Paper-based packaging film with multi-layer barrier film

Abstract

The present disclosure relates to paper-based packaging films and methods of producing the same. The total composition of the paper-based packaging film comprises greater than or equal to 80% by weight of paper components and less than or equal to 5% by weight of non-compostable materials. The paper-based packaging film can be readily recycled by repulping while maintaining high performance packaging properties, including improved barrier properties and high running speeds on packaging equipment.

Description

Technical Field

[0001] The present disclosure relates to paper-based packaging films and methods of producing the same. Embodiments of the present disclosure relate to paper-based packaging films comprising greater than or equal to 80% by weight of a cellulose fiber. Background Art

[0002] The goal of increasing the recyclability of paper-based packaging films becomes challenging when attempting to form packaging films with improved barrier properties. Traditionally, improved barrier properties have been achieved in paper-based packaging films by forming polymeric multilayer films. Multilayer films contain multiple layers dedicated to forming a barrier layer. As performance requirements increase, the number of layers or the thickness of each layer in the multilayer film increases, which is detrimental to the recyclability of the structure because the paper content is reduced on a percentage basis.

[0003] Typically, when high performance is required for paper-based packaging films, relatively large amounts of additional non-paper materials are added to the paper-based packaging films (e.g., structures with improved barrier properties). In order to maintain the recyclability of the paper-based packaging films, the paper component thickness and / or weight is increased to obtain the paper content required to designate the packaging material as "recyclable". This additional paper thickness / weight may be problematic because the additional volume of the packaging film may cause processing problems on the packaging forming equipment. Increased film thickness and hardness typically result in slower line speeds because the film is more difficult to pull through the forming collar. The packaging film may also be more difficult to seal because the additional paper weight tends to absorb heat from the sealing bar and / or prevent evenly distributed pressure from being applied.

[0004] Without questioning the relative merits of prior art systems, there is a need for a high barrier paper-based packaging film suitable for both recycling and composting. Summary of the invention

[0005] Embodiments of the present disclosure relate to flexible paper-based packaging films having improved barrier properties and excellent sealing performance while maintaining recyclability in a paper recycling process. The paper-based packaging film comprises a paper component, a barrier layer, a compostable polymer, and includes a minimal amount of non-compostable material (i.e., a minimal amount of non-paper and non-compostable polymer material). Advantageously, the paper-based packaging film provides at least two end-of-life options: (1) a paper recycling (repulpable) process and / or (2) a composting process.

[0006] In some embodiments, the total composition of the paper-based packaging film comprises greater than or equal to 80 wt%, greater than or equal to 85 wt%, greater than or equal to 90 wt%, or greater than or equal to 95 wt% of the paper component.

[0007] In some embodiments, the paper-based packaging film comprises less than or equal to 5 weight percent non-compostable material.

[0008] In some embodiments, the basis weight of the paper component is 30 g / m 2 Up to 360g / m 2 within the range.

[0009] In some embodiments, the paper-based packaging film comprises a multi-layer barrier film, the multi-layer barrier film being attached to the paper component. In some embodiments, the paper-based packaging film comprises an adhesive layer, the adhesive layer attaching the multi-layer barrier film to the paper component. In some embodiments, the combined thickness of the multi-layer barrier film and the adhesive layer is less than or equal to 10 μm. In some embodiments, the combined thickness is in the range of 4 μm to 8 μm.

[0010] In some embodiments, the multilayer barrier film comprises a transfer substrate and a barrier layer, the barrier layer being deposited on the transfer substrate by physical vapor deposition (PVD).In some embodiments, the transfer substrate comprises a heat seal layer and optionally a lacquer layer.

[0011] In some embodiments, the heat seal layer comprises a non-oriented film. In some embodiments, the heat seal layer comprises a compostable polymer. In some embodiments, the heat seal layer comprises one or more of: polylactic acid (PLA), polybutylene adipate terephthalate (PBAT), polybutylene succinate (PBS), polyhydroxyalkanoate (PHA) and / or polyvinyl alcohol (PVOH).

[0012] In some embodiments, the heat seal layer has a thickness in the range of 2 μm to 10 μm, including all values ​​and subranges therebetween. In some embodiments, the heat seal layer has a thickness in the range of 2 μm to 8 μm or in the range of 2 μm to 6 μm. In some embodiments, the heat seal layer is directly connected to the barrier layer.

[0013] In some embodiments, the transfer substrate further comprises a paint layer. The paint layer may be located between the heat seal layer and the barrier layer. In some embodiments, the paint layer comprises one or more of the following: polyurethane (PU), polyvinyl alcohol (PVOH) and / or ethylene vinyl alcohol (EVOH). In some embodiments, the thickness of the paint layer is in the range of 1 μm to 2 μm.

[0014] In some embodiments, the barrier layer comprises one or more of the following: metal, metal oxide and / or inorganic oxide. In some embodiments, the barrier layer comprises one or more of the following: aluminum (Alu), aluminum oxide (AlOx) and / or silicon oxide (SiOx).

[0015] Additional embodiments are directed to a method of producing a paper-based packaging film. In some embodiments, the method comprises: coating a base web with a multilayer barrier film, the base web having a thickness in a range of 6 μm to 50 μm; attaching the multilayer barrier film to a paper component by a lamination process to form an intermediate structure; and removing the base web from the intermediate structure to produce the paper-based packaging film.

[0016] In some embodiments, a single transfer operation comprises: attaching the multilayer barrier film to the paper component and removing the base web from the intermediate structure. In some embodiments, attaching the multilayer barrier film to the paper component and removing the base web from the intermediate structure are performed as separate operations.

[0017] The base film may be an oriented film (uniaxial or biaxially oriented) or an unoriented film (i.e., a blown film or cast film having no orientation). In some embodiments, the base web comprises one or more of an oriented polyethylene (OPE) film, an oriented polyethylene terephthalate (OPET) film, an oriented polypropylene (OPP) film, and / or an oriented polyamide (OPA) film.

[0018] In some embodiments, the coating of the base web comprises depositing a transfer substrate on the base web and depositing a barrier layer on the transfer substrate by physical vapor deposition (PVD), the combination of the barrier layer and the transfer substrate defining the multilayer barrier film.

[0019] In some embodiments, attaching the multi-layer barrier film to the paper component includes disposing an adhesive layer between the multi-layer barrier film and the paper component.

[0020] In other embodiments, a method for producing a paper-based packaging film includes: producing a base web and a heat seal layer by coextrusion; depositing a barrier layer on the heat seal layer by physical vapor deposition (PVD); attaching the barrier layer to a paper component by a lamination process to form an intermediate structure; and removing the base web from the intermediate structure to expose the heat seal layer and produce the paper-based packaging film. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The present disclosure may be more fully understood by considering the following detailed description of various embodiments of the present disclosure in conjunction with the accompanying drawings, in which:

[0022] Figure 1 A process flow chart showing a method of producing a paper-based packaging film according to one or more embodiments is shown;

[0023] Figure 2 A process flow chart showing a method of producing a paper-based packaging film according to one or more embodiments; and

[0024] Figure 3 , 4 5 are schematic cross-sectional views of film structures in an intermediate step of forming a paper-based packaging film.

[0025] Figure 6 and 7 is a schematic cross-sectional view of an embodiment of a final paper-based packaging film.

[0026] The accompanying drawings show some but not all embodiments. The elements depicted in the drawings are illustrative and not necessarily drawn to scale, and the same (or similar) reference numerals represent the same (or similar) features throughout the drawings. DETAILED DESCRIPTION

[0027] Provided herein are paper-based packaging films that overcome the shortcomings of previously provided films. The paper-based packaging films of the present disclosure are uniquely designed to achieve the key combination of 1) recyclability (high paper content), 2) ease of packaging conversion, and 3) high barrier properties. Additionally, this unique combination of layers and materials allows for an overall high paper content and low thickness, thereby achieving excellent runnability (i.e., high run speeds) on packaging equipment.

[0028] As described herein, the "total composition" of paper-based packaging film refers to all materials covered therein. The total composition of paper-based packaging film can include a paper component greater than or equal to 80 wt%, greater than or equal to 85 wt%, greater than or equal to 90 wt%, or greater than or equal to 95 wt%. The total composition of paper-based packaging film can include a paper component less than or equal to 99 wt%, less than or equal to 98 wt%, less than or equal to 97 wt%, or less than or equal to 96 wt%. For example, the total composition of paper-based packaging film can be included in the paper component in the range of 85 wt% to 98 wt% (including all values ​​and subranges therebetween). The total composition of paper-based packaging film can include a non-compostable material less than or equal to 5 wt%, less than or equal to 4 wt%, less than or equal to 3 wt%, less than or equal to 2 wt%, or less than or equal to 1 wt%. The total composition of paper-based packaging film can include compostable materials (e.g., compostable polymers) that are not paper components. For example, the total composition of the paper-based packaging film can include less than or equal to 15 weight %, less than or equal to 10 weight %, less than or equal to 5 weight %, less than or equal to 4 weight %, less than or equal to 3 weight %, less than or equal to 2 weight % or less than or equal to 1 weight % of the compostable material that is not a paper component. For example, the total composition of the paper-based packaging film can include 90 weight % of paper components, 5 weight % of compostable polymers and 5 weight % of non-compostable materials. In another example, the total composition of the paper-based packaging film can include between 80 weight % and 95 weight % of paper components, between 5 weight % and 20 weight % of compostable polymers and less than or equal to 5% of non-compostable materials.

[0029] The paper-based packaging films described herein include a multilayer barrier film attached to a paper component. In some embodiments, the multilayer barrier film is attached to the paper component as a whole. As used herein, the term "whole" means, for example, less than or equal to 1% or less than or equal to 0.5% of the multilayer barrier film is not attached to the paper component. In some embodiments, a portion of the multilayer barrier film is attached to the paper component. As described herein, a portion of the multilayer barrier film is attached to the paper component means that the multilayer barrier film remains at least partially attached to the paper component, so that the multilayer barrier film remains intact and attached to the paper component during production / processing. Additionally, the multilayer barrier film is partially or completely coextensive with the paper component.

[0030] The paper-based packaging film may include additional layers. The combination of these materials may be described as a multilayer film (e.g., a structure or laminate). As used herein, the term "layer" refers to the building blocks of a film. In other words, a film is constructed from one or more layers. A layer is a structure of a single material type or a uniform blend of materials. A layer may be a single polymer, a blend of materials within a single polymer type, or a blend of various polymers. A layer may contain a metallic material and may have an additive. A layer may be continuous with the film, or may be discontinuous or patterned. Both layers and films have a relatively insignificant thickness (z direction) compared to their respective length and width (xy direction).

[0031] As used herein, the term "compostable" means that a material such as a polymer, layer, film or packaging is capable of decomposing and biodegrading under industrial and home composting conditions (12 weeks at 58°C or 26 weeks at 21°C, respectively) and meets industrial compostability standards such as EN 13432-2000, ASTM D6400 "Standard Specification for Labeling of Plastics Designed to be Aerobically Composted in Municipal or Industrial Facilities" or ASTM D6868 "Standard Specification for Labeling of End Items that Incorporate Plastics and Polymers as Coatings or Additives with Paper and Other Substrates Designed to be Aerobically Composted in Municipal or Industrial Facilities." Compostable polymers may include, but are not limited to, polylactic acid (PLA), polybutylene adipate terephthalate (PBAT), and / or polyvinyl alcohol (PVOH).

[0032] As used herein, "PLA polymer" or "PLA" is a compostable polymer based on polylactic acid. Commercial examples of PLA polymers are available from Total Corbion and NatureWorks. A layer of a film comprising PLA may include at least 50 wt%, at least 75 wt%, or at least 95 wt% PLA polymer.

[0033] As used herein, "PBAT polymer" or "PBAT" is a compostable biopolymer based on poly (adipate-co-butylene terephthalate). Commercial examples of PBAT biopolymers are available from many suppliers, including but not limited to Mitsubishi, Novamont, Jiangsu Torise Biomaterials Co., Ltd., and BASF. The layer of the film containing PBAT can include at least 50 weight %, at least 75 weight %, or at least 95 weight % of the PBAT polymer.

[0034] As used herein, the term "non-compostable" refers to materials that are not capable of being composted (i.e., materials that are not decomposable and biodegradable under industrial and home composting conditions (12 weeks at 58°C or 26 weeks at 21°C, respectively). Examples of layers in paper-based packaging films that may include non-compostable materials include, but are not limited to, adhesive layers, barrier layers, and / or paint layers. Examples of non-compostable materials include, but are not limited to, polyolefins, EVOH, SiOx, vapor deposited metals, inks, and / or topcoats.

[0035] All layers and films described herein have two major surfaces relative to each other, defined by the xy plane. As used herein, the term "external layer" refers to one or more layers of a film on any one major surface of the film, i.e., a layer that is not between two other layers of the film. The film has an outer surface that becomes the exterior of a package in which the film is used. When formed into a package, the outer surface of the film is exposed to the environment. The film has an inner surface that becomes the interior of a package in which the film is used. When formed into a package, the inner surface is used to form a seal and is exposed to the packaged product.

[0036] One or more of the layers or films of the paper-based packaging film may be partially or fully coextensive with each other.

[0037] As used herein, the term "adjacent" means that the items (such as layers of a film) are close to each other with or without the use of an intermediate material (such as an adhesive layer). As used herein, the terms "directly adjacent," "directly connected," or "directly in contact with" mean that the items are in contact with each other without intermediate materials.

[0038] All layers and films can be produced by any suitable method known to the person skilled in the art.The layers and films can be produced by coextrusion, curtain coating and multi-station lacquering.

[0039] There are several challenges associated with the paper converting process and forming layers / films on paper components. Vacuum coating of paper materials is problematic because the water content of the paper causes degassing in the vacuum process. In addition, fibers shed by the paper can contaminate the vacuum pump. Packaging paper is typically quite thick compared to film - greater than or equal to 40 μm, where the thickness of polymer films ranges from 10 μm to 20 μm, making paper PVD coating very inefficient in intermittent vacuum deposition processes.

[0040] The surface of the paper assembly is not ideal for high quality vacuum deposition of the barrier layer, and even the smoothest paper surface is not flat enough to provide a defect-free coating for PVD. Normal suction on the paper can cause the PVD layer to crack. In addition, the combination of PVD layers onto paper is not ideal for flex crack resistance.

[0041] A typical process for applying a PVD barrier layer to a paper assembly involves applying a primer coating to the paper prior to the PVD coating. If the primer coating is water sensitive like EVOH, the coating will tend to absorb water through the paper assembly, causing the paper assembly to swell and subsequently crack the PVD layer. By having the PVD layer facing the paper assembly, but between the laminating adhesive and the EVOH support layer, the support layer is protected by the PVD layer from excessive moisture and swelling, thereby also preventing the PVD layer from cracking. PVD coating of primer coated paper is not efficient and suffers from the same problems as PVD coating of uncoated paper.

[0042] The methods of producing paper-based packaging films described herein advantageously maintain the barrier functionality of the multi-layer barrier film of the paper-based packaging film, protecting the multi-layer barrier film from the negative effects of the paper converting process.

[0043] Figure 1 A process flow diagram of a method 100 for producing a paper-based packaging film according to one or more embodiments is shown. The method 100 includes: coating a base web with a multi-layer barrier film (operation 102); attaching the multi-layer barrier film to a paper component by a lamination process to form an intermediate structure (operation 104); and removing the base web from the intermediate structure to produce a paper-based packaging film (operation 106). In some embodiments, a single transfer operation includes: attaching the multi-layer barrier film to the paper component (operation 104), and removing the base web from the intermediate structure (operation 106).

[0044] In some embodiments, at operation 102 , coating of the base web includes depositing a transfer substrate on the base web and depositing a barrier layer on the transfer substrate by physical vapor deposition (PVD).

[0045] In some embodiments, attaching the multi-layer barrier film to the paper component at operation 104 includes disposing an adhesive layer between the multi-layer barrier film and the paper component.

[0046] In some embodiments, the second paper component is attached to the paper-based packaging film by a second lamination process. In a specific embodiment where the paper-based packaging film has a paper component and a second paper component, the paper component is attached to the top surface of the multi-layer barrier film by an adhesive layer. In a specific embodiment where the paper-based packaging film has a paper component and a second paper component, the second paper component is attached to the bottom surface of the multi-layer barrier film by placing an adhesive layer between the bottom surface of the multi-layer barrier film and the bottom surface of the second paper component.

[0047] In a specific embodiment, the second paper component can have the same or similar properties as the "paper component" described herein. In a specific embodiment, the second lamination process can have the same or similar properties as the "lamination process" described herein or require the same process conditions as the "lamination process" described herein.

[0048] Figure 2 A process flow diagram of a method 150 for producing a paper-based packaging film according to one or more embodiments is shown. The method 150 includes: producing a base web and a transfer substrate by coextrusion (operation 152); depositing a barrier layer on a heat seal layer by physical vapor deposition (PVD) (operation 154); attaching the barrier layer to a paper component by a lamination process to form an intermediate structure (operation 156); and removing the base web from the intermediate structure and producing a paper-based packaging film having a heat seal layer on a surface (operation 158). In operation 158, separation occurs between the base web and the heat seal layer. The coextruded transfer substrate includes a heat seal layer. The coextruded transfer substrate may include other layers (such as a paint layer).

[0049] In some embodiments, a single transfer operation includes attaching the barrier layer to the paper component via a lamination process to form an intermediate structure (operation 156 ), and removing the base web from the intermediate structure (operation 158 ).

[0050] The methods described herein advantageously allow the PVD-deposited barrier layer to remain intact and attached to the heat seal layer (and ultimately to the paper component) when the base web is removed from the intermediate structure (operation 158). In a specific embodiment, the PVD-deposited barrier layer advantageously is integrally attached to the heat seal layer (and ultimately to the paper component) when the base web is removed from the intermediate structure (operation 158).

[0051] Advantageously, the methods described herein allow each layer added to the paper component to be very thin. By utilizing a PVD barrier layer, attaching the multilayer barrier film to the paper component by adhesive lamination, and removing the base film, the adhesive layer, barrier layer, and heat seal layer (and lacquer layer, if present) can be very thin, thus contributing less material to the overall structure. In this way, the paper-based packaging film remains recyclable due to the high paper component content while benefiting from high performance barrier and seal layers.

[0052] Figure 3 , 4 and 5 are formed Figure 6 Schematic cross-sectional view of the film structure in an intermediate step of a paper-based packaging film is shown. Figure 7 is a schematic cross-sectional view of another embodiment of a paper-based packaging film. Figure 6 and Figure 7 The paper-based packaging film shown in FIG. 1 may be formed by method 100 and / or method 150 .

[0053] Figure 3 A transfer substrate 203 is shown on a base web 250. The base web 250 comprises one or more of an oriented polyethylene (OPE) film, an oriented polyethylene terephthalate (OPET) film, an oriented polypropylene (OPP) film, and / or an oriented polyamide (OPA) film.

[0054] exist Figure 3 In the illustrated embodiment, the transfer substrate 203 comprises a heat seal layer 204 and a paint layer 205. In some embodiments, the heat seal layer 204 comprises a non-oriented film. In some embodiments, the heat seal layer 204 comprises a compostable polymer. In some embodiments, the heat seal layer 204 comprises one or more of the following: polylactic acid (PLA), polybutylene adipate terephthalate (PBAT) and / or polyvinyl alcohol (PVOH).

[0055] Figure 4 Demonstrated application in Figure 3 As a result of operation 156 of method 150 on a film of the transfer substrate 203, a barrier layer 206 is deposited on the transfer substrate 203 including the heat seal layer 204 and the lacquer layer 205. The transfer substrate 203 and the barrier layer 206 deposited on the transfer substrate 203 form the multi-layer barrier film 202. In some embodiments, the heat seal layer 204 is directly connected to the barrier layer 206, such that there is no intermediate element / layer / film between the heat seal layer 204 and the barrier layer 206 (i.e., there is no lacquer layer 205).

[0056] Figure 5 The results of operation 104 of method 100 and operation 156 of method 150 are shown: Figure 4The multilayer barrier film 202 of the illustrated structure is attached to a paper component 210 to form an intermediate structure. In some embodiments, at operation 104, attaching the multilayer barrier film 202 to the paper component 210 includes disposing an adhesive layer 208 between the multilayer barrier film 202 and the paper component 210.

[0057] Figure 6 The results of operation 106 of method 100 and operation 158 of method 150 are shown: from the intermediate structure (shown in Figure 5 Middle) removing the base web 250 to expose the heat seal layer 204 and produce the paper-based packaging film 200.

[0058] Figure 7 A schematic cross-sectional view of a paper-based packaging film 200' having a transfer substrate 203 is shown. In one or more embodiments, the transfer substrate 203 comprises a single layer. In some embodiments, the transfer substrate 203 comprises a heat seal layer having the same or similar properties as the heat seal layer 204. Figure 7 In the illustrated embodiment, the transfer substrate 203 has a barrier layer 206 deposited thereon by physical vapor deposition (PVD), the transfer substrate 203 and the barrier layer 206 defining the multi-layer barrier film 202 . Figure 7 An adhesive layer 208 between the multi-layer barrier film 202 and the paper assembly 210 is also shown.

[0059] Figure 3-7 Each of the layers / films shown in has a thickness measured in the z-direction. In some embodiments, the thickness 204A of the heat seal layer 204 is in the range of 2 μm to 10 μm. In some embodiments, the thickness 204A of the heat seal layer 204 is in the range of 2 μm to 8 μm or in the range of 2 μm to 6 μm. In some embodiments, the thickness 205A of the lacquer layer 205 is in the range of 1 μm to 2 μm. In some embodiments, the thickness of the transfer substrate 203 including the heat seal layer 204 and the lacquer layer 205 is in the range of 3 μm to 12 μm. In some embodiments, the thickness 250A of the base web 250 is in the range of 6 μm to 50 μm.

[0060] In some embodiments, the combined thickness of the multilayer barrier film 202 and the adhesive layer 208 is less than or equal to 10 μm. In some embodiments, the combined thickness is in a range of 4 μm to 8 μm.

[0061] Referring again to the paper component, the paper component is the outer layer of the paper-based packaging film (located at the outer surface of the paper-based packaging film). In some embodiments, the paper component includes additional components (such as ink or topcoat) adjacent to or on the outer surface of the paper component. These additional components can cover a portion of the outer surface or the entire outer surface.

[0062] A "paper component" may be any type of paper that can be processed in a paper recycling (repulpable) process. As used herein, the term "paper component" may be described relative to the amount of cellulose fibers in the paper component. For example, a paper component contains or may consist essentially of cellulose fibers. As used in this context, "consisting essentially of" means that the total composition of the paper component includes greater than or equal to 95%, greater than or equal to 98%, greater than or equal to 99%, greater than or equal to 99.9%, or 100% cellulose fibers. In some cases, a paper component may contain up to 20% by weight of mineral fillers and, correspondingly, an amount of greater than or equal to 80% cellulose fibers.

[0063] Therefore, in embodiments where the total composition of the paper-based packaging film comprises greater than or equal to 80 wt. %, greater than or equal to 85 wt. %, greater than or equal to 90 wt. %, or greater than or equal to 95 wt. % of the paper component, the total composition of the paper-based packaging film comprises greater than or equal to 80 wt. %, greater than or equal to 85 wt. %, greater than or equal to 90 wt. %, or greater than or equal to 95 wt. % of cellulose fibers.

[0064] In some embodiments, the basis weight of the paper component is 30 g / m 2 Up to 360g / m 2 In the range of (including all values ​​and subranges therebetween), including 30g / m 2 Up to 100g / m 2 In the range of 30g / m 2 Up to 70g / m 2 In the range of. Lower paper component weight is possible, while maintaining easy recyclability, because the additional components are minimized. Examples of paper components that can be used for paper-based packaging films include, but are not limited to, kraft paper, parchment paper, and bleached paper. The paper component can be coated (i.e., clay-coated) or uncoated. Examples of commonly used paper in acceptable packaging in the paper-based packaging films described herein include machine-bleached kraft paper (MGBK), single-sided clay-coated paper (C1S), and double-sided clay-coated paper (C2S), but less commonly used paper that provides improved mechanical or barrier properties through the use of special fibers or additives can also be a part of the paper-based packaging film described in the present application. Clay-coated paper can contain a coating of up to 15gsm, resulting in a large portion of latex being applied. This generally means that clay-coated paper is not considered to be compostable unless the latex used is a compostable polymer. In embodiments of coated paper components, the total composition of the paper component has greater than or equal to 95%, greater than or equal to 98%, greater than or equal to 99%, greater than or equal to 99.9%, or 100% cellulosic fibers.

[0065] As used herein, the term "basis weight" is used to refer to the weight of a material present in a predetermined area of ​​a film or layer. Typically, the defined area is a square meter, but any area can be used. The area is defined in the length-width (i.e., xy direction) of the film or layer. A material of a given thickness (z direction) and density has a specific weight when covering a defined area (i.e., square meters). Basis weight is a common weight measurement for paper because the density of paper can vary greatly. In other words, it may be difficult to measure paper by thickness in the z direction. Materials applied in discontinuous layers (such as patterned materials) can also be defined by basis weight. In the case of a pattern, basis weight refers to the amount of material by weight present when covering a defined area. It is common in the film conversion industry to use basis weight to measure the weight of materials such as paper and patterned materials.

[0066] In some embodiments, the paper-based packaging film comprises a multi-layer barrier film attached to the paper component. In some embodiments, the paper-based packaging film comprises an adhesive layer attaching the multi-layer barrier film to the paper component.

[0067] In some embodiments, the multilayer barrier film comprises a transfer substrate and a barrier layer, the barrier layer being deposited on the transfer substrate by physical vapor deposition (PVD).In some embodiments, the transfer substrate comprises a heat seal layer and optionally a lacquer layer.

[0068] In some embodiments, the transfer substrate further comprises the paint layer. In some embodiments, the paint layer comprises one or more of the following: polyurethane (PU), polyvinyl alcohol (PVOH) and / or ethylene vinyl alcohol (EVOH).

[0069] In some embodiments, the barrier layer comprises one or more of the following: a metal, a metal oxide, and / or an inorganic oxide. In some embodiments, the barrier layer comprises one or more of the following: aluminum oxide (AlOx) and / or silicon oxide (SiOx). The barrier layer can reduce the permeation of oxygen, moisture, or both.

[0070] The barrier material may be multi-layered and contain different layers of barrier materials. The barrier material may be a blend of multiple barrier materials.

[0071] In some embodiments, the average oxygen transmission rate (OTR) value of the paper-based packaging film containing the multi-layer barrier film described herein is less than or equal to 5 cm 3 / m 2 / day, less than or equal to 1cm 3 / m 2 / day or less than or equal to 0.5cm 3 / m 2 / day, the value is measured according to ASTM F1927 using the conditions of 1 atmosphere, 23°C and 50% RH. In some embodiments, the average moisture vapor transmission rate (MVTR) value (sometimes referred to as water vapor transmission rate (WVTR)) of the paper-based packaging film containing the barrier material coated on the polymer film is less than or equal to 1 g / m 2 / day, which is measured according to ASTM F1249 using the conditions of 1 atmosphere, 38°C and 90% RH.

[0072] The paper-based packaging film may include an adhesive layer that bonds the paper component to the barrier material. The adhesive layer may be in direct contact with the paper component. The adhesive layer may be in direct contact with the multilayer barrier film. The adhesive layer may be applied by any known web-to-web lamination method (such as dry bond lamination, wet bond lamination, or thermal lamination). The dry basis weight of the adhesive layer (i.e., after solvent removal) may be between 0.5 g / m 2 Up to 4.0g / m 2 between.

[0073] Embodiments of the present disclosure advantageously provide a paper-based packaging film comprising a water-sensitive adhesive layer. As used herein, the term "water-sensitive" means that the adhesive layer loses its adhesive and / or adhesive properties when exposed to or immersed in liquid water for a long time, thereby enabling the paper component to be delaminated (i.e., separated) from the rest of the paper-based packaging film structure during the repulping process. Examples of materials that can be used in the adhesive layer between the paper component and the multilayer barrier film include, but are not limited to, latex / casein blends, starch, sugar derivatives, cellulose, amino resins, (poly)acrylates, polyvinyl alcohol (PVOH), polyvinyl acetate, polyacrylic acid, maleic acid-modified ethylene copolymers, methylcellulose, carboxymethylcellulose, carboxyl-functional polyesters, polyethylene succinate, polybutylene succinate, ionomers, or hydrophilic polyurethanes.

[0074] As mentioned previously, the paper-based packaging film may also include ink located on the outer surface of the paper-based packaging film. The type of ink and the amount of ink may vary within the requirements to comply with local paper recycling guidelines.

[0075] Paper-based packaging films can be advantageously used to form packages. The term "package" is used herein to describe an article that can hold an object (i.e., a product), which is formed by bonding one or more paper-based packaging films or other packaging components to itself or to each other around the periphery, thereby forming a package interior space. "Packaged product" refers to one or more packaging components and products therein that form an airtight package. As used herein, airtightness refers to a fully closed and substantially airtight sealed package or a sealed package. The airtight package usually needs to realize storage and package integrity over a period of several days. Package integrity includes consistent appearance, barrier properties, lamination bonding, and sealing.

[0076] The product can be any type of food, beverage, medicine or other medical aid, nutritional supplement, consumer product or industrial commodity. The product can be fluid in nature. Examples of products include, but are not limited to, condiments (such as ketchup, mustard, mayonnaise or relish), pudding, yogurt, cheese sauce, nut butter, jam / jelly, dairy or non-dairy creamer, guacamole, applesauce, pure baby food, infant formula, nutritional drink / milkshake, beverage or supplement concentrate, cough syrup, fish oil, lotion, ointment / ointment, personal care products, soap / detergent or solvent.

[0077] As mentioned, the product can be fluid in nature or can have a fluid component. The product can be water-based (i.e., having water as a medium or major component) or oil-based (i.e., having oil as a medium or major component). The paper-based packaging films described herein may be particularly useful in containing acidic products with significant shelf life (several days, weeks or months) with minimal barrier loss. The pH of the product can be below 7, below 6, below 5, below 4 or even below 3.

[0078] The packaged products disclosed herein include packaging formed by at least one paper-based packaging film and optionally other components. In some embodiments of the packaged products, the entire package is formed by a single paper-based packaging film that has been folded and sealed to itself (i.e., a flow-wrap or stick-wrap configuration).

[0079] In each of the packaged products, the first surface of the paper-based packaging film faces away from the product, exposed to the external environment, and the second surface of the compostable multilayer film faces the product, exposed to the product and the internal environment. The paper component can be at or near the first surface, facing away from the packaged product. The second surface can include a heat seal layer.

[0080] The paper-based packaging films disclosed herein are particularly suitable for packaged products having small dimensions, such as 6" x 9", 5" x 7", 5" x 5", 3" x 3", 3" x 2", etc., because these types of packaging are difficult to collect and / or sort for recycling. Small packages and small packaging components may be more suitable for compostable end-of-life solutions rather than recycling.

[0081] The paper-based packaging films disclosed herein are particularly suitable for packaged product forms and / or product types that result in considerable product residue remaining in the packaging after use by the consumer. The packaged product may have a style or configuration that prevents / makes it impossible to completely remove the product. The packaged product may have a style or configuration that prevents / makes it impossible to clean the packaging after use. The packaged product may be a product that is easily attached to or adhered to the packaging. In these cases, the packaging should not be recycled because the product residues contaminate the recycling process. In these cases, composting is an excellent solution because the product residues can promote the decomposition process.

[0082] In some embodiments of the packaged product, the paper-based packaging film is sealed to another paper-based packaging film (i.e., a pouch configuration). In some embodiments of the packaged product, the paper-based packaging film is a lidding component that is sealed to a formed container such as a cup or tray. A package that includes a component that does not conform to the paper-based packaging film disclosed herein can also be compostable, such that the entire package is compostable. In some embodiments, the package includes a component that is not compostable but can be separated from the compostable portion for proper disposal.

[0083] The heat seal layer of the paper-based packaging film can have a composition that will allow the formation of an airtight sealed package. In some embodiments, the heat seal layer comprises a non-oriented film (i.e., the heat seal layer is a portion of a non-oriented film). In some embodiments, the heat seal layer comprises a compostable polymer. In some embodiments, the heat seal layer comprises one or more of: polylactic acid (PLA), polybutylene adipate terephthalate (PBAT) and / or polyvinyl alcohol (PVOH).

[0084] Heat seal layer allows two or more surfaces to be bonded together by applying both heat and pressure. Heat sealing is a well-known and commonly used method for producing packaging, and is familiar to those skilled in the art. It is not intended to be bound by theory, during heat sealing, the seal layer softens due to the application of heat, thereby allowing the formation of heat seal bonding. Since heat must be driven through the entire paper-based packaging film to raise the temperature of the sealable material, and the paper assembly often absorbs most of the heat, it is advantageous if the heat sealable material softens and seals at a relatively low temperature. Lower seal initiation temperature (SIT) can achieve faster packaging line speed. For example, some embodiments of paper-based packaging films can include heat sealable materials that show a SIT of less than or equal to 110°C, less than or equal to 100°C, or less than or equal to 90°C. Possible heat sealable materials can include but are not limited to acrylate copolymers, PET, PE, PP, or hot melts (wax-based).

[0085] The heat seal layer is applied at a thickness that allows for an airtight seal. In some embodiments, the heat seal layer may be applied at a thickness greater than or equal to 1 g / m 2 Or greater than or equal to 3g / m 2 In other embodiments, the heat seal layer may be applied at a basis weight of less than or equal to 8 g / m 2 , less than or equal to 9g / m 2 Or less than or equal to 10g / m 2 For example, the basis weight of the heat seal layer can be about 1 g / m 2 About 10g / m 2 In the range of about 3g / m 2 About 9g / m 2 within the range.

[0086] The present disclosure will now be described with reference to the following examples.

[0087] Examples

[0088] Example 1 is a prophetic example based on the paper-based packaging film described above. Example 1 can be obtained by adding 67g / m 2 The multilayer barrier film can be produced by laminating a paper component of 1.3 g / m 2 The PVOH-based barrier lacquer layer is produced by applying a 12 μm polyester film. The lacquer can be applied in such a way that the adhesion to the polyester film is low, for example, by omitting an adhesion promoter in the lacquer layer. After lacquering, the PVOH-based barrier lacquer layer can be coated with 50 mg / m 2 SiOx is SiOx coated. The SiOx coated layer can be with 3g / m 2 A layer of a suitable adhesive is laminated to the paper to form an intermediate structure. The 12 μm polyester film can then be removed to produce a 67 g / m 2 / / Adhesive 3g / m 2 / / SiOx coating 0.05g / m 2 / / PVOH coating 1.3g / m 2 The total composition of the paper-based packaging film of Example 1 will include about 94% by weight of paper components and about 4% by weight of non-compostable materials.

[0089] The paper-based packaging film of Example 1 can be made of 1.5g / m 2 The heat seal layer and / or lacquer layer is painted for use as a packaging film. The heat seal layer can be added in a mode that minimizes the level of non-compostable materials and keeps it below 5%.

[0090] Example 2 is a prophetic example based on a paper-based packaging film as described above. Example 2 can be produced by first coextruding a 20 μm polyethylene / 6 μm amorphous PLA / 4 μm PVOH multilayer film. In a second step, the PE / aPLA / PVOH film is coated with 50 mg / m 2 SiOx was SiOx coated. Finally, the SiOx coated surface of the film was laminated to paper (67 gsm) with a suitable adhesive and the PE layer was peeled off. The final structure of the paper-based packaging film was: paper 67 g / m 2 / / Adhesive 3g / m 2 / / SiOx coating 0.05g / m 2 / / PVOH coating 3.0g / m 2 / / Amorphous PLA heat seal layer 7.5g / m 2 The total composition of the paper-based packaging film of Example 2 will include about 83% by weight of the paper component and about 4% by weight of non-compostable materials.

[0091] Example 3 is a prophetic example based on a paper-based packaging film as described above. Example 3 can be produced by first coextruding a 25 μm polyethylene / 8 μm amorphous PLA multilayer film. In a second step, the PE / aPLA film is coated with 50 mg / m 2 SiOx was SiOx coated. Finally, the SiOx coated surface of the film was laminated to paper (67 gsm) with a suitable adhesive and the PE layer was peeled off. The final structure of the paper-based packaging film was: paper 67 g / m 2 / / Adhesive 3g / m 2 / / SiOx coating 0.05g / m 2 / / Amorphous PLA heat seal layer 10.0g / m 2 The total composition of the paper-based packaging film of Example 3 will include about 84% by weight of the paper component and about 4% by weight of non-compostable materials.

[0092] Examples 4, 5 and 6 are paper-based packaging films produced by the methods disclosed herein. The films were produced by coextruding a base web and a heat seal layer (i.e., a transfer substrate), depositing a PVD aluminum layer (negligible weight) as a barrier layer onto the heat seal layer, laminating onto a paper assembly and removing the base web. The structures of the films produced are shown in Table 1.

[0093] Table 1: Structural details of Examples 4, 5 and 6

[0094]

[0095] Example:

[0096] Embodiment 1: A paper-based packaging film comprising: a paper component attached to a multilayer barrier film, the multilayer barrier film comprising a compostable polymer; wherein the total composition of the paper-based packaging film comprises greater than or equal to 80 weight percent of the paper component and less than or equal to 5 weight percent of non-compostable material.

[0097] Embodiment 2: The paper-based packaging film according to embodiment 1, wherein the basis weight of the paper component is 30 g / m 2 Up to 360g / m 2 within the range.

[0098] Embodiment 3: The paper-based packaging film of any of the preceding embodiments, further comprising an adhesive layer attaching the multi-layer barrier film to the paper component.

[0099] Embodiment 4: The paper-based packaging film according to any of the preceding embodiments, wherein the multi-layer barrier film comprises a transfer substrate and a barrier layer, wherein the barrier layer is deposited on the transfer substrate by physical vapor deposition (PVD).

[0100] Embodiment 5: The paper-based packaging film of any one of Embodiments 1 to 4, wherein the transfer substrate comprises a heat seal layer.

[0101] Embodiment 6: The paper-based packaging film according to any one of embodiments 1 to 5, wherein the heat seal layer comprises a non-oriented film.

[0102] Embodiment 7: The paper-based packaging film according to any one of embodiments 1 to 6, wherein the heat seal layer comprises a compostable polymer.

[0103] Embodiment 8: The paper-based packaging film according to any one of embodiments 1 to 7, wherein the compostable polymer is selected from the group consisting of polylactic acid (PLA), polybutylene adipate terephthalate (PBAT), polybutylene succinate (PBS), polyhydroxyalkanoate (PHA).

[0104] Embodiment 9: The paper-based packaging film according to any one of embodiments 5 to 8, wherein the thickness of the heat sealing layer is in the range of 2 μm to 10 μm.

[0105] Embodiment 10: The paper-based packaging film according to any one of embodiments 5 to 9, wherein the heat seal layer is directly connected to the barrier layer.

[0106] Embodiment 11: The paper-based packaging film according to any one of embodiments 5 to 10, wherein the transfer substrate further comprises the paint layer, the paint layer comprising one or more of the following: polyurethane (PU), polyvinyl alcohol (PVOH) and / or ethylene vinyl alcohol (EVOH).

[0107] Embodiment 12: The paper-based packaging film according to embodiment 11, wherein the thickness of the paint layer is in the range of 1 μm to 2 μm.

[0108] Embodiment 13: The paper-based packaging film according to any one of embodiments 4 to 12, wherein the barrier layer comprises one or more of the following: a metal, a metal oxide and / or an inorganic oxide.

[0109] Embodiment 14: The paper-based packaging film according to Embodiment 13, wherein the barrier layer comprises one or more of the following: aluminum oxide (AlOx) and / or silicon oxide (SiOx).

[0110] Embodiment 15: The paper-based packaging film of any one of Embodiments 5 to 14, wherein the combined thickness of the multilayer barrier film and the adhesive layer is less than or equal to 10 μm.

[0111] Embodiment 16: The paper-based packaging film of Embodiment 15, wherein the combined thickness is in the range of 4 μm to 8 μm.

[0112] Embodiment 17: The paper-based packaging film according to any one of the preceding embodiments, wherein the total composition of the paper-based packaging film comprises greater than or equal to 85 wt% of the paper component and less than or equal to 5 wt% of the non-compostable material.

[0113] Embodiment 18: A method for producing a paper-based packaging film, the method comprising: coating a base web with a multilayer barrier film comprising a compostable polymer, the base web having a thickness in a range of 6 μm to 50 μm; attaching the multilayer barrier film to a paper component by a lamination process to form an intermediate structure; and removing the base web from the intermediate structure to produce the paper-based packaging film, wherein the total composition of the paper-based packaging film comprises greater than or equal to 80 weight % of the paper component and less than or equal to 5 weight % of non-compostable materials.

[0114] Embodiment 19: The method of Embodiment 18, wherein a single transfer operation comprises attaching the multilayer barrier film to the paper component and removing the base web from the intermediate structure.

[0115] Embodiment 20: The method according to any one of embodiments 18 and 19, wherein the base web comprises one or more of the following: an oriented polyethylene (OPE) film, an oriented polyethylene terephthalate (OPET) film, an oriented polypropylene (OPP) film and / or an oriented polyamide (OPA) film.

[0116] Embodiment 21: A method according to any one of embodiments 18 to 20, wherein the coating of the base web comprises: depositing a transfer substrate on the base web and depositing a barrier layer on the transfer substrate by physical vapor deposition (PVD), the combination of the barrier layer and the transfer substrate defining the multilayer barrier film.

[0117] Embodiment 22: The method of any one of Embodiments 18 to 21, wherein the attaching the multilayer barrier film to the paper component comprises disposing an adhesive layer between the multilayer barrier film and the paper component.

[0118] Embodiment 23: The method of Embodiment 21, wherein the transfer substrate comprises a heat seal layer and optionally a lacquer layer.

[0119] Embodiment 24: The method of Embodiment 23, wherein the heat seal layer comprises a non-oriented film.

[0120] Embodiment 25: The method of any one of Embodiments 23 to 24, wherein the heat seal layer comprises a compostable polymer.

[0121] Embodiment 26: A method according to any one of embodiments 23 to 25, wherein the heat sealing layer comprises one or more of the following: polylactic acid (PLA), polybutylene adipate terephthalate (PBAT), polybutylene succinate (PBS), polyhydroxyalkanoate (PHA), polyethylene vinyl alcohol (EVOH) and / or polyvinyl alcohol (PVOH).

[0122] Embodiment 27: The method according to any one of embodiments 23 to 26, wherein the thickness of the heat seal layer is in the range of 2 μm to 10 μm.

[0123] Embodiment 28: The method of any one of Embodiments 23 to 27, wherein the heat seal layer is directly attached to the barrier layer.

[0124] Embodiment 29: The method according to Embodiment 23, wherein the transfer substrate further comprises the paint layer, the paint layer comprising one or more of the following: polyurethane (PU), polyvinyl alcohol (PVOH) and / or ethylene vinyl alcohol (EVOH).

[0125] Embodiment 30: The method according to any one of Embodiments 21 to 29, wherein the barrier layer comprises one or more of the following: aluminum oxide (AlOx) and / or silicon oxide (SiOx).

[0126] Embodiment 31: The method of any one of Embodiments 18 to 30, wherein the total composition of the paper-based packaging film comprises greater than or equal to 85 wt% of the paper component and less than or equal to 5 wt% of the non-compostable material.

[0127] Example 32: A method for producing a paper-based packaging film, the method comprising: producing a base web and a heat-sealing layer by coextrusion; depositing a barrier layer on the heat-sealing layer by physical vapor deposition (PVD); attaching the barrier layer to a paper component by a lamination process to form an intermediate structure; and removing the base web from the intermediate structure to expose the heat-sealing layer and produce the paper-based packaging film, wherein the total composition of the paper-based packaging film comprises greater than or equal to 80 weight % of the paper component.

[0128] Embodiment 33: A paper-based packaging film comprising: a multilayer barrier film, the multilayer barrier film comprising a transfer substrate and a barrier layer deposited by physical vapor deposition (PVD); and an adhesive layer, the adhesive layer attaching a paper component to the multilayer barrier film, wherein the transfer substrate comprises a heat seal layer, the thickness of the heat seal layer is in the range of 2 μm to 8 μm, the barrier layer comprises one or more of the following: metal, aluminum oxide (AlOx) and / or silicon oxide (SiOx), and the total composition of the paper-based packaging film comprises greater than or equal to 85 weight % of the paper component.

[0129] Embodiment 34: The paper-based packaging film of Embodiment 33, wherein the heat seal layer comprises a compostable polymer.

[0130] Embodiment 35: The paper-based packaging film of any one of Embodiments 33 to 34, wherein the heat seal layer comprises a non-oriented film.

[0131] Embodiment 36: According to any one of embodiments 33 to 35, the heat sealing layer comprises one or more of the following: polylactic acid (PLA), polybutylene adipate terephthalate (PBAT) and / or polyvinyl alcohol (PVOH).

Claims

1. A paper-based packaging film, comprising: a paper component attached to a multi-layer barrier film, the multi-layer barrier film comprising a compostable polymer; The total composition of the paper-based packaging film comprises greater than or equal to 80 wt % of the paper component and less than or equal to 5 wt % of non-compostable materials.

2. The paper-based packaging film according to claim 1, wherein the basis weight of the paper component is 30 g / m 2 Up to 360g / m 2 within the range.

3. The paper-based packaging film of claim 1, further comprising an adhesive layer attaching the multi-layer barrier film to the paper component.

4. The paper-based packaging film of claim 1, wherein the multi-layer barrier film comprises a transfer substrate and a barrier layer, wherein the barrier layer is deposited on the transfer substrate by physical vapor deposition (PVD).

5. The paper-based packaging film of claim 4, wherein the transfer substrate comprises a heat seal layer.

6. The paper-based packaging film of claim 5, wherein the heat seal layer comprises a non-oriented film.

7. The paper-based packaging film of claim 5, wherein the heat seal layer comprises the compostable polymer.

8. The paper-based packaging film according to claim 1, wherein the compostable polymer is selected from the group consisting of polylactic acid (PLA), polybutylene adipate terephthalate (PBAT), polybutylene succinate (PBS), polyhydroxyalkanoate (PHA). 9 . The paper-based packaging film according to claim 5 , wherein the heat sealing layer has a thickness in the range of 2 μm to 10 μm.

10. The paper-based packaging film of claim 5, wherein the heat seal layer is directly connected to the barrier layer.

11. The paper-based packaging film according to claim 5, wherein the transfer substrate further comprises a lacquer layer, the lacquer layer is located between the heat seal layer and the barrier layer, and the lacquer layer comprises one or more of the following: polyurethane (PU), polyvinyl alcohol (PVOH) and / or ethylene vinyl alcohol (EVOH). 12 . The paper-based packaging film according to claim 11 , wherein the thickness of the paint layer is in the range of 1 μm to 2 μm.

13. The paper-based packaging film according to claim 4, wherein the barrier layer comprises one or more of the following: a metal, a metal oxide and / or an inorganic oxide.

14. The paper-based packaging film according to claim 13, wherein the barrier layer comprises one or more of the following: aluminum oxide (AlOx) and / or silicon oxide (SiOx).

15. The paper-based packaging film of claim 5, wherein the combined thickness of the multi-layer barrier film and the adhesive layer is less than or equal to 10 μm.

16. The paper-based packaging film according to claim 15, wherein the combined thickness is in the range of 4 μm to 8 μm.

17. The paper-based packaging film according to claim 1, wherein the total composition of the paper-based packaging film comprises greater than or equal to 85 wt% of the paper component and less than or equal to 5 wt% of the non-compostable material.

18. A method for producing a paper-based packaging film, the method comprising: coating a base web with a multilayer barrier film comprising a compostable polymer, the base web having a thickness in a range of 6 μm to 50 μm; attaching the multilayer barrier film to a paper component by a lamination process to form an intermediate structure; and removing the base web from the intermediate structure to produce the paper-based packaging film, The total composition of the paper-based packaging film comprises greater than or equal to 80 wt % of the paper component and less than or equal to 5 wt % of non-compostable materials.

19. The method of claim 18, wherein a single transfer operation comprises attaching the multilayer barrier film to the paper component and removing the base web from the intermediate structure.

20. The method of claim 18, wherein the base web comprises one or more of an oriented polyethylene (OPE) film, an oriented polyethylene terephthalate (OPET) film, an oriented polypropylene (OPP) film, and / or an oriented polyamide (OPA) film.

21. The method of claim 18, wherein the coating of the base web comprises depositing a transfer substrate on the base web and depositing a barrier layer on the transfer substrate by physical vapor deposition (PVD), the combination of the barrier layer and the transfer substrate defining the multilayer barrier film.

22. The method of claim 18, wherein said attaching the multi-layer barrier film to the paper component comprises disposing an adhesive layer between the multi-layer barrier film and the paper component.

23. The method of claim 21, wherein the transfer substrate comprises a heat seal layer and optionally a lacquer layer.

24. The method of claim 23, wherein the heat seal layer comprises a non-oriented film.

25. The method of claim 23, wherein the heat seal layer comprises a compostable polymer.

26. The method of claim 25, wherein the heat seal layer comprises one or more of the following: polylactic acid (PLA), polybutylene adipate terephthalate (PBAT), polybutylene succinate (PBS), polyhydroxyalkanoate (PHA), polyethylene vinyl alcohol (EVOH) and / or polyvinyl alcohol (PVOH).

27. The method of claim 23, wherein the heat seal layer has a thickness in the range of 2 μm to 10 μm.

28. The method of claim 23, wherein the heat seal layer is directly attached to the barrier layer.

29. The method of claim 23, wherein the transfer substrate further comprises the paint layer, the paint layer comprising one or more of: polyurethane (PU), polyvinyl alcohol (PVOH) and / or ethylene vinyl alcohol (EVOH).

30. The method of claim 21, wherein the barrier layer comprises one or more of: aluminum oxide (AlOx) and / or silicon oxide (SiOx).

31. The method of claim 18, wherein the total composition of the paper-based packaging film comprises greater than or equal to 85 weight percent of the paper component.

32. A method of producing a paper-based packaging film, the method comprising: producing a base web and a heat seal layer by coextrusion, the heat seal layer comprising a compostable polymer; depositing a barrier layer on the heat seal layer by physical vapor deposition (PVD); attaching the barrier layer to the paper component by a lamination process to form an intermediate structure; and removing the base web from the intermediate structure to expose the heat seal layer and produce the paper-based packaging film, The total composition of the paper-based packaging film comprises greater than or equal to 80% by weight of the paper component.

33. A paper-based packaging film comprising: a multilayer barrier film comprising a transfer substrate and a barrier layer deposited by physical vapor deposition (PVD); and an adhesive layer attaching the paper assembly to the multilayer barrier film, wherein the transfer substrate comprises a heat seal layer, the thickness of the heat seal layer is in the range of 2 μm to 8 μm, The barrier layer comprises one or more of the following: metal, aluminum oxide (AlOx) and / or silicon oxide (SiOx), and The total composition of the paper-based packaging film comprises greater than or equal to 85% by weight of the paper component.

34. The paper-based packaging film of claim 33, wherein the heat seal layer comprises a compostable polymer.

35. The paper-based packaging film of claim 33, wherein the heat seal layer comprises a non-oriented film.

36. The paper-based packaging film according to claim 33, wherein the heat sealing layer comprises one or more of the following: polylactic acid (PLA), polybutylene adipate terephthalate (PBAT), polybutylene succinate (PBS), polyhydroxyalkanoate (PHA) and / or polyvinyl alcohol (PVOH).

37. The paper-based packaging film of claim 33, wherein the combined thickness of the multi-layer barrier film and the adhesive layer is in the range of 4 μm to 10 μm.

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