packaging films and laminate articles of the present disclosure, which benefit from the use of a high content of HDPE, are easily biodegradable, durable, and have strong commercial potential to compete with the less - recyclable and less - transparent packaging films currently used in the market.

[0182] Although the subject matter has been described in considerable detail with reference to certain embodiments of the subject matter, other embodiments are possible. Therefore, the spirit and scope of the present disclosure should not be limited to the description of the embodiments included herein.

Claims

1. A recyclable article, comprising: At least one polyethylene having a density in the range of 0.94 g / cm to 0.97 g / cm and constituting 50 wt% to 90 wt% of the article, wherein the article exhibits a Young's modulus of less than 700 MPa; and a haze value of less than or equal to 50%, 3 to 0.97 g / cm 3 wherein the article exhibits a Young's modulus of less than 700 MPa; and a haze value of less than or equal to 50%, wherein the article is a film made by a downward blown film extrusion process or a laminate comprising the film, and wherein the article is recyclable in an HDPE recycle stream; and wherein the film comprises: at least one printable layer selected from high density polyethylene, low density polyethylene, linear low density polyethylene, medium density polyethylene, or a combination thereof; at least one first tie layer comprising a polymer adhesive selected from: maleated polyethylene, acid anhydride grafted ethylene / 1-butene copolymer, acid anhydride grafted ethylene / 1-hexene copolymer, propylene ethylene copolymer, ethylene vinyl acetate copolymer, ethylene methyl acrylate copolymer, acid anhydride grafted ethylene / 1-octene copolymer, modified polypropylene, and combinations thereof; at least one barrier layer which is ethylene vinyl alcohol; at least one second tie layer comprising a polymer adhesive selected from: maleated polyethylene, acid anhydride grafted ethylene / 1-butene copolymer, acid anhydride grafted ethylene / 1-hexene copolymer, propylene ethylene copolymer, ethylene vinyl acetate copolymer, ethylene methyl acrylate copolymer, acid anhydride grafted ethylene / 1-octene copolymer, modified polypropylene, and combinations thereof; and at least one sealant layer selected from high density polyethylene, low density polyethylene, linear low density polyethylene, medium density polyethylene, or a combination thereof.

2. The article according to claim 1, wherein the article exhibits a Young's modulus of less than 500 MPa; and a haze value of less than or equal to 50%.

3. The article according to claim 1, wherein the film is a multilayer film having 3 to 11 layers.

4. The article according to claim 1, wherein the at least one polyethylene is selected from high density polyethylene, medium density polyethylene, or a combination thereof.

5. The article according to claim 1, wherein the article further comprises one or more components selected from high density polyethylene, low density polyethylene, linear low density polyethylene, or medium density polyethylene.

6. The article according to claim 1, wherein the article optionally comprises a UV blocker, a pigment, a functional masterbatch, or a combination thereof.

7. The article according to any one of claims 1 to 6, wherein the thickness of the article is in the range of 50 μm to 520 μm.

8. The article according to claim 1, wherein the at least one barrier layer is less than 10% by weight of the recyclable article.

9. The article according to claim 1, wherein the film has at least 5 layers: having the at least one first tie layer between the at least one printable layer and the at least one barrier layer; the at least one second tie layer between the at least one sealant layer and the at least one barrier layer, and the thickness of the film is in the range of 50 μm to 260 μm.

10. The article according to claim 1, wherein the film is capable of sticking during a blown film extrusion process and has a thickness in the range of 100 μm to 520 μm.

11. The article according to claim 1, wherein the article comprises at least two films.

12. The article according to claim 11, wherein the article comprises a laminate made by extruding and laminating or adhesively laminating at least two of the films, wherein each film has 5 to 7 layers, is made by a downward extrusion blown film process, and comprises at least one polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 range.

13. The article according to claim 11, wherein the article comprises a laminate made by extruding and laminating or adhesively laminating at least two of the films, wherein each film has at least 5 layers: at least one first connecting layer located between at least one printable layer and at least one barrier layer; at least one second connecting layer located between at least one sealant layer and the at least one barrier layer, and the thickness of the film is in the range of 50 μm to 260 μm.

14. The article according to claim 11, wherein the article comprises a laminate made by extruding and laminating or adhesively laminating a first film and a second film, wherein the first film has 5 to 7 layers, is made by a downward extrusion blow film process, and comprises at least one polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 wherein the second film has at least 5 layers: at least one first tie layer located between at least one printable layer and at least one barrier layer; at least one second tie layer located between at least one sealant layer and the at least one barrier layer, and the thickness of the film is in the range of 50 μm to 260 μm.

15. The article according to claim 11, wherein the article comprises a laminate made by extrusion laminating or adhesive laminating the following with an extrusion laminate layer or an adhesive laminate layer: a film having 3 to 7 layers with a thickness in the range of 40 μm to 125 μm made by an upward extrusion blow molding process and containing HDPE and such a film: wherein the film has 5 to 7 layers, is made by a downward extrusion blow molding process, contains at least one polyethylene having a density in the range of 3 0.94 g / cm 3 to 0.97 g / cm, or with such a film: wherein the second film has at least 5 layers: at least one first connecting layer located between at least one printable layer and at least one barrier layer; at least one second connecting layer located between at least one sealant layer and the at least one barrier layer, and the thickness of the film is in the range of 50 μm to 260 μm.

16. The article according to claim 11, wherein the article comprises a laminate made by extrusion laminating or adhesive laminating the following with a first extruded laminate / adhesive laminate and a second extruded laminate / adhesive laminate: a film having 3 to 7 layers made of HDPE with a thickness in the range of 40 μm to 60 μm and made by an upward extrusion blow film process; and at least two such films: each of which has 5 to 7 layers, is made by a downward extrusion blown film process, and comprises at least one polyethylene having a density in the range of 0.94 g / cm 3 to 0.97 g / cm 3 ; or each of which has at least 5 layers: having at least one first connecting layer located between at least one printable layer and at least one barrier layer; At least one second connecting layer located between at least one sealant layer and the at least one barrier layer, and the thickness of the film is in the range of 50 μm to 260 μm.

17. The article according to claim 11, wherein the laminate comprises an extruded laminate layer or an adhesive laminate layer, and the extruded laminate layer or the adhesive laminate layer comprises high density polyethylene, low density polyethylene, linear low density polyethylene, medium density polyethylene, polyurethane, modified polyethylene, or a combination thereof.

18. The article according to claim 1, wherein the modified polypropylene comprises maleated polypropylene.

19. A method for preparing a recyclable article comprising a film according to any one of claims 1 to 11, the method comprising: a. melting the at least one polyethylene to obtain a polyethylene melt stream; b. extruding the polyethylene melt stream from an annular die to obtain an extruded material; c. inflating the extruded material to obtain a blown film bubble; and d. quenching the blown film bubble with cold water to obtain the recyclable article comprising the film.

20. A method for preparing a recyclable article comprising a laminate according to any one of claims 12 to 18, the method comprising: a. obtaining at least two films by the method according to claim 19; b. obtaining at least one extruded laminate layer or an adhesive laminate layer; and c. laminating at least two films with the at least one extruded laminate layer or the adhesive laminate layer to obtain a recyclable article comprising a laminate.

21. Use of the article according to any one of claims 1 to 18 as a packaging material, wherein the packaging material is a laminated tube, a shoulder barrier liner, or an inner barrier liner.

22. A laminated tube comprising the article according to any one of claims 1 to 18.

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