High barrier paper packaging film and method for producing the same

Abstract

A high barrier paper packaging film useful as a flexible packaging material for forming into a package. The high barrier paper packaging film includes a paper, a sealing layer, and a vacuum deposited barrier layer positioned between the paper and the sealing layer. The film comprises an amount of paper necessary to ensure that it is capable of being recycled and / or repulped into a paper-based recycling stream. To form the film with adequate barrier properties, a method of construction utilizes a multilayer film with one or more base layers and the sealing layer to form the barrier layer upon. The multilayer film with barrier layer is then affixed to the paper to form an intermediate structure. This intermediate structure is then processed to remove the one or more base layers while the barrier layer and sealing layer remain affixed to the paper to form the high barrier packaging film.

Description

HIGH BARRIER PAPER PACKAGING FILM AND METHOD FOR PRODUCING THE SAMETECHNICAL FIELD

[0001] The present disclosure is related to high barrier paper laminates useful for packaging applications, and production methods thereof.BACKGROUND

[0002] It has become increasingly desirable to design flexible packaging structures that are more sustainable. Increased sustainability may be in the form of using raw materials that are renewably resourced, such as paper or starch-based polymers. Increased sustainability may also be in the form of an end-of-life solution that is something other than waste, such as reusable or recyclable options. For flexible packaging that is used for extended shelf-life food products, it can be difficult to match the required performance properties to any of these more sustainable options.

[0003] When it is desired to use paper as a major constituent of these packaging materials, often the paper must be modified or attached to additional materials to provide the necessary gas barrier and / or moisture barrier that a typical flexible packaging material requires. Typical techniques for providing these necessary barrier properties to paper materials include the application of a coating to a surface of the paper or through a lamination process affixing a filmic material to a surface of the paper.

[0004] One such disclosure is WO 2024 / 054210 entitled Paper-based Packaging Films Having a Multilayer Barrier Film providing a paper-based packaging film comprising a paper component attached to a compostable polymer type multilayer barrier film. By including a compostable polymer in this packaging structure, the final disposition includes options for both recycling through a paper repulping process and / or composting. Although the packaging film of this disclosure is useful and helpful, this use of compostable polymers may not be desired in all situations and particularly when the compostability of a given package is not desired.

[0005] Another such disclosure is US Patent AppL PubL No. 2023 / 068867 (hereinafter “the ‘867 publication”) providing a barrier paper having excellent gas barrier properties. The ‘867 application provides for a paper substrate layer, an adhesive layer, and an inorganic vapor deposited layer in that order with theadhesive layer contacting the inorganic vapor deposited layer. In addition to the above materials, the disclosure provides for an optional heat seal layer that may be utilized in package formation. This heat seal layer may be formed from a general thermoplastic resin and is usually about 15 urn or more in thickness. The ‘867 publication is silent as to the amount of fiber recovered from the structure during recycling and does provide some generic guidance that when the paper substrate layer thickness is greater than 60% of the total barrier paper thickness a decrease in recyclability and biodegradability can be inhibited.

[0006] To achieve recyclability within a paper recycling stream a typical flexible packaging material utilizing paper, in most markets, often needs to achieve a threshold of 80% of the fibers of the paper being recovered in this processing. Often, to achieve this fiber recovery, the selection of materials and amounts of these materials for a given layer is critical. In packages requiring sealing for formation of a package, the thickness, amount, and materials constituting the sealing layer is of particular importance. Therefore improvements to this sealing layer for paper-based high barrier paper laminates is necessary to ensure superior sealing performance resulting in formed packages that are hermetic.BRIEF SUMMARY

[0007] The developments herein provide an improved paper-based package having a high barrier to gas and moisture. A packaging film comprising a paper, a sealing layer of a predetermined thickness and specific non-oriented polymer morphology, and a vacuum deposited barrier with dedicated positioning between the paper and the sealing layer is disclosed. The composition of the packaging film is intended to allow for the formation of a paper-based package that meets industry requirements in a paper-based recycling stream. In accordance with some of these requirements, the packaging film of the present disclosure in a preferred assembly includes paper in an amount of about greater than 80% by weight of the packaging film. In another embodiment, in accordance with these recycling requirements, in a preferred assembly, the packaging film composition includes greater than about 80% of recoverable fiber by weight of the packaging film.

