Barrier films for laminates and method of producing the same

Abstract

Embodiments of the present disclosure are directed to high barrier films comprising a machine direction oriented film comprising HDPE, EVOH, between 0 and 75% of an alpha olefin polyethylene, by weight, between 0 and 50% of a polar polymer compatibilizer, by weight, and between 10 and 50% of a multi-component blend material, by weight. Methods of producing high barrier films and packages comprising high barrier films are also described.

Description

BARRIER FILMS FOR LAMINATES AND METHOD OF PRODUCING THE SAMETECHNICAL FIELD

[0001] The present disclosure is related to barrier films for laminates and methods of producing the same.BACKGROUND

[0002] Mono-polyethylene (Mono-PE) structures offer a recycling-ready alternative to traditional flexible packaging multilayer materials such as, for example, polyethylene terephthalate (PET) / polyethylene (PE) structures or oriented polyamide (OPA) / polyethylene (PE) structures, or other structures having a gas barrier layer such as metallized biaxially oriented polyethylene terephthalate (BOPET) or aluminum foil.

[0003] Significant progress has been made in the flexible packaging industry to develop mono-PE structures with improved heat-resistance, drop resistance, or gas barrier properties, for example. However, functionalities like easy opening remains a challenge in a large number of flexible packaging applications, not limited to mono- PE structures.

[0004] Easy opening of flexible packaging is a common embedded functionality requested by end consumers to obtain easy access to (a portion of) the content of the package without using alternative cutting techniques, e.g., scissors. Film formulation, laminate composition, and / or scoring processes are typically used to meet easy opening requirements.

[0005] The use of biaxially oriented polyethylene (BOPE), for example, may also facilitate easy tear. However, it has been found that biaxially oriented polyethylene (BOPE) provides limited benefits in practice due to the significant (and potentially detrimental) impact from the sealing film in the laminate, especially because the sealing film must be designed with low Seal Initiation Temperature (SIT) to provide sufficient heatsealing window on the packing lines in a mono-PE specification. The typical rubberynature of plastomers and / or PE terpolymers, used in such sealing films are generally detrimental to the easy tear functionality.

[0006] Without contesting the associated advantages of the state-of-the-art systems, there exists a need for high barrier films comprising mono-PE that have improved heat-resistance, drop resistance, gas barrier properties, and meet easy opening (e.g., tearing) requirements.SUMMARY

[0007] Embodiments of the present disclosure are directed to high barrier films having improved heat-resistance, drop resistance, and gas barrier properties, and meet easy opening (e.g., tearing) requirements.

[0008] The high barrier films according to one or more embodiments of the present disclosure advantageously facilitate easy tear in a laminate structure in the machine direction (MD) and in the transverse direction (which may also be referred to herein as "cross direction (CD)"). It has been unexpectedly and advantageously found that the high barrier films according to one or more embodiments of the present disclosure which include a machine direction oriented film also facilitate easy tear in the cross direction (CD).

[0009] Advantageously, the high barrier films according to one or more embodiments of the present disclosure do not require an extra process operation (e.g., a laser scoring process-which may also locally impact barrier performance) nor an extra (separate) layer addition (ultra-thin BOPP) for imparting the easy tear properties.

[0010] The high barrier films according to one or more embodiments of the present disclosure can advantageously be used as a 2-ply laminate structure for packaging, such as for food packaging including single serve wet condiment sachets or stick packs, as examples.

[0011] The high barrier films according to one or more embodiments of the present disclosure include a machine direction oriented film comprising HDPE, EVOH, between 0 and 75% of an alpha olefin polyethylene, by weight, between 0 and 50% of a polar polymer compatibilizer, by weight, and between 10 and 50% of a multicomponent blend material, by weight.

[0012] In some embodiments, the high barrier films comprise i) a first outer layer comprising HDPE, ii) a second outer layer comprising HDPE, iii) an EVOH layer comprising at least 90% EVOH, by weight, iv) a first tie layer located between the first outer layer and the EVOH layer, and v) a second tie layer located between the second outer layer and the EVOH layer, and b) a sealing film adhesively attached to the machine direction oriented film, wherein the first tie layer comprises between 0 and 75% of an alpha olefin polyethylene, by weight, between 0 and 50% of a polar polymer compatibilizer, by weight, and between 10 and 50% of a multi-component blend material, by weight, and wherein the multi-component blend material comprises HDPE and EVOH.

[0013] In some embodiments, the high barrier films advantageously provide a high oxygen barrier with reduced moisture sensitivity compared to, for example, nonoriented PE sealants with a buried EVOH layer, due to molecular orientation & higher degree of crystallinity induced in stretched conditions.

[0014] In some embodiments, the high barrier films advantageously provide a reduced amount of non-PE contaminant compared to, for example, ultra-thin BOPP laminates or non-oriented PE sealant with a buried EVOH layer providing similar oxygen barrier) in a PE recycling stream.

[0015] In some embodiments, the high barrier films advantageously provide improved heat-stability and heat resistance due to the orientation-induced crystallinity of the buried EVOH layer in the MDOPE film, as compared to conventional HDPE-rich MDOPE films.

[0016] In some embodiments, the high barrier films advantageously have improved caulkability, i.e., triple point closure of the laminate with EVOH integrated in the MDOPE film, as compared to laminates having a sealing film containing EVOH.

[0017] The inventors have found that while a 2-ply mono-PE laminate using a standard MDOPE film as an external layer, for example, shows (as expected) poor easy tear performance in the cross direction (CD), it has been surprisingly and advantageously found that a 2-ply mono-PE laminate using a coextruded MDOPE with a buried EVOH layer, combined with a very low SIT and, preferably low tear, sealant, in accordancewith one or more embodiments of the present disclosure, can generate an easy tear behavior in the cross direction (CD). In accordance with one or more embodiments, the MDOPE with a buried EVOH layer includes a multi-component blend material and a sealing film as described herein, preferably containing a PE and / or comonomers with a density greater than or equal to 0.926 g / cm3, can compete with in MD tearing and even outperform in CD tearing versus a 2-ply mono-PE laminate having an exterior BOPE layer in terms of easy tear from a sealed area in a final package configuration.

[0018] In some embodiments, the multi-component blend material is provided as a "virgin" material. As used herein, a "virgin" material refers to an unused raw material that has not been subjected to conversion along the value chain, other than for its production. One or more materials of the high barrier films as described herein may be provided as a "virgin" materials. In some embodiments, the multi-component blend material is obtained from a closed loop trim stream from a coextrusion process, and thus is not a virgin material. In some embodiments, the multi-component blend material further comprises the alpha olefin polyethylene and the polar polymer compatibilizer. In some embodiments, the multi-component blend material has a composition essentially equal to the composition of the machine direction oriented film.

[0019] In some embodiments, the EVOH layer comprises a thickness of at least 1.0 micron, preferably of at least 2.0 microns.

[0020] In some embodiments, the machine direction oriented film comprises a total thickness in a range of from 15 to 40 micron and the EVOH layer comprises a thickness of at least 2.5%, preferably at least 5%, more preferably at least 10%, of the total thickness of the machine direction oriented film. In some embodiments, the EVOH has an ethylene content in a range of from 25 to 38 mole % ethylene.

[0021] In some embodiments, the first tie layer comprises a first layer comprising a MAH grafted PEand a second layer including between 0 and 75% of the alpha olefin polyethylene, by weight, between 0 and 50% of the polar polymer compatibilizer, by weight, and between 10 and 50% of the multi-component blend material, by weight.

[0022] In some embodiments, the high barrier film has a seal initiation temperature (SIT) of less than 100°C when the sealing film is heat sealed to itself according to ASTM F2029-08 and ASTM F88. The sealing film can include any low SIT sealing material known to the skilled artisan. In some embodiments, the sealing film is a non-oriented film or a biaxially oriented film. In some embodiments, the sealing film comprises a low SIT polyethylene (PE).

[0023] In some embodiments, the sealing film comprises a polyethylene having a density less than or equal to 0.92 g / cm3. Examples of the ethylene copolymer include polyethylene plastomers, polyolefin plastomers, alpha-olefin copolymers, linear- alpha-olefin copolymers, the like, or combinations or blends thereof. Examples of alpha-olefin copolymers include, but are not limited to, ethylene vinyl acetate (EVA), ethylene methyl acrylate (EMA), ethylene acrylic acid (EAA), the like, or combinations thereof. Examples of linear-alpha-olefin copolymers include, but are not limited, to metallocene linear low density polyethylene (mLLDPE) and copolymers of 1 -butene, 1 -hexene, 1 -octene, the like, or combinations thereof.

[0024] In some embodiments, the high barrier film has a total composition including greater than 80% polyethylene, by weight.

[0025] In some embodiments, the alpha olefin polyethylene is a terpolymer.

[0026] In some embodiments, the polar polymer compatibilizer is present in the first tie layer in a range of between 10 and 20%, by weight.

[0027] In some embodiments, the multi-component blend material is present in the first tie layer in a range of between 20 and 50%, preferably 30 and 50%, or more preferably 40 and 50%, by weight.

[0028] In some embodiments, the second tie layer comprises between 0 and 75% of a second alpha olefin polyethylene, by weight, between 0 and 50% of a second polar polymer compatibilizer, by weight, and between 10 and 50% of the multi-component blend material, by weight. In some embodiments, the second tie layer comprises a first layer including between 0 and 75% of the alpha olefin polyethylene, by weight, between 0 and 50% of the polar polymer compatibilizer, by weight, and between 10and 50% of the multi-component blend material, by weight, and a second layer comprising a MAH grafted PE, by weight.

[0029] In some embodiments, the polar polymer compatibilizer is present in the second tie layer in a range of between 10 and 20%, by weight.

[0030] In some embodiments, the multi-component blend material is present in the second tie layer in a range of between 20 and 50%, preferably 30 and 50%, or more preferably 40 and 50%, by weight.

