Recyclable multilayer metallized laminate and tubes thereof

Abstract

The present disclosure provides a recyclable laminate, the laminate comprising: a multilayer blown film with a haze value of less than 22 measured according to ASTM D1003-21; and a metallized multilayer film, wherein the laminate has a Gloss (20°) value >115 measured as per ASTM D-2457. The present disclosure further provides process of preparing the laminate, a recyclable tube and process thereof.

Description

RECYCLABLE MULTILAYER METALLIZED LAMINATE AND TUBES THEREOFFIELD OF INVENTION

[0001] The subject matter disclosed herein relates to the field of packaging materials and in particular, relates to recyclable multilayer metallized laminates for packaging material.BACKGROUND OF THE INVENTION

[0002] Packaging industry has emerged as one of the fastest growing sectors in the world economy. The multilayer films, laminates, and articles, as tubes thereof are extensively used in packaging products such as food, pharma, and cosmetic industries. After use, much of these packaging materials gets disposed in landfills. The disposal and recycling of these used packaging articles is of importance especially for environmental and economic reasons. Therefore, due to sustainability reasons these industries started with, aluminum tubes, then moved to aluminum barrier layer tubes (ABL), but over the years it has migrated to laminated plastic barrier layer tubes (PBL), due to its enhanced functionalities and for sustainability reasons.

[0003] In addition, the aesthetic appearance of the packaging was improved by metallic luster, via the metallization at top of multilayer film or article. To preserve the metallic luster the metallized films are generally laminated with transparent film on top without compromising the metallic luster. However, recycling of such metallized laminates has been challenging.

[0004] Although, during the last few years for recycling plastic waste, the NearInfrared spectroscopy (NIR) sorting technology played a significant role, yet the highly lustrous glossy cosmetic packaging materials are difficult to recycle or appropriately sorted using NIR detector system. Actually, the radiation of NIR is fully reflected from the glossy side, and thus, the spectra and its material could not be classified in respective stream of recyclability. Therefore, there is a need for glossy laminate whichcan overcome these sorting issues, in particular related to these high lustrous packaging materials.SUMMARY OF THE INVENTION

[0005] In a first aspect of the present disclosure, there is provided a recyclable laminate, the laminate comprising: a multilayer blown film with a haze value of less than 22 measured according to ASTM DI 003 -21; and a metallized multilayer film, wherein the laminate has a Gloss (20°) value > 115 measured as per ASTM D-2457.

[0006] In a second aspect of the present disclosure, there is provided a NIR detectable laminate, the laminate comprising: a multilayer film obtained by downward blown film process; and a metallized multilayer film, wherein the multilayer blown film comprises polyethylene selected from high density polyethylene, medium density polyethylene, or combinations thereof, and the laminate has a Gloss (20°) value > 115 measured as per ASTM D-2457.

[0007] In a third aspect of the present disclosure, there is provided a process of preparing the laminate as disclosed herein, the process comprising lamination of a multilayer blown film with a metallized multilayer film, wherein the multilayer blown film is obtained by downward extrusion.

[0008] In a fourth aspect of the present disclosure, there is provided a recyclable tube comprising: a. a tube body comprising the laminate as disclosed herein; and b. a shoulder; wherein, the tube has an overall density in a range of 0.938 g / cm3- 0.99 g / cm3.

[0009] In a fifth aspect of the present disclosure, there is provided a process of manufacturing the tube.

[0010] These and other features, aspects, and advantages of the present subject matter will be better understood with reference to the following detailed description and appended claims. This summary is provided to introduce a selection of concepts in asimplified form. This summary is not intended to identify key features or essential features of the claimed subject matter.DESCRIPTION OF THE INVENTION

[0011] Those skilled in the art will be aware that the present disclosure is subject to variations and modifications other than those specifically described. It is to be understood that the present disclosure includes all such variations and modifications. The disclosure also includes all such steps, features, compositions, and compounds referred to or indicated in this specification, individually or collectively, and any and all combinations of any or more of such steps or features.Definitions

[0012] For convenience, before further description of the present disclosure, certain terms employed in the specification, and examples are delineated here. These definitions should be read in the light of the remainder of the disclosure and understood as by a person of skill in the art. The terms used herein have the meanings recognized and known to those of skill in the art, however, for convenience and completeness, particular terms and their meanings are set forth below.

[0013] The articles “a”, “an” and “the” are used to refer to one or to more than one (i.e., to at least one) of the grammatical object of the article.

[0014] The terms “comprise” and “comprising” are used in the inclusive, open sense, meaning that additional elements may be included. It is not intended to be construed as “consists of only”.

[0015] Throughout this specification, unless the context requires otherwise the word “comprise”, and variations such as “comprises” and “comprising”, will be understood to imply the inclusion of a stated element or step or group of element or steps but not the exclusion of any other element or step or group of element or steps.

[0016] The term “including” is used to mean “including but not limited to”. “Including” and “including but not limited to” are used interchangeably.

[0017] The term “at least one” used herein refers to one or more and thus, includes individual components as well as mixtures / combinations.

[0018] The term “laminate” used herein refers to a wall between the packaged product and the surrounding environment comprising at least two films joined through lamination. The laminate may be molded to various shaped articles, such as packaging tubes, cans, containers, or rolled bodies for the packaging of products / materials. Such laminates are highly chemical resistant such that when in contact with aggressive chemicals or the environment, the laminates are stable and do not degrade or delaminate. The laminate of the present disclosure has a density in a range of 0.938 g / cm3- 0.99 g / cm. The laminates of the present disclosure shines having good aesthetics yet is detectable by NIR (near-infra red) and NIR sortable into polyethylene rigid stream.

[0019] The term “recyclable tube” or “tube” used herein refers to any packaging tube made from the laminate of the present disclosure. The laminated tubes are widely used for packaging chemicals, cosmetic material, toothpaste, and other viscous food products.

[0020] The phrase “thermoplastic polymer” or “polyolefin” refers to a polymer of olefin may be polyethylene having a density in the range 0.910 to 0.99 g / cm3. The term polyolefin as used herein refers to any polyethylene having density in the range of 0.910 to 0.99 g / cm3, wherein the polyethylene may include high density polyethylene, medium density polyethylene, low density polyethylene, linear low-density polyethylene, modified polyethylene(s), such as metal-modified polyethylene, chemically modified polyethylene, and the like.

[0021] The phrases “high-density polyethylene”, “medium density polyethylene”, “low-density polyethylene” and “linear low-density polyethylene” as used herein refer to polyethylene having densities well known to the person skilled in the art.

[0022] The term “film” used herein refers to single layer or multilayer wall between the packaged product and the surrounding environment, wherein the layer comprisesat least one polyethylene is selected from high-density polyethylene, low density polyethylene, or combinations thereof.

[0023] The term “haze value” used herein refers to measure of the haziness of the sample and is described as the amount of light scattered (large scale deflection) with respect to the amount of light that gets transmitted. The lower the haze measurement value, the higher the clarity of the sample indicating better viewability. Haze is the percentage of light which passing through deviates from the incident beam greater than 2.5 degree on the average. Haze value is calculated using the Formula Td / Tt (Scattered light which is greater than 2.5 degree (Td) / Total transmitted light (Tt)). In the present disclosure, the haze value of the film is less than 25% which indicated the higher transparency of the material.

[0024] The term “multilayer blown film” refers to a film comprising multiple layers of polyethylene obtained by downward extrusion and optionally, a first barrier layer, with polyethylene on either side of the first barrier layer. The first barrier layer is sandwiched by the polyethylene layers in the presence of a tie layer. The multilayer blown film form the outer film of the laminate.

[0025] The term “metallized multilayer film” refers to a film comprising multiple layers of polyethylene and optionally a second barrier layer, with polyethylene on either side of the second barrier layer. At least one of the layers of polyethylene is metallized. In the metallized multilayer film, the polyethylene layers are sandwiched with the second barrier layer in the presence of a tie layer.

[0026] The term “tie layer” refers to a layer which binds any two layers having dissimilar polarity in a film. In the present disclosure, the tie layer binds polyolefin layer with barrier layer and the tie layer comprises polymeric adhesive selected from the group consisting of maleated polyethylene, anhydride grafted ethylene / 1 -butene copolymer, anhydride grafted ethylene / 1 -hexene copolymer, anhydride grafted polypropylene, anhydride grafted propylene ethylene copolymer, ethylene vinyl acetate copolymer, ethylene methyl acrylate copolymer, anhydride grafted ethylene / 1 -octene copolymer, and combinations thereof. The term “anhydride grafted (ethylene / 1- hexene copolymer, polypropylene, propylene ethylene copolymer) refers to anhydride grafted ethylene / 1 -hexene copolymer, anhydride grafted polypropylene, and anhydride grafted propylene ethylene copolymer.

[0027] The term “lamination” used herein refers to a process in which two or more films are joined together by a lamination layer in-between the films either by extrusion lamination and / or adhesive lamination. The lamination layer thus acts as a bonding agent to convert multiple films into a laminate. The adhesives can be polyurethane or acrylic based. The adhesive lamination can be dry or wet.

[0028] The term “NIR detectable” or “NIR sortable” used herein refers to laminates / tubes, which when passed through a Plastic Recycling Facility having NIR based Sorting shows a maximum of absorption in NIR region and hence are sorted > 70% into polyethylene rigid stream.

[0029] Ratios, concentrations, amounts, and other numerical data may be presented herein in a range format. It is to be understood that such range format is used merely for convenience and brevity and should be interpreted flexibly to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For example, a thickness range of 120 pm to 200 pm should be interpreted to include not only the explicitly recited limits of 120 pm to 200 pm, but also to include sub-ranges, such as 165 pm to 200 pm, 170 pm to 200 pm, and so forth, as well as individual amounts, including fractional amounts, within the specified ranges, such as 165.2 pm, 170.6 pm, and 191.3 pm, for example.

[0030] As discussed in the background, there are several issues associated with the recyclability of highly lustrous packaging materials. For beauty and cosmetic applications, metallized films having high gloss are on high demand. To preserve the metallic luster during downstream (secondary) processing and usage stages, themetallized films are generally laminated / sandwiched with transparent film on top without compromising the gloss / metallic luster. The thickness of the polymer layer above metallized surface can’t be increased beyond a limit as haziness would increase with thickness, which in-turn would affect the gloss.

[0031] In one of the steps during segregation of post-consumer mixed wastes, NIR sorting is used to separate out different plastic packages namely PET, PP, HDPE, Etc., into their respective bins / containers. Due to the light (Electro-magnetic Radiation) reflection effect of metallic packages, these packages are improperly sorted and not separated into appropriate material class. This will create contamination of single material stream mechanically recycling. Hence, there is a need for making these packages recyclable in the current recycling infrastructure, meaning appropriate sorting during NIR based sorting stage.

[0032] To address the sortability, the amount of polymer (thickness of the top film) over the metallized surface can be increased, which will absorb more amount of NIR radiation. But the challenge associated with the increase of polymer (polyethylene, especially HDPE) is its higher crystallinity which increases the haze and further leads to loss of metallic luster or gloss. As soon as the top film becomes hazy with increasing thickness, gloss decreases. On the other hand, to overcome the decreased aesthetics, mainly loss of metallic luster or gloss, if other LDPE films of higher thickness are used, it may solve the sorting issue, but may not fulfil the upcycling requirement of HDPE recycling stream, as the mechanical properties would be compromised.

[0033] Generally, upward blown film extrusion process is used for making mono and multi-layer films. The alternative methods available for making films include cast film and thermally quenched film by downward extrusion methods. In view of the above, the present disclosure aims to provide an environment friendly laminate of packaging materials by utilizing downward extrusion blown film process for making higher density (>0.938 g / cc, more specifically > 0.940g / cc) polymer based films. Such films and laminates thereof, improves the luster (due to lower haze) and also meets therequirements of recycling in specific codes. The downward made film cum laminate addresses both the needs, namely glossy luster and good mechanical. The present disclosure also accomplishes NIR sortability of the multilayer laminate comprising a metallized layer, hence the recyclability in the current recycling infrastructure. Further, in view of the several existing environmental problems, the packaging material made using such environmentally friendly recyclable laminate of the present disclosure has a strong market potential in both short and long term.

[0034] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the disclosure, the preferred methods and materials are now described. All publications mentioned herein are incorporated herein by reference.

[0035] The present disclosure is not to be limited in scope by the specific embodiments described herein, which are intended for the purposes of exemplification only. Functionally-equi valent products, compositions, and methods are clearly within the scope of the disclosure, as described herein.

[0036] In an embodiment of the present disclosure, there is provided a recyclable laminate, the laminate comprising: a multilayer blown film with a haze value of less than 22 measured according to ASTM DI 003 -21; and a metallized multilayer film, wherein the laminate has a Gloss (20°) value > 115 measured as per ASTM D-2457.

[0037] In an embodiment of the present disclosure, there is provided a recyclable laminate as disclosed herein, wherein the laminate has a density in a range of 0.938 g / cm3- 0.99 g / cm3'

[0038] In an embodiment of the present disclosure, there is provided a recyclable laminate as disclosed herein, wherein the multilayer blown film comprises polyethylene selected from high density polyethylene, medium density polyethylene, or combinations thereof.

[0039] In an embodiment of the present disclosure, there is provided a recyclable laminate as disclosed herein, wherein the multilayer blown film is obtained by downward blown film process.

[0040] In an embodiment of the present disclosure, there is provided a recyclable laminate as disclosed herein, wherein the multilayer blown film independently comprises a barrier layer. In another embodiment of the present disclosure, wherein the multilayer blown film comprises a first barrier layer sandwiched by a thermoplastic polymeric layer on either side.

[0041] In an embodiment of the present disclosure, there is provided a recyclable laminate as disclosed herein, wherein the metallized multilayer film comprises a second barrier layer sandwiched by a thermoplastic polymeric layer on either side.

[0042] In an embodiment of the present disclosure, there is provided a recyclable laminate as disclosed herein, wherein the metallized multilayer film comprises an upper thermoplastic polymeric layer and a lower thermoplastic polymeric layer. In another embodiment of the present disclosure, wherein the upper thermoplastic polymeric layer is metallized by physical vapour deposition, or chemical vapour deposition.

[0043] In an embodiment of the present disclosure, there is provided a recyclable laminate as disclosed herein, wherein the laminate further comprises a multilayer sealing film comprising a thermoplastic polymeric layer.

[0044] In an embodiment of the present disclosure, there is provided a recyclable laminate as disclosed herein, wherein the thermoplastic polymeric layer comprises high-density polyethylene, medium density polyethylene, low density polyethylene, linear low-density polyethylene, or combinations thereof. In another embodiment of the present disclosure, the thermoplastic polymeric layer comprises high-density polyethylene, medium density polyethylene, or combinations thereof.

[0045] In an embodiment of the present disclosure, there is provided a recyclable laminate as disclosed herein, wherein the thermoplastic polymeric layer comprises at least 50% (w / w) of a polyethylene having density in a range of 0.938 to 0.99 g / cm3.

[0046] In an embodiment of the present disclosure, there is provided a recyclable laminate as disclosed herein, wherein the first barrier layer and the second barrier layer independently comprises one or more layers made of ethylene vinyl alcohol, polyamides, low melting polyamides, polyvinyl alcohol, ceramic coatings, polyethylene terephthalate, low melting polyesters, or combinations thereof.

[0047] In an embodiment of the present disclosure, there is provided a recyclable laminate as disclosed herein, wherein each of the films of the laminate are linked by an extrusion laminating layer comprising a polyolefin, a polyolefin copolymer, or combinations thereof; and the copolymer is selected from ethylene-(meth) acrylic acid polymer, maleic anhydride-grafted-polyethylene, or combinations thereof.

[0048] In an embodiment of the present disclosure, there is provided a recyclable laminate as disclosed herein, wherein each of the film further comprises one or more tie layer comprising an adhesive selected from the group consisting of maleated polyethylene, anhydride grafted ethylene / 1 -butene copolymer, anhydride grafted (ethylene / 1 -hexene copolymer, polypropylene, propylene ethylene copolymer), ethylene vinyl acetate copolymer, ethylene methyl acrylate copolymer, anhydride grafted ethylene / 1 -octene copolymer, and combinations thereof.

[0049] In an embodiment of the present disclosure, there is provided a recyclable laminate as disclosed herein, wherein each of the film has thickness in a range of 50 to 200 pm.

[0050] In an embodiment of the present disclosure, there is provided a recyclable laminate, the laminate comprising: a multilayer blown film obtained by downward blown film process with a haze value of less than 22 measured according to ASTM D1003-21; and a metallized multilayer film, wherein the laminate has a Gloss (20°) value > 115 measured as per ASTM D-2457.

[0051] In an embodiment of the present disclosure, there is provided a recyclable laminate as disclosed herein, wherein the laminate is NIR sortable into polyethylene rigid stream.

[0052] In an embodiment of the present disclosure, there is provided a NIR detectable laminate, the laminate comprising: a multilayer blown film obtained by downward blown film process; and a metallized multilayer film, wherein the multilayer blown film comprises polyethylene selected from high density polyethylene, medium density polyethylene, or combinations thereof, and the laminate has a Gloss (20°) value > 115 measured as per ASTM D-2457.

[0053] In an embodiment of the present disclosure, there is provided a NIR detectable laminate as disclosed herein, wherein the laminate has a density in a range of 0.938 g / cm3- 0.99 g / cm3-

[0054] In an embodiment of the present disclosure, there is provided a NIR detectable laminate as disclosed herein, wherein the laminate is a tube laminate.

[0055] In an embodiment of the present disclosure, there is provided a process of preparing the laminate as disclosed herein, the process comprising extrusion lamination of a multilayer (downward) blown film with a metallized multilayer film, wherein the multilayer blown film is obtained by downward extrusion.

[0056] In an embodiment of the present disclosure, there is provided a process of preparing the laminate as disclosed herein, wherein the process further comprises laminating a multilayer sealing film.

[0057] In an embodiment of the present disclosure, there is provided a process of preparing the laminate as disclosed herein, wherein each of the multilayer blown film and the metallized multilayer film are independently obtained by attaching a barrier layer with a thermoplastic polymeric layer on either side in the presence of a tie layer.

[0058] In an embodiment of the present disclosure, there is provided a process of preparing the laminate as disclosed herein, wherein the thermoplastic polymeric layer of the metallized multilayer film is metallized with a metal selected from aluminum,nickel, chromium, or combinations thereof, by physical vapor deposition, or chemical vapor deposition.

[0059] In an embodiment of the present disclosure, there is provided a recyclable tube comprising: a. a tube sleeve comprising the laminate; and b. a shoulder; wherein, the tube has an overall density in a range of 0.938 g / cm3-0.99 g / cm3.

[0060] In an embodiment of the present disclosure, there is provided a recyclable tube as disclosed herein, wherein the shoulder comprises at least one ethylene polymer having a melt flow index in the range of 0.5 - 7.0 g / 10 minutes and a density in the range of 0.938 - 0.990 gm / cm3.

[0061] In an embodiment of present disclosure, there is provided a recyclable tube as disclosed herein, wherein the tube has a thickness in the range of 120 pm - 400 pm.

[0062] In an embodiment of the present disclosure, there is provided a process of manufacturing the tube.

[0063] In an embodiment of the present disclosure, there is provided a process of manufacturing the tube, said process comprises the steps of forming the layers and laminating the layers together, then slitting into reels of desired width in the range of 63 - 320 mm, followed by tubing from the reels.

[0064] In an embodiment of the present disclosure, there is provided an article comprising the laminate as disclosed herein, wherein the article is selected from a packaging tube.

[0065] Although the subject matter has been described in considerable detail with reference to certain examples and implementations thereof, other implementations are possible.EXAMPLES

[0066] The disclosure will now be illustrated with the working examples, which is intended to illustrate the working of disclosure and not intended to take restrictively to imply any limitations on the scope of the present disclosure. Unless defined otherwise,all technical and scientific terms used herein have the same meaning as commonly understood to one ordinary person skilled in the art to which this disclosure belongs. Although methods and materials similar or equivalent to those described herein can be used in the practice of the disclosed methods and compositions, the exemplary methods, devices and materials are described herein. It is to be understood that this disclosure is not limited to particular methods, and experimental conditions described, as such methods and conditions may apply.EXAMPLE 1Process of preparing the laminate film

[0067] The laminate of the present disclosure comprises multilayer blown film and a metallized multilayer film.

[0068] The multilayer blown film was prepared by downward blown film extrusion process. The layers of film were prepared by well-known blown film extrusion process. As explained in the references [ Blown Film Extrusion An Introduction, page 77, Kirk Cantor, (2006), Hanser Publishers, Munich].

[0069] For preparing a multilayer blown film, firstly a polyethylene was melted to obtain a polyethylene melt stream. This melt stream was forced through an extruder into an annular die to obtain an extruded material which was then inflated by blowing air to form a balloon shape tube. Finally, quenching of the blown film bubble was done using chilled water and a transparent recyclable film was obtained. The film may have 3-11 layers made by downward extrusion blown film process comprising the at least one high-density polyethylene (HDPE) layer. The multilayer blown film comprised a barrier layer sandwiched by polyethylene film on either sides obtained by downward extrusion process. The barrier layer and polyethylene layers were held together by a tie layer.

[0070] The metallized multilayer film was prepared from a second barrier layer and both sides thermoplastic polymeric layers. The metallized multilayer film comprisedan upper polyethylene layer which is metallized by vapor deposition method and a lower polyethylene layer. The second barrier layer and the polyethylene layers were held together by a tie layer.

[0071] The laminate further comprised a multilayer sealing film comprising one or more polyethylene.

[0072] Each of the films of the laminate were attached to each other by an extrusion laminating layer.

[0073] In an example, the laminate of the present disclosure was obtained by extrusion lamination of multilayer blown film and a metallized multilayer film. The multilayer blown film comprised a first barrier layer of EVOH sandwiched by polyethylene layers. The polyethylene layers of the multilayer blown film were obtained by downward extrusion process as explained above. The first barrier layer and the polyethylene layers were held together by a tie layer. The laminate comprised a metallized multilayer film which was obtained by attaching together a layer of metallized polyethylene with a second barrier layer of EVOH using a tie layer. The laminate comprised multilayer sealing film which comprised 3 to 7 layers of high-density polyethylene. The multilayer sealing film and the metallized multilayer film were linked together by extrusion lamination. The extrusion lamination layer comprised either ethylene acrylic acid copolymer (ACP) or low density polyethylene (LD) or a co-extrusion of ACP and LD. Tie layer comprised an adhesive selected from the group consisting of maleated polyethylene, anhydride grafted ethylene / 1 -butene copolymer, anhydride grafted (ethylene / 1 -hexene copolymer, polypropylene, propylene ethylene copolymer), ethylene vinyl acetate copolymer, ethylene methyl acrylate copolymer, anhydride grafted ethylene / 1 -octene copolymer, and combinations thereof.

[0074] The structure of the laminate of the present disclosure is multilayer blown film / / extrusion layer (EL) / / a metallized multilayer film / / extrusion layer (EL) multilayer sealing film. The laminate (LI) is represented asLI- ( 140( ) PE / tie / EVOH / tie / PE (downward extrusion) / / EL-(30 p) ACP / / (60p) metallized PE / tie / EVOH / tie / PE / / (25p) EL / / (95 p) PE.

[0075] For comparative purpose, laminates / films of below structures were prepared, wherein the PE films were obtained by upward extrusion. The structure of laminates (L2 and L3) are represented as below:L2- (1 lOp) PE / PE / PE (upward extrusion) / / EL-(30 p) ACP / / (60p) metallized PE / tie / EVOH / tie / PE / / (30p) EL / / (95 p) PE.L3- (130p) PE / PE / PE (upward extrusion) / / EL-(30 p) ACP / / (60p) metallized PE / tie / EVOH / tie / PE / / (30p) EL / / (95 p) PE.EXAMPLE 2

[0076] The laminate of the present disclosure is used in preparing packaging tubes. The present disclosure provides a packaging tube which was tested for NIR detectability properties for recycling. For this purpose, the packaging tube of the present disclosure was subjected to NIR for recycling.

[0077] The FT-NIR studies and gloss measurements of the laminates were carried out. For FT-NIR analysis of laminates, surface was impinged with NIR rays. FT-NIR spectrum of the laminates confirmed that the laminate LI of the present disclosure showed absorption bands in NIR region and hence confirmed its detectability in NIR region. The gloss values, haze values and the % HDPE in the laminates are presented in Table 1 below.Table 1

[0078] The data as shown in Table 1 revealed that LI showed higher gloss, was detectable in NIR and was recyclable. On the other hand, L2 and L3 having multilayer blown film obtained by upward extrusion had the higher haze values and the gloss values are much lesser than LI, thereby did not meet the aesthetic requirements. Hence, the laminate of the present disclosure provided aesthetics and metallic appearance yet detectable in NIR stream aiding recyclability, which are essential features for sustainability and in terms of commercial aspects.Advantages of the present disclosure

[0079] The present disclosure provides an environmentally friendly laminate of packaging materials. The laminate comprises a multilayer blown film with a haze value of less than 22 and a metallized multilayer film. The downward blown process preparation method and thickness of the multilayer film are key features of this laminate. These characteristic features make this laminate highly susceptible for recyclability. Without compromising the metallic luster, recyclability of these laminate are achieved. Hence, the laminate of the present disclosure is highly sustainable in all environments and can be used for recyclable tube packaging. Therefore, the present invention will be a step towards sustainable development.

Claims

I / We claim:

1. A recyclable laminate, the laminate comprising: a. a multilayer blown film with a haze value of less than 22 measured according to ASTM DI 003 -21; and b. a metallized multilayer film, wherein the laminate has a Gloss (20°) value >115 measured as per ASTM D- 2457.

2. The laminate as claimed in claim 1, wherein the laminate has a density in a range of 0.938 g / cm3- 0.99 g / cm3-3. The laminate as claimed in claim 1, wherein the multilayer blown film comprises polyethylene selected from high density polyethylene, medium density polyethylene, or combinations thereof.

4. The laminate as claimed in claim 1, wherein the multilayer blown film is obtained by downward blown film process.

5. The laminate as claimed in claim 1, wherein the multilayer blown film independently comprises a barrier layer.

6. The laminate as claimed in claim 1, wherein the multilayer blown film comprises a first barrier layer sandwiched by a thermoplastic polymeric layer on either side.

7. The laminate as claimed in claim 1, wherein the metallized multilayer film comprises a second barrier layer sandwiched by a thermoplastic polymeric layer on either side.

8. The laminate as claimed in claim 1, wherein the metallized multilayer film comprises an upper thermoplastic polymeric layer and a lower thermoplastic polymeric layer.

9. The laminate as claimed in claim 8, wherein the upper thermoplastic polymeric layer is metallized by physical vapor deposition, or chemical vapor deposition.

10. The laminate as claimed in claim 1, wherein the laminate further comprises a multilayer sealing film comprising a thermoplastic polymeric layer.

11. The laminate as claimed in any one of the claims 6 to 10, wherein the thermoplastic polymeric layer comprises high-density polyethylene, medium density polyethylene, low density polyethylene, linear low-density polyethylene, or combinations thereof.

12. The laminate as claimed in any one of the claims 6 to 10, wherein the thermoplastic polymeric layer comprises high-density polyethylene, medium density polyethylene, or combinations thereof.

13. The laminate as claimed in any one of the claims 6 to 10, wherein the thermoplastic polymeric layer comprises at least 50% (w / w) of a polyethylene having density in a range of 0.938 to 0.99 g / cm3.

14. The laminate as claimed in any one of the claims 1 to 13, wherein the first barrier layer and the second barrier layer independently comprises one or more layers made of ethylene vinyl alcohol, polyamides, low melting polyamides, polyvinyl alcohol, ceramic coatings, polyethylene terephthalate, low melting polyesters, or combinations thereof.

15. The laminate as claimed in any one of the claims 1 to 14, wherein each of the films of the laminate are linked by a lamination layer comprising a polyolefin, a polyolefin copolymer, or combinations thereof or polyurethane adhesive or acrylic adhesive; and the copolymer is selected from ethylene-(meth) acrylic acid polymer, maleic anhydride-grafted-polyethylene, or combinations thereof.

16. The laminate as claimed in any one of the claims 1 to 15, wherein each of the film further comprises one or more tie layer comprising an adhesive selected from the group consisting of maleated polyethylene, anhydride grafted ethylene / 1 -butene copolymer, anhydride grafted (ethylene / 1 -hexene copolymer, polypropylene, propylene ethylene copolymer), ethylene vinylacetate copolymer, ethylene methyl acrylate copolymer, anhydride grafted ethylene / 1 -octene copolymer, and combinations thereof.

17. The laminate as claimed in any one of the claims 1 to 16, wherein each of the film has thickness in a range of 50 to 200 pm.

18. The laminate as claimed in any one of the claims 1 to 17, wherein the laminate is NIR (Near-Infrared spectroscopy) sortable into polyethylene rigid stream.

19. A NIR detectable laminate, the laminate comprising: a. a multilayer blown film obtained by downward blown film process; and b. a metallized multilayer film, wherein the multilayer blown film comprises polyethylene selected from high density polyethylene, medium density polyethylene, or combinations thereof, and the laminate has a Gloss (20°) value > 115 measured as per ASTM D-2457.

20. The laminate as claimed in claim 19, wherein the laminate has a density in a range of 0.938 g / cm3- 0.99 g / cm321. The laminate as claimed in claims 1-20, wherein the laminate is a tube laminate.

22. A process of preparing the laminate as claimed in claim 1-21, the process comprising extrusion lamination of a multilayer blown film with a metallized multilayer film, wherein the multilayer blown film is obtained by downward extrusion.

23. The process as claimed in claim 22, wherein the process further comprises laminating a multilayer sealing film.

24. The process as claimed in claim 22, wherein each of the multilayer blown film and the metallized multilayer film are independently obtained by attaching a barrier layer with a thermoplastic polymeric layer on either side in the presence of a tie layer.

25. The process as claimed in claim 22, wherein the thermoplastic polymeric layer of the metallized multilayer film is metallized with a metal selected fromaluminum, nickel, chromium, or combinations thereof, by physical vapor deposition, or chemical vapor deposition.

26. A recyclable tube comprising: a. a tube body comprising the laminate as claimed in claim 1 or claim 19; and b. a shoulder; wherein, the tube has an overall density in a range of 0.938 g / cm3-0.99 g / cm3.

27. The tube as claimed in claim 26, wherein the shoulder comprises at least one ethylene polymer having a melt flow index in the range of 0.5 - 7.0 g / 10 minutes and a density in the range of 0.938 - 0.990 gm / cm3.

28. The tube as claimed in claim 26, wherein the tube has a thickness in the range of 120 pm - 400 pm.

29. A process of manufacturing the tube as claimed in claim 26.

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