[0008] In some embodiments, the paper is located at a first outer surface of the packaging film and the sealing layer is located at a second outer surface of the packaging film. In some embodiments, the first outer surface comprises a printedindicia. In some embodiments, the paper includes a second surface opposite the first outer surface with the second surface being an uncoated paper surface.

[0009] Embodiments of the disclosure provide packaging films comprising paper that may be converted into a paper-based package and / or a paper-based flexible package. This paper-based package in embodiments may utilize an adhesive layer positioned between the vacuum deposited barrier layer and the paper.

[0010] In some embodiments, the barrier layer comprises metal or metal oxide. In some embodiments, the barrier layer has thickness less than about 0.1 microns.

[0011] In some embodiments, the sealing layer comprises a composition of polyolefin greater than an amount of about 90% by weight of the sealing layer. In further embodiments, the sealing layer comprises a first surface with the vacuum deposited barrier layer positioned on this first surface. In some embodiments, a second surface of the sealing layer is opposite the first surface and positioned as an outer surface of the packaging film.

[0012] In additional embodiments, the sealing layer comprises a pair of sub-layers in an inner sub-layer positioned at the sealing layer first surface and an outer sublayer located at the sealing layer second surface. In further embodiments, the sealing layer inner sub-layer and outer sub-layer may comprise a first polyolefin. In alternate embodiments, the sealing layer inner sub-layer may comprise the first polyolefin and the outer sub-layer may comprise a second polyolefin. In additional embodiments, the first polyolefin may be an ethylene vinyl alcohol copolymer, a cyclic olefin copolymer, a linear low-density polyethylene, or combinations thereof. In still further embodiments, the inner sub-layer is free of any anti-block particles. In some embodiments, the second polyolefin is a polyethylene plastomer.

[0013] In further embodiments, the sealing layer may have a defined thickness within a thickness of about 2 micron to 15 micron. In additional embodiments this sealing layer may comprise an orientation or alternately be provided without orientation, although it is preferred that the sealing layer be unoriented. In some embodiments the sealing layer defined thickness may be a result of a defined thickness of the inner sub-layer and the outer sub-layer, wherein the thickness of at least one of the inner sub-layer or the outer sub-layer is in a range of about from 1 micron to 10 micron. In some embodiments, the thickness of at least one of the inner sub-layer or the outer sub-layer is less than about 5 micron.

[0014] In an embodiment, the packaging film comprising paper can be constructed in at least a method of manufacture to produce a high barrier packaging film by providing an unoriented multilayer film having one or more base layers and a sealing layer having a sealing layer exposed surface. The sealing layer is then coated on the sealing layer exposed surface with a vacuum deposited barrier layer by a vacuum deposition process to produce a multilayer barrier film. A paper is then attached to the vacuum deposited barrier layer to form an intermediate structure. After the intermediate structure is formed, it is further processed by removing the one or more base layers to yield the resultant high barrier packaging film having the paper, the vacuum deposited barrier layer, and the sealing layer with a layered assembly positioning the paper at a first outer surface of the high barrier packaging film and the sealing layer at a second outer surface of the high barrier packaging film, with the vacuum deposited barrier layer between the paper and the sealing layer.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0015] To easily identify the discussion of any particular element or act, generally, the most significant digit or digits in a reference number refer to the figure number in which that element is first introduced.

[0016] 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 drawings, in which:

[0017] FIG. 1 is a cross sectional view of a high barrier packaging film, according to the present disclosure;

[0018] FIG. 2 is a cross sectional view of an embodiment of the high barrier packaging film, according to the present disclosure;

[0019] FIG. 3 is a cross sectional view of a further embodiment of the high barrier packaging film, according to the present disclosure;

[0020] FIG. 4 is a cross sectional view of an embodiment of a sealing layer of the high barrier packaging film, according to the present disclosure;

[0021] FIG. 5 is a cross sectional view of an embodiment of the high barrier packaging film, according to the present disclosure;

