Film, laminated film, rigid article, package, and method of making a film

Abstract

This invention discloses a membrane comprising a matrix phase comprising 75% to 99.5% polyethylene by weight of the membrane. The membrane also comprises a dispersed phase comprising 0.5% to 25% polyester by weight of the membrane. The dispersed phase comprises droplets. 90% of the droplets have an average length of 0.2 micrometers to 5.0 micrometers. The droplets are dispersed in the matrix phase.

Description

Technical Field

[0001] This application relates in its entirety to films, laminated films, rigid articles, packaging including the film and / or laminated films, and methods of manufacturing the film. Background Technology

[0002] Various types of films used for packaging are known in the art. Global demand for reducing plastic waste and for sustainable packaging solutions is rising. Recycling is often effective, or perhaps only possible when the materials in the packaging are of the same polymer, as combinations of incompatible materials in the packaging film can create difficulties in recycling it.

[0003] One example of packaging film includes a PET / PE laminated film structure. There is a trend towards replacing films containing polyester (PET) with more recyclable options, such as films made entirely of polyethylene (PE). However, PET can offer unique physical and cost-effective properties that PE alone cannot provide. However, PET is considered a contaminant in PE recycling streams. In such packaging films, PET can adhere strongly to PE, thus requiring a chemical separation process to separate PET from PE. This chemical separation process can be complex and is currently under development.

[0004] Furthermore, during the recycling of such PET / PE packaging films, PET and PE are often incompatible due to their different melting points. Therefore, using high processing temperatures to melt PET during recycling may cause PE degradation, while using low processing temperatures to melt PE may not melt PET; either of these situations can further clog the filters of the recycling equipment. In other cases, due to the challenges of processing these incompatible polymers, the packaging film is destined for landfills or incineration facilities. Summary of the Invention

[0005] A membrane comprising micronized polyester has been developed. This membrane allows for the reuse of polyester-containing waste. Specifically, the membrane allows for the reuse of polyester-containing membranes, whether for post-industrial recycling (PIR) and / or post-consumer recycling (PCR). Furthermore, the membrane can have improved stiffness due to the presence of polyester, and can allow for the use of less material (thinning) for packaging purposes.

[0006] One embodiment of this disclosure is a membrane. The membrane may include a matrix phase comprising 75% to 99.5% polyethylene by weight of the membrane. The membrane may also include a dispersed phase comprising 0.5% to 25% polyester by weight of the membrane. The dispersed phase may include droplets. 90% of the droplets may have an average length of 0.2 micrometers to 5.0 micrometers. The droplets are dispersed in the matrix phase.

[0007] The membrane may comprise micronized polyester in the form of droplets dispersed in a matrix phase, which includes polyethylene. The use of polyester in the membrane allows for the reuse of polyester-containing waste that would otherwise typically be disposed of in landfills and incineration facilities. Therefore, the membrane may be sustainable due to the use of recycled materials (i.e., recycled polyester-containing waste). Furthermore, the presence of micronized polyester increases the membrane's stiffness, which could further allow for the use of less material (thinning) for packaging purposes.

[0008] Membranes incorporating micronized polyester can be manufactured without complex chemical separation processes. These membranes can be produced by recycling PET / PE structures without the need for compatibilizers to facilitate the micronization of PET within the PET / PE structure. Compatibilizers can optionally be added during membrane extrusion after PET micronization. Therefore, these membranes can be both environmentally and economically friendly.

[0009] In some implementations, the membrane is a co-extruded membrane.

[0010] In some implementations, the membrane is a multilayer membrane.

[0011] In some embodiments, polyethylene may include ultra-low density polyethylene, low density polyethylene, linear low density polyethylene, medium density polyethylene, linear medium density polyethylene, metallocene low density polyethylene, high density polyethylene, ethylene-vinyl acetate copolymer (EVA), or combinations thereof.

[0012] In some implementations, the polyester may include a melting point from 250°C to 290°C.

[0013] In some implementations, the membrane may also include a compatibilizer.

[0014] In some implementations, the polyester may include industrial post-recycled (PIR) polyester or consumer post-recycled (PCR) polyester.

[0015] Another embodiment of this disclosure may include a laminated film. The laminated film may include the film itself. The laminated film may also include a second film laminated onto the film. The film may include exposed surfaces of the laminated film.

[0016] In some embodiments, the laminate may also include a substrate. The substrate may include oriented polyester, oriented nylon, or oriented polypropylene.

[0017] Another embodiment of this disclosure may include packaging that includes the film or the laminated film.

[0018] Another embodiment of this disclosure may include a laminated film. The laminated film may include a first film comprising a first layer, a second layer, and a third layer, each layer comprising a first surface and an opposite second surface. The laminated film may also include a second film. The first and third layers may comprise polyethylene. The second layer may comprise a matrix phase and a dispersed phase, wherein the matrix phase comprises polyethylene in an amount of 75% to 99.5% by weight of the first film, and the dispersed phase comprises polyester in an amount of 0.5% to 25% by weight of the first film. The dispersed phase may comprise droplets. 90% of the droplets may have an average length of 0.2 micrometers to 5.0 micrometers. The droplets are dispersed in the matrix phase. The first, second, and third layers are co-extruded together and positioned relative to each other in a sequential manner. The second film is laminated onto the first film and includes an exposed surface of the laminated film.

[0019] In some implementations, the second membrane is an oriented membrane.

[0020] In some implementations, the second membrane and the first membrane are laminated by heating, extrusion or adhesive.

[0021] In some implementations, the laminate may also include printed markings.

[0022] In some embodiments, the polyethylene in the first, second, and third layers includes ultra-low density polyethylene, low density polyethylene, linear low density polyethylene, medium density polyethylene, linear medium density polyethylene, metallocene low density polyethylene, high density polyethylene, ethylene-vinyl acetate copolymer (EVA), or combinations thereof.

[0023] Another embodiment of this disclosure is packaging that includes a laminated film.

[0024] Another embodiment of this disclosure is a membrane. The membrane may include a matrix phase comprising 75% to 99.5% polyolefin by weight of the membrane. The membrane may also include a dispersed phase comprising 0.5% to 25% by weight of a polymer chemically incompatible with PE. The dispersed phase may include droplets. 90% of the droplets may have an average length of 0.2 micrometers to 5.0 micrometers. The droplets are dispersed in the matrix phase.

[0025] In some implementations, the matrix phase includes polyethylene, polypropylene, or combinations thereof.

[0026] Another embodiment of this disclosure is a rigid article. The rigid article may include a matrix phase comprising polyethylene in an amount of 75% to 99.5% by weight of the rigid article. The rigid article may also include a dispersed phase comprising polyester in an amount of 0.5% to 25% by weight of the rigid article. The dispersed phase comprises droplets. 90% of the droplets may have an average length of 0.2 micrometers to 5.0 micrometers. The droplets are dispersed in the matrix phase.

[0027] Another embodiment of this disclosure is a method of manufacturing a membrane. The method may include obtaining a polyethylene membrane comprising 10% to 15% by weight of a polymer chemically incompatible with PE, and 85% to 90% by weight of polyethylene. The method may also include using a continuous melt filter granulator, comprising a filter having a plurality of openings ranging from 5 micrometers to 150 micrometers, in a temperature range above the melting point of polyethylene and at least 5% below the melting point of the polymer chemically incompatible with PE. The method may also include maintaining the continuous melt filter granulator at a pressure below 112 MPa. The method may also include forming a plurality of pellets. Each pellet may include a dispersed phase comprising less than 25% by weight of a polymer chemically incompatible with PE. The dispersed phase may include droplets with an average length of 0.2 micrometers to 5.0 micrometers. The method may also include melting the pellets during extrusion. The method may further include forming a membrane comprising a matrix phase and a dispersed phase, wherein the matrix phase comprises 75% to 99.5% polyethylene by weight, and the dispersed phase comprises 0.5% to 25% by weight a polymer chemically incompatible with PE. The dispersed phase may include droplets. 90% of the droplets may have an average length of 0.2 micrometers to 5.0 micrometers. The droplets are dispersed in the matrix phase.