[0031] Additional embodiments are directed to a package comprising a high barrier film and a sealed area. In some embodiments, the high barrier films comprise i) a first outer layer comprising HDPE, ii) a second outer layer comprising HDPE, iii) an EVOH layer comprising at least 90% EVOH, by weight, iv) a first tie layer located between the first outer layer and the EVOH layer, and v) a second tie layer located between the second outer layer and the EVOH layer, and b) a sealing film adhesively attached to the machine direction oriented film, and the sealed area comprising a tear notch, wherein the first tie layer comprises between 0 and 75% of an alpha olefin polyethylene, by weight, between 0 and 50% of a polar polymer compatibilizer, by weight, and between 10 and 50% of a multi-component blend material, by weight, and wherein the multi-component blend material comprises HDPE and EVOH.

[0032] In some embodiments, the tear notch is positioned for tearing the high barrier film in the machine direction. In some embodiments, the tear notch is positioned for tearing the high barrier film in the transverse direction.

[0033] Further embodiments are directed to a method of producing a high barrier film including the steps of: a) coextruding i) a first outer layer comprising HDPE, ii) a second outer layer comprising HDPE, iii) an EVOH layer comprising at least 90% EVOH, by weight, iv) a first tie layer located between the first outer layer and the EVOH layer, and v) a second tie layer located between the second outer layer and the EVOH layer, wherein the first tie layer comprises between 0 and 75 % of an alpha olefin polyethylene, by weight, between 0 and 50% of a polar polymer compatibilizer, by weight, and between 10 and 50% of a multi-component blend material, by weight, and wherein the multi-component blend material is obtained from a closed loop trimstream from the coextrusion process, to produce a first film, b) stretching the first film in the machine direction at a stretch ratio in a range of from 5:1 to 7:1 to produce a machine direction oriented film, and c) adhering a sealing film to the machine direction oriented film.BRIEF DESCRIPTION OF THE DRAWINGS

[0034] The disclosure may be more completely understood in consideration of the following detailed description of various embodiments of the disclosure in connection with the accompanying Figures, in which:

[0035] Figure 1A illustrates a schematic cross-sectional view of a high barrier film including a machine direction oriented film according to one or more embodiments;

[0036] Figure 1 B and 1C illustrate schematic cross-sectional views of different embodiments of the machine direction oriented film of Figure 1A;

[0037] Figure 2 illustrates a process flow diagram of a method of producing a high barrier film according to one or more embodiments;

[0038] Figures 3A and 3B illustrate schematic cross-sectional views of packages having a high barrier film and a sealed area with a tear notch positioned for tearing in the transverse direction according to one or more embodiments; and

[0039] Figures 3C and 3D illustrate schematic cross-sectional views of packages having a high barrier film and a sealed area with a tear notch positioned for tearing in the machine direction according to one or more embodiments.

[0040] The Figures show some, but not all embodiments. The elements depicted in the Figures are illustrative and not necessarily to scale, and the same (or similar) reference numbers denote the same (or similar) features throughout the Figures.DETAILED DESCRIPTION

[0041] Provided herein are high barrier films having improved heat-resistance, drop resistance, and gas barrier properties, and meet easy opening (e.g., tearing) requirements.

[0042] The high barrier films according to one or more embodiments of the present disclosure advantageously facilitate easy tear in a laminate structure in the machinedirection (MD) and in the transverse direction (which may also be referred to herein as "cross direction (CD)"). It has been unexpectedly and advantageously found that the high barrier films according to one or more embodiments of the present disclosure which include a machine direction oriented film also facilitate easy tear in the cross direction (CD).

[0043] Advantageously, the high barrier films according to one or more embodiments of the present disclosure do not require an extra process operation (e.g., a laser scoring process - which may also locally impact barrier performance) nor an extra (separate) layer addition (ultra-thin BOPP) for imparting the easy tear properties.

[0044] The high barrier films according to one or more embodiments of the present disclosure may be used in any one of a variety of packaging configurations or forms (or packages) known to a person of ordinary skill in the packaging arts.

[0045] The high barrier films according to one or more embodiments of the present disclosure can advantageously be used as a 2-ply laminate structure for packaging, such as for food packaging including single serve wet condiment sachets or stick packs, as examples.

[0046] The high barrier films according to one or more embodiments of the present disclosure include a machine direction oriented film comprising HDPE, EVOH, between 0 and 75% of an alpha olefin polyethylene, by weight, between 0 and 50% of a polar polymer compatibilizer, by weight, and between 10 and 50% of a multicomponent blend material, by weight.

[0047] In some embodiments, the high barrier films comprise i) a first outer layer comprising HDPE, ii) a second outer layer comprising HDPE, iii) an EVOH layer comprising at least 90% EVOH, by weight, iv) a first tie layer located between the first outer layer and the EVOH layer, and v) a second tie layer located between the second outer layer and the EVOH layer, and b) a sealing film adhesively attached to the machine direction oriented film, wherein the first tie layer comprises between 0 and 75% of an alpha olefin polyethylene, by weight, between 0 and 50% of a polar polymer compatibilizer, by weight, and between 10 and 50% of a multi-componentblend material, by weight, and wherein the multi-component blend material comprises HDPE and EVOH.

[0048] In some embodiments, the high barrier films advantageously provide a high oxygen barrier with reduced moisture sensitivity compared to, for example, nonoriented PE sealants with a buried EVOH layer, due to molecular orientation & higher degree of crystallinity induced in stretched conditions.

[0049] In some embodiments, the high barrier films advantageously provide improved heat-stability and heat resistance due to the orientation-induced crystallinity of the buried EVOH layer in the MDOPE film, as compared to conventional HDPE-rich MDOPE films.

[0050] In some embodiments, the high barrier films advantageously have improved caulkability, i.e., triple point closure of the laminate with EVOH integrated in the MDOPE film, as compared to laminates having a sealing film containing EVOH.

[0051] The inventors have found that while a 2-ply mono-PE laminate using a standard MDOPE film as an external layer, for example, shows (as expected) poor easy tear performance in the cross direction (CD), it has been surprisingly found that a 2-ply mono-PE laminate using a coextruded MDOPE with a buried EVOH layer, combined with a very low SIT and, preferably low tear, sealant, in accordance with one or more embodiments of the present disclosure, can generate an easy tear behavior in the cross direction (CD). In accordance with one or more embodiments, the MDOPE with a buried EVOH layer includes a multi-component blend material and a sealing film as described herein, preferably containing a PE and / or comonomers with a density greater than or equal to 0.926 g / cm3, can compete with in MD tearing and even outperform in CD tearing versus a 2-ply mono-PE laminate having an exterior BOPE layer in terms of easy tear from a sealed area in a final package configuration.

[0052] In some embodiments, the multi-component blend material is provided as a "virgin" material. As used herein, a "virgin" material refers to an unused raw material that has not been subjected to conversion along the value chain, other than for its production. One or more materials of the high barrier films as described herein may be provided as a "virgin" materials. In some embodiments, the multi-component blend material isobtained from a closed loop trim stream from a coextrusion process. In some embodiments, the multi-component blend material further comprises the alpha olefin polyethylene and the polar polymer compatibilizer. In some embodiments, the multicomponent blend material has a composition essentially equal to the composition of the machine direction oriented film.

[0053] Definitions

[0054] The term "layer", as used herein, refers to a building block of films. A layer is a structure of a single material type or a homogeneous blend of materials. A layer may be a single polymer, a blend of materials within a single polymer type or a blend of various polymers, may contain metallic materials, and may have additives.

[0055] Layers may be continuous with the film or may be discontinuous or patterned. Both layers and films have a relatively insignificant thickness (z-direction) as compared to their respective length and width (x-y direction), and is therefore defined to have two major surfaces, opposite each other, defined by the x-y plane. The area of the two major surfaces are defined by the length and width of the layer.

[0056] An "exterior layer" or "outer layer" is a layer that is connected to another layer at only one of the major surfaces. In other words, one major surface of an exterior layer or outer layer is exposed. An "interior layer" or "inner layer" is a layer that is connected to another layer at both major surfaces. In other words, an interior layer or inner layer is between two other layers. A layer may have sub-layers.

[0057] The films described herein may include more than one layer or sub-layers. The combination of these materials can be described as, for example, a structure or a laminate.

[0058] As used herein, a “laminate” is a film that may be built from an unlimited number of films and / or layers, the films and / or layers being bonded together by any known process such as, but not limited to, coextrusion, coating or laminating, to form a composite article.

[0059] As used herein, the term "polyethylene" or “PE” refers to, unless indicated otherwise, ethylene homopolymers or copolymers. Such copolymers of ethylene include copolymers of ethylene with at least one alpha-olefin and copolymers ofethylene with other units or groups such as vinyl acetate, acid groups, acrylate groups, or otherwise. The term “polyethylene” or “PE” is used without regard to the presence or absence of substituent branch groups. Polyethylene includes, but is not limited to, medium density polyethylene, high density polyethylene, low density polyethylene, linear low-density polyethylene, ultra-low density polyethylene, ethylene alpha-olefin copolymer, ethylene vinyl acetate, ethylene acid copolymers, ethylene acrylate copolymers, neutralized ethylene copolymers such as ionomer, maleic anhydride grafted polyethylene and blends of such. Various polyethylene polymers may be recycled as reclaimed polyethylene or reclaimed polyolefin.

[0060] As used herein, the term "multi-component blend material" refers to a layer or a plurality of layers comprising a mixture of multiple different materials. The multicomponent blend material may be provided as a "virgin" material. As used herein, a "virgin" material refers to an unused raw material that has not been subjected to conversion along the value chain, other than for its production. The multi-component blend material may be obtained from a closed loop trim stream from a coextrusion process, such as, for example, a blown film coextrusion process.

[0061] As used herein, "MAH" refers to maleic anhydride having a formula of C2H2(CO)2O. MAH is typically used as a functional group grafted onto a polymer chain, such as polyethylene or polypropylene.

[0062] As used herein, one or more of the layers / films described in this disclosure may be oriented. Orientation may be the result of monoaxially oriented (machine direction or transverse direction), or biaxially oriented (machine direction and transverse direction) stretching of the film, increasing the machine direction and / or transverse direction dimension and subsequently decreasing the thickness of the material. Biaxial orientation may be imparted to the film simultaneously or successively. In some embodiments, the film stretched in either or both directions at a temperature just below the melt temperature of the polymers in the film. In this manner, the stretching causes the polymer chains to “orient”, changing the physical properties of the film. At the same time, the stretching thins the film. The resulting oriented filmsare thinner and can have significant changes in mechanical properties such as toughness, heat resistance, stiffness, tear strength and barrier.

[0063] Orientation is typically accomplished by a double- or triple-bubble process, by a tenter-frame process or an MDO process using heated rolls. A typical blown film process does impart some stretching of the film, but not enough to be considered oriented as described herein. An oriented film may be heat set (i.e. annealed) after orientation, such that it is relatively dimensionally stable under elevated temperature conditions that might be experienced during conversion of the retort film laminate (i.e. printing or laminating) or during the use of the laminate (i.e. heat sealing or retort sterilization).

[0064] As used herein, the terms “machine-direction oriented” and “MDO”, indicate that the film has been heated to a temperature lower than the melting point of the material and stretched at least 2X in the machine-direction. This is typically accomplished by an MDO process using heated rolls. A typical blown film process does impart some stretching of the film, but not enough to be considered oriented as described herein. An oriented film may also be heat set (i.e. annealed) after orientation, such that it is dimensionally stable under elevated temperature conditions that might be experienced during conversion of the film (i.e. printing or laminating) or during the use of the packaging film (i.e. heat sealing). A film may be produced using specific polymers and may be oriented using specific conditions which optimize the heat resistance of the film.

[0065] As used herein, the phrase “machine direction”, herein abbreviated “MD”, refers to a direction “along the length” of the film, i.e., in the direction of the film as the film is formed during extrusion and / or coating.

[0066] As used herein, the phrase “transverse direction”, herein abbreviated “TD”, refers to a direction across the film, perpendicular to the machine or longitudinal direction.

[0067] As used herein, “free shrink” is an unrestrained linear shrinkage that a film or layer undergoes due to exposure to elevated temperature. The shrink is irreversible and relatively rapid (i.e., evident within seconds or minutes). Shrinkage value is expressed as a percentage of the original dimension, (i.e., 100 x (pre-shrinkdimension - post-shrink dimension) / (pre-shrink dimension)). Free shrink can be measured using any suitable method that is capable of measuring shrinkage value differences of at least 0.2 %. Free shrink can be measured using ASTM D2732-03. As described in ASTM D2732-03, the entire disclosure of which is incorporated herein by reference, free shrink is a value obtained by measuring unrestrained (i.e., free) shrink of a 10 cm square sample immersed in water at 90 °C for five seconds.

[0068] As used herein, the term “terpolymer” refers to a copolymer produced from three different monomers. The term “polyethylene terpolymer” refers to a polyethylene molecular chain modified with two additional co-monomers in the polymerization process.

[0069] As used herein, the term “ethylene vinyl alcohol copolymer”, “EVOH copolymer” or “EVOH” refers to copolymers comprised of repeating units of ethylene and vinyl alcohol. Ethylene vinyl alcohol copolymers may be represented by the general formula: [(CH2-CH2)n-(CH2-CH(OH))]n. Ethylene vinyl alcohol copolymers may include saponified or hydrolyzed ethylene vinyl acetate copolymers. EVOH refers to a vinyl alcohol copolymer having an ethylene co-monomer and prepared by, for example, hydrolysis of vinyl acetate copolymers or by chemical reactions with vinyl alcohol. Ethylene vinyl alcohol copolymers may comprise from 28 mole percent (or less) to 48 mole percent (or greater ethylene). In some embodiments, the EVOH has an ethylene content in a range of from 25 to 38 mole % ethylene.

[0070] As used herein, the “total composition” of the high barrier film refers to all materials encompassed therein. The total composition of the high barrier film may include greater than or equal to 80 %, greater than or equal to 85 %, greater than or equal to 90 %, or greater than or equal to 95 % polyethylene, by weight.

[0071] The high barrier films described herein include a machine direction oriented film attached to a sealing film. In some embodiments, the machine direction oriented film is attached in its entirety to the sealing film. As used herein, the term "in its entirety" means that, for example, less than or equal to 1 % or less than or equal to 0.5 % of the machine direction oriented film is not attached to the sealing film.

[0072] As used herein, the term “adjacent” means that the items, such as layers of a film, are near each other, with or without intervening material, such as an adhesive layer. As used herein, the term “directly adjacent,” "directly connected" or “in direct contact with” means that the items are in contact with each other, without intervening material.

[0073] The high barrier films described herein include a machine direction oriented film attached to a sealing film by an adhesive layer. As used herein, the term “adhesive layer” refers to a layer which has a primary function of bonding two adjacent layers together. The adhesive layer may comprise any suitable composition known to the skilled artisan. The adhesive layers may be positioned between two layers of a multilayer film to maintain the two layers in position relative to each other and prevent undesirable delamination. Unless otherwise indicated, an adhesive layer can have any suitable composition that provides a desired level of adhesion with the one or more surfaces in contact with the adhesive layer material. The adhesive layer may be any conventional laminating material including, but not limited to, one- or two- component adhesive systems (i.e., adhesive lamination) or polymeric adhesives applied by extrusion (i.e., extrusion lamination process). The adhesive layer may be deposited by any suitable method known to the skilled artisan.

[0074] As used herein, the term “sealing layer” or "sealing film" refers to a layer of a film, sheet, etc., involved in the sealing of the film, sheet, etc., to itself and / or to another layer of the same or another film, sheet, etc. As used herein, the terms “heat seal”, “heat sealed”, “heat sealing”, “heat sealable”, and the like, refer to both a film layer which is heat sealable to itself or other thermoplastic film layer, and the formation of a fusion bond between two polymer surfaces by conventional indirect heating means. It will be appreciated that conventional indirect heating generates sufficient heat on at least one film contact surface for conduction to the contiguous film contact surface such that the formation of a bond interface therebetween is achieved without loss of the film integrity.

[0075] As used herein, the term “seal initiation temperature (SIT)” refers to a sealing temperature at which a seal strength of approximately 4 N / 15 mm is achieved. Seal initiation temperature (SIT) and seal strength may be evaluated using ASTM F2029-8 (Standard Practices for Making Heatseals for Determination of Heatsealability of Flexible Webs as Measured by Seal Strength" and ASTM F88, A Standard Test Method for Seal Strength of Flexible Barrier Materials, the entireties of which are incorporated herein by reference.

[0076] In general use, a "compatibilizer" is any material that, when added to a multiphase polymer blend, reduces the tendency for the blend’s dispersed phase to coalesce. The average dispersed phase droplet size in a blend that comprises a compatibilizer will be less than the droplet size in a blend that does not comprise a compatibilizer. The primary function of the compatibilizer as used in the currently described system is to bond non-compatible polymer layers, such as, for example "polar" materials (e.g., EVOH) and "non-polar" materials (e.g., PE) and homogenize the blend in the tie layers during coextrusion. As used herein, a “polar polymer compatibilizer” may be an ionomer, a MAH grafted PE, an EAA (ethylene acrylic acid copolymer) or an EMA (ethylene methyl acrylate copolymer).

[0077] As used herein, the terms "coextrusion" and "coextruded" refer to the process by which the resin outputs of two or more extruders are brought smoothly together in a feed block to form a multilayer stream that is fed to a die to produce a layered extrudate. Coextrusion can be employed in cast and blown film coextrusion methods.

[0078] As used herein, the phrase "blown film coextrusion" refers to a coextrusion process which includes an apparatus having a multi-manifold circular die head through which the film layers are forced and formed into a cylindrical multilayer film bubble. The bubble may be quenched, e.g., via cooled water bath, solid surface and / or air, and then ultimately collapsed and formed into a multilayer film. Films produced using blown film processes are known in the art and have been described, for example, in the Encyclopedia of Chemical Technology, Kirk-Othmer, 3rd ed., John Wiley & Sons, New York, 1981 , Vol. 16, pp. 416-417 and Vol. 18, pp. 191 -192, the disclosures of which are incorporated herein by reference. Typically, the resins and any additives forming one or more film layers are introduced to an extruder where the resins are melt-plastified by heating and then transferred to an extrusion (or coextrusion) die for formation into the bubble or tube. If desired, resins may be blended or mechanicallymixed by well-known methods using commercially available equipment including tumblers, mixers or blenders, and well-known additives such as processing aids, slip agents, anti-blocking agents, pigments and mixtures thereof may be incorporated into the resin by blending prior to extrusion. The extruder and die temperatures will generally depend upon the particular resin(s) containing mixtures being processed, and suitable temperature ranges for commercially available resins are generally known in the art or are provided in technical bulletins made available by resin manufacturers. Processing temperatures may vary depending upon other processing parameters chosen. After formation, the bubble is cooled, collapsed, and wound around a roller for further processing.

[0079] As used herein, the term "tearing resistance" generally refers to measurement of how well a material can withstand the effects of tearing.

[0080] In some embodiments, the tearing resistance is measured using a quantitative method and / or a qualitative process.

[0081] In some embodiments, the tearing resistance is measured using ASTM 1922, a Standard Test Method for Propagation Tear Resistance of Plastic Film and Thin Sheeting by Pendulum Method (Elmendorf Tear), the entirety of which is incorporated herein by reference.

[0082] In some embodiments, the tearing resistance is measured using ASTM D1938, a Standard Test Method for Tear- Propagation Resistance (Trouser Tear) of Plastic Film and Thin Sheeting by a Single-Tear Method, the entirety of which is incorporated herein by reference.

[0083] In some embodiments, the tearing resistance is measured using a hand qualitative tearing process.

[0084] As used herein, the term "laser scoring" generally refers to a process in which a laser beam vaporizes portions of a layer / f ilm to create an easy-open feature, such as a "tear line."

[0085] Figure 1A illustrates a schematic cross-sectional view of a high barrier film 10 including a machine direction oriented film 20 according to one or more embodiments. Figure 1 B and 1C illustrate schematic cross-sectional views ofdifferent embodiments of the machine direction oriented film 20 of Figure 1A. The machine direction oriented film 20 illustrated in Figures 1A, 1 B, and 1C may be produced by method 100 illustrated in Figure 2.

[0086] In the illustrated embodiment of Figure 1 A, the high barrier film 10 comprises a) a machine direction oriented film 20 comprising: i) a first outer layer 11 comprising HDPE, ii) a second outer layer 15 comprising HDPE, iii) an EVOH layer 13 comprising at least 90% EVOH, by weight, iv) a first tie layer 12 located between the first outer layer 11 and the EVOH layer 13, and v) a second tie layer 14 located between the second outer layer 15 and the EVOH layer 13, and b) a sealing film 17 adhesively attached to the machine direction oriented film 20. In one or more embodiments, the sealing film 17 is adhesively attached to the machine direction oriented film 20 by an adhesive layer 16 as shown in Figure 1A.

[0087] In one or more embodiments, the high barrier film 10 comprises the machine direction oriented film 20 comprising: the first outer layer 11 , the second outer layer 15, the EVOH layer 13, the first tie layer 12, the second tie layer 14, and the sealing film 17, and the adhesive layer 16. In one or more embodiments, the high barrier film 10 consists essentially of the machine direction oriented film 20 comprising: the first outer layer 11 , the second outer layer 15, the EVOH layer 13, the first tie layer 12, the second tie layer 14, and the sealing film 17, and the adhesive layer 16. In one or more embodiments, the high barrier film 10 consists of the machine direction oriented film 20 comprising: the first outer layer 11 , the second outer layer 15, the EVOH layer 13, the first tie layer 12, the second tie layer 14, and the sealing film 17, and the adhesive layer 16.

[0088] In the illustrated embodiments of Figures 1A and 1 B, each of the first tie layer 12 and the second tie layer 14 are independently shown as single layers.

[0089] In the illustrated embodiment of Figure 1C, each of the first tie layer 12 and the second tie layer 14 independently comprise more than one layer or sub-layers.

[0090] In the illustrated embodiment of Figure 1C, the first tie layer 12 comprises a first layer 12' and a second layer 12". In some embodiments, the first layer 12' and / or the second layer 12" comprises a polar polymer compatibilizer. In some embodiments,the first layer 12' comprises between 0 and 75% of the alpha olefin polyethylene, by weight, between 0 and 50% of the polar polymer compatibilizer, by weight, and between 10 and 50% of the multi-component blend material, by weight.

[0091] In the illustrated embodiment of Figure 1C, the second tie layer 14 comprises a first layer 14' and a second layer 14". In some embodiments, the second layer 14" comprises between 0 and 75% of the alpha olefin polyethylene, by weight, between 0 and 50% of the polar polymer compatibilizer, by weight, and between 10 and 50% of the multi-component blend material, by weight. In some embodiments, the second layer 14" and / or the first layer 14' comprises a polar polymer compatibilizer.

[0092] In one or more embodiments, the first tie layer 12 comprises between 0 and 75% of an alpha olefin polyethylene, by weight, between 0 and 50% of a polar polymer compatibilizer, by weight, and between 10 and 50% of a multi-component blend material, by weight. In one or more embodiments, the multi-component blend material comprises HDPE and EVOH. In one or more embodiments, the multi-component blend material further comprises the alpha olefin polyethylene and the polar polymer compatibilizer. In one or more embodiments, the multi-component blend material comprises HDPE, EVOH, the alpha olefin polyethylene, and the polar polymer compatibilizer. In one or more embodiments, the multi-component blend material consists essentially of HDPE, EVOH, the alpha olefin polyethylene, and the polar polymer compatibilizer. In one or more embodiments, the multi-component blend material consists of HDPE, EVOH, the alpha olefin polyethylene, and the polar polymer compatibilizer. In one or more embodiments, the multi-component blend material has a composition essentially equal to the composition of the machine direction oriented film 20.

[0093] In one or more embodiments, the multi-component blend material is provided as a "virgin" material. In one or more embodiments, the multi-component blend material is obtained from a closed loop trim stream from a coextrusion process.

[0094] In some embodiments, the sealing film 17 comprises a non-oriented film. In some embodiments, the sealing film 17 comprises a biaxially oriented film.

[0095] In some embodiments, the high barrier film 10 has a seal initiation temperature of less than 100°C when the sealing film 17 is heat sealed to itself according to ASTM F2029-08 and ASTM F88.

[0096] Each of the layers / films of the high barrier film 10 may have any suitable thickness.

[0097] In some embodiments, the high barrier film 10 has a total thickness in a range of from 15 to 40 micron and the EVOH layer comprises a thickness of at least 2.5%, preferably at least 5%, more preferably at least 10%, of the total thickness of the machine direction oriented film 20.

[0098] In some embodiments, the EVOH layer 13 comprises a thickness of at least 1.0 micron. In some embodiments, the EVOH layer 13 comprises a thickness of at least 2.0 microns.

[0099] Figure 2 illustrates a process flow diagram of the method 100 of producing a high barrier film, e.g., the high barrier film 10 according to one or more embodiments. The method 100 includes the steps of: a) coextruding i) a first outer layer comprising HDPE, ii) a second outer layer comprising HDPE, iii) an EVOH layer comprising at least 90% EVOH, by weight, iv) a first tie layer located between the first outer layer and the EVOH layer, and v) a second tie layer located between the second outer layer and the EVOH layer, wherein the first tie layer comprises between 0 and 75 % of an alpha olefin polyethylene, by weight, between 0 and 50% of a polar polymer compatibilizer, by weight, and between 10 and 50% of a multi-component blend material, by weight, and wherein the multi-component blend material is obtained from a closed loop trim stream from the coextrusion process, to produce a first film (operation 110), b) stretching the first film in the machine direction at a stretch ratio in a range of from 5:1 to 7:1 to produce a machine direction oriented film (operation 120), and c) adhering a sealing film to the machine direction oriented film (operation 130).

[0100] In some embodiments, the method 100 comprises operation 110, operation 120, and operation 130. In some embodiments, the method 100 consists essentially of operation 110, operation 120, and operation 130. In some embodiments, the method 100 consists of operation 110, operation 120, and operation 130.

[0101] The high barrier films according to one or more embodiments of the present disclosure advantageously facilitate easy tear in a laminate structure in the machine direction (MD) and in the transverse direction, e.g., the cross direction (CD). It has been unexpectedly and advantageously found that the high barrier films according to one or more embodiments of the present disclosure which include a machine direction oriented film also facilitate easy tear in the cross direction (CD).

[0102] Advantageously, the high barrier films according to one or more embodiments of the present disclosure do not require an extra process operation (e.g., a laser scoring process-which may also locally impact barrier performance) nor an extra (separate) layer addition (ultra-thin BOPP) for imparting the easy tear properties.

[0103] The high barrier films according to one or more embodiments of the present disclosure may be used in any one of a variety of packaging configurations or forms (or packages) known to a person of ordinary skill in the packaging arts.

[0104] The term “package” is used herein to describe an article that may house an object (i.e., a product), the article formed by bonding one or more high barrier films or other packaging components to itself or each other around a periphery, thus forming a package interior space. A “packaged product” refers to the one or more packaging components forming a hermetically sealed package and the product therein. As used herein, "hermeticity" refers to a seal or sealed package that is completely closed and essentially airtight. Hermetically sealed packages generally have a need for storage and package integrity over a period of time that is greater than a few days. Package integrity includes a consistent appearance, maintenance of barrier properties, maintenance of lamination bonds, and maintenance of seals.

[0105] The product may be any type of food, beverage, pharmaceutical or other medical aid, nutraceutical, consumer good or industrial good. The product may be fluid in nature. Examples of products include, but are not limited to, condiments such as ketchup, mustard, mayonnaise, or relish, pudding, yogurt, cheese sauce, nut butter, jam / jelly, dairy or non-dairy creamer, guacamole, applesauce, pureed baby food, baby formula, nutritional drinks / shakes, beverage or supplement concentrates,cough syrup, fish oil, lotion, salve / ointment, personal care items, soap / detergent, or solvent.

[0106] As mentioned, the product may be fluid in nature, or may have a fluid component. The product may be water-based (i.e., has water as a medium or main ingredient) or oil-based (i.e., has oil as a medium or main ingredient).

[0107] The packaged products disclosed herein include a package formed from at least one high barrier film and optionally other components. In some embodiments of the packaged product, the entire package is formed from a single high barrier film that has been folded over and sealed to itself (i.e., a flow wrap or stick pack configuration).

[0108] In some embodiments, the high barrier film is used in a lap-seal package configuration. In some embodiments, the high barrier film is sealed to another high barrier film (i.e., a sachet configuration). In some embodiments of the packaged product, the high barrier film is a lidding component which is sealed to a formed container such as a cup or tray.

[0109] Figures 3A and 3B illustrate schematic cross-sectional views of a package 200 having a high barrier film, e.g., the high barrier film 10 and a sealed area 17' with a tear notch 210 positioned for tearing in the transverse direction, e.g., the cross direction (CD) in accordance with one or more embodiments of the present disclosure. In the illustrated embodiments of Figures 3A and 3B, the package 200 includes the machine direction oriented film 20 of the high barrier film 10 adhesively attached to the sealed area 17’. In one or more embodiments, the sealed area 17’ comprises the sealing film 17, sealed to itself.

[0110] Figures 3C and 3D illustrate schematic cross-sectional views of a package 200 having a high barrier film, e.g., the high barrier film 10 and a sealed area 17' with a tear notch 210 positioned for tearing in the machine direction (MD) in accordance with one or more embodiments of the present disclosure. In the illustrated embodiments of Figures 3C and 3D, the package 200 includes the machine direction oriented film 20 of the high barrier film 10 adhesively attached to the sealed area 17’.In one or more embodiments, the sealed area 17’ comprises the sealing film 17, sealed to itself.

[0111] In the illustrated embodiments of Figures 3A, 3B, 3C, and 3D, the package 200 includes a single tear notch 210. It will be appreciated that the package 200 can include any suitable number of tear notches. In some embodiments, the package 200 includes a plurality of tear notches 210. In one or more embodiments, the package 200 includes two tear notches 210. In one or more embodiments where the package 200 includes two tear notches 210, one or both of the tear notches 210 is positioned for tearing in the transverse direction, e.g., the cross direction (CD). In one or more embodiments where the package 200 includes two tear notches 210, one or both of the tear notches 210 is positioned for tearing in the machine direction (MD).

[0112] Although the disclosure herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present disclosure. It will be apparent to those skilled in the art that various modifications and variations can be made to the barrier films and the methods of producing the same of the present disclosure without departing from the spirit and scope of the disclosure. Thus, it is intended that the present disclosure include modifications and variations that are within the scope of the appended claims and their equivalents.

[0113] The disclosure is now described with reference to the following examples.EXAMPLES

[0114] Comparative Examples 1 and 2 are directed to a machine direction oriented film that has been tested and is described herein in comparison to the Inventive Examples.

[0115] The machine direction oriented film of Comparative Example 1 was produced by blown film coextrusion and has a stretch ratio of about 5:1 . The machine direction oriented film of Comparative Example 1 comprises a first outer layer, a second outer layer, an EVOH layer, a first tie layer located between the first outer layer and the EVOH layer, and a second tie layer located between the second outerlayer and the EVOH layer. Each of the first outer layer and the second outer layer independently has a composition of 99% HDPE, by weight, and 1 % additive (i.e., slip, antiblock or processing aid), by weight. Each of the first outer layer and the second outer layer independently has a thickness of 4 microns.

[0116] The first tie layer comprises a first layer having 70 % of an alpha olefin polyethylene, by weight, and 30 % HDPE, by weight, and a second layer having a 100 % MAH grafted PE, by weight. The first layer of the first tie layer has a thickness of 4 microns and the second layer of the first tie layer has a thickness of 3 microns.

[0117] The second tie layer comprises a first layer having a 100% MAH grafted PE, by weight, and a second layer having 70 % of an alpha olefin polyethylene, by weight, and 30 % HDPE, by weight. The first layer of the second tie layer has a thickness of 3 microns and the second layer of the second tie layer has a thickness of 4 microns.

[0118] The EVOH layer comprises 100 % EVOH, by weight. The EVOH layer has a thickness of 2.5 microns.

[0119] The machine direction oriented film of Comparative Example 2 was produced by blown film coextrusion and has a stretch ratio of about 5:1 . The machine direction oriented film of Comparative Example 2 comprises a first outer layer, a second outer layer, an EVOH layer, a first tie layer located between the first outer layer and the EVOH layer, and a second tie layer located between the second outer layer and the EVOH layer. Each of the first outer layer and the second outer layer independently has a composition of 99% HDPE, by weight, and 1 % additive (i.e., slip, antiblock or processing aid), by weight. Each of the first outer layer and the second outer layer independently has a thickness of 4 microns.

[0120] The first tie layer comprises a first layer having 70 % of an alpha olefin polyethylene, by weight, and 30 % HDPE, by weight, and a second layer having a 100 % MAH grafted PE, by weight. The first layer of the first tie layer has a thickness of 4 microns and the second layer of the first tie layer has a thickness of 3 microns.

[0121] The second tie layer comprises a first layer having a 100% MAH grafted PE, by weight, and a second layer having 70 % of an alpha olefin polyethylene, byweight, and 30 % HDPE, by weight. The first layer of the second tie layer has a thickness of 3 microns and the second layer of the second tie layer has a thickness of 4 microns.

[0122] The EVOH layer comprises 100 % EVOH, by weight. The EVOH layer has a thickness of 3.5 microns.

[0123] The machine direction oriented film of Inventive Example 1 was produced by blown film coextrusion and has a stretch ratio of about 5:1 . The machine direction oriented film of Inventive Example 1 comprises a first outer layer, a second outer layer, an EVOH layer, a first tie layer located between the first outer layer and the EVOH layer, and a second tie layer located between the second outer layer and the EVOH layer. Each of the first outer layer and the second outer layer independently has a composition of 99% HDPE, by weight, and 1 % additive (i.e., slip, antiblock or processing aid), by weight. Each of the first outer layer and the second outer layer independently has a thickness of 4 microns.

[0124] The first tie layer comprises a first layer having 70 % of an alpha olefin polyethylene, by weight, 20 % of a multi-component blend material, by weight, and 10 % MAH grafted PE, by weight, and a second layer having 100 % of MAH grafted PE, by weight. The first layer of the first tie layer has a thickness of 4 microns and the second layer of the first tie layer has a thickness of 3 microns.

[0125] The second tie layer comprises a first layer having 100% MAH grafted PE, by weight, and a second layer having 70 % of an alpha olefin polyethylene, by weight, 20 % multi-component blend material, by weight, and 10 % MAH grafted PE, by weight. The first layer of the second tie layer has a thickness of 3 microns and the second layer of the second tie layer has a thickness of 4 microns.

[0126] In some experiments, the multi-component blend material comprised HDPE and EVOH. In some experiments, the multi-component blend material comprised HDPE, EVOH, the alpha olefin polyethylene, and the polar polymer compatibilizer. In some experiments, the multi-component blend material comprised a composition essentially equal to the composition of the machine direction oriented film, e.g., the composition of the first outer layer, the second outer layer, the EVOH layer, the firsttie layer located between the first outer layer and the EVOH layer, and the second tie layer located between the second outer layer and the EVOH layer.

[0127] In some experiments, the multi-component blend material was provided as a "virgin" material. In some experiments, the multi-component blend material was obtained from a closed loop trim stream from a coextrusion process, e.g., the blown film coextrusion process used to produce the machine direction oriented film of Inventive Example 1 .

[0128] The EVOH layer comprises 100 % EVOH, by weight. The EVOH layer has a thickness of 2.5 microns.

[0129] The machine direction oriented film of Inventive Example 2 was produced by blown film coextrusion and has a stretch ratio of in a range of from about 5:1 to about 5.5:1 . The machine direction oriented film of Inventive Example 2 comprises a first outer layer, a second outer layer, an EVOH layer, a first tie layer located between the first outer layer and the EVOH layer, and a second tie layer located between the second outer layer and the EVOH layer.

[0130] Each of the first outer layer and the second outer layer independently has a composition of 99% HDPE, by weight, and 1 % additive (i.e., slip, antiblock or processing aid), by weight. Each of the first outer layer and the second outer layer independently has a thickness of 4 microns.

[0131] The first tie layer comprises a first layer having 50 % of an alpha olefin polyethylene, by weight, 40 % multi-component blend material, by weight, and 10 % MAH grafted PE, by weight, and a second layer having 100 % MAH grafted PE, by weight. The first layer of the first tie layer has a thickness of 4 microns and the second layer of the first tie layer has a thickness of 3 microns.

[0132] The second tie layer comprises a first layer having 100% MAH grafted PE, by weight, and a second layer having 50 % of an alpha olefin polyethylene, by weight, 40 % multi-component blend material, by weight, and 10 % MAH grafted PE, by weight. The first layer of the second tie layer has a thickness of 3 microns and the second layer of the second tie layer has a thickness of 4 microns.

[0133] The EVOH layer comprises 100 % EVOH, by weight. The EVOH layer has a thickness of 2.5 microns.

[0134] Inventive Examples 3-6 are prophetic examples based on machine direction oriented films according to one or more embodiments of the present disclosure.

[0135] The prophetic machine direction oriented film of Inventive Example 3 is produced by blown film coextrusion. The machine direction oriented film of Inventive Example 3 comprises a first outer layer, a second outer layer, an EVOH layer, a first tie layer located between the first outer layer and the EVOH layer, and a second tie layer located between the second outer layer and the EVOH layer.

[0136] Each of the first outer layer and the second outer layer independently has a composition of 99% HDPE, by weight, and 1 % additive (i.e., slip, antiblock or processing aid), by weight. Each of the first outer layer and the second outer layer independently has a thickness of 4 microns.

[0137] The first tie layer comprises a first layer having 60 % of an alpha olefin polyethylene, by weight, 30 % multi-component blend material, by weight, and 10 % of a polar polymer compatibilizer, by weight, and a second layer having 100 % of a polar polymer compatibilizer, by weight. The first layer of the first tie layer has a thickness of 4 microns and the second layer of the first tie layer has a thickness of 3 microns.

[0138] The second tie layer comprises a first layer having 100% of a polar polymer compatibilizer, by weight, and a second layer having 60 % of an alpha olefin polyethylene, by weight, 30% multi-component blend material, by weight, and 10 % of a polar polymer compatibilizer, by weight. The first layer of the second tie layer has a thickness of 3 microns and the second layer of the second tie layer has a thickness of 4 microns.

[0139] The multi-component blend material can include HDPE and EVOH. The multi-component blend material can include HDPE, EVOH, the alpha olefin polyethylene, and the polar polymer compatibilizer. The multi-component blend material can include a composition essentially equal to the composition of themachine direction oriented film, e.g., the composition of the first outer layer, the second outer layer, the EVOH layer, the first tie layer located between the first outer layer and the EVOH layer, and the second tie layer located between the second outer layer and the EVOH layer.

[0140] The multi-component blend material can be provided as a "virgin" material. The multi-component blend material can be obtained from a closed loop trim stream from a coextrusion process.

[0141] The polar polymer compatibilizer can include, but is not limited to, an ionomer, a MAH grafted PE, EAA, or EMA.

[0142] The EVOH layer comprises 100 % EVOH, by weight. The EVOH layer has a thickness of 2.5 microns.

[0143] The prophetic machine direction oriented film of Inventive Example 4 is produced by blown film coextrusion. The machine direction oriented film of Inventive Example 4 comprises a first outer layer, a second outer layer, an EVOH layer, a first tie layer located between the first outer layer and the EVOH layer, and a second tie layer located between the second outer layer and the EVOH layer.

[0144] Each of the first outer layer and the second outer layer independently has a composition of 99% HDPE, by weight, and 1 % additive (i.e., slip, antiblock or processing aid), by weight. Each of the first outer layer and the second outer layer independently has a thickness of 4 microns.

[0145] The first tie layer comprises a first layer having 50 % of an alpha olefin polyethylene, by weight, 40% of a multi-component blend material, by weight, and 10 % of a polar polymer compatibilizer, by weight, and a second layer having 100 % of a polar polymer compatibilizer, by weight. The polar polymer compatibilizer can include, but is not limited to, an ionomer, a MAH grafted PE, EAA, or EMA. The first layer of the first tie layer has a thickness of 4 microns and the second layer of the first tie layer has a thickness of 3 microns.

[0146] The second tie layer comprises a first layer having 100% of a polar polymer compatibilizer, by weight, and a second layer having 50 % of an alpha olefin polyethylene, by weight, 40% multi-component blend material, by weight, and 10 %of a polar polymer compatibilizer, by weight. The first layer of the second tie layer has a thickness of 3 microns and the second layer of the second tie layer has a thickness of 4 microns.

[0147] The multi-component blend material can include HDPE and EVOH. The multi-component blend material can include HDPE, EVOH, the alpha olefin polyethylene, and the polar polymer compatibilizer. The multi-component blend material can include a composition essentially equal to the composition of the machine direction oriented film, e.g., the composition of the first outer layer, the second outer layer, the EVOH layer, the first tie layer located between the first outer layer and the EVOH layer, and the second tie layer located between the second outer layer and the EVOH layer.

[0148] The multi-component blend material can be provided as a "virgin" material. The multi-component blend material can be obtained from a closed loop trim stream from a coextrusion process.

[0149] The polar polymer compatibilizer can include, but is not limited to, an ionomer, a MAH grafted PE, EAA, or EMA.

[0150] The EVOH layer comprises 100 % EVOH, by weight. The EVOH layer has a thickness of 1 .2 microns.

[0151] The prophetic machine direction oriented film of Inventive Example 5 is produced by blown film coextrusion. The machine direction oriented film of Inventive Example 5 comprises a first outer layer, a second outer layer, an EVOH layer, a first tie layer located between the first outer layer and the EVOH layer, and a second tie layer located between the second outer layer and the EVOH layer.

[0152] Each of the first outer layer and the second outer layer independently has a composition of 99% HDPE, by weight, and 1 % additive (i.e., slip, antiblock or processing aid), by weight. Each of the first outer layer and the second outer layer independently has a thickness of 4 microns.

[0153] The first tie layer comprises a first layer having 30 % of an alpha olefin polyethylene, by weight, 50% multi-component blend material, by weight, and 20 % of a polar polymer compatibilizer, by weight, and a second layer having 100 % of apolar polymer compatibilizer, by weight. The first layer of the first tie layer has a thickness of 4 microns and the second layer of the first tie layer has a thickness of 3 microns.

[0154] The second tie layer comprises a first layer having 100% of a polar polymer compatibilizer, by weight, and a second layer having 30 % of an alpha olefin polyethylene, by weight, 50% multi-component blend material, by weight, and 20 % of a polar polymer compatibilizer, by weight. The first layer of the second tie layer has a thickness of 3 microns and the second layer of the second tie layer has a thickness of 4 microns.

[0155] The multi-component blend material can include HDPE and EVOH. The multi-component blend material can include HDPE, EVOH, the alpha olefin polyethylene, and the polar polymer compatibilizer. The multi-component blend material can include a composition essentially equal to the composition of the machine direction oriented film, e.g., the composition of the first outer layer, the second outer layer, the EVOH layer, the first tie layer located between the first outer layer and the EVOH layer, and the second tie layer located between the second outer layer and the EVOH layer.

[0156] The multi-component blend material can be provided as a "virgin" material. The multi-component blend material can be obtained from a closed loop trim stream from a coextrusion process.

[0157] The polar polymer compatibilizer can include, but is not limited to, an ionomer, a MAH grafted PE, EAA, or EMA.

[0158] The EVOH layer comprises 100 % EVOH, by weight. The EVOH layer has a thickness of 2.5 microns.

[0159] The prophetic machine direction oriented film of Inventive Example 6 is produced by blown film coextrusion. The machine direction oriented film of Inventive Example 6 comprises a first outer layer, a second outer layer, an EVOH layer, a first tie layer located between the first outer layer and the EVOH layer, and a second tie layer located between the second outer layer and the EVOH layer.

[0160] Each of the first outer layer and the second outer layer independently has a composition of 99% HDPE, by weight, and 1 % additive (i.e., slip, antiblock or processing aid), by weight. Each of the first outer layer and the second outer layer independently has a thickness of 4 microns.

[0161] The first tie layer comprises a first layer having 45 % of an alpha olefin polyethylene, by weight, 50 % multi-component blend material, by weight, and 5 % of a polar polymer compatibilizer, by weight, and a second layer having 100 % of a polar polymer compatibilizer, by weight. The first layer of the first tie layer has a thickness of 4 microns and the second layer of the first tie layer has a thickness of 3 microns.

[0162] The second tie layer comprises a first layer having 100% of a polar polymer compatibilizer, by weight, and a second layer having 45 % of an alpha olefin polyethylene, by weight, 50 % multi-component blend material, by weight, and 5 % of a polar polymer compatibilizer, by weight. The first layer of the second tie layer has a thickness of 3 microns and the second layer of the second tie layer has a thickness of 4 microns.

[0163] The multi-component blend material can include HDPE and EVOH. The multi-component blend material can include HDPE, EVOH, the alpha olefin polyethylene, and the polar polymer compatibilizer. The multi-component blend material can include a composition essentially equal to the composition of the machine direction oriented film, e.g., the composition of the first outer layer, the second outer layer, the EVOH layer, the first tie layer located between the first outer layer and the EVOH layer, and the second tie layer located between the second outer layer and the EVOH layer.

[0164] The multi-component blend material can be provided as a "virgin" material. The multi-component blend material can be obtained from a closed loop trim stream from a coextrusion process.

[0165] The polar polymer compatibilizer can include, but is not limited to, an ionomer, a MAH grafted PE, EAA, or EMA.

[0166] The EVOH layer comprises 100 % EVOH, by weight. The EVOH layer has a thickness of 2.5 microns.

[0167] Embodiments of the present disclosure advantageously provide high barrier films having improved tearing resistance. In Table 1 , tearing resistance in Machine Direction (MD) and Cross Direction (CD) of varying film structures is shown.

[0168] As a general matter, the tearing resistances values measured using ASTM 1922 (Elmendorf Tear), and can be evaluated as optimal, increased tearing force, or substantially impossible to tear. Without intending to be bound by any particular theory, a tearing resistance of less than 800 mN in each direction, e.g., Machine Direction (MD) and Cross Direction (CD) is generally considered to provide an optimal tear force for easy tearing. A tearing resistance in a range of from 800 to 1200 mN in each direction is generally considered to require increased tearing force as compared to optimal tear force. A tearing resistance of greater than 1200 mN in each direction is generally considered to be substantially impossible to tear, relative to the optimal tear force and the increased tearing force.Table 1 : Overview of Tearing Resistance of Film Structures in Machine Direction (MD) and Cross Direction (CD)

[0169] Table 1 provides tearing resistances values measured using ASTM 1922 (Elmendorf Tear) and Hand qualitative tearing resistance values in Machine Direction (MD). Table 1 shows improved tearing resistance in the machine direction (MD) and the cross direction (CD) exhibited by the high barrier films according to one or more embodiments of the present disclosure. In particular, the films comprising MDOPE- EVOH (with regrind) advantageously demonstrate optimal tearing resistance in the machine direction (MD) and the cross direction (CD).

[0170] Six trial laminates were made to test by quantitative and qualitative measures. Each Laminate Structure in Table 2 includes an Oriented Polyethylene (OPE) film having a thickness of 25 microns and a sealing layer having a thickness of 60 microns. Each Laminate Structure in Table 2 is described using the conventions of "OPE Film / Sealing layer." In Table 2, tearing resistance values in Machine Direction (MD) and Cross Direction (CD) measured using ASTM 1922 (Elmendorf Tear). Table 3 shows qualitative tearing results for Trials 1 through 6 in sealed and precut areas of the laminates.Table 2: Overview of Tearing Resistance of Laminate Structures in Machine Direction (MD) and Cross Direction (CD)Table 3: Overview of Hand Tearing of Sealed and Pre-cut Laminate Structures in Machine Direction (MD) and Cross Direction (CD). Laminate structures were sealed to themselves and a small cut was placed in the sealed area. Samples were then torn by hand at the pre-cut and into the non-sealed area. A qualitative score of 1 :optimal, 2:insufficient and 3:no tearing, is also noted.

[0171] Trials 1 through 4 represent comparative laminations and Trials 5 and 6 represent laminations according to this disclosure.

[0172] Without intending to be bound by any particular theory, a tearing resistance of less than 800 mN in each direction, e.g., Machine Direction (MD) and Cross Direction (CD) is generally considered to provide an optimal tear force for easy tearing. A tearing resistance in a range of from 800 to 1200 mN in each direction is generally considered to require increased tearing force as compared to optimal tear force. A tearing resistance of greater than 1200 mN in each direction is generally considered to be substantially impossible to tear, relative to the optimal tear force and the increased tearing force.

[0173] The Laminate Structures of Trials 1 , 2, and 5 exhibit increased tearing force in MD and CD as compared to optimal tear force values. The Laminate Structures of Trials 3 and 4 exhibit optimal tearing resistance values in Machine Direction (MD) and Cross Direction (CD) measured using ASTM 1922 (Elmendorf Tear). The Laminate Structures of Trials 3 and 4, as measured using a Hand qualitative tearing resistance process in the CD exhibit low force, shifting to MD in both sides not following the same direction.

[0174] In Trial 6, in which the Laminate Structures correspond to that of the high barrier films of one or more embodiments, optimal tearing resistance in the machine direction (MD) and the cross direction (CD) was achieved.EMBODIMENTS:

[0175] Embodiment 1 : A high barrier film comprising: a) a machine direction oriented film comprising: i) a first outer layer comprising HDPE, ii) a second outer layer comprising HDPE, iii) an EVOH layer comprising at least 90% EVOH, by weight, iv) a first tie layer located between the first outer layer and the EVOH layer, and v) a second tie layer located between the second outer layer and the EVOH layer, and b) a sealing film adhesively attached to the machine direction oriented film, wherein the first tie layer comprises between 0 and 75% of an alpha olefin polyethylene, by weight, between 0 and 50% of a polar polymer compatibilizer, by weight, and between 10 and 50% of a multi-component blend material, by weight, and wherein the multi-component blend material comprises HDPE and EVOH

[0176] Embodiment 2: The high barrier film according to Embodiment 1 , wherein the multi-component blend material further comprises the alpha olefin polyethylene and the polar polymer compatibilizer.

[0177] Embodiment 3: The high barrier film according to Embodiment 1 or 2, wherein the multi-component blend material has a composition essentially equal to the composition of the machine direction oriented film.

[0178] Embodiment 4: The high barrier film according to any previous Embodiment, wherein the multi-component blend material is obtained from a closed loop trim stream from a coextrusion process.

[0179] Embodiment 5: The high barrier film according to any previous Embodiment, wherein the EVOH layer comprises a thickness of at least 1 .0 micron, preferably of at least 2.0 microns.

[0180] Embodiment 6: The high barrier film according to any previous Embodiment, wherein the machine direction oriented film comprises a total thickness in a range of from 15 to 40 micron and the EVOH layer comprises a thickness of at least 2.5%, preferably at least 5%, more preferably at least 10%, of the total thickness of the machine direction oriented film.

[0181] Embodiment 7: The high barrier film according to any previousEmbodiment, wherein the EVOH has an ethylene content in a range of from 25 to 38 mole % ethylene.

[0182] Embodiment 8: The high barrier film according to any previousEmbodiment, wherein the first tie layer comprises a first layer comprising a MAH grafted PE and a second layer including between 0 and 75% of the alpha olefin polyethylene, by weight, between 0 and 50% of the polar polymer compatibilizer, by weight, and between 10 and 50% of the multi-component blend material, by weight.

[0183] Embodiment 9: The high barrier film according to any previous Embodiment, wherein the sealing film is a non-oriented film or a biaxially oriented film.

[0184] Embodiment 10: The high barrier film according to any previous Embodiment, further comprising a seal initiation temperature of less than 100°C when the sealing film is heat sealed to itself according to ASTM F2029-08 and ASTM F88.

[0185] Embodiment 1 1 : The high barrier film according to any previous Embodiment, further comprising a total composition including greater than 80% polyethylene, by weight.

[0186] Embodiment 12: The high barrier film according to any previousEmbodiment, wherein the alpha olefin polyethylene is a terpolymer.

[0187] Embodiment 13: The high barrier film according to any previousEmbodiment, wherein the polar polymer compatibilizer is present in the first tie layer in a range of between 10 and 20%, by weight.

[0188] Embodiment 14: The high barrier film according to any previous Embodiment, wherein the multi-component blend material is present in the first tie layer in a range of between 20 and 50%, preferably 30 and 50%, or more preferably 40 and 50%, by weight.

[0189] Embodiment 15: The high barrier film according to any previous Embodiment, wherein the second tie layer comprises between 0 and 75% of a second alpha olefin polyethylene, by weight, between 0 and 50% of a second polar polymercompatibilizer, by weight, and between 10 and 50% of the multi-component blend material, by weight.

[0190] Embodiment 16: The high barrier film according to any previous Embodiment, wherein the second tie layer comprises a first layer including between 0 and 75% of the alpha olefin polyethylene, by weight, between 0 and 50% of the polar polymer compatibilizer, by weight, and between 10 and 50% of the multicomponent blend material, by weight, and a second layer comprising a MAH grafted PE, by weight.

[0191] Embodiment 17: A package comprising a high barrier film and a sealed area, the high barrier film comprising: a) a machine direction oriented film comprising: i) a first outer layer comprising HDPE, ii) a second outer layer comprising HDPE, iii) an EVOH layer comprising at least 90% EVOH, by weight, iv) a first tie layer located between the first outer layer and the EVOH layer, and v) a second tie layer located between the second outer layer and the EVOH layer, and b) a sealing film adhesively attached to the machine direction oriented film, and the sealed area comprising a tear notch, wherein the first tie layer comprises between 0 and 75 % of an alpha olefin polyethylene, by weight, between 0 and 50% of a polar polymer compatibilizer, by weight, and between 10 and 50 % of a multi-component blend material, by weight, and wherein the multi-component blend material comprises HDPE and EVOH.

[0192] Embodiment 18: The package according to Embodiment 17, wherein the multi-component blend material further comprises the alpha olefin polyethylene and the polar polymer compatibilizer.

[0193] Embodiment 19: The package according to Embodiment 17 or 18, wherein the multi-component blend material has a composition essentially equal to the composition of the machine direction oriented film.

[0194] Embodiment 20: The package according to any of Embodiments 17-19, wherein the multi-component blend material is obtained from a closed loop trim stream from a coextrusion process.

[0195] Embodiment 21 : The package according to any of Embodiments 17-20, wherein the tear notch is positioned for tearing the high barrier film in the machine direction.

[0196] Embodiment 22: The package according to any of Embodiments 17-21 , wherein the tear notch is positioned for tearing the high barrier film in the transverse direction.

[0197] Embodiment 23: The package according to any of Embodiments 17-22, wherein the EVOH layer comprises a thickness of at least 1.0 micron, preferably of at least 2.0 microns.

[0198] Embodiment 24: The package according to any of Embodiments 17-23, wherein the machine direction oriented film comprises a total thickness in a range of from 15 to 40 micron and the EVOH layer comprises a thickness of at least 2.5%, preferably at least 5%, more preferably at least 10%, of the total thickness of the machine direction oriented film.

[0199] Embodiment 25: The package according to any of Embodiments 17-24, wherein the EVOH has an ethylene content in a range of from 25 to 38 mole % ethylene.

[0200] Embodiment 26: The package according to any of Embodiments 17-25, wherein the first tie layer comprises a first layer comprising a MAH grafted PEand a second layer including between 0 and 75% of the alpha olefin polyethylene, by weight, between 0 and 50% of the polar polymer compatibilizer, by weight, and between 10 and 50% of the multi-component blend material, by weight.

[0201] Embodiment 27: The package according to any of Embodiments 17-26, wherein the sealing film is a non-oriented film or a biaxially oriented film.

[0202] Embodiment 28: The package according to any of Embodiments 17-27, wherein the high barrier film further comprises a seal initiation temperature of less than 100°C when the sealing film is heat sealed to itself according to ASTM F2029- 08 and ASTM F88.

[0203] Embodiment 29: The package according to any of Embodiments 17-28, wherein the package further comprises a total composition including greater than 80% polyethylene, by weight.

[0204] Embodiment 30: The package according to any of Embodiments 17-29, wherein the alpha olefin polyethylene is a terpolymer.

[0205] Embodiment 31 : The package according to any of Embodiments 17-30, wherein the polar polymer compatibilizer is present in the first tie layer in a range of between 10 and 20%, by weight.

[0206] Embodiment 32: The package according to any of Embodiments 17-31 , wherein the multi-component blend material is present in the first tie layer in a range of between 20 and 50%, preferably 30 and 50%, or more preferably 40 and 50%, by weight.

[0207] Embodiment 33: The package according to any of Embodiments 17-32, wherein the second tie layer comprises between 0 and 75% of a second alpha olefin polyethylene, by weight, between 0 and 50% of a second polar polymer compatibilizer, by weight, and between 10 and 50% of the multi-component blend material, by weight.

[0208] Embodiment 34: The package according to any of Embodiments 17-33, wherein the second tie layer comprises a first layer including between 0 and 75% of the alpha olefin polyethylene, by weight, between 0 and 50% of the polar polymer compatibilizer, by weight, and between 10 and 50% of the multi-component blend material, by weight, and a second layer comprising a MAH grafted PE, by weight.

[0209] Embodiment 35: A method of producing a high barrier film including the steps of: a) coextruding i) a first outer layer comprising HDPE, ii) a second outer layer comprising HDPE, ill) an EVOH layer comprising at least 90% EVOH, by weight, iv) a first tie layer located between the first outer layer and the EVOH layer, and v) a second tie layer located between the second outer layer and the EVOH layer, wherein the first tie layer comprises between 0 and 75 % of an alpha olefin polyethylene, by weight, between 0 and 50% of a polar polymer compatibilizer, by weight, and between 10 and 50% of a multi-component blend material, by weight, and wherein the multi-component blend material is obtained from a closed loop trim stream from the coextrusion process, to produce a first film, b) stretching the first film in the machine direction at a stretch ratio in a range of from 5:1 to 7:1 to produce a machine direction oriented film, and c) adhering a sealing film to the machine direction oriented film.

[0210] Embodiment 36: The method according to Embodiment 35, wherein the EVOH layer comprises a thickness of at least 1 .0 micron, preferably of at least 2.0 microns.

[0211] Embodiment 37: The method according to Embodiment 35 or 36, wherein the machine direction oriented film comprises a total thickness in a range of from 15 to 40 micron and the EVOH layer comprises a thickness of at least 2.5%, preferably at least 5%, more preferably at least 10%, of the total thickness of the machine direction oriented film.

[0212] Embodiment 38: The method according to any of Embodiments 35-37, wherein the EVOH has an ethylene content in a range of from 25 to 38 mole % ethylene.

[0213] Embodiment 39: The method according to any of Embodiments 35-38, wherein the first tie layer comprises a first layer comprising a MAH grafted PEand a second layer including between 0 and 75% of the alpha olefin polyethylene, by weight, between 0 and 50% of the polar polymer compatibilizer, by weight, and between 10 and 50% of the multi-component blend material, by weight.

[0214] Embodiment 40: The method according to any of Embodiments 35-39, wherein the sealing film is a non-oriented film or a biaxially oriented film.

[0215] Embodiment 41 : The method according to any of Embodiments 35-40, wherein the high barrier film further comprises a seal initiation temperature of less than 100°C when the sealing film is heat sealed to itself according to ASTM F2029- 08 and ASTM F88.

[0216] Embodiment 42: The method according to any of Embodiments 35-41 , wherein the high barrier film further comprises a total composition including greater than 80% polyethylene, by weight.

[0217] Embodiment 43: The method according to any of Embodiments 35-42, wherein the alpha olefin polyethylene is a terpolymer.

[0218] Embodiment 44: The method according to any of Embodiments 35-43, wherein the polar polymer compatibilizer is present in the first tie layer in a range of between 10 and 20%, by weight.

[0219] Embodiment 45: The method according to any of Embodiments 35-44, wherein the multi-component blend material is present in a range of between 20 and 50%, preferably 30 and 50%, or more preferably 40 and 50%, by weight.

[0220] Embodiment 46: The method according to any of Embodiments 35-45, wherein the second tie layer comprises between 0 and 75% of a second alpha olefin polyethylene, by weight, between 0 and 50% of a second polar polymer compatibilizer, by weight, and between 10 and 50% of the multi-component blend material, by weight.

[0221] Embodiment 47: The method according to any of Embodiments 35-46, wherein the second tie layer comprises a first layer including between 0 and 75% of the alpha olefin polyethylene, by weight, between 0 and 50% of the polar polymer compatibilizer, by weight, and between 10 and 50% of the multi-component blend material, by weight, and a second layer comprising a MAH grafted PE, by weight.

Claims

What is claimed is:

1. A high barrier film comprising: a) a machine direction oriented film comprising: i) a first outer layer comprising HDPE, ii) a second outer layer comprising HDPE, iii) an EVOH layer comprising at least 90% EVOH, by weight, iv) a first tie layer located between the first outer layer and the EVOH layer, and v) a second tie layer located between the second outer layer and the EVOH layer, and b) a sealing film adhesively attached to the machine direction oriented film, wherein the first tie layer comprises between 0 and 75% of an alpha olefin polyethylene, by weight, between 0 and 50% of a polar polymer compatibilizer, by weight, and between 10 and 50% of a multi-component blend material, by weight, and wherein the multi-component blend material comprises HDPE and EVOH.

2. The high barrier film according to claim 1 , wherein the multi-component blend material further comprises the alpha olefin polyethylene and the polar polymer compatibilizer.

3. The high barrier film according to claim 1 , wherein the multi-component blend material has a composition essentially equal to the composition of the machine direction oriented film.

4. The high barrier film according to claim 1 , wherein the multi-component blend material is obtained from a closed loop trim stream from a coextrusion process.

5. The high barrier film according to claim 1 , wherein the EVOH layer comprises a thickness of at least 1 .0 micron, preferably of at least 2.0 microns.

6. The high barrier film according to claim 1 , wherein the machine direction oriented film comprises a total thickness in a range of from 15 to 40 micron and the EVOH layer comprises a thickness of at least 2.5%, preferably at least 5%, more preferably at least 10%, of the total thickness of the machine direction oriented film.

7. The high barrier film according to claim 1 , wherein the EVOH has an ethylene content in a range of from 25 to 38 mole % ethylene.

8. The high barrier film according to claim 1 , wherein the first tie layer comprises a first layer comprising a MAH grafted PE and a second layer including between 0 and 75% of the alpha olefin polyethylene, by weight, between 0 and 50% of the polar polymer compatibilizer, by weight, and between 10 and 50% of the multi-component blend material, by weight.

9. The high barrier film according to claim 1 , wherein the sealing film is a non-oriented film or a biaxially oriented film.

10. The high barrier film according to claim 1 , further comprising a seal initiation temperature of less than 100°C when the sealing film is heat sealed to itself according to ASTM F2029-08 and ASTM F88.1 1 . The high barrier film according to claim 1 , further comprising a total composition including greater than 80% polyethylene, by weight.

12. The high barrier film according to claim 1 , wherein the alpha olefin polyethylene is a terpolymer.

13. The high barrier film according to claim 1 , wherein the polar polymer compatibilizer is present in the first tie layer in a range of between 10 and 20%, by weight.

14. The high barrier film according to claim 1 , wherein the multi-component blend material is present in the first tie layer in a range of between 20 and 50%, preferably 30 and 50%, or more preferably 40 and 50%, by weight.

15. The high barrier film according to claim 1 , wherein the second tie layer comprises between 0 and 75% of a second alpha olefin polyethylene, by weight, between 0 and 50% of a second polar polymer compatibilizer, by weight, and between 10 and 50% of the multi-component blend material, by weight.

16. The high barrier film according to claim 1 , wherein the second tie layer comprises a first layer including between 0 and 75% of the alpha olefin polyethylene, by weight, between 0 and 50% of the polar polymer compatibilizer, by weight, and between 10 and 50% of the multi-component blend material, by weight, and a second layer comprising a MAH grafted PE, by weight.

17. A package comprising a high barrier film and a sealed area, the high barrier film comprising: a) a machine direction oriented film comprising: i) a first outer layer comprising HDPE, ii) a second outer layer comprising HDPE, iii) an EVOH layer comprising at least 90% EVOH, by weight, iv) a first tie layer located between the first outer layer and the EVOH layer, and v) a second tie layer located between the second outer layer and the EVOH layer, and b) a sealing film adhesively attached to the machine direction oriented film, and the sealed area comprising a tear notch, wherein the first tie layer comprises between 0 and 75 % of an alpha olefin polyethylene, by weight, between 0 and 50% of a polar polymer compatibilizer, byweight, and between 10 and 50 % of a multi-component blend material, by weight, and wherein the multi-component blend material comprises HDPE and EVOH.

18. The package according to claim 17, wherein the multi-component blend material further comprises the alpha olefin polyethylene and the polar polymer compatibilizer.

19. The package according to claim 17, wherein the multi-component blend material has a composition essentially equal to the composition of the machine direction oriented film.

20. The package according to claim 17, wherein the multi-component blend material is obtained from a closed loop trim stream from a coextrusion process.21 . The package according to claim 17, wherein the tear notch is positioned for tearing the high barrier film in the machine direction.

22. The package according to claim 17, wherein the tear notch is positioned for tearing the high barrier film in the transverse direction.

23. The package according to claim 17, wherein the EVOH layer comprises a thickness of at least 1 .0 micron, preferably of at least 2.0 microns.

24. The package according to claim 17, wherein the machine direction oriented film comprises a total thickness in a range of from 15 to 40 micron and the EVOH layer comprises a thickness of at least 2.5%, preferably at least 5%, more preferably at least 10%, of the total thickness of the machine direction oriented film.

25. The package according to claim 17, wherein the EVOH has an ethylene content in a range of from 25 to 38 mole % ethylene.

26. The package according to claim 17, wherein the first tie layer comprises a first layer comprising a MAH grafted PE and a second layer including between 0 and 75% of the alpha olefin polyethylene, by weight, between 0 and 50% of the polar polymer compatibilizer, by weight, and between 10 and 50% of the multi-component blend material, by weight.

27. The package according to claim 17, wherein the sealing film is a non-oriented film or a biaxially oriented film.

28. The package according to claim 17, wherein the high barrier film further comprises a seal initiation temperature of less than 100°C when the sealing film is heat sealed to itself according to ASTM F2029-08 and ASTM F88.

29. The package according to claim 17, wherein the package further comprises a total composition including greater than 80% polyethylene, by weight.

30. The package according to claim 17, wherein the alpha olefin polyethylene is a terpolymer.

31. The package according to claim 17, wherein the polar polymer compatibilizer is present in the first tie layer in a range of between 10 and 20%, by weight.

32. The package according to claim 17, wherein the multi-component blend material is present in the first tie layer in a range of between 20 and 50%, preferably 30 and 50%, or more preferably 40 and 50%, by weight.

33. The package according to claim 17, wherein the second tie layer comprises between 0 and 75% of a second alpha olefin polyethylene, by weight, between 0 andof the multi-component blend material, by weight.

34. The package according to claim 17, wherein the second tie layer comprises a first layer including between 0 and 75% of the alpha olefin polyethylene, by weight, between 0 and 50% of the polar polymer compatibilizer, by weight, and between 10 and 50% of the multi-component blend material, by weight, and a second layer comprising a MAH grafted PE, by weight.

35. A method of producing a high barrier film including the steps of: a) coextruding i) a first outer layer comprising HDPE, ii) a second outer layer comprising HDPE, iii) an EVOH layer comprising at least 90% EVOH, by weight, iv) a first tie layer located between the first outer layer and the EVOH layer, and v) a second tie layer located between the second outer layer and the EVOH layer, wherein the first tie layer comprises between 0 and 75 % of an alpha olefin polyethylene, by weight, between 0 and 50% of a polar polymer compatibilizer, by weight, and between 10 and 50% of a multi-component blend material, by weight, and wherein the multi-component blend material is obtained from a closed loop trim stream from the coextrusion process, to produce a first film, b) stretching the first film in the machine direction at a stretch ratio in a range of from 5:1 to 7:1 to produce a machine direction oriented film, and c) adhering a sealing film to the machine direction oriented film.

36. The method according to claim 35, wherein the EVOH layer comprises a thickness of at least 1 .0 micron, preferably of at least 2.0 microns.

37. The method according to claim 35, wherein the machine direction oriented film comprises a total thickness in a range of from 15 to 40 micron and the EVOH layercomprises a thickness of at least 2.5%, preferably at least 5%, more preferably at least 10%, of the total thickness of the machine direction oriented film.

38. The method according to claim 35, wherein the EVOH has an ethylene content in a range of from 25 to 38 mole % ethylene.

39. The method according to claim 35, wherein the first tie layer comprises a first layer comprising a MAH grafted PE and a second layer including between 0 and 75% of the alpha olefin polyethylene, by weight, between 0 and 50% of the polar polymer compatibilizer, by weight, and between 10 and 50% of the multi-component blend material, by weight.

40. The method according to claim 35, wherein the sealing film is a non-oriented film or a biaxially oriented film.41 . The method according to claim 35, wherein the high barrier film further comprises a seal initiation temperature of less than 100°C when the sealing film is heat sealed to itself according to ASTM F2029-08 and ASTM F88.

42. The method according to claim 35, wherein the high barrier film further comprises a total composition including greater than 80% polyethylene, by weight.

43. The method according to claim 35, wherein the alpha olefin polyethylene is a terpolymer.

44. The method according to claim 35, wherein the polar polymer compatibilizer is present in the first tie layer in a range of between 10 and 20%, by weight.

45. The method according to claim 35, wherein the multi-component blend material is present in a range of between 20 and 50%, preferably 30 and 50%, or more preferably 40 and 50%, by weight.

46. The method according to claim 35, wherein the second tie layer comprises between 0 and 75% of a second alpha olefin polyethylene, by weight, between 0 and 50% of a second polar polymer compatibilizer, by weight, and between 10 and 50% of the multi-component blend material, by weight.

47. The method according to claim 35, wherein the second tie layer comprises a first layer including between 0 and 75% of the alpha olefin polyethylene, by weight, between 0 and 50% of the polar polymer compatibilizer, by weight, and between 10 and 50% of the multi-component blend material, by weight, and a second layer comprising a MAH grafted PE, by weight.

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