[0022] FIG. 6 is cross sectional view of an embodiment for a multilayer film provided as a step in a method of construction for a high barrier packaging film, according to the present disclosure;

[0023] FIG. 7 is cross sectional view of an embodiment for a multilayer barrier film provided as a step in a method of construction for a high barrier packaging film, according to the present disclosure;

[0024] FIG. 8 is a cross sectional view of an embodiment for an intermediate film provided in a step in a method of construction for a high barrier packaging film, according to the present disclosure;

[0025] FIG. 9 is a cross sectional view of an alternate embodiment for an intermediate film provided in a step in a method of construction for a high barrier packaging film, according to the present disclosure; and

[0026] FIG. 10 is a block diagram for the method steps in forming an embodiment for a high barrier packaging film, according to the present disclosure.

[0027] The drawings show some but not all embodiments. The elements depicted in the drawings are illustrative and not necessarily to scale.DETAILED DESCRIPTION

[0028] Before the disclosure is further described, it is understood that this disclosure is not limited to the particular embodiments set forth herein. Additionally, it is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.

[0029] Various changes may be made to the invention described and equivalents may be substituted without departing from the true spirit and scope of the invention. In addition, many modifications may be made to adapt a particular situation, material, composition of matter, process, process act(s) or step(s), to the objective(s), spirit or scope of the present invention. All such modifications are intended to be within the scope of the disclosure made herein.

[0030] Unless otherwise indicated, the words and phrases presented in this document have their ordinary meanings to one of skill in the art. Such ordinary meanings can be obtained by reference to their use in the art and by reference to general and scientific dictionaries.

[0031] References in the specification to “one embodiment” indicate that the embodiment described may include a particular feature, structure, or characteristic,but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment.

[0032] Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.Definitions

[0033] The following explanations of certain terms are meant to be illustrative rather than exhaustive. These terms have their ordinary meanings given by usage in the art and in addition include the following explanations.

[0034] As used herein, the term “and / or” refers to any one of the items, any combination of the items, or all of the items with which this term is associated - for example, “A, B, and / or C” would mean “A, B, C, A and B, A and C, B and C, or the combination of A, B, and C.”

[0035] As used herein, the singular forms “a,” “an,” and “the” include plural reference unless the context clearly dictates otherwise. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the embodiments and does not pose a limitation on the scope of the claims unless otherwise stated. No language in the specification should be construed as indicating any non-claimed element as essential.

[0036] A combination of materials can be described as a multilayer film (e.g., a structure or a laminate). The term "layer", as used herein, refers to a building block of films. In other words, a film is built from one or more layers. 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. A layer may contain metallic materials and may have additives. Layers may be continuous with the film or may be discontinuous or patterned. Bothlayers and films have a relatively insignificant thickness (z-direction) as compared to their respective length and width (x-y direction).

[0037] 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 adhesive. As used herein, the term “directly adjacent” or “in direct contact with” means that the items are in contact with each other, without intervening material.

[0038] As used herein, the term "unoriented" or “non-oriented” refers to a monolayer or multilayer film, sheet or web that is substantially free of post-extrusion orientation. A film is unoriented if each of the layers or films that are part of the film is substantially free of post extrusion orientation. As understood in the flexible packaging industry, 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. Orientation may be imparted into a film 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 films are thinner and can have significant changes in mechanical properties such as toughness, heat resistance, stiffness, tear strength and barrier. Orientation is typically accomplished by a double and / or triple bubble process, by a tenter-frame process or an MDO process using heated rolls. A typical blown film process or cast film process does impart some stretching of the film, but not enough to be considered oriented as described herein.

[0039] As used herein the term “paper” and / or “paper component" may be any type of paper that can be processed in a paper recycling (repulpability) process. As used herein, the term “paper” and / or "paper component" may be described with respect to an amount of cellulose fibers in the paper and / or paper component. For example, the paper and / or component comprises or may consist essentially of cellulose fibers. As used in this context, "consisting essentially of" means that the total composition of the paper component includes greater than or equal to 95 %, greater than or equal to 98 %, greater than or equal to 99 %, greater than or equal to 99.9% or 100% cellulose fibers. In some cases the paper and / or paper component may contain up to 20 % mineral filler by weight and correspondingly an amount greater than or equal to 80 % cellulose fibers.

