Moisture resistant carrier tape and cover for electronic components

Abstract

Multi-layer packages for packaging components of products such as electronic devices are provided, and these multi-layer packages are particularly suitable for manufacturing carrier tapes. The packages include a container component and at least one cover component, each of the container component and the at least one cover component comprising a fluoropolymer (fluoropolymer) layer. Multilayer container films are shaped to include dimples extending from one or both flat surfaces and exhibit excellent barrier properties and structural strength.

Description

[0001] Cross Reference to Related Applications

[0002] This application claims the benefit of co-pending U.S. Provisional Application Serial No. 63 / 497,300, filed April 20, 2023, the disclosure of which is incorporated herein by reference in its entirety. BACKGROUND TECHNICAL FIELD

[0003] The present disclosure relates generally to multilayer articles for packaging components of products such as electronic devices.

[0004] State of the Art

[0005] Carrier tapes are commonly used products in the electronics packaging industry for packaging small electronic components such as integrated circuits, capacitors, connectors, etc., and for protecting them during shipment and storage. A typical carrier tape is formed from a multilayer film that is embossed, stamped, or otherwise shaped to include a plurality of successive pockets (recesses) along the axial length of the tape for storing products. The carrier tape is then sealed with a lidding film to enclose the stored products within the pockets, and the tape is typically subsequently wound and stored on a spool, thereby allowing mass delivery of components without causing damage. Specialized machines are designed to strip the lidding film and individually remove the stored electronic devices from the pockets in an automated assembly line for downstream processing by the electronic device manufacturer.

[0006] Similar to the case with storing pharmaceuticals, it is very important that the storage solution for electronic components have good barrier properties, including barrier to gases, aromas, and / or vapors such as water vapor, as well as physical properties such as toughness, transparency, abrasion and weather resistance, optical clarity, and chemical inertness. For example, it is known that very small electronic components used in the manufacture of printed circuit boards (PCBs) are prone to absorbing atmospheric moisture, and components containing residual moisture can present problems when soldered to the circuit board. Therefore, when manufacturing PCBs, these components are typically dried in an oven for several hours before mounting them on the circuit board. This additional drying step is time-consuming, inefficient, and costly, and therefore a problem in the art.

[0007] As in the pharmaceutical packaging industry, carrier tapes are known to be made from multilayer films having desired barrier properties. Typically, embossed or stamped carrier tapes are composed primarily of polymers such as polycarbonate, polystyrene, and acrylonitrile-butadiene-styrene (ABS) copolymer. However, incorporation of fluoropolymers in carrier tape constructions is not generally known. In the pharmaceutical packaging industry, fluoropolymer films are well known for their barrier properties, inertness to most chemicals, high temperature resistance, low coefficient of friction, and excellent toughness, and it is desirable to use or introduce fluoropolymer films in packaging applications. See, for example, U.S. Patents 4,146,521; 4,659,625; 4,677,017; 5,139,878; 5,855,977; 6,096,428; 6,138,830; and 6,197,393, which teach multilayer films containing fluoropolymers. Films containing polytrifluorochloroethylene ("PCTFE") homopolymers or copolymers are particularly advantageous due to their superior properties. However, such use of fluoropolymers is limited to special packaging applications due to their relatively high cost. A suitable method of reducing the cost of packaging materials made from expensive polymers is to form multilayer structures in which the polymer is laminated with other, less costly polymer layers. This approach is particularly desirable for fluoropolymer packaging applications because a thin layer of fluoropolymer is usually all that is needed to take advantage of the desirable properties of fluoropolymers while minimizing cost. However, fluoropolymers do not adhere strongly to most other polymers. In fact, most fluoropolymers are known for their non-stick properties. This is highly disadvantageous because poor adhesion between the layers can result in delamination of the multilayer structure.

[0008] To improve the adhesion strength between the fluoropolymer layer and the non-fluoropolymer layer, an adhesive layer can be used between the adjacent layers. For example, U.S. Patent 4,677,017 discloses coextruded multilayer films that include at least one fluoropolymer film and at least one thermoplastic film connected by the use of an ethylene / vinyl acetate adhesive layer. U.S. Patent 4,659,625 discloses a fluoropolymer multilayer film structure utilizing an adhesive layer of a vinyl acetate polymer. U.S. Patent 5,139,878 discloses a fluoropolymer film structure using an adhesive layer of a modified polyolefin. U.S. Patent 6,451,925 teaches laminates of a fluoropolymer layer and a non-fluoropolymer layer using an adhesive layer that is a blend of an aliphatic polyamide and a fluorine-containing graft polymer. In addition, U.S. Patent 5,855,977 teaches applying an aliphatic diamine or polyamine to one or more surfaces of the fluoropolymer or non-fluoropolymer material layer.

[0009] However, packaging solutions such as those described above, which are well suited for the pharmaceutical packaging industry, are not sufficiently moisture resistant to meet the needs of the electronics packaging industry, particularly when tiny electronic components are packaged in carrier tape. The present disclosure provides a solution to this need in the art. SUMMARY

[0010] The present disclosure is particularly directed to a packaging article comprising both a container portion and a lid portion, wherein both the container portion and the lid portion are multilayer films comprising a fluoropolymer layer or a fluorine-containing polymer layer. It is particularly useful for the manufacture of carrier tape for packaging small electronic components used in electronic devices such as mobile phones and precision instruments. The packaging solution of the present disclosure overcomes the need to dry the components in an oven prior to use, thereby extending the shelf life of the components and improving production efficiency.

[0011] More particularly, the present disclosure provides a package comprising:

[0012] a) a formed container comprising a multilayer film, the container comprising one or more pockets, the container having a top surface and a bottom surface, the multilayer film comprising:

[0013] i. a first base layer;

[0014] ii. a first intermediate adhesive layer;

[0015] iii. a first fluoropolymer layer adhered to the first base layer via the first intermediate adhesive layer;

[0016] iv. a second intermediate adhesive layer; and

[0017] v. a second base layer adhered to the first fluoropolymer layer via the second intermediate adhesive layer;

[0018] b) a top cover adhered to the top surface of the container, the top cover comprising:

[0019] i. a first heat seal layer attached to the first base layer;

[0020] ii. a third intermediate adhesive layer; and

[0021] iii. a second fluoropolymer layer adhered to the first heat seal layer via the third intermediate adhesive layer.

[0022] Also provided is a packaging product comprising:

[0023] a) a formed container comprising a multilayer film, the container comprising one or more pockets, the container having a top surface and a bottom surface, the multilayer film comprising:

[0024] i. a first base layer;

[0025] ii. a first intermediate adhesive layer;

[0026] iii. a first fluoropolymer layer adhered to the first base layer via the first intermediate adhesive layer;

[0027] iv. a second intermediate adhesive layer; and

[0028] v. a second base layer adhered to the first fluoropolymer layer via the second intermediate adhesive layer;

[0029] b) a product housed within one or more of the pockets;

[0030] c) a top cover adhered to a top surface of the container, the top cover comprising:

[0031] i. a first heat seal layer attached to the first base layer;

[0032] ii. a third intermediate adhesive layer; and

[0033] iii. a second fluoropolymer layer adhered to the first heat seal layer via the third intermediate adhesive layer;

[0034] and optionally,

[0035] d) a bottom cover adhered to a bottom surface of the container, the bottom cover comprising:

[0036] i. a second heat seal layer attached to the second base layer;

[0037] ii. a fifth intermediate adhesive layer; and

[0038] iii. a third fluoropolymer layer adhered to the second heat seal layer via the fifth intermediate adhesive layer.

[0039] A method for forming a carrier tape that can be used to store a plurality of products is also provided, the method comprising:

[0040] a) forming a multi-layer film, the multi-layer film comprising:

[0041] i. a first base layer;

[0042] ii. a first intermediate adhesive layer;

[0043] iii. a first fluoropolymer layer adhered to the first base layer via the first intermediate adhesive layer;

[0044] iv. a second intermediate adhesive layer; and

[0045] v. a second base layer adhered to the first fluoropolymer layer via a second intermediate adhesive layer;

[0046] b) embossing the multilayer film to form a shaped container comprising one or more depressions, the container having a top surface and a bottom surface;

[0047] c) placing a product in one or more of the depressions; and

[0048] d) heat sealing a top cover to the top surface of the container, the top cover comprising:

[0049] i. a first heat seal layer;

[0050] ii. a third intermediate adhesive layer; and

[0051] iii. a second fluoropolymer layer adhered to the first heat seal layer via the third intermediate adhesive layer;

[0052] wherein the first heat seal layer is attached to the first base layer. BRIEF DESCRIPTION OF DRAWINGS

[0053] Figure 1 is a schematic side perspective view of a package of the present disclosure showing the layered structure of the container with a shaped depression and a top cover enclosing a product in the depression.

[0054] Figure 2 is a schematic side perspective view of a carrier tape of the present disclosure showing the layered structure of the container with a plurality of shaped depressions and both a top cover and a bottom cover enclosing products in the depressions.

[0055] Figure 3 is a schematic top perspective view of a carrier tape comprising a detection hole in the depression and a bottom cover sealing the detection hole.

[0056] Figure 4 is a schematic side perspective view of a package of the present disclosure showing the layered structure of the container with a shaped depression, a detection hole extending through each layer of the container at the bottom of the shaped depression, and a top cover and a bottom cover.

[0057] Figure 5 is a schematic side perspective view of a carrier tape of the prior art in which the depressions containing products are covered by discrete film patches. DETAILED DESCRIPTION

[0058] An exemplary package 12 of the present disclosure is shown in FIG. 1. The package 12 comprises a container 14 having a top surface 16 and a bottom surface 18. The container 14 is formed from a multilayer film 20. The multilayer film 20 comprises a first base layer 22, a first intermediate adhesive layer 24, a first fluoropolymer layer 26, a second intermediate adhesive layer 28, a second fluoropolymer layer 30, a third intermediate adhesive layer 32, a first heat seal layer 34, and a second heat seal layer 36. Figure 1The figure illustrates a molded container 2 sealed with a top cover 4. The molded container 2 is formed of a multilayer film and has a top surface 8 and a bottom surface 10. The container 2 is formed (e.g., embossed; molded; stamped) to have one or more recesses (grooves) 34. Each recess 34 is formed to store a product 36. The top cover 4 (also a film) is attached to the top surface 8 of the container 2, thereby sealing the container 2 to protect the product 36. Optionally, the encapsulation 12 may also be formed such that it includes additional recesses 34 formed by forming (e.g., embossing) the film of the container 2 at both the top surface 8 and the bottom surface 10 of the container. In any embodiment (i.e., the recess is formed only at the top surface 8, or at both the top surface 8 and the bottom surface 10), a bottom cover 6 (also a film) is attached to the bottom surface 10.

[0059] like Figure 2 Schematably shown, the encapsulation 12 is preferably in the form of a carrier strip having a plurality of recesses 34 formed between the top cover 4 and the top container surface 8. The carrier strip structure is shown in... Figure 3 In the middle. For example Figure 3 As shown, in conventional carrier belts, positioning / conveying holes are typically stamped on either side of the forming cavity. These positioning / conveying holes are used to guide and convey the carrier belt through the processing device. However, in the context of this disclosure, detection holes are optionally stamped into the bottom of each recess 34 to allow the processing device to detect whether the recess 34 is filled with product 36. Any number of such detection holes can be stamped into the bottom of the recess, wherein... Figure 3 and Figure 4 The diagram shows a recess with two detection holes. In such an embodiment, the bottom cover 6 seals those holes at the bottom of the recess. Even without the detector holes, the bottom cover 6 still helps enhance the barrier properties of the package.

[0060] Each of the covers 4 and 6 may independently comprise a monolayer film consisting of a single fluoropolymer layer (excluding any desired adhesive layer), or may independently be a multilayer film in which one or more additional polymeric or nonpolymeric layers are attached to the fluoropolymer layer. Figure 1 and Figure 2 As shown, container 2 is preferably a multilayer film, such as a five-layer multilayer film, which incorporates a first base layer 14 attached to a first fluoropolymer layer 18 via a first intermediate adhesive layer 16 and a second base layer 22 attached to the first fluoropolymer layer 18 via a second intermediate adhesive layer 20. The top cover 4 is also preferably a multilayer film, such as a three-layer film, which incorporates a first heat-sealing layer 24A attached to a second fluoropolymer layer 28A via a third intermediate adhesive layer 26A. In this embodiment, the first heat-sealing layer 24A is attached to the first base layer 14 of container 2.Figure 1 and Figure 2 As shown, in a preferred embodiment, the top cover 4 may be a five-layer film, wherein the first support layer 32A is attached to the second fluoropolymer layer 28A via a fourth intermediate adhesive layer 30A.

[0061] like Figure 2 As shown, in the encapsulation 38 comprising a pouch 34 formed from the top surface 8 of container 2, both the top cover 4 and the bottom cover 6 are included as part of the encapsulation structure 38. The bottom cover 6 is also a film, preferably a multilayer film, which introduces a second heat-sealing layer 24B attached to a third fluoropolymer layer 28B via a fifth intermediate adhesive layer 26B. In this embodiment, the second heat-sealing layer 24B is attached to the second base layer 22 of container 2. Figure 2 As shown in the figure, the bottom cover 6 may be a five-layer film, wherein the second support layer 32B is attached to the third fluoropolymer layer 28B via the sixth intermediate adhesive layer 30B.