[0028] Multiple pellets can be formed without the use of compatibilizers to promote the micronization of the polyethylene film from polymers that are chemically incompatible with PE. Compatibilizers can optionally be added during the extrusion process.

[0029] The subject matter of this disclosure has several aspects, which may be embodied alone or together. These aspects may be used alone or in combination with other aspects of the subject matter described herein, and the description of these aspects together is not intended to exclude the use of these aspects alone or to claim protection for these aspects alone or in different combinations. Attached Figure Description

[0030] This disclosure will be more fully understood by considering the following detailed description of various embodiments of the disclosure in conjunction with the accompanying drawings, in which:

[0031] Figure 1 This is a schematic cross-sectional view of a membrane according to one embodiment of the present disclosure;

[0032] Figure 2 This is a schematic cross-sectional view of a laminated film according to one embodiment of the present disclosure;

[0033] Figure 3 This is a schematic cross-sectional view of a first membrane according to one embodiment of the present disclosure;

[0034] Figure 4A This is a schematic cross-sectional view of a laminated film according to one embodiment of the present disclosure;

[0035] Figure 4B yes Figure 4A A schematic top view of the laminated film;

[0036] Figure 5 This is a schematic perspective view of a package according to one embodiment of the present disclosure;

[0037] Figure 6 This is a schematic cross-sectional view of a rigid article according to one embodiment of the present disclosure;

[0038] Figures 7A to 7D Various steps for filtering and micronizing polyethylene membranes using a continuous melt filter granulator are shown according to one embodiment of this disclosure;

[0039] Figure 7E This is a schematic diagram of a plurality of pellets according to one embodiment of the present disclosure;

[0040] Figure 8 This is a flowchart depicting the steps of a method for manufacturing a membrane according to one embodiment of the present disclosure;

[0041] Figure 9 This is a scanning electron microscope (SEM) image of the first pellet; and

[0042] Figure 10 This is an SEM image of the second pellet.

[0043] The accompanying drawings are not necessarily drawn to scale. Similar numbers used in the drawings refer to similar parts. However, it should be understood that the use of numbers to refer to parts in a given drawing is not intended to limit parts labeled with the same numbers in another drawing. Detailed Implementation

[0044] This application describes a membrane. The membrane includes a matrix phase comprising polyethylene in an amount of 75% to 99.5% by weight of the membrane. The membrane also includes a dispersed phase comprising polyester in an amount of 0.5% to 25% by weight of the membrane. The dispersed phase comprises droplets. 90% of the droplets have an average length of 0.2 micrometers to 5.0 micrometers. The droplets are dispersed in the matrix phase.

[0045] The membrane may comprise micronized polyester in the form of droplets dispersed in a matrix phase, which includes polyethylene. The use of polyester in the membrane allows for the reuse of polyester-containing waste that would otherwise typically be disposed of in landfills and incineration facilities. Therefore, the membrane may be sustainable due to the use of recycled materials (i.e., recycled polyester-containing waste). Furthermore, the presence of micronized polyester increases the membrane's stiffness, which could further allow for the use of less material (thinning).

[0046] Membranes incorporating micronized polyester can be manufactured without the use of complex chemical separation processes. These membranes can be produced by recycling PET / PE structures (i.e., laminated structures) without the need for compatibilizers to facilitate the micronization of PET within the PET / PE structure. Compatibilizers can optionally be added during membrane extrusion after PET micronization. Therefore, these membranes can be both environmentally and economically friendly.

[0047] As used herein, the term "membrane" is a material with a very high length or width-to-thickness ratio. A membrane has two main surfaces defined by its length and width. Membranes typically exhibit good flexibility and are suitable for a wide range of applications, including flexible packaging. Membranes may also have a certain thickness and / or material composition, making them flexible, semi-rigid, or rigid (i.e., highly flexible, limited flexible, or almost non-flexible, respectively). Membranes can be described as single-layered or multi-layered.

[0048] As used herein, the term "layer" refers to a material of a certain thickness that can be homogeneous or heterogeneous. A layer can be any type of material, including polymeric, cellulose, and metallic materials, or blends thereof. A given polymeric layer can consist of a single polymer type or a blend of polymers and may include additives. In some cases, a layer may include a matrix phase and a dispersed phase dispersed within the matrix phase. The matrix phase may include a first polymer, and the dispersed phase may include a second polymer different from the first polymer. A given layer can be combined with or connected to other layers to form a membrane. A layer can be partially or completely continuous with respect to adjacent layers or membranes. A given layer can extend partially or completely with adjacent layers. A layer may contain sublayers.

[0049] As used herein, the terms “inner” and “outer” refer to the main surface of a film or layer, and specifically to the location in which the film or layer is used within a packaging structure. An inner film or layer may comprise the innermost main surface of the packaging structure. An outer film or layer may comprise the outermost main surface of the packaging structure.

[0050] As used herein, the term "adhesive layer" refers to a layer that has the primary function of bonding two adjacent layers together. An adhesive layer may be positioned between two layers of a multilayer film to hold the two layers in place relative to each other and prevent undesirable delamination. Unless otherwise stated, the adhesive layer may have any suitable composition that provides the desired level of adhesion to one or more surfaces in contact with the adhesive layer material.

[0051] As used herein, the term “sealing membrane” refers to a membrane, sheet, etc., which involves sealing the membrane, sheet, etc. to itself and / or to another layer of the same or another membrane, sheet, etc.

[0052] As used herein, the term "barrier" refers to any material that controls the resistance of a permeable element of a membrane, sheet, web, packaging, etc., to corrosive agents, including but not limited to oxygen barriers, humidity (e.g., water, moisture, etc.) barriers, chemical barriers, thermal barriers, light barriers, and odor barriers. The term "barrier layer" refers to a layer in a membrane, sheet, web, packaging, etc., that controls such a permeable element.

[0053] As used herein, the terms “heat-sealing,” “heat-sealing,” “heat-sealable,” etc., refer both to the ability of a film layer to be heat-sealed onto itself or another thermoplastic film layer, and to the formation of a molten bond between two polymer surfaces through conventional indirect heating. It should be understood that conventional indirect heating generates sufficient heat on at least one film contact surface to conduct to adjacent film contact surfaces, thereby enabling the formation of an adhesive interface between them without compromising film integrity.

[0054] As used in this article, the term "cold seal" refers to joining two surfaces by applying glue or adhesive.

[0055] As used herein, the term "metallocene" refers to a compound typically composed of two cyclopentadienyl anions (C5H5-, abbreviated as Cp) bonded in oxidation state II to a metal center (M), resulting in the general formula (C5H5)2M.

[0056] As used herein, the terms “polyolefin” and “polyolefin-based polymer” refer to polyethylene homopolymers, polyethylene copolymers, polypropylene homopolymers, or polypropylene copolymers.

[0057] As used herein, the term "polyethylene-based polymer" refers to a polymer containing ethylene bonds. Polyethylene can be a homopolymer, copolymer, or interpolymer. Polyethylene copolymers or interpolymers can include other types of polymers (i.e., non-polyethylene polymers). Polyethylene can have functional groups incorporated by grafting or other means. Polyethylene includes, but is not limited to, low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), medium-density polyethylene (MDPE), ultra-low-density polyethylene (ULDPE), high-density polyethylene (HDPE), cyclic olefin copolymers (COC), ethylene-vinyl acetate copolymers (EVA), ethylene-acrylic acid copolymers (EAA), ethylene-methacrylic acid copolymers (EMAA), neutralized ethylene copolymers (such as ionomers), and maleic anhydride-grafted polyethylene (MAHgPE).

[0058] As used herein, the terms "high-density polyethylene" or "HDPE" refer to polyethylene with a density of approximately 0.960 g / cm³. 3 Approximately 0.970 g / cm³ 3 Ethylene homopolymer, also referring to a homopolymer with a density of approximately 0.940 g / cm³. 3 Approximately 0.958 g / cm³ 3 HDPE is a copolymer of ethylene and α-olefins (typically 1-butene or 1-hexene). HDPE includes high molecular weight "polyethylene". The term "blow-molded HDPE film" refers to HDPE film manufactured through a blow-molded film extrusion process.