[0040] As used herein, the terms “fiber” and / or “fiber-based” may include, but not be limited to, cellulose and / or cellulose-based fibers including virgin cellulose-based fibers, recycled fibers including materials like paper fibers and craft papers, textiles, non-wovens, wood-based fibers, cotton, linen, hemp, sugar cane or sorghum commonly known as bagasse fibers, or grains. These fibers may be untreated and / or treated to provide enhancements or improvements to their inherent properties. These fibers may be provided in a plurality of dimensions / lengths including micro and nano fibrillated types, such as, but not limited to, microfibrillated and / or nanofibrillated cellulose.

[0041] As used herein, the term “basis weight” is used to refer to the amount of material by weight is present in a predetermined area of a film or a layer or a component, such as, but not limited to a paper. Typically, the area defined is a square meter, but any area can be used. The area is defined in the length-width (i.e., x-y direction) of the film or layer. A material of a given thickness (z-direction) and density, has a specific weight when covering a defined area (i.e., a square meter). Basis weight is a commonly used measurement of weight for paper because the density of paper can vary widely. Stated differently, measuring paper by thickness in the z-direction can be difficult. Materials that are applied in discontinuous layers, such as a patterned material, can also be defined by basis weight. In the case of patterns, the basis weight refers to the amount of material by weight that is present when covering a defined area. The use of basis weight to measure weight of materials such as paper and patterned materials is common in the film converting industry.

[0042] As used herein, the phrase “metallized” or "metal coating" (which when applied forms the metal layer) refers to a coating that may be applied to one or both surfaces of a film by any known method such as sputtering, vacuum deposition or electroplating (all of which fall within the definition of "metallizing" the film and involve some act or method of "depositing" a continuous metal, metal oxide or metal alloy layer onto the surface of a polymer substrate). The metal used can vary, though aluminum, zinc, gold, silver or appropriate alloys of such are preferred, with aluminum or aluminum-containing alloys being particularly preferred. As will be recognized by those skilled in the art, while the metal coating predominantly consists of the identified metal (such as aluminum), amounts of other additives may be present to improve assorted physical and optical properties of the deposited metal layer. In some occasions, pure aluminum (or the metal of choice) may beused. Other additives maybe used in minor amounts such that aluminum (or the metal of choice) is the major component. Vacuum deposition is a preferred method of metallization in tends of processing and cost. Preferred values for the average thickness of the metal coating layer are within the range of about 1 .0 to 100 nanometers, with the preferred average thickness being within the range of about 3 to 25 nanometers. (1 micron equals 10. sup. -7 meters, and 1 nanometer equals 10. sup. -8 meters.) Regardless, the metal coating preferably has a thickness less than the polymer substrate on which it is deposited, preferably substantially less than said substrate. In contrast, typical metal foils used in packaging film application have a thickness of between 4.3 to 150 microns, as noted in "Foil, Aluminum" in The Wiley Encyclopedia of Packaging Technology, 2. sup. nd. Ed., by Foil Division of the Aluminum Association, Inc., pp. 458-463, which is incorporated herein by reference. For an aluminized coating layer, the key conditions are optical density (metal deposition) of approximately 0.75 to 4, preferably 1.0-3.0.

[0043] Polyethylene is the name for a polymer whose basic structure is characterized by the chain -(CH2- CH2-)n. As used herein, the term "polyethylene" includes homopolymers and copolymers of ethylene. Polyethylene homopolymer is generally described as being a solid which has a partially amorphous phase and partially crystalline phase with a density of between 0.870 to 0.980 grams per cubic centimeter. The relative crystallinity of polyethylene is known to affect its physical properties. The amorphous phase imparts flexibility and high impact strength while the crystalline phase imparts a high softening temperature and rigidity.

[0044] "Linear low density polyethylene" (LLDPE) are copolymers of ethylene with alpha-olefins having densities from 0.915 to 0.940 grams per cubic centimeter. The alpha-olefin utilized is usually 1 -butene, 1 -hexene, or 1 -octene and Ziegler-type catalysts are usually employed (although Phillips catalysts are also used to produce LLDPE having densities at the higher end of the range, and metallocene and other types of catalysts are also employed to produce other well-known variations of LLDPEs). An LLDPE produced with a metallocene or constrained geometry catalyst is often referred to as "mLLDPE".

[0045] "High density polyethylene" (HDPE) is ordinarily used in the art to refer to both (a) homopolymers of densities between about 0.960 to 0.980 grams per cubic centimeter and (b) copolymers of ethylene and an a-olefin (usually 1 -butene, 1 - hexene or 1 -octene) which have densities between 0.940 and 0.958 grams percubic centimeter. HDPE includes polymers made with Ziegler, Phillips and single site, e.g., metallocene, type catalysts.

[0046] As used throughout this application, the term “polypropylene” or “PP” refers to a plastomer, homopolymer or copolymer having at least one propylene monomer linkage within the repeating backbone of the polymer. The propylene linkage may be represented by the general formula: [CH2CH(CH3)]n. Such polypropylene may be a polypropylene impact copolymer, a polypropylene random copolymer, or a polypropylene homopolymer, may be syndiotactic or isotactic, or may or may not be clarified.

[0047] As used herein, “barrier” or “barrier film” or “barrier layer” or “barrier material” refers to providing for reduced transmission to gases such as oxygen (i.e. containing an oxygen barrier material). The barrier material may provide reduced transmission to moisture (i.e. containing a moisture barrier material). The barrier characteristic may be provided by one or more, or a blend, of multiple barrier materials. The barrier layer may provide the specific barrier required to preserve the product within a package throughout an extended shelf-life which may be several months or even more than one year.

[0048] The barrier may reduce the influx of moisture or water through the barrier film during the shelf-life of a packaged product (i.e., while the package is hermetically sealed). The moisture vapor transmission rate (MVTR or WVTR) of the barrier film is an indication of the barrier provided and can be measured according to ASTM F1249 using conditions of 1 atmosphere, 23°C and 90% RH.

[0049] As used herein, the phrase "sealant film" refers to a portion of the packaging web surface (i.e., formed from a single layer or multiple layers) which is capable of forming a fusion bond to a second portion of a film or packaging web surface. A sealant film is capable of fusion bonding by conventional, indirect heating means which generate sufficient heat on at least one film contact surface for conduction to the contiguous film contact surface and formation of a bond interface therebetween without loss of the film integrity. Those skilled in the art will appreciate that the bond interface between contiguous inner layers preferably has sufficient physical strength to withstand the packaging process and subsequent handling, including, for example, tensions resulting from stretching or shrinking attendant with the presence of a food body sealed within a package utilizing a sealant film. Advantageously, the bond interface is preferably sufficiently thermally stable to prevent gas or liquidleakage therethrough when exposed to above or below ambient temperatures, such as those during packaging operations, storage, handling, transport, display or processing of food. Heat seals may be designed to meet different conditions of expected use, and various heat seal formulations are known in the art and may be employed with the present disclosure. For use in cook-in applications, heat seals should withstand elevated temperatures up to about 160-180. degree. F. (71 - 82. degree. C.) or higher, for example, 212. degree. F. (100. degree. C.), for extended periods of time, such as up to 4 to 12 hours in environments which may range from heated humidified air to steam to submersion in heated water. Preferably, the sealant layer is heat sealable to itself, but may be sealable to other objects, films or layers, such as to a tray when used as a lidding film or to an outer layer in a lap seal or in certain tray overwrap embodiments. Also, in certain embodiments, the sealing layer is also a food contact layer. In other embodiments, the sealant layer may be adapted to provide a peelable bond interface between film surfaces without the loss of sufficient physical strength. Methods of forming a peelable bond interface in packaging films using a sealant layer or in combination with other layers are known in the art and have been described in, for example, U.S. Pat. No. RE37,171 to Busche et al. and U.S. Patent Application Publication No. 2006 / 0269707 to Berbert. In still other embodiments, the sealant film may be further adapted to provide a peelable and resealable bond interface. Exemplary of known peelable and resealable sealant and film layers include those structures described in U.S. Patent Application Publication Nos. 2006 / 0172131 to Haedt et al. and 2007 / 0082161 to Cruz et al.

[0050] As used herein, the term "packaging film" refers to a film capable of being formed into a package. The packaging film may be flexible, semi-rigid or rigid. A flexible packaging film may be bent or flexed into a shape and then bonded to itself or other packaging components such that the package forms a cavity and generally retains the shape. A packaging film may be capable of forming hermetic seals and may provide oxygen and / or moisture barrier properties. A packaging film has two outer surfaces defined by a length and a width.

[0051] The term "polyamide" means a high molecular weight polymer having amide linkages (-CONH-)n which occur along the molecular chain, and includes "nylon" resins which are well known polymers having a multitude of uses including utility as packaging films, bags, and casings. See, e.g., Modern Plastics Encyclopedia, 88 Vol. 64, No. 10A, pp 34-37 and 554-555 (McGraw-Hill, Inc., 1987) which is herebyincorporated by reference. Polyamides are preferably selected from nylon compounds approved for use in producing articles intended for use in processing, handling, and packaging food.

[0052] The term "nylon" as used herein refers more specifically to synthetic polyamides, either aliphatic or aromatic, either in crystalline, semi-crystalline, or amorphous form characterized by the presence of the amide group -CONH. It is intended to refer to both polyamides and co-polyamides.

[0053] Provided herein is a high barrier paper packaging film and a method of manufacturing the same. The high barrier packaging film is intended to have a construction and combination of material amounts and properties to enable for recycling within a paper-based recycling stream. The high barrier packaging film is useful for forming into a package, such as, but not limited to, a flexible paper-based package. The high barrier packaging film at a minimum includes a paper, a sealing layer having a thickness in a range of about from 2 micron to 15 micron, and a vacuum deposited barrier layer positioned between the paper and the sealing layer. To create a stable barrier layer and preferred sealing layer thickness, the high barrier packaging film is constructed in a preferred method of manufacture utilizing a multilayer film with one or more base layers and the sealing layer to form the barrier layer upon. The multilayer film with barrier layer is then affixed to a paper with the barrier layer adjacent the paper to form an intermediate structure. This intermediate structure is then processed to remove the one or more base layers while the barrier layer and sealing layer remain affixed to the paper to form the high barrier packaging film.

[0054] Referring now to FIG. 1 , a high barrier paper packaging film of the present disclosure is shown and generally referred to as packaging film 100. Packaging film 100 can generally be described as a flexible paper-based packaging film that is useful for forming into a package. Packing film 100 is a multilayer film having a paper component, a sealing layer, and a barrier layer positioned between the sealing layer and the paper component. Accordingly, packaging film 100 has a first outer surface 102 and a second outer surface 104. First outer surface 102 is generally aligned with an exterior of a package when packaging film 100 is utilized as such with the paper component adjacent the first outer surface 102. Second outer surface 104 is generally aligned with an interior of the package when utilized as such with the sealing layer component adjacent the second outer surface 104. In this positioning, the sealing layer is in adjacency to the second outer surface 104and useful in forming a package. Of particular importance, in some embodiments the sealing layer of packaging film 100 has a thickness within a range from about 2 micron to 15 micron and comprises a polyolefin polymer. In some embodiments, this polyolefin is non-oriented or unoriented. The barrier layer is positioned between the first outer surface 102 and the second outer surface 104 and is a vacuum deposited barrier layer. To form a consistent barrier, this vacuum deposited barrier layer is formed upon the sealing layer and comprises a metal or a metal oxide and is positioned adjacent the paper component of the packaging film 100.

[0055] The importance of sealing layer thickness has additional benefits related to the percentage of a given material in reference to the total weight of the packaging film 100. This has particular significance when a goal of the packaging film 100 is to maintain and / or provide for recyclability within a paper-based recycling stream. Accordingly, packaging film 100 has a composition of greater than 80% of paper by total weight of the packaging film 100. In some embodiments, the paper layer relative to the total weight of the packaging film 100, allows for the recovery of greater than 80% recoverable fiber during a repulping process applicable in a paper-based recycling stream.