[0062] In each of the molded container 2 and the top cover 4 and bottom cover 6, the fluoropolymer layer (also referred to herein as a fluoropolymer-containing layer) may be composed of one or more homopolymers or copolymers or blends thereof, as well known in the art and described, for example, in U.S. Patent Nos. 4,510,301, 4,544,721, and 5,139,878. Particularly preferred fluoropolymers suitable for forming the multilayer films of this disclosure include homopolymers and copolymers of trifluorochloroethylene, copolymers of ethylene-trifluorochloroethylene, copolymers of trifluorochloroethylene and vinylidene fluoride, and copolymers of trifluorochloroethylene and tetrafluoroethylene. Such copolymers of trifluorochloroethylene may contain up to 10% by weight, preferably up to 8% by weight, other comonomers such as vinylidene fluoride and tetrafluoroethylene. As used herein, copolymers comprise polymers having two or more monomer components. The most preferred fluoropolymer layer in each embodiment of this disclosure comprises, is composed of, or is substantially composed of a polytrifluorochloroethylene (PCTFE) homopolymer resin. Such fluoropolymer layers can be used as Resin or in film form such as membrane or The membranes were purchased, each from Honeywell International Inc. of Charlotte, North Carolina. and PCTFE fluoropolymer films are crystalline, transparent, chemically stable, biochemically inert films that provide excellent moisture barrier properties for clean, thermoformable films. They are free of plasticizers and stabilizers and provide up to 10 times the moisture barrier properties of other transparent blister packaging films. Fluoropolymer films are also antistatic, exhibit excellent electrical properties, and can be laminated and metallized. They are commercially available in a variety of thicknesses, and for the purposes of this disclosure, or The PCTFE layer preferably has a thickness of about 1 pm to about 150 pm, more preferably about 1 pm to about 100 pm, and most preferably about 10 pm to about 50 pm, whether oriented or non-oriented.

[0063] Each cover in the cover assembly of the present disclosure can independently be a monolayer film consisting of a single fluoropolymer layer (not including the adhesive layer required), but as noted above, each cover is preferably independently a multilayer film with one or more additional support layers attached to the fluoropolymer layer. In the preferred embodiments described herein, the top cover includes at least one support layer 32A and the bottom cover includes at least one support layer 32B, where the support layers 32A, 32B can be polymeric or non-polymeric. Suitable polymeric support layers include, without exclusion, support layers formed from polyamides, homopolymers and copolymers; polyolefins, including linear or branched polyolefin homopolymers, linear or branched polyolefin copolymers, cyclic olefin homopolymers, cyclic olefin copolymers, copolymers of cyclic olefins with linear or branched polyolefin homopolymers, and copolymers of cyclic olefins with linear or branched polyolefin copolymers; ethylene-vinyl acetate copolymers; ethylene-vinyl alcohol copolymers; polyesters such as polyethylene terephthalate (PET) or polyethylene naphthalate (PEN) or blends thereof; polyvinyl chloride; polyvinylidene chloride; polystyrene (PS); styrenic copolymers; polyisoprene; polyurethane; ethylene-ethyl acrylate; ethylene-acrylic acid copolymers; polycarbonates; acrylonitrile-butadiene-styrene (ABS) copolymers; and blends of any of the foregoing. Suitable non-polymeric layers include, without exclusion, paper and metal foils such as aluminum foils, as commonly used in blister packaging for storing pharmaceuticals.

[0064] Suitable polyamides (nylons) within the scope of the present disclosure include, without exclusion, homopolymers or copolymers selected from aliphatic polyamides and aliphatic / aromatic polyamides having a molecular weight of about 10,000 to about 100,000. Useful polyamide homopolymers include poly(4-aminobutyric acid) (Nylon 4), poly(6-aminohexanoic acid) (Nylon 6, also known as poly(caprolactam)), poly(7- aminoheptanoic acid) (Nylon 7), poly(8-aminooctanoic acid) (Nylon 8), poly(9- aminononanoic acid) (Nylon 9), poly(10-aminodecanoic acid) (Nylon 10), poly(11- aminoundecanoic acid) (Nylon 11), poly(12-aminododecanoic acid) (Nylon 12), Nylon 4,6, poly(hexamethylene adipamide) (Nylon 6,6), poly(hexamethylene sebacamide) (Nylon 6,10), poly(heptamethylene pimelamide) (Nylon 7,7), poly(octamethylene suberamide) (Nylon 8,8), poly(hexamethylene nonamethylenesebacamide) (Nylon 6,9), poly(nonamethylene nonamethylenesebacamide) (Nylon 9,9), poly(decamethylene nonamethylenesebacamide) (Nylon 10,9), poly(tetramethylenediamine-co-oxalic acid) (Nylon 4,2), polyamide of n-dodecanedioic acid and hexamethylenediamine (Nylon 6,12), polyamide of dodecamethylenediamine and n-dodecanedioic acid (Nylon 12,12), and the like. Useful aliphatic polyamide copolymers include caprolactam / hexamethylene adipamide copolymer (Nylon 6,6 / 6), hexamethylene adipamide / caprolactam copolymer (Nylon 6 / 6,6), trimethyleneadipamide / hexamethylene nonamethylenesebacamide copolymer (Nylon trimethyl 6,2 / 6,2), hexamethylene adipamide-hexamethylene- nonamethylenesebacamide caprolactam copolymer (Nylon 6,6 / 6,9 / 6), and the like. Other nylons not specifically depicted here are also included. Preferred polyamides include Nylon 6, Nylon 6,6, Nylon 6 / 6,6, and mixtures thereof.

[0065] The aliphatic polyamides used in the practice of the present disclosure can be obtained from commercial sources or can be prepared according to known preparation techniques. For example, poly(caprolactam) is available under the trademark obtained from Honeywell International Inc., Morristown, New Jersey.

[0066] Exemplary aliphatic / aromatic polyamides include poly(tetramethylene diamine-co- isophthalic acid) (Nylon 4, I), polyhexamethylene isophthalamide (Nylon 6, I), hexamethylene adipamide / hexamethylene isophthalamide (Nylon 6,6 / 6I), hexamethylene adipamide / hexamethylene terephthalamide (Nylon 6,6 / 6T), poly(2,2,2-trimethylhexamethylene terephthalamide), poly(m-xylylene adipamide) (MXD6), poly(p-xylylene adipamide), poly(hexamethylene terephthalamide), poly(dodecamethylene terephthalamide), polyamide 6T / 6I, polyamide 6 / MXDT / I, polyamide MXDI, and the like. Blends of two or more aliphatic / aromatic polyamides can also be used. The aliphatic / aromatic polyamides can be prepared by known preparation techniques or can be obtained from commercial sources. Other suitable polyamides are described in U.S. Patents 4,826,955 and 5,541,267, which are incorporated herein by reference.

[0067] Polyolefins suitable for use herein include polymers of alpha-olefin monomers having from about 3 to about 20 carbon atoms, and include homopolymers, copolymers (including graft copolymers), and terpolymers of alpha-olefins. Exemplary homopolymers include low density polyethylene (LDPE), very low density polyethylene (ULDPE), linear low density polyethylene (LLDPE), metallocene linear low density polyethylene (m-LLDPE), medium density polyethylene (MDPE), and high density polyethylene (HDPE), polypropylene, polybutene, polybutene-l, poly-3-methylbutene-l, poly-pentene-l, poly-4,4-dimethylpentene-l, poly-3-methylpentene-l, polyisobutylene, poly-4-methylhexene-l, poly-5-ethylhexene-l, poly-6-methylheptene-l, polyhexene-l, polyoctene-l, polynonene-l, polydecene-l, polydodecene-l, and the like.

[0068] Exemplary copolymers and terpolymers include copolymers and terpolymers of alpha-olefins with other olefins, such as ethylene-propylene copolymers; ethylene-butene copolymers; ethylene-pentene copolymers; ethylene-hexene copolymers; and ethylene-propylene-diene copolymers (EPDM). As used herein, the term polyolefin also includes acrylonitrile-butadiene-styrene (ABS) polymers, copolymers with ethyl vinyl acetate, acrylate and methacrylate esters, and the like. Preferred polyolefins are polyolefins made from alpha-olefins, most preferably ethylene polymers, copolymers and terpolymers. The above polyolefins can be obtained by any known method. The polyolefins can have a weight average molecular weight of from about 1,000 to about 1,000,000, preferably from about 10,000 to about 500,000, as measured by high performance liquid chromatography (HPLC). Preferred polyolefins are polyethylene, polypropylene, polybutylene, and copolymers and blends thereof. The most preferred polyolefin is polyethylene. The most preferred polyethylene is low density polyethylene.

[0069] Suitable cyclic (cyclic) olefin polymers (homopolymers, copolymers or blends) are described, for example, in U.S. Patents 5,218,049; 5,783,273 and 5,912,070, which are incorporated herein by reference. U.S. Patent 5,218,049 discloses a film composed of cyclic olefins. U.S. Patent 5,783,273 discloses a press-through blister packaging material including a sheet of cyclic olefin copolymer. U.S. Patent 5,912,070 discloses a packaging material including a layer of cyclic olefin, a layer of polyester and an intermediate adhesive. Cyclic olefins are commercially available from Mitsui Petrochemical Industries, Ltd. of Tokyo, Japan or Ticona of Summit, New Jersey.

[0070] Most preferably, both the first support layer 32A and the second support layer 32B comprise, consist of, or consist essentially of polyethylene terephthalate. Each of the above polyolefin polymers are also suitable for use in making the first heat seal layer 24A of the top cover 4 and the second heat seal layer 24B of the bottom cover 6. The heat seal layers 24A, 24B that are useful can also comprise an ethylene-vinyl acetate (EVA) copolymer, an ethylene-propylene (EP) copolymer, an ethylene-propylene-butene (EPB) terpolymer, or a combination thereof. The most preferred heat seal layers 24A, 24B in each of the top cover 4 and the bottom cover 6 comprise, consist of, or consist essentially of low density polyethylene (LDPE).

[0071] As noted above, the shaped container 2 includes at least one fluoropolymer (fluorine-containing) layer 18 and at least a first substrate layer 14 that is attached to the fluoropolymer layer via a first intermediate adhesive layer 16. The first substrate layer 14 and optional second substrate layer 22 provide the container with structural integrity sufficient to retain its shaped structure after being embossed or otherwise molded to form the dimples 34. The fluoropolymer layer 18 provides the desired barrier properties. Suitable substrate layers 14 and 22 include, without exclusion, each of the polymer layers disclosed herein as suitable for the support layers 32A, 32B. Most preferably, both the first substrate layer 14 and the second substrate layer 22 comprise, consist of, or consist essentially of, polystyrene.

[0072] In preferred embodiments of the present disclosure, adjacent layers within each of the container 2, the top cover 4, and the bottom cover 6 are attached via an intermediate adhesive layer (also referred to in the art as a “tie” layer) between the layers. Any conventionally known adhesive material can be used herein as any of these intermediate adhesive layers. Suitable adhesive polymers include, without exclusion, polyurethanes, epoxies, ethylene-vinyl acetate copolymers, polyesters, acrylics, modified polyolefin compositions, and blends thereof. In this regard, a preferred modified polyolefin composition is one having at least one functional moiety selected from the group consisting of unsaturated polybasic carboxylic acids and anhydrides thereof. Such unsaturated carboxylic acids and anhydrides include maleic acid and anhydride, fumaric acid and anhydride, crotonic acid and anhydride, citraconic acid and anhydride, itaconic acid and anhydride, and the like. Of these, maleic anhydride is most preferred. Modified polyolefins suitable for use in the present disclosure include those described in U.S. Patents 3,481,910; 3,480,580; 4,612,155; and 4,751,270. Other adhesive layers include, without exclusion, alkyl ester copolymers of olefins and alkyl esters of alpha, beta-ethylenically unsaturated carboxylic acids, such as those described in U.S. Patent 5,139,878. Preferred modified polyolefin compositions contain from about 0.001 wt.% to about 20 wt.% of the functional moiety, based on the total weight of the modified polyolefin. More preferably, the functional moiety comprises from about 0.05 wt.% to about 10 wt.%, and most preferably from about 0.1 wt.% to about 5 wt.%. The modified polyolefin composition can also contain up to about 40 wt.% of a thermoplastic elastomer and alkyl ester, as described in U.S. Patent 5,139,878. Particularly preferred are polyurethane-based adhesive layers, including both polyester-based polyurethanes and polyether-based polyurethanes, wherein each of the intermediate adhesive layers in each embodiment of the present disclosure comprises, consists of, or consists essentially of one or more polyurethanes (one or more urethane-based adhesives) such as a hydroxyl-terminated polyurethane. Preferred urethane-based adhesives are commercially available from, for example, Henkel Technologies, headquartered in Düsseldorf, Germany, including those under the trademarks Liofol® polyurethanes commercially available from Liofol Corporation, a division of Henkel Technologies.

[0073] In preferred embodiments of the present disclosure, the multi-layer cover films 4, 6 comprise a three- or five-layer polymeric film structure, including adhesive tie layers between adjacent polymeric layers, to facilitate attachment of the layers to one another. A particularly preferred three-layer film for the top cover 4 and the bottom cover 6 comprises a fluoropolymer / adhesive / polyester construction, wherein the fluoropolymer is the outermost layer of the cover, and the polyester is a polyethylene terephthalate. In another preferred embodiment, a three-layer film for the top cover 4 and the bottom cover 6 comprises a fluoropolymer / adhesive / polyolefin construction, wherein the fluoropolymer is the outermost layer of the cover, and the polyolefin is, for example, a polyethylene, a polypropylene, or a cyclic olefin homopolymer or copolymer. In another preferred embodiment, a three-layer film construction for the covers 4 and 6 comprises a fluoropolymer / adhesive / polyamide construction, wherein the fluoropolymer is the outermost film layer, and the polyamide is, for example, a nylon 6, a nylon 6,6, or a nylon 6,6,6 polymer. Other preferred constructions include, for example, fluoropolymer / adhesive / polyvinyl chloride and fluoropolymer / adhesive / polyvinylidene chloride. In each of these embodiments, the layered structure of each of the top cover 4 and the bottom cover 6 is independent of the other, i.e., each cover can have the same layered construction or can have a different layered construction relative to the other. Preferred five-layer constructions for the top cover 4 and the bottom cover 6 include polyester (e.g., PET) / adhesive / fluoropolymer (e.g., PCTFE) / adhesive / polyolefin (e.g., LDPE) and polyester / adhesive / fluoropolymer / adhesive / polyamide (e.g., nylon 6).

[0074] Such constructions are exemplary and non-limiting, and each of the layers within each of the top cover 4 and the bottom cover 6 can generally comprise any polymeric (or non-polymeric) material suitable for use in a multi-layer film, so long as at least one film layer comprises a fluoropolymer (fluorine-containing) layer. Thus, each cover 4, 6 can independently comprise three, four, five, or even more layers, as desired by the skilled artisan. Similarly, each of the layers of the container 2 can generally comprise any polymeric material suitable for use in a multi-layer film, so long as at least one film layer comprises a fluoropolymer (fluorine-containing) layer and at least one non-fluoropolymer substrate layer 14 is introduced for structural strength.

[0075] Each polymer layer of the container 2 and / or the cover 4, 6 can also optionally contain one or more conventional additives, the use of which will be well known to those skilled in the art. The use of such additives can be desirable to enhance processing of the composition and to improve the products or articles formed therefrom. Examples of such additives include: oxidation and heat stabilizers, lubricants, release agents, flame retardants, oxidation inhibitors, oxygen scavengers, dyes, pigments and other colorants, ultraviolet absorbers and stabilizers, organic or inorganic fillers including particulate and fibrous fillers, reinforcing agents, nucleating agents, plasticizers, and other conventional additives known in the art. Such additives can be used, for example, in amounts up to about 10% by weight of the total layer composition. Representative ultraviolet stabilizers include various substituted resorcinols, salicylates, benzotriazoles, benzophenones, and the like. Suitable lubricants and release agents include stearic acid, stearyl alcohol, and stearamide. Exemplary flame retardants include organic halogenated compounds (including decabromodiphenyl ether and the like) as well as inorganic compounds. Suitable colorants (including dyes and pigments) include cadmium sulfide, cadmium selenide, titanium dioxide, phthalocyanines, ultramarine blue, aniline blue, carbon black, and the like. Representative oxidation stabilizers and heat stabilizers include Group I metals of the Periodic Table halides, such as sodium halide, potassium halide, lithium halide; and cuprous halides; and additionally, chlorides, bromides, iodides. Also hindered phenols, hydroquinones, aromatic amines, and substituted members of those groups as described above, and combinations thereof. Exemplary plasticizers include lactams, such as caprolactam and lauryl lactam; sulfonamides, such as o-toluenesulfonamide, p-toluenesulfonamide, and N-ethyl, N-butylbenzenesulfonamide; and combinations of any of the foregoing; and other plasticizers known in the art.

[0076] The multilayer films suitable for making each of the containers 2, top covers 4, and bottom covers 6 of the present disclosure can be formed by any conventional technique for forming films, including lamination and co-extrusion. In the most preferred method, the multilayer films are formed by co-extrusion. For example, the materials for the individual layers are fed into the cross feed hoppers of a similar number of extruders, each extruder handling the material for one or more of the layers. The molten and plasticized streams of material from the individual extruders are fed into a single manifold co-extrusion die. While in the die, the layers are juxtaposed and combined, and then emerge from the die as a single multilayer film of polymeric material. After exiting the die, the film is cast onto a first temperature controlled casting roll, passed around the first roll, and then onto a second temperature controlled roll, which is usually colder than the first roll. The temperature controlled rolls control to a large extent the rate of cooling of the film after it exits the die. The temperature of the individual rolls is selected to achieve the desired properties of the film, and is also based on the type of polymer employed. Typically, the first casting roll temperature is in the range of about 50°F to about 250°F (10°C to 121°C), preferably in the range of about 75°F to about 200°F (24°C to 93°C), and more preferably in the range of about 100°F to about 175°F (38°C to 79°C). The temperature of the second temperature controlled roll (also referred to as a preheat roll) is typically in the range of about 50°F to about 250°F (10°C to 121°C), preferably in the range of about 75°F to about 200°F (24°C to 93°C), and more preferably in the range of about 100°F to about 175°F (38°C to 79°C). The temperature of the individual rolls need not be the same. A chill roll can be employed to provide dimensional stability to the film. Typically, the temperature of this roll is in the range of about 50°F to about 300°F (10°C to 149°C), preferably in the range of about 100°F to about 250°F (38°C to 121°C), and more preferably in the range of about 150°F to about 225°F (66°C to 107°C).

[0077] In another method, the film forming equipment can be equipment referred to in the art as "blown film" equipment, and includes a multi-manifold circular die for bubble blowing a film, through which the plasticized film composition is forced and formed into a film "bubble" which can ultimately collapse and be formed into a film. Methods of co-extrusion to form films and sheet laminates are well known. See, for example, "Modern Plastics Encyclopedia", Vol. 56, No. 10A, pp. 131-132, McGraw Hill, October 1979.

[0078] Alternatively, the individual layers can first be formed as separate layers, which are then laminated together under heat and pressure, with or without the use of an intermediate adhesive layer. Lamination techniques are well known in the art. Typically, the individual layers are positioned on top of one another under conditions of sufficient heat and pressure to cause the layers to combine into a single film. Typically, the individual layers are positioned on top of one another, and the combination is then passed through the nip of a pair of heated laminating rolls, typically by techniques well known in the art. Lamination heating can be carried out at temperatures ranging from about 120 °C to about 175 °C, preferably from about 150 °C to about 175 °C, at pressures ranging from about 5 psig (0.034 MPa) to about 100 psig (0.69 MPa), for about 5 seconds to about 5 minutes, preferably for about 30 seconds to about 1 minute.

[0079] If desired, the monolayer / multilayer films of the present disclosure can optionally be stretched or oriented in any direction using methods known to those skilled in the art. In such a stretching operation, the layer / film can be stretched in a direction coincident with the direction of movement of the film as it is reeled off the casting roll, also referred to as the "machine direction," or can be stretched in a direction perpendicular to the machine direction, also referred to in the art as the "transverse direction," so that the resulting film is "uniaxially" or "uniaxially oriented." Alternatively, the monolayer / multilayer films of the present disclosure can be stretched in both the machine and transverse directions, whereby the resulting film is "biaxially" oriented. The films typically used in the present disclosure are oriented in the machine and / or transverse directions at a draw ratio of about 1.5: 1 to about 10: 1, and preferably at a draw ratio of about 1.5: 1 to about 4: 1. As used herein, the term "draw ratio" indicates the increase in dimension in the direction of drawing. Thus, a film having a 2: 1 draw ratio doubles in length during the drawing process. Typically, the film is drawn by passing it through a series of preheating and heating rolls. The heated film moves through a set of nip rolls downstream at a faster rate than the film enters the nip rolls at an upstream location. The change in rate is compensated for by stretching in the film.

[0080] Typical methods and conditions ranges for uniaxial orientation of polyamide films are disclosed, for example, in U.S. Patent No. 4,362,385. The monolayer / multilayer films of the present disclosure can also be biaxially oriented using blown tube equipment or stenter equipment well known in the art, and films that are biaxially stretched can be drawn in these two biaxial directions sequentially or simultaneously.

[0081] Each individual film layer and each overall multilayer film of the present disclosure can have any desired thickness. For example, each individual film can have a thickness of about 0.1 mil (2.5 pm) to about 15 mils (381 pm), more preferably about 0.2 mils (5.1 pm) to about 5 mils (127 pm), and most preferably about 0.5 mils (12.7 pm) to about 2 mils (50.8 pm) after optional orientation. Each of the container 2, the top cover 4, and the bottom cover 6 can have a thickness of about 20 pm to about 1000 pm, more preferably about 30 pm to about 600 pm, and most preferably about 50 pm to about 500 pm after optional orientation. The thickness of each film prior to stretching is chosen based on the stretch ratio employed so that the desired thickness is achieved after stretching, as is known in the art. While such thicknesses are mentioned, it is understood that other layer thicknesses can be produced to meet particular needs and still fall within the scope of the present disclosure.

[0082] After processing and shaping and optional stretching, the multilayer film used to form the shaped container 2 is shaped to form one or more dimples using conventional embossing or molding techniques. In one preferred embodiment, the shaped container 2 is manufactured to have a shape such as Figure 3The illustrated carrier tape, wherein a plurality of spaced apart pockets are sequentially stamped or imprinted into the film along the longitudinal axis of the tape. Techniques suitable for forming the illustrated carrier tape having a plurality of pockets are well known in the art. See, for example, U.S. Pre-Grant Publication 2017 / 0162418, U.S. Patent 9,635,791, and U.S. Patent 9,911,079, each of which is incorporated herein by reference to the extent consistent herewith, each of which teaches a carrier tape design including pockets / grooves formed in a continuous polymeric strip that are suitable for packaging microelectronic components as contemplated herein. As described in U.S. Patent 2017 / 0162418, the pockets are manufactured by hot forming a sheet or strip of the multilayer film of the container 2 with one or more suitable dies having the desired dimensions. In this regard, the multilayer film of the container 2 can be preheated, or the dies themselves can be heated to assist the hot forming process, as is well known in the art, to form the pockets having the desired dimensions and shapes, wherein each pocket includes a floor wall and four side walls extending from the floor wall, wherein the floor wall is generally planar and parallel to the surfaces 8, 10 of the cover. The walls can be oriented at an angle of about 90°, so that the pockets have a generally square or rectangular shape, or they can be fabricated to have any other shape that can be determined by those skilled in the art. The shape and / or dimensions of the pockets / grooves are not intended to be limiting herein. However, in preferred embodiments, the shape of the pockets / grooves is generally square or rectangular, having length and width dimensions of about 0.5 mm to about 100 mm, more preferably about 0.5 mm to about 80 mm, and most preferably about 1 mm to about 70 mm, and a depth of about 0.5 mm to about 15 mm, more preferably about 0.5 mm to about 12 mm, and most preferably about 1 mm to about 10 mm. However, these preferences are not intended to be limiting.

[0083] Similarly, the dimensions of the carrier tape itself are not intended to be limiting, but a typical carrier tape will have a width of about 5 mm to about 100 mm, more preferably about 5 mm to about 88 mm, and most preferably about 8 mm to about 72 mm. A typical carrier tape will have a continuous length of about 1 m to about 300 m, more typically about 1 m to about 200 m. In preferred carrier tapes, the pockets / grooves are preferably spaced apart from each other by about 1 mm to about 10 mm, more preferably about 3 mm to about 8 mm, and most preferably about 3 mm to about 5 mm. The pocket side edge distance of the carrier tape can also vary depending on the desired dimensions of the pockets and the desired layout of the positioning holes on one or both side edges (such as Figure 3 illustrated) and typically range from about 2 mm to about 5 mm in width.

[0084] The cavities are then filled with the desired product 36 (e.g., microchips or other small electronic components) using techniques well known in the art. If desired, the thermoformed carrier web is then typically cooled and solidified. After the cavities are suitably filled, they are completely sealed with top and bottom cover members 4 and 6, as shown in Figure 2 After filling one or more of the cavities 34 with the product 36, the cavities are then completely sealed with the cover members 4, 6. Methods of sealing the cover members 4, 6 to the formed containers 2 are conventionally known, and the preferred method is heat sealing. As shown in U.S. Patent 9,911,079, this method can include applying the cover member film 4, 6 as a continuous film to the entire surface area of the formed containers / carrier web 2, as shown in U.S. Patent 9,911,079, FIG. C, or, alternatively, smaller discrete patches of the cover member film 4, 6 can be selectively applied to completely seal only the individual formed cavity areas, whereby the patches are discontinuous and spaced apart from one another, such as shown in U.S. Patent 9,911,079, FIG. E, and the Figure 4 C of U.S. Patent 9,911,079, or, alternatively, smaller discrete patches of the cover member film 4, 6 can be selectively applied to completely seal only the individual formed cavity areas, whereby the patches are discontinuous and spaced apart from one another, such as shown in U.S. Patent 9,911,079, FIG. E, and the Figure 4 E of U.S. Patent 9,911,079, or, alternatively, smaller discrete patches of the cover member film 4, 6 can be selectively applied to completely seal only the individual formed cavity areas, whereby the patches are discontinuous and spaced apart from one another, such as shown in U.S. Patent 9,911,079, FIG. E, and the Figure 5 C of U.S. Patent 9,911,079, or, alternatively, smaller discrete patches of the cover member film 4, 6 can be selectively applied to completely seal only the individual formed cavity areas, whereby the patches are discontinuous and spaced apart from one another, such as shown in U.S. Patent 9,911,079, FIG. E, and the

[0085] As is well known in the art, the carrier web can also be subjected to other processing steps, such as stamping push-through holes along at least one edge of the web as desired. Additionally, at least one of the outer layers of the cover members 4 and / or 6 can have a printable surface, and can be printed with decorative products and / or informational indicia. If it is intended that the cover member film be ultimately manually separated from the formed containers 2 to allow access to the stored products, the cover members 4, 6 can also be manufactured with a pull tab, so as to be easily peeled away for removal with the fingers. Such peeling can be performed manually by the operator, or can also be performed automatically. It should also be understood that the present disclosure is not intended to be limited by the methods used to form such carrier webs, and the methods described in U.S. Published Application 2017 / 0162418, U.S. Patent 9,635,791, and U.S. Patent 9,911,079 are not intended to be strictly limiting.

[0086] With respect to other carrier webs / packaging of the prior art, the fully assembled packages 12, 38 of the present disclosure will have improved barrier properties to water vapor and oxygen transmission. The water vapor transmission rate (WVTR) of such articles of the present disclosure can be determined via the procedure set forth in ASTM F 1249. In preferred embodiments, the packages of the present disclosure have a water vapor transmission rate (WVTR) of preferably less than about 0.05 g / 100 in 2 / day (0.775 g / m 2 / day), more preferably less than about 0.03 g / 100 in 2 / day (0.465 g / m 2and most preferably less than about 0.015 g / 100 in 2 / day (0.233 g / m 2 / day) WVTR / mil film as determined by water vapor transmission rate measuring equipment available from, for example, Mocon, Inc. Preferably, the packages of the present disclosure have a water vapor transmission rate that is at least about 20% less than that of a similar package, more preferably at least about 25% less than that of a similar package, and most preferably at least about 30% less than that of a similar package.

[0087] Oxygen transmission barrier is typically measured using the procedure of ASTM F1927 at 23°C / 50% relative humidity (RH). Generally, using the foregoing method, the packages of the present disclosure also preferably have an oxygen transmission rate (O2 TR) at 23°C at 50% RH equal to or less than about 7 cm 3 / 100 in 2 (645 cm 2 ) / 24 hours / atm. The O2 TR of the cover 4, 6 preferably has less than or equal to the oxygen transmission rate of the container 2. The superior oxygen barrier properties of the packages of the present disclosure make them particularly useful in electronic component storage applications.

[0088] In use, the carrier tape is formed using conventional carrier tape forming machines commonly used in the industry, where the strip of film (tape) is pre-heated and then formed into having the aforementioned pockets / cavities by conventional thermoforming or stamping techniques, etc. Optionally, as is conventionally known in the art, the bottoms of the pockets / cavities can be stamped with one or more holes that allow for mechanical verification that the product has been stored within the pocket / cavity. Thereafter, the pockets / cavities are then filled with one or more products, followed by sealing the pockets / cavities with the top cover 4 and bottom cover 6 to form a sealed tape. The sealed tape can then be wound onto a spool for storage (e.g., a 3-7 inch spool as is typical in the industry, which typically holds about 100-400 meters of tape). The end user then peels off the top cover 4, as shown, exposing the stored components, which are then removed and used / installed as needed. These removal and installation steps are typically mechanically automated, but can also be performed manually. Figure 3

[0089] The following examples are intended to illustrate preferred embodiments:

[0090] Example

[0091] A. Multilayer film lamination - container sheet

[0092] A 51 pm clear PCTFE homopolymer film (available from DuPont) was laminated to a 51 pm clear PCTFE homopolymer film (available from DuPont) using a solvent-based two-component (i.e., polyol and diisocyanate) polyurethane adhesive layer.​ A film commercially available from Honeywell International Inc.) was laminated between two 200 μιη black polystyrene (PS) films. The polyurethane adhesive applied between each of these layers contained a polyester polyol terminated with hydroxyl groups and a polyester-based methylene diphenyl diisocyanate (MDI), with each adhesive layer having a dry coating weight of about 3-4 grams. The five-layer laminate was then transferred to a curing chamber maintained at a temperature of 45°C and 50% RH for 72 hours to fully cure the two adhesive layers.

[0093] B. Cover film

[0094] A 15 μιη PCTFE homopolymer film was also laminated between two 200 μιη black polystyrene (PS) films with the same solvent-based two-component polyurethane adhesive layer applied between each of these layers as used in forming the container sheet. The adhesive layer had a dry coating weight of about 3-4 grams. The five-layer laminate was then transferred to a curing chamber maintained at a temperature of 45°C and 50% RH for 72 hours to fully cure the adhesive layer. A PCTFE homopolymer film was laminated to a 20 μιη transparent polyethylene terephthalate (PET) film with an adhesive layer having a dry coating weight of about 3-4 grams. The five-layer laminate was then transferred to a curing chamber maintained at a temperature of 45°C and 50% RH for 72 hours to fully cure the adhesive layer. After curing, a 10 μιη ethylene-vinyl acetate (EVA) copolymer resin (melt index of 25-40 g / 10 min according to ASTM D1238) sealing resin was extrusion coated onto the PET surface.

[0095] C. Forming and sealing

[0096] The container sheet from A was slit into continuous 24 mm wide strips, while the cover film from B was slit into continuous 12 mm wide strips, each cut from the master roll of film using a conventional industrial slitter (although any other suitable slitting device is acceptable). The strips of container sheet A were then softened by passing them through a pre-heat station set at 110°C at a speed of 2 m / min. After softening, the cover sheet strip was embossed by passing it through an embossing station at an embossing pressure of 3 bar (300 kPa), where a series of 1 mm x 12 mm x 1.8 mm sized dimples were formed in the strip. After the strip passed through the embossing station, it was then passed through a punch station to punch two 0.3 mm diameter holes in the bottom of each dimple with two needles mounted on the upper side of the punch station. The carrier tape thus formed was then wound onto a 3 inch core spool. Thereafter, the formed tape was unwound and transferred to a fill-seal machine where an electronic component was first inserted into each cavity, and then sealed by applying one lidding film to each of the top and bottom surfaces of the carrier tape. The sealed tape was then rewound onto a spool and stored.

[0097] Barrier verification ​

[0098] Blue humidity indicating paper was used to verify the barrier properties of the cavities. If the humidity inside the cavities is higher than 20%, the paper will turn pink. Three sample carrier tape strips (each strip having 100 pockets / cavities) were placed into a humidity chamber held at 20°C and 80% RH, after 3 weeks the paper was still blue. The calculated moisture vapor transmission rate of the sealed carrier tape was about 0.033 mg / cavity / day at 40°C / 75% RH.

[0099] Barrier properties were also evaluated by comparing representative samples of both the cover (lid) film and the container formed sheet having a PCTFE layer to comparative samples having a PCTFE layer in only one of the cover (lid) film or the container formed sheet.

[0100] Sample 1 : PCTFE film on both container surfaces

[0101] A 63 μιη thick PCTFE film was laminated to a 50 μιη thick low density polyethylene (LDPE) layer using an intermediate adhesive layer that was the same solvent based two component polyurethane adhesive used for the container sheet and cover film. Two of these multilayer films were then heat sealed together (LDPE to LDPE directly heat sealed, no intermediate adhesive was used) to form a 12 cm x 14 cm size pocket (container) having two outer PCTFE films. The four edges of the pocket were heat sealed together one by one with 10 mm wide sealing tape. Before the last edge was completely sealed, 50 silica gel desiccant particles were placed in the pocket and set aside as Sample 1.

[0102] Sample 2: PCTFE film on one container surface

[0103] A PCTFE / adhesive / LDPE film formed as for Sample 1 was heat sealed to a PET / EVA film (50 μιη thick polyethylene terephthalate layer / 10 μιη thick ethylene-vinyl acetate layer) to form a pocket as formed for making Sample 1 with the LDPE film heat sealed directly to the EVA film (i.e., no intermediate adhesive was used). The pocket thus formed was filled with 50 silica gel desiccant particles as in Sample 1 and set aside as Sample 2.

[0104] The initial weight of both samples was recorded as the Day 0 weight for each sample. Both samples were then placed in a humidity chamber set at 60 °C and 85% RH for 24 hours to allow moisture to penetrate into the dimples via the dimple walls. The samples were then removed from the chamber and allowed to sit for 1 hour under standard atmospheric room conditions (i.e., at a temperature of about 25 °C and 50% relative humidity) to allow the outer dimple surface to dry naturally. The weight of both samples was then checked and identified as the Day 1 weight for each sample. The Day 1 weight minus the Day 0 weight for each sample was the amount of moisture that penetrated into the dimples via the dimple walls. The results indicated that the moisture penetration for the sample with two layers of PCTFE (Sample 1) was 0.02971 grams / container, while the moisture penetration for the other sample (Sample 2) with only one layer of PCTFE was 0.59126 grams / container, which was about 20 times higher than the sample with PCTFE film on both sides.

[0105] While the disclosure has been particularly shown and described with reference to the preferred embodiments, it will be understood by those skilled in the art that various changes in form and details can be made therein without departing from the spirit and scope of the disclosure. It is intended that the claims be interpreted to cover all such alternatives, equivalents and modifications which have been discussed above and all equivalents thereof.

Claims

1. A package, the package comprising: a) A molded container comprising a multilayer film, the container including one or more recesses, the container having a top surface and a bottom surface, the multilayer film comprising: i. First basal layer; ii. First intermediate adhesive layer; iii. A first fluoropolymer layer, the first fluoropolymer layer being adhered to the first substrate layer via the first intermediate adhesive layer; iv. Second intermediate adhesive layer; and v. A second substrate layer, wherein the second substrate layer is adhered to the first fluoropolymer layer via a second intermediate adhesive layer; b) A top cover adhered to the top surface of the container, the top cover comprising: i. A first heat-sealing layer, the first heat-sealing layer being attached to the first base layer; ii. Third intermediate adhesive layer; and iii. A second fluoropolymer layer, which is adhered to the first heat-sealing layer via the third intermediate adhesive layer.

2. The encapsulation according to claim 1, the encapsulation further comprising a first support layer adhered to the second fluoropolymer layer via a fourth intermediate adhesive layer.

3. The package according to claim 1, wherein the package further comprises: c) A bottom cover adhered to the bottom surface of the container, the bottom cover comprising: i. A second heat-sealing layer, the second heat-sealing layer being attached to the second base layer; ii. Fifth intermediate adhesive layer; and iii. A third fluoropolymer layer, which is adhered to the second heat-sealing layer via the fifth intermediate adhesive layer.

4. The encapsulation of claim 3, further comprising a first support layer adhered to the second fluoropolymer layer via a fourth intermediate adhesive layer and a second support layer adhered to the third fluoropolymer layer via a sixth intermediate adhesive layer.

5. The encapsulation according to claim 4, wherein each fluoropolymer layer comprises a polytrifluorochloroethylene (PCTFE) homopolymer or copolymer.

6. The encapsulation of claim 5, wherein each support layer comprises polyester, polyamide, polyolefin, polycarbonate, or acrylonitrile butadiene styrene.

7. The encapsulation of claim 6, wherein each intermediate adhesive layer comprises polyurethane.

8. The encapsulation of claim 7, wherein each base layer comprises polystyrene, polycarbonate, acrylonitrile butadiene styrene, or paper.

9. The encapsulation of claim 8, wherein each heat-sealing layer comprises a polyolefin homopolymer or copolymer.

10. The encapsulation of claim 9, wherein each heat-sealed layer comprises polyethylene.

11. A packaging product, the packaging product comprising: a) A molded container comprising a multilayer film, the container including one or more recesses, the container having a top surface and a bottom surface, the multilayer film comprising: i. First basal layer; ii. First intermediate adhesive layer; iii. A first fluoropolymer layer, the first fluoropolymer layer being adhered to the first substrate layer via the first intermediate adhesive layer; iv. Second intermediate adhesive layer; and v. A second substrate layer, wherein the second substrate layer is adhered to the first fluoropolymer layer via a second intermediate adhesive layer; b) Products contained within one or more recesses in the recess; c) A top cover adhered to the top surface of the container, the top cover comprising: i. A first heat-sealing layer, the first heat-sealing layer being attached to the first base layer; ii. Third intermediate adhesive layer; and iii. A second fluoropolymer layer, which is adhered to the first heat-sealing layer via the third intermediate adhesive layer; And optional, d) A bottom cover adhered to the bottom surface of the container, the bottom cover comprising: i. A second heat-sealing layer, the second heat-sealing layer being attached to the second base layer; ii. Fifth intermediate adhesive layer; and iii. A third fluoropolymer layer, which is adhered to the second heat-sealing layer via the fifth intermediate adhesive layer.

12. The packaged product of claim 11, wherein the package is a carrier strip comprising a plurality of recesses, and wherein the product is received in one or more of the recesses.

13. The packaged product of claim 12, wherein the bottom cover is present.

14. A method for forming a carrier belt that can be used to store multiple products, the method comprising: a) Forming a multilayer film, the multilayer film comprising: i. First basal layer; ii. First intermediate adhesive layer; iii. A first fluoropolymer layer, the first fluoropolymer layer being adhered to the first substrate layer via the first intermediate adhesive layer; iv. Second intermediate adhesive layer; and v. A second substrate layer, wherein the second substrate layer is adhered to the first fluoropolymer layer via a second intermediate adhesive layer; b) Imprinting the multilayer film to form a molded container including one or more recesses, the container having a top surface and a bottom surface; c) Placing the product in one or more of the recesses; and d) Heat-sealing the top cover to the top surface of the container, the top cover comprising: i. First heat-sealing layer; ii. Third intermediate adhesive layer; and iii. A second fluoropolymer layer, which is adhered to the first heat-sealing layer via the third intermediate adhesive layer; The first heat-sealing layer is attached to the first base layer.

15. The method of claim 14, further comprising heat-sealing a bottom cover to the bottom surface of the container, the bottom cover comprising: i. Second heat-sealing layer; ii. Fifth intermediate adhesive layer; and iii. A third fluoropolymer layer, which is adhered to the second heat-sealing layer via the fifth intermediate adhesive layer; The second heat-sealing layer is attached to the second base layer.

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