[0059] As used herein, the terms "polypropylene" and "polypropylene-based polymers" refer to polymers derived from propylene monomers. Polypropylene can be a homopolymer, copolymer, or interpolymer. Polypropylene copolymers or interpolymers can include other types of polymers (i.e., non-polypropylene polymers). Propylene bonds can be represented by the general formula: [CH2—CH(CH3)]n. Polypropylene can have functional groups incorporated by grafting or other means. Polypropylene includes, but is not limited to, propylene-ethylene copolymers, ethylene-propylene copolymers, and maleic anhydride-grafted polypropylene (MAHgPP).

[0060] As used herein, the terms "ethylene / vinyl alcohol copolymer" and "EVOH" both refer to polymerized ethylene-vinyl alcohol. Ethylene / vinyl alcohol copolymers include saponified (or hydrolyzed) ethylene / vinyl acrylate copolymers and refer to ethylene alcohol copolymers having ethylene comonomers prepared, for example, by hydrolysis of ethylene acrylate copolymers or by a chemical reaction with ethylene alcohol. The degree of hydrolysis is preferably at least 50%, more preferably at least 85%. Preferably, the ethylene / vinyl alcohol copolymer contains about 28-48 mol% ethylene, more preferably about 32-44 mol% ethylene, and even more preferably about 38-44 mol% ethylene.

[0061] As used herein, the term "oriented" refers to a single or multiple layer of film, sheet, or web that has been elongated in at least one of the longitudinal or transverse / cross directions. Non-limiting examples of such procedures include single-bubble blown film extrusion and slotted sheet extrusion, followed by stretching (e.g., by stretching) to provide orientation. Another example of such procedures is tucked-bubble or double-bubble extrusion. (See, for example, U.S. Patent Nos. 3,546,044 and 6,511,688, each of which is incorporated herein by reference in its entirety.) In tucked-bubble or double-bubble extrusion, the primary tube exiting the tubular extrusion die is cooled, collapsed, and then oriented by reheating, re-expanding to form secondary bubbles, and then cooling again. Transverse orientation can be achieved by expansion that radially extends the heated film tube. Longitudinal orientation can be achieved by using rolls rotating at different speeds to pull or stretch the film tube longitudinally. The combination of elongation at elevated temperatures and subsequent cooling causes the polymer chains to align into a more parallel structure, thereby improving the mechanical properties of films, sheets, webs, packaging, or other materials. Thermal shrinkage (measured according to ASTM D2732, "Standard Test Method for Unrestrained Linear Thermal Shrinkage of Plastic Film and Sheeting") may occur when the unrestrained, unannealed oriented article is subsequently heated to its orientation temperature. Thermal shrinkage can be reduced by annealing or heat-setting the oriented article by heating it to an elevated temperature, preferably above the glass transition temperature of the polymer constituting the article but below its crystallization melting point. This reheating / annealing / heat-setting step also provides polymer webs with a uniform, flat width. The polymer web can be annealed (i.e., heated to an elevated temperature) sequentially with (and after) the orientation process or separately (in a separate process).

[0062] As used herein, the terms “unoriented” and “non-oriented” refer to single-layer or multi-layer films, sheets or webs that are substantially not oriented after extrusion.

[0063] As used herein, the term "printed mark" refers to a mark, image, text, and / or symbol located on the surface of a film, sheet, or web. Printed marks can be affixed to a surface by any suitable method (e.g., ink printing, laser printing, etc.). Marks may include, for example, printed information or instructions for use, a list of ingredients (active and inactive), product weight, manufacturer's name and address, manufacturer's trademarks, etc.

[0064] As used herein, the term "polyester" refers to homopolymers and copolymers having recurring ester bonds, which can be formed by any method known in the art. The recurring ester bonds can be formed by reacting one or more diols with one or more diacids. Non-limiting examples of suitable diols include ethylene glycol, diethylene glycol, 1,3-propanediol, 1,4-butanediol, resorcinol, 1,4-cyclohexanediol, 2,2,4,4-tetramethyl-1,3-cyclobutanediol, and polyoxytetramethylene glycol. Non-limiting examples of suitable diacids include terephthalic acid, isophthalic acid, 2,6-naphthalenedicarboxylic acid, 2,5-furandicarboxylic acid, 1,4-cyclohexanedicarboxylic acid, trimellitic anhydride, succinic acid, adipic acid, and azelaic acid.

[0065] Non-limiting examples of suitable polyesters include polyethylene terephthalate (PET), poly(ethylene terephthalate-co-cyclohexanediol terephthalate) (PETG), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), polyethylene furfurylate (PEF), polypropylene furfurylate (PPF), and poly(butylene adipate-co-terephthalate) (PBAT).

[0066] Suitable polyesters can also be formed by the ring-opening polymerization of suitable cyclic monomers, such as lactide to form, for example, polylactic acid (PLA); glycolide to form, for example, polyglycolic acid (PGA); and lactones to form, for example, polycaprolactone and polybutyrolactone.

[0067] Suitable polyesters can also be formed through the direct condensation reaction of α-hydroxy acids. For example, PGA can be formed through the condensation reaction of glycolic acid.

[0068] Suitable polyesters can also be synthesized by microorganisms. Examples of suitable polyesters include various polyhydroxyalkanoates, such as polyhydroxybutyrate (PHB) and polyhydroxyvalerate (PHV).

[0069] As used herein, the term "compensator" refers to a surfactant that alters the properties of immiscible polymer blends or composites, promoting the formation of homogeneous blends and increasing interfacial adhesion between phases. A compatibilizer can consist of two parts: one part is compatible with one of the two polymers to be compatibilized, and the other part is compatible with the second polymer. A compatibilizer can be reactive and linked to the polymer, or it can be non-reactive and miscible only with the polymer.

[0070] Examples of reactive compatibilizers include acrylic functional groups (e.g., maleic anhydride, glycidyl methacrylate) grafted onto polyolefins, polyethylene, and polypropylene (PP), which allow for increased compatibility with polyamides (PA), ethylene-vinyl alcohol copolymers (EVOH), polybutylene terephthalate (PBT), and polyesters (PET). Examples of non-reactive compatibilizers include ethylene-ethyl acrylate copolymers (EEA) for PP / PA recycling; and ethylene-butyl acrylate copolymers (EBA) and ethylene-methacrylate copolymers (EMA) for increasing the compatibility of PP, PE, PBT, PA, acrylonitrile-butadiene-styrene copolymers (ABS), and polycarbonate (PC). Grafting polymethyl methacrylate (PMMA) or polystyrene onto PP can increase the compatibility of polypropylene with PMMA, styrene-acrylonitrile copolymers (SAN), acrylonitrile-styrene-acrylate copolymers (ASA), ABS, polyvinyl chloride (PVC), PC, and polyphenylene ether (PPE). Acrylic-imide copolymers can increase the compatibility of PPE / PA and PC / PE. Styrene block copolymers can increase the compatibility of PP / HDPE, PPE / PA, olefins and styrene-based styrene-butadiene (SB), PS and ABS. An example of a compatibilizer is a random ethylene-methyl acrylate-glycidyl methacrylate terpolymer.

[0071] As used herein, the term "polymer chemically incompatible with PE" refers to a polymer that has a different chemical affinity for polyethylene. For example, a polymer chemically incompatible with PE can be a polar polymer. The melting point of a polymer chemically incompatible with PE may be higher than that of polyethylene. Examples of polymers chemically incompatible with PE can include polyesters, EVOH, PA, PC, PBT, and so on.

[0072] As used herein, the term "droplet" refers to any fragment or segment of a polymer. This does not imply any particular size of the particle, as polymer particles can have any size, ranging from microscopic fragments and powders to visible fine particles. Furthermore, this does not imply any particular shape, as polymer particles can have any shape.

[0073] For example, droplets can have a “spherical” shape, which has a smooth surface, rounded edges and corners, and a generally spherical shape. However, the term “spherical” is not intended to imply that such particles only have a perfectly spherical shape. The term “spherical” refers to a generally spherical shape, such as a small sphere, egg-shaped, or bead-shaped, and also involves elongated spheres, such as capsule-shaped or rod-shaped. In addition, the term “spherical” also refers to flattened spheres with a disc-shaped, spherical, or pellet-like shape. Droplets can also have a “non-spherical” shape, that is, a polymer particle shape that is different from the “spherical” shape as defined above. “Non-spherical” particles may have rough surfaces, serrated edges, and / or sharp corners.

[0074] As used herein, the term "extrusion process" refers to the process of forming a continuous shape by forcing molten plastic material through a mold, followed by cooling and solidification.

[0075] Figure 1 A schematic cross-sectional view of a membrane 100 according to one embodiment of the present disclosure is shown.

[0076] Membrane 100 includes a matrix phase 102 containing a polyolefin. Specifically, in some embodiments, matrix phase 102 includes polyethylene, polypropylene, or combinations thereof. In some embodiments, matrix phase 102 may include a polyethylene-based polymer, a polypropylene-based polymer, or a combination thereof.

[0077] In some embodiments, polyethylene includes ultra-low density polyethylene (ULDPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE), medium density polyethylene (MDPE), linear medium density polyethylene (LMDPE), metallocene LDPE, high density polyethylene (HDPE), ethylene-vinyl acetate copolymer (EVA), or combinations thereof.

[0078] Examples of polypropylene-based polymers may include polypropylene homopolymers, polypropylene random copolymers (PPR or PP-R), polypropylene terpolymers, heterogeneous propylene copolymers, rubber-modified polypropylene copolymers, etc.

[0079] In some embodiments, the matrix phase 102 comprises 75% to 99.5% polyolefin by weight of the membrane 100. In some embodiments, the matrix phase 102 may comprise at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, or at least 99% polyolefin by weight of the membrane 100.

[0080] In some embodiments, the matrix phase 102 comprises polyethylene in an amount of 75% to 99.5% by weight of the membrane 100. In some embodiments, the matrix phase 102 may comprise polyethylene in an amount of at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, or at least 99% by weight of the membrane 100. The polyethylene may comprise a melting point from 80 degrees Celsius (°C) to 135°C. That is, the polyethylene may comprise a melting point from 176 degrees Fahrenheit (°F) to 275°F.

[0081] Membrane 100 also includes a dispersed phase 104 comprising a polymer chemically incompatible with PE. The polymer chemically incompatible with PE in dispersed phase 104 may have a higher melting point than the polyolefin of matrix phase 102. In some embodiments, the polymer chemically incompatible with PE comprises polyester. However, in some other embodiments, the polymer chemically incompatible with PE may include ethylene-vinyl alcohol copolymer (EVOH), polyamide (PA), polycarbonate, polybutylene terephthalate (PBT), and so on.

[0082] In some embodiments, the dispersed phase 104 comprises 0.5% to 25% polyester by weight of the membrane 100. In some embodiments, the dispersed phase 104 may comprise less than 1%, less than 5%, less than 10%, less than 15%, less than 20%, or less than 25% polyester by weight of the membrane 100. In some embodiments, the polyester comprises post-industrial recycled (PIR) polyester or post-consumer recycled (PCR) polyester. In some embodiments, the polyester has a melting point from 250°C to 290°C. That is, in some embodiments, the polyester has a melting point from 482°F to 554°F.

[0083] The dispersed phase 104 also includes droplets 106. Droplets 106 are dispersed in the matrix phase 102. Droplets 106 may have a spherical or non-spherical shape. 90% of the droplets 106 have an average length 106L of 0.2 micrometers to 5.0 micrometers. In some embodiments, 90% of the droplets 106 may have an average length 106L of about 0.5 micrometers, about 1 micrometer, about 1.5 micrometers, about 2 micrometers, about 2.5 micrometers, about 3 micrometers, about 3.5 micrometers, about 4 micrometers, about 4.5 micrometers, or about 5 micrometers. Droplets 106 may be formed by micronization of a polymeric material, such as polyester.

[0084] In some embodiments, membrane 100 further includes a compatibilizer. The compatibilizer may include maleic anhydride, acrylate, etc. The compatibilizer can help increase the compatibility between the polyolefin of the matrix phase 102 and the polymer of the dispersed phase 104 that is chemically incompatible with PE. In some embodiments, membrane 100 may include a compatibilizer in an amount of about 1% to about 10% by weight of membrane 100. In some embodiments, membrane 100 may include a compatibilizer in an amount of about 5% by weight of membrane 100. However, the compatibilizer is optional and may be omitted from membrane 100.

[0085] exist Figure 1 In the illustrated embodiment, membrane 100 is a single-layer membrane. However, in some other embodiments, membrane 100 is a multilayer membrane. Furthermore, in some embodiments, membrane 100 is a co-extruded membrane. In other words, membrane 100 may have two or more layers co-extruded from each other.

[0086] Membrane 100 can utilize polyester-containing waste that would otherwise typically be disposed of in landfills and incineration facilities. Therefore, membrane 100 may be sustainable due to the use of recycled materials (i.e., recycled polyester-containing waste). Furthermore, the stiffness of membrane 100 can be increased due to the micronized polyester (i.e., droplets 106) compared to polyolefin-based membranes that do not contain micronized polyester. This increased stiffness can further allow for the use of less material (thinning) for packaging purposes.

[0087] Membrane 100 can be manufactured without using complex chemical separation processes. Membrane 100 can be manufactured by recycling PET / PE structures without using compatibilizers to promote the micronization of PET in the PET / PE structure. Compatibilizers can optionally be added during the extrusion of membrane 100 after PET micronization. Therefore, membrane 100 can be environmentally and economically friendly.

[0088] Figure 2 A schematic cross-sectional view of a laminated membrane 110 according to another embodiment of the present disclosure is shown.

[0089] exist Figure 2 In the illustrated embodiment, the laminated membrane 110 includes membrane 100. Specifically, in Figure 2 In the illustrated embodiment, the laminated film 110 further includes a second film 108 laminated onto the film 100. Furthermore, in Figure 2 In the illustrated embodiment, membrane 100 further includes an exposed surface 112 of laminated membrane 110.

[0090] The second membrane 108 can be laminated onto the membrane 100 by any suitable lamination process. Non-limiting examples of lamination processes include flame lamination, hot roll lamination, cold lamination, belt lamination, ultrasonic lamination, calender lamination, and extrusion lamination. In some embodiments, the membrane 100 and the second membrane 108 can be laminated by heating, extrusion, or adhesives. Depending on the application requirements, any suitable adhesive can be used to laminate the second membrane 108 onto the membrane 100. For example, the adhesive can be selected from the group consisting of: polyurethane dispersions, acrylic emulsions, water-based polyvinyl alcohol, vinyl acetate copolymers, modified polyolefins, polyesters, synthetic or natural rubbers, solvent-based acrylic resins, one-component or two-component solvent-based polyurethanes, and radiation-curable adhesives.

[0091] In some embodiments, the second membrane 108 is an oriented membrane. Specifically, depending on application requirements, the second membrane 108 may be longitudinally oriented or transversely oriented. However, in some other embodiments, the second membrane 108 is a non-oriented membrane. In other words, in some embodiments, the second membrane 108 is unoriented.

[0092] exist Figure 2 In the illustrated embodiments, the laminate 110 further includes a substrate 109. The substrate 109 may be disposed on the second membrane 108. In some embodiments, the substrate 109 comprises oriented polyester, oriented nylon, or oriented polypropylene. In some embodiments, the substrate 109 may comprise an oriented polymer film, a metallized film, a release liner, a foil, paper, polyethylene, a biopolymer, etc.

[0093] Figure 3 A schematic cross-sectional view of a first membrane 200 according to one embodiment of the present disclosure is shown.

[0094] The first membrane 200 is a multilayer membrane. Specifically, the first membrane 200 includes a first layer 202, a second layer 204, and a third layer 206, each of which includes a first surface and an opposite second surface. Figure 3 In the illustrated embodiment, the first layer 202 includes a first surface 202A and an opposite second surface 202B, the second layer 204 includes a first surface 204A and an opposite second surface 204B, and the third layer 206 includes a first surface 206A and an opposite second surface 206B.

[0095] The first layer 202, the second layer 204, and the third layer 206 are co-extruded together and positioned relative to each other in a sequential manner. Specifically, the first layer 202, the second layer 204, and the third layer 206 are co-extruded together such that the first surface 204A of the second layer 204 is disposed adjacent to the second surface 202B of the first layer 202, and the first surface 206A of the third layer 206 is disposed adjacent to the second surface 204B of the second layer 204.

[0096] The first layer 202 and the third layer 206 comprise polyethylene. The second layer 204 is substantially similar to membrane 100 (in...). Figure 1 (as shown in the figure), where similar elements are indicated by similar reference numerals. Specifically, the second layer 204 comprises a matrix phase 102 and a dispersed phase 104, wherein the matrix phase comprises polyethylene in an amount of 75% to 99.5% by weight of the first membrane 200, and the dispersed phase comprises polyester in an amount of 0.5% to 25% by weight of the first membrane 200.

[0097] In some embodiments, the polyethylene of the first layer 202, the second layer 204, and the third layer 206 includes ultra-low density polyethylene (ULDPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE), medium density polyethylene (MDPE), linear medium density polyethylene (LMDPE), metallocene LDPE, high density polyethylene (HDPE), ethylene-vinyl acetate copolymer (EVA), or combinations thereof.

[0098] Figure 4A A schematic cross-sectional view of a laminated film 250 according to one embodiment of the present disclosure is shown.

[0099] exist Figure 4A In the illustrated embodiment, the laminated film 250 includes a first film 200 and a second film 108 laminated onto the first film 200. Specifically, in Figure 4A In the illustrated embodiment, the second membrane 108 is laminated to the first membrane 200 on the first surface 202A of the first layer 202 of the first membrane 200. Additionally, in Figure 4A In the illustrated embodiment, the second membrane 108 further includes an exposed surface 210 of the laminated membrane 250. The second membrane 108 can be laminated onto the first membrane 200 by any suitable lamination process.

[0100] Figure 4B A schematic top view of the laminated film 250 is shown. See also Figure 4A and Figure 4B The laminate 250 also includes printed markings 212, indicated by "XYZ" and "123". Printed markings 212 may include any suitable combination of alphanumeric characters, symbols, visual or graphic elements, colors, etc. Printed markings 212 may be formed by any suitable printing process, such as offset printing, aniline printing, rotary gravure printing, digital printing, etc.

[0101] In some embodiments, the printed mark 212 may be printed on the second film 108. Specifically, in some embodiments, the printed mark 212 may be printed on the exposed surface 210 of the laminated film 250. In some embodiments, the printed mark 212 may be printed on the first film 200. Specifically, in some embodiments, the printed mark 212 may be printed on the first surface 202A of the first layer 202 of the first film 200.

[0102] Figure 5 A schematic perspective view of package 300 is shown. Figure 5 In the illustrated embodiment, packaging 300 is a corner pouch. However, in some other embodiments, packaging 300 may be, for example, a stand-up pouch, a pillow pouch, a retort pouch, a small pouch, a brick pouch, a flow parcel pouch, a strip pouch, etc.

[0103] See Figures 1 to 5 In some embodiments, packaging 300 includes film 100. In other words, in some embodiments, film 100 can be used to form packaging 300. In some embodiments, packaging 300 may include laminated film 110. In other words, in some embodiments, laminated film 110 can be used to form packaging 300. In some embodiments, packaging 300 includes laminated film 250. In other words, in some embodiments, laminated film 250 can be used to form packaging 300.

[0104] Figure 6 A schematic cross-sectional view of a rigid article 400 is shown. The rigid article 400 can be any article produced by injection molding, blow molding, thermoforming, rotational molding, 3D printing, etc. Non-limiting examples of rigid articles include injection-molded filled resins for bottles, pallets, and plastic-wood composites. Rigid articles have little to no flexibility.

[0105] The rigid article 400 is substantially similar to the membrane 100, with similar elements designated by similar reference numerals. Specifically, the rigid article 400 includes a matrix phase 102 comprising polyethylene in an amount of 75% to 99.5% by weight of the rigid article 400. However, in some embodiments, the matrix phase 102 of the rigid article 400 may include polyolefins other than polyethylene.

[0106] The rigid article 400 also includes a dispersed phase 104 comprising 0.5% to 25% polyester by weight of the rigid article 400. However, in some embodiments, the dispersed phase 104 of the rigid article 400 may include any other polymer chemically incompatible with PE, such as ethylene-vinyl alcohol copolymer (EVOH), polyamide (PA), polycarbonate, or polybutylene terephthalate (PBT). Figure 6As shown, the dispersed phase 104 of the rigid article 400 also includes droplets 106. The droplets 106 are dispersed in the matrix phase 102. 90% of the droplets have an average length 106L of 0.2 micrometers to 5 micrometers.

[0107] Figures 7A to 7D Various filtration and micronization steps of a polyethylene membrane 500 are illustrated, the polyethylene membrane 500 comprising 10% to 15% by weight of a polymer chemically incompatible with PE, and 85% to 90% polyethylene. The polyethylene membrane 500 may include, for example, post-industrial recycled (PIR) polyester or post-consumer recycled (PCR) polyester.

[0108] The filtration and micronization of polyethylene membrane 500 can be carried out using a continuous melt filter granulator 502. Figures 7A to 7D The continuous melt filter granulator 502 shown includes a filter 504, which includes a plurality of openings 506 ranging from 5 micrometers to 150 micrometers. Figures 7A to 7D (One is shown in the figure). For example, multiple openings 506 can have diameters 506D ranging from 5 micrometers to 150 micrometers.

[0109] In some embodiments, the polyethylene film 500 can be melted at a temperature above the melting point of polyethylene and at least 5% lower than the melting point of polymers chemically incompatible with PE. Once melted, the polyethylene film 500 can be fed through filter 504. A scraper disc (not shown) can remove filtered contaminants from filter 504, which are then disposed of. In some embodiments, a fixed blade can be used instead of a scraper disc. The fixed blade can be configured to filter a rotating drum with the polymer material to be filtered on its surface.

[0110] Figure 7A , Figure 7B , Figure 7C and Figure 7DThese correspond to filtration and micronization steps T0, T1, T2, and T3 of the polyethylene membrane 500, respectively. Prior to filtration and micronization, the polyethylene membrane 500 is melted at a temperature range above the melting point of polyethylene and at least 5% lower than the melting point of a polymer chemically incompatible with PE to form melt 508. At step T0, melt 508 of the polyethylene membrane 500 is obtained for the filtration and micronization process. At step T1, melt 508 of the polyethylene membrane 500 is fed into filter 504 of a continuous melt filter granulator 502, specifically into openings 506 of filter 504. At step T2, melt 508 is received from the opposite side of filter 504. Melt 508 comprises polyethylene and micronized polymers chemically incompatible with PE dispersed within the polyethylene. At step T3, the blade 510 of the continuous melt filter granulator 502 scrapes away the melt 508 accumulated in front of the polyethylene membrane 500 to prevent the filter 504 from becoming clogged.

[0111] Figure 7E A schematic diagram of a plurality of pellets 512 according to one embodiment of the present disclosure is shown.

[0112] See Figures 7A to 7E The melt 508 can be cooled and solidified. After cooling and solidification, the melt 508 can be extruded and formed into pellets 512. As described above, the pellets 512 can be formed using a continuous melt filter granulator 502.

[0113] Each pellet 512 includes a dispersed phase 514 comprising less than 25% by weight of a polymer chemically incompatible with PE. The dispersed phase 514 comprises droplets 516 with an average length 516L of 0.2 μm to 5.0 μm.

[0114] Figure 8 A method 600 for manufacturing a membrane according to one embodiment of the present disclosure is shown. In some embodiments, method 600 can be used to manufacture membrane 100 (in... Figure 1 (as shown in the diagram). In some embodiments, method 600 can be used to manufacture a second layer 204 of the first membrane 200 (in... Figure 3 (as shown in the diagram). In some embodiments, method 600 can be used to manufacture rigid article 400 (in... Figure 6 (As shown in the image). The following will refer to... Figure 1 and Figures 7A to 7E Let's describe method 600.

[0115] At step 602, method 600 includes obtaining a polyethylene film comprising 10% to 15% by weight of a polymer chemically incompatible with PE, and 85% to 90% by weight of polyethylene. For example, method 600 may include obtaining a polyethylene film 500 comprising 10% to 15% by weight of a polymer chemically incompatible with PE, and 85% to 90% by weight of polyethylene.

[0116] At step 604, method 600 further includes utilizing a continuous melt filter granulator in a temperature range above the melting point of polyethylene and at least 5% lower than the melting point of a polymer chemically incompatible with PE. The granulator includes a filter comprising a plurality of openings from 5 micrometers to 150 micrometers. For example, method 600 may include utilizing a continuous melt filter granulator 502 in a temperature range above the melting point of polyethylene and at least 5% lower than the melting point of a polymer chemically incompatible with PE. This granulator includes a filter 504 comprising a plurality of openings 506 from 5 micrometers to 150 micrometers.

[0117] At step 606, method 600 further includes maintaining the continuous melt filter granulator at a pressure below 112 MPa. For example, method 600 may include maintaining the continuous melt filter granulator 502 at a pressure below 112 MPa.

[0118] At step 608, method 600 further includes forming a plurality of pellets. Each pellet includes a dispersed phase comprising less than 25% by weight of a polymer that is chemically incompatible with PE. The dispersed phase comprises droplets with an average length of 0.2 micrometers to 5.0 micrometers.

[0119] For example, method 600 may include forming a plurality of pellets 512. Each pellet 512 may include a dispersed phase 514 comprising less than 25% by weight of a polymer that is chemically incompatible with PE. The dispersed phase 514 may include droplets 516 with an average length 516L of 0.2 micrometers to 5.0 micrometers.

[0120] Multiple pellets 512 can be formed without the use of compatibilizers to promote the micronization of the polyethylene film 500 from polymers that are chemically incompatible with PE.

[0121] At step 610, method 600 further includes melting the pellets during extrusion. For example, method 600 may also include melting the pellets 512 during extrusion. In some instances, a compatibilizer may optionally be added during extrusion.

[0122] At step 612, method 600 further includes forming a membrane comprising a matrix phase and a dispersed phase, wherein the matrix phase comprises 75% to 99.5% polyethylene by weight of the membrane, and the dispersed phase comprises 0.5% to 25% by weight of a polymer chemically incompatible with PE. For example, method 600 may include forming a membrane 100 comprising a matrix phase 102 and a dispersed phase 104, wherein the matrix phase comprises 75% to 99.5% polyethylene by weight of membrane 100, and the dispersed phase comprises 0.5% to 25% by weight of membrane 100 a polymer chemically incompatible with PE.

[0123] Method 600 allows for the reuse of polyester-containing waste. Specifically, Method 600 can utilize polyester-containing post-industrial recycling (PIR) waste and / or polyester-containing post-consumer recycling (PCR) waste. Therefore, Method 600 can be environmentally and economically friendly.

[0124] Example

[0125] The following illustrative embodiments are intended to be used to illustrate the invention only, but are not intended to limit or otherwise restrict the scope of this disclosure.

[0126] In the following embodiments, the following resin grades were used:

[0127] HDPE: AC59, purchased from Braskem. Paulo, Brazil).

[0128] LLDPE: DOWLEX 2085, purchased from Dow Chemical Company (Houston, TX, USA).

[0129] LDPE: DOW 219M, purchased from Dow Chemical Company (Houston, TX, USA).

[0130] White masterbatch: 911082, purchased from Ampacet (Tarrytown, New York, USA).

[0131] Compatibilizer: LOTADER AX8900, purchased from SK Functional Polymer (Paris, France).

[0132] In the following embodiments, PIR material refers to the following post-industrial recycled material: comprising 81.7% polyethylene by weight of PIR material and 14.4% micronized polyester by weight of PIR material. Table 1 below provides the composition of the PIR material.

[0133] Table 1

[0134]

[0135] Example 1

[0136] Using a continuous melt filter granulator (e.g., purchased from Erema) Figures 7A to 7D The continuous melt filtration granulator 502 shown uses a continuous melt filtration process to recover a packaging film having the following structure: 48 gauge (12 microns) OPET / ink / adhesive / 4.0 mil (102 microns) white HDPE-mLLDPE. Additionally, the packaging film is extruded at a temperature range above the melting point of polyethylene and at least 5% lower than the melting point of polyester to form a plurality of first pellets (e.g., pellet 512). The plurality of first pellets are compressed and then frozen to fracture for scanning electron microscopy (SEM) analysis.

[0137] Example 2

[0138] Using a continuous melt filter granulator (e.g., purchased from NGR / Ettlinger) Figures 7A to 7D The continuous melt filtration granulator 502 shown uses a continuous melt filtration process to recover another packaging film having the following structure: 48 gauge (12 microns) OPET / ink / adhesive / 4.0 mil (102 microns) white HDPE-mLLDPE. Additionally, the packaging film is extruded at a temperature range above the melting point of polyethylene and at least 5% lower than the melting point of polyester to form multiple second pellets (e.g., pellet 512). The multiple second pellets are compressed and then frozen to fracture for scanning electron microscopy (SEM) analysis.

[0139] Examples 3 to 14 include a multilayer structure. Each example membrane includes a first layer, a second layer, and a third layer. In this example membrane, the first layer has a weight percentage of 30%. In this example membrane, the second layer has a weight percentage of 40%. In this example membrane, the third layer has a weight percentage of 30%.

[0140] Example 3: Formulation of a comparative packaging film. The comparative packaging film does not include any PET-containing PIR or PET-containing PCR.

[0141] The first layer consists of 70% LLDPE and 30% LDPE.

[0142] The second layer consists of 70% HDPE, 15% LDPE, and 15% white masterbatch.

[0143] The third layer consists of 70% LLDPE and 30% LDPE.

[0144] Example 4: A packaging film was developed. The packaging film comprises 100% by weight of the post-industrial recycled (PIR) material from Table 1, which was manufactured using a continuous melt filter granulator provided by NGR / Ettlinger.

[0145] Example 5: A packaging film was developed. The packaging film comprises 100% by weight of the PIR material from Table 1, which was manufactured using a continuous melt filter granulator provided by Erema.

[0146] Example 6: A packaging film was developed.

[0147] The first layer consists of 70% LLDPE and 30% LDPE.

[0148] The second layer comprises 60% HDPE, 25% PIR material (shown in Table 1), and 15% white masterbatch, the PIR material being manufactured using a continuous melt filter granulator supplied by NGR / Ettlinger.

[0149] The third layer consists of 70% LLDPE and 30% LDPE.

[0150] Example 7: A packaging film was developed.

[0151] The first layer consists of 70% LLDPE and 30% LDPE.

[0152] The second layer comprises 60% HDPE, 25% PIR material (shown in Table 1), and 15% white masterbatch, the PIR material being manufactured using a continuous melt filter granulator supplied by Erema.

[0153] The third layer consists of 70% LLDPE and 30% LDPE.

[0154] Example 8: A packaging film was developed.

[0155] The first layer consists of 70% LLDPE and 30% LDPE.

[0156] The second layer comprises 55% HDPE, 25% PIR material (shown in Table 1), 15% white masterbatch, and 5% compatibilizer, the PIR material being manufactured using a continuous melt filter granulator supplied by NGR / Ettlinger.

[0157] The third layer consists of 70% LLDPE and 30% LDPE.

[0158] Example 9: A packaging film was developed.

[0159] The first layer consists of 70% LLDPE and 30% LDPE.

[0160] The second layer comprises 55% HDPE, 25% PIR material (shown in Table 1), 15% white masterbatch, and 5% compatibilizer, the PIR material being manufactured using a continuous melt filter granulator supplied by Erema.

[0161] The third layer consists of 70% LLDPE and 30% LDPE.

[0162] Example 10: A packaging film was developed.

[0163] The first layer consists of 70% LLDPE and 30% LDPE.

[0164] The second layer comprises 35% HDPE, 50% PIR material (shown in Table 1), and 15% white masterbatch, the PIR material being manufactured using a continuous melt filter granulator supplied by NGR / Ettlinger.

[0165] The third layer consists of 70% LLDPE and 30% LDPE.

[0166] Example 11: A packaging film was developed.

[0167] The first layer consists of 70% LLDPE and 30% LDPE.

[0168] The second layer comprises 35% HDPE, 50% PIR material (shown in Table 1), and 15% white masterbatch, the PIR material being manufactured using a continuous melt filter granulator supplied by Erema.

[0169] The third layer consists of 70% LLDPE and 30% LDPE.

[0170] Example 12: A packaging film was developed.

[0171] The first layer consists of 70% LLDPE and 30% LDPE.

[0172] The second layer comprises 30% HDPE, 50% PIR material (shown in Table 1), 15% white masterbatch, and 5% compatibilizer, the PIR material being manufactured using a continuous melt filter granulator supplied by NGR / Ettlinger.

[0173] The third layer consists of 70% LLDPE and 30% LDPE.

[0174] Example 13: A packaging film was developed.

[0175] The first layer consists of 70% LLDPE and 30% LDPE.

[0176] The second layer comprises 30% HDPE, 50% PIR material (shown in Table 1), 15% white masterbatch, and 5% compatibilizer, the PIR material being manufactured using a continuous melt filter granulator supplied by Erema.

[0177] The third layer consists of 70% LLDPE and 30% LDPE.

[0178] Example 14: A packaging film was developed.

[0179] The first layer consists of 70% LLDPE and 30% LDPE.

[0180] The second layer comprises 30% HDPE, 50% PIR material (shown in Table 1), 15% LDPE and 5% compatibilizer, the PIR material being manufactured using a continuous melt filter granulator supplied by Erema.

[0181] The third layer consists of 70% LLDPE and 30% LDPE.

[0182] Experimental results

[0183] Experiments were conducted on different freeze-fracture pellets (i.e., Examples 1 and 2) and packaging films (i.e., Examples 3 to 14) to determine their sealing, tensile, and tear properties.

[0184] Experiment 1: Referring to Example 1, the first pellet among a plurality of first pellets was examined using a scanning electron microscope (SEM).

[0185] Figure 9 An SEM image 700 of the first pellet of Example 1 is shown. SEM image 700 depicts the first pellet comprising multiple polyester microdroplets, including a first droplet 702, a second droplet 704, a third droplet 706, a fourth droplet 708, a fifth droplet 710, and a sixth droplet 712. The first droplet 702 has a maximum length of 0.849 micrometers. The second droplet 704 has a maximum length of 2.161 micrometers. The third droplet 706 has a maximum length of 1.276 micrometers. The fourth droplet 708 has a maximum length of 0.885 micrometers. The fifth droplet 710 has a maximum length of 1.498 micrometers. The sixth droplet 712 has a maximum length of 2.240 micrometers. The maximum length of the polyester microdroplets in the first pellet manufactured using a continuous melt filter granulator provided by Erema is between 0.5 micrometers and 2.2 micrometers.

[0186] Experiment 2: Referring to Example 2, the second pellets in a plurality of second pellets were examined using SEM.

[0187] Figure 10An SEM image 800 of the second pellet of Example 2 is shown. SEM image 800 depicts the second pellet comprising multiple polyester microdroplets, including a first droplet 802, a second droplet 804, a third droplet 806, a fourth droplet 808, and a fifth droplet 810. The first droplet 802 has a maximum length of 1.106 micrometers. The second droplet 804 has a maximum length of 0.960 micrometers. The third droplet 806 has a maximum length of 0.646 micrometers. The fourth droplet 808 has a maximum length of 0.569 micrometers. The fifth droplet 810 has a maximum length of 1.219 micrometers. The maximum length of the polyester microdroplets in the second pellet manufactured using a continuous melt filter granulator provided by NGR / Ettlinger is between 0.5 micrometers and 1.2 micrometers.

[0188] SEM image 800 further depicts that the second pellet comprises titanium dioxide microparticles, which include a first particle 812 and a second particle 814. (See image 800.) Figure 10 As shown, the number of titanium dioxide microparticles in the second pellet is lower than the number of polyester microdroplets in the second pellet. However, the average length of the titanium dioxide microparticles in the second pellet is greater than the average length of the polyester microdroplets in the second pellet.

[0189] Experiment 3: The packaging films corresponding to Examples 3 and 6 to 14 were tested using a dart impact test to determine their impact resistance.

[0190] Approximate peak loads (in pounds or lbs) on the packaging films corresponding to Examples 3 and 6 to 14 are provided in Table 2 below.

[0191] Table 2

[0192] 3 21.8 6 19.6 7 18.75 8 15.7 9 17.1 10 17.3 11 16 12 15.3 13 16.25 14 15.7

[0193] The report data in Table 2 was obtained using ASTM D7192-10. Additionally, the report data in Table 2 can be expressed in international standard units, in kilograms (kg), using a conversion factor of 0.454; for example, 21.8 lb equals 9.89 kg.

[0194] The approximate total deformation (in inches) of the packaging films corresponding to Examples 3 and 6 to 14 is provided in Table 3 below.

[0195] Table 3

[0196]

[0197] The report data in Table 3 was obtained using ASTM D7192-10. Additionally, the report data in Table 3 can be expressed in international standard units, in meters (m), using a conversion factor of 0.0254; for example, 1.36 in equals 0.0345 m.

[0198] Experiment 4: The packaging films corresponding to Examples 3 and 6 to 14 were tested using a 1600-gram pendulum in the Elmendorf tear test to determine their tear resistance.

[0199] The approximate tear resistance (in g) of the packaging films corresponding to Examples 3 and 6 to 14 is provided in Table 4 below.

[0200] Table 4

[0201]

[0202]

[0203] The report data in Table 4 were obtained using ASTM D1922-09.

[0204] Experiment 5: The packaging films corresponding to Examples 3 and 6 through 14 were tested using a ring stiffness test to determine their ring stiffness characteristics. For the ring stiffness measurement, an Instron company (Norwood, MA, USA) was used. A tensile testing machine with a 100-pound (approximately 45.36 kg) load cell was used. Specimens were prepared by cutting 4-inch (10.16 cm) x 4-inch (10.16 cm) samples of each material and then folding the opposite ends of the samples towards themselves to form a loop. The folded samples were placed in the specimen holder with the opposite sides of the samples separated by a 1.0-inch (2.54 cm) gap. A 0.25-inch (0.635 cm) thick x 5-inch (12.7 cm) long stainless steel test probe was mounted on the Instron® Mechanical Testing Instrument. The instrument was set to the “Stiffness” internal protocol. The force required to bend or deflect the sample by approximately 0.5 inches (1.27 cm) at the apex of the loop was measured.

[0205] The approximate ring stiffness (in grams or gf) of the packaging films corresponding to Examples 3 and 6 to 14 in the longitudinal (MD) and transverse (TD) directions is provided in Table 5 below.

[0206] Table 5

[0207]

[0208]

[0209] The data in Table 5 can be expressed in international standard units, in Newtons (N), using a conversion factor of 0.0098. For example, 11.6 gf equals 0.11375714 N.

[0210] Experiment 6: Puncture tests were conducted on the packaging films corresponding to Examples 3 and 6 through 14 to determine their puncture resistance.

[0211] Approximate puncture resistance (in pounds or lbs) on the packaging films corresponding to Examples 3 and 6 to 14 is provided in Table 6 below.

[0212] Table 6

[0213] 3 2.6 6 2.25 7 2.9 8 2.2 9 2.6 10 2.7 11 2.55 12 2.5 13 1.95 14 2.25

[0214] The report data in Table 6 were obtained using ASTM F1306-16. Additionally, the report data in Table 6 can be expressed in international standard units, in kilograms (kg), using a conversion factor of 0.454; for example, 2.6 lb equals 1.179 kg.

[0215] Experiment 7: Tensile tests were conducted on the packaging films corresponding to Examples 3 and 6 to 14 to determine their tensile properties.

[0216] The approximate breaking stress (in pounds per square inch or psi) of the packaging films corresponding to Examples 3 and 6 to 14 on MD and TD is provided in Table 7 below.

[0217] Table 7

[0218]

[0219] The report data in Table 7 were obtained using ASTM D882-12. Additionally, the report data in Table 7 can be expressed in International Standard Units (ISUs) in Pascals (Pa) using the conversion factor 6984.76; for example, 1 psi equals 6984.76 Pa.

[0220] The approximate elongation at break (in %) of the packaging films corresponding to Examples 3 and 6 to 14 on MD and TD is provided in Table 8 below.

[0221] Table 8

[0222]

[0223] The report data in Table 8 were obtained using ASTM D882-12.

[0224] The approximate moduli of the packaging films corresponding to Examples 3 and 6 to 14 in terms of MD and TD are provided in Table 9 below.

[0225] Table 9

[0226]

[0227]

[0228] The report data in Table 9 is obtained using ASTM D882-12. Additionally, the report data in Table 9 can be expressed in International Standard Units (ISUs) in Pascals (Pa) using the conversion factor 6984.76; for example, 1 psi equals 6984.76 Pa.

[0229] Tests measuring the sealing, tensile, and tear properties of Examples 3 and 6 to 14 showed that the presence of micronized polyester dispersed in the PE structure did not significantly alter any physical properties due to the addition of PIR material.

[0230] The specific embodiments, examples, implementations, and drawings disclosed in this invention are merely illustrative and should not be construed as limiting. This invention includes the disclosed specific embodiments, examples, implementations, and drawings; however, it is not limited to these specific embodiments, examples, implementations, and drawings. As briefly described above, the reader should assume that features of one embodiment disclosed in this invention can also be applied to all other embodiments disclosed in this invention, unless explicitly stated otherwise. Modifications and other embodiments will be apparent to those skilled in the art of packaging, and all such modifications and other embodiments are intended and are considered to fall within the scope of this invention.

Claims

1. A packaging film comprising a first layer, a second layer, and a third layer, each layer comprising a first surface and an opposite second surface, wherein the first layer and the third layer comprise polyethylene, wherein the second layer comprises: The matrix phase comprises polyethylene in an amount of 75% to 99.5% by weight of the membrane; as well as The dispersed phase comprises polyester in an amount of 0.5% to 25% by weight of the membrane; The dispersed phase comprises droplets; wherein 90% of the droplets have an average length of 0.2 micrometers to 5.0 micrometers; and wherein the droplets are dispersed in the matrix phase.

2. The membrane of claim 1, wherein the membrane is a co-extruded membrane.

3. The membrane according to any one of claims 1 to 2, wherein the polyethylene comprises ultra-low density polyethylene, low density polyethylene, linear low density polyethylene, medium density polyethylene, linear medium density polyethylene, metallocene low density polyethylene, high density polyethylene, ethylene-vinyl acetate copolymer (EVA), or combinations thereof.

4. The film according to any one of claims 1 to 2, wherein the polyester has a melting point from 250°C to 290°C.

5. The membrane according to any one of claims 1 to 2 further comprises a compatibilizer.

6. The membrane according to any one of claims 1 to 2, wherein the polyester comprises post-industrial recycled (PIR) polyester or post-consumer recycled (PCR) polyester.

7. A laminated film comprising the film of any one of claims 1 to 6, the laminated film further comprising a second film laminated onto the film, and wherein the second film comprises an exposed surface of the laminated film.

8. The laminated film of claim 7, further comprising a substrate, wherein the substrate comprises oriented polyester, oriented nylon, or oriented polypropylene.

9. A package comprising the film of any one of claims 1 to 6, or the laminated film of claim 7 or 8.

10. A laminated film, comprising: A first membrane, comprising a first layer, a second layer, and a third layer, each layer comprising a first surface and an opposite second surface; as well as Second membrane; The first and third layers comprise polyethylene, the second layer comprises a matrix phase and a dispersed phase, wherein the matrix phase comprises 75% to 99.5% polyethylene by weight of the first membrane, the dispersed phase comprises 0.5% to 25% polyester by weight of the first membrane, wherein the dispersed phase comprises droplets, wherein 90% of the droplets have an average length of 0.2 micrometers to 5.0 micrometers, wherein the droplets are dispersed in the matrix phase, wherein the first, second, and third layers are co-extruded together and positioned relative to each other in a sequential manner, and wherein the second membrane is laminated onto the first membrane, including the exposed surface of the laminated membrane.

11. The laminated film of claim 10, wherein the second film is an oriented film.

12. The laminated film of any one of claims 10 to 11, wherein the second film and the first film are laminated by heating, extrusion or adhesive.

13. The laminated film according to any one of claims 10 to 11 further includes printed markings.

14. The laminated film according to any one of claims 10 to 11, wherein the polyethylene in the first layer, the second layer, and the third layer comprises ultra-low density polyethylene, low density polyethylene, linear low density polyethylene, medium density polyethylene, linear medium density polyethylene, metallocene low density polyethylene, high density polyethylene, ethylene-vinyl acetate copolymer (EVA), or combinations thereof.

15. A package comprising the laminated film according to any one of claims 10 to 14.

16. A packaging film comprising a first layer, a second layer, and a third layer, each layer comprising a first surface and an opposite second surface, wherein the first layer and the third layer comprise polyethylene, wherein the second layer comprises: The matrix phase comprises a polyolefin comprising 75% to 99.5% of the amount of the polyolefin by weight of the membrane; as well as The dispersed phase comprises a polymer that is chemically incompatible with PE, in an amount of 0.5% to 25% by weight of the membrane. The dispersed phase comprises droplets; wherein 90% of the droplets have an average length of 0.2 micrometers to 5.0 micrometers; and wherein the droplets are dispersed in the matrix phase.

17. The membrane of claim 16, wherein the matrix phase comprises polyethylene, polypropylene, or a combination thereof.

18. A method of manufacturing a packaging film, the packaging film comprising a first layer, a second layer, and a third layer, each layer comprising a first surface and an opposite second surface, wherein the first layer and the third layer comprise polyethylene, wherein the first layer, the second layer, and the third layer are co-extruded together and positioned relative to each other in a sequential manner, and wherein the method of manufacturing the second layer comprises: A polyethylene film is obtained, the polyethylene film comprising 0.5% to 25% by weight of a polymer chemically incompatible with PE, and 75% to 99.5% by weight of polyethylene. A continuous melt filter granulator is used in a temperature range above the melting point of the polyethylene and at least 5% lower than the melting point of the polymer that is chemically incompatible with PE. The granulator includes a filter comprising a plurality of openings ranging from 5 micrometers to 150 micrometers. The continuous melt filter granulator is maintained at a pressure below 112 MPa; Multiple pellets are formed, each pellet comprising a dispersed phase comprising less than 25% by weight of the polymer that is chemically incompatible with PE, and wherein the dispersed phase comprises droplets with an average length of 0.2 micrometers to 5.0 micrometers. The pellets are melted during the extrusion process; as well as A membrane is formed, the membrane comprising a matrix phase and a dispersed phase, wherein the matrix phase comprises polyethylene in an amount of 75% to 99.5% by weight of the membrane, and the dispersed phase comprises a polymer that is chemically incompatible with PE in an amount of 0.5% to 25% by weight of the membrane. The dispersed phase comprises droplets; wherein 90% of the droplets have an average length of 0.2 micrometers to 5.0 micrometers; and wherein the droplets are dispersed in the matrix phase.

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