[0056] Referring now to FIG. 2, an embodiment of the high barrier packaging film is shown in cross-section and generally referred to as packaging film 200. Packaging film 200 includes a paper 210, a vacuum deposited barrier layer 220, and a sealing layer 230. The paper 210 having a first surface of the paper 212 and a second surface of the paper 214. A distance between the first surface of the paper 212 and the second surface of the paper 214 defines a thickness of the paper 210. Paper 210 is an outer layer of the packaging film 200 with the first surface of the paper 212 at an exterior surface. In some embodiments, the paper 210 includes additional components adjacent to or on the first surface of the paper 210, such as ink or over lacquer. These additional components may cover a portion of the first surface 212 or the entire first surface 212. The paper 210 component has a basis weight in a range of from 20 g / m2(gsm) to 70 g / m2(gsm) including all values and subranges therebetween, including in a range of from 30 g / m2to 60 g / m2. A lower paper 210 weight is possible, while retaining easy recyclability, because the additional nonpaper components are minimized. Examples of paper 210 that may be useful in any embodiments of the high barrier paper packaging films include, but are not limited to, kraft paper, parchment, and bleached paper. The paper 210 component may be coated (i.e., clay coated) or uncoated. Examples of commonly used paper inpackaging that would be acceptable in the high barrier paper packaging films described herein include machine glazed bleached kraft paper (MGBK), one-side clay-coated paper (C1 S) and two-side clay-coated paper (C2S) although less common papers providing improved mechanical or barrier performance by using certain fibers or additives could also be a part of the high barrier paper packaging films described in this application. The paper 210 has a composition of greater than 80% of paper by total weight of the packaging film 200. In some embodiments, the paper 210 relative to the total weight of the packaging film 200, allows for the recovery of greater than 80% recoverable fiber during a repulping process applicable in a paper-based recycling stream.

[0057] The vacuum deposited barrier layer 220 is adjacent the second surface 214 of paper 210 and between the paper 210 and the sealing layer 230. The vacuum deposited barrier layer 220 preferably is a metalized layer to provide for a reduced transmission of oxygen, moisture, and / or both oxygen and moisture. Accordingly, the vacuum deposited barrier layer 220 comprises a metal, a metal oxide, and / or inorganic oxide. In some embodiments, this vacuum deposited barrier layer 220 comprises an aluminum oxide (AIOx) and / or a silicon oxide (SiOx). Although vacuum deposited layer 220 provides for a specific type of deposition, the purpose is to provide barrier to the packaging film 200 and therefore, this barrier can be provided in alternate processes. In some embodiments, the packaging film 200 containing the barrier has an average moisture vapor transmission rate (MVTR) value (sometimes referred to as water vapor transmission rate (WVTR)) that is less than or equal to 1 g / m2 / day, measured according to ASTM F1249 using conditions of 1 atmosphere, 38°C and 90% RH. In some embodiments, the average MVTR is less than or equal to 0.1 g / m2 / day. In embodiments, the vacuum deposited barrier layer 220 is metal or metal oxide and provided in layer having a thickness less than about 0.1 micron (pm).

[0058] The sealing layer 230 includes a first surface of the sealing layer 232 and second surface of the sealing layer 234 opposite the first surface of the sealing layer 232. A distance between the first surface of the sealing layer 232 and the second surface of the sealing layer 234 defines a thickness of the sealing layer 230. The thickness of the sealing layer 230 is provided in a range of from about 2 micron to 15 micron or within a range from about 3 micron to 8 micron. The relative thin thickness of the sealing layer 232 is selected to maintain recyclability of the packaging film 200 within a paper-based recycling stream, wherein the amount ofpaper within the packaging film 200 can be maintained at an amount of at least 80%. The sealing layer 230 is preferably comprised of a non-oriented polymer morphology. In some embodiments, the sealing layer 230 comprises a composition of greater than about 90% polyolefin, by weight. The sealing layer 230 first surface 232 provides the base for the barrier vacuum deposited barrier layer 220, wherein the vacuum deposited barrier layer 220 is formed upon the first surface of the sealing layer 232. Accordingly, it is beneficial for the formation of adequate barrier to have this first surface of the sealing layer 232 be as smooth as possible to allow for an even distribution of the vacuum deposited barrier material.

[0059] Referring now to FIG. 3, an embodiment of the high barrier packaging film is shown in cross-section and generally referred to as packaging film 300. Packaging film 300 incorporates the teachings and overall structure of the previous embodiments including having a paper 310, a sealing layer 330, and a vacuum deposited barrier layer 320 positioned between the sealing layer 330 and the paper 310. Packaging film 300 includes the addition of an adhesive layer 340. The adhesive layer 340 is positioned adjacent to the vacuum deposited barrier layer 320 and the paper 310. The adhesive layer 340 secures the paper 310 to the vacuum deposited barrier layer 320 and sealing layer 330 to form a cohesive structure that provides a high barrier while maintaining an amount of paper of at least 80% and / or recoverable fiber in an amount of at least 80% to be recyclable within a paperbased recycling stream. The adhesive layer 340 may be selected from a water based adhesive, a one part high viscosity solventless adhesive. The adhesive layer 340 is selected to achieve optimal fiber recovery during recycling, wherein this adhesive layer 340 is selected to bond the paper 310 to the barrier layer 320 without sacrificing and / or adhering too much of the paper 310 to meet the repulping criteria discussed herein.

[0060] Referring now to FIG. 4, a cross sectional view of an embodiment of a sealing layer 430 of the high barrier packaging film, according to the present disclosure. The sealing layer 430 incorporates the teachings and overall structure of the previous embodiments. Sealing layer 430 comprising a pair of distinct layers in the form of inner sub-layer 436 and outer sub-layer 438. Inner sub-layer 436 is aligned with a first surface of the sealing layer 432 and positioned adjacent to outer sub-layer 438. The outer sub-layer 438 is aligned with a second surface of the sealing layer 434 opposed the inner sub-layer 436. In the configuration of this embodiment, the sealing layer 430 sub-layers 436, 438 may be comprised ofpolyolefin of the same type or may be comprised of first polyolefin polymer and / or a second polyolefin polymer. Accordingly, the inner sub-layer 436 may comprise a first polyolefin and the outer sub-layer 438 may comprise a second polyolefin. In some embodiments, the sealing layer 430 is unoriented. In some embodiments, the first polyolefin polymer is an ethylene vinyl alcohol copolymer, a cyclic olefin copolymer, or a linear low-density polyethylene. In some embodiments, the second polyolefin polymer is a polyethylene plastomer. In some embodiments, the inner sub-layer 436 is free of anti-block particles. In some embodiments, the sealing layer 430 has a thickness of about between 2 micron to 15 micron. In some embodiments, the sealing layer 430 has a thickness of about between 2 micron and 10 micron. In some embodiments the sealing layer 430 thickness is further subdivided between the inner sub-layer 436 and the outer sub-layer 438, wherein the thickness of at least one of the inner sub-layer 436 or the outer sub-layer 438 is in a range from about 1 micron to 10 micron. In some embodiments, the thickness of at least one of the inner sub-layer 436 or the outer sub-layer 438 is less than about 5 micron.

[0061] Referring now to FIG. 5, an embodiment of the high barrier packaging film is shown in cross-section and generally referred to as packaging film 500. Packaging film 500 incorporates the teachings and overall structure of the previous embodiments including having a paper 510, a sealing layer 530, a vacuum deposited barrier layer 520 positioned between the sealing layer 530 and the paper 510, and an adhesive layer 540 securing the vacuum deposited layer 520 to the paper 510. The paper 510 includes a first surface of the paper 512 and a second surface of the paper 514 opposed to the first surface of the paper 512. A distance between the first surface of the paper 512 and the second surface of the paper 514 defines a thickness of the paper 510. The first surface of the paper 512 is additionally a first surface outer surface 502 of the packaging film 500 and generally functions as an exterior surface of the packaging film 500 when formed into a package. Accordingly, the first surface of the paper 512 may include additional layers, such as a printed indicia layer 550. Printed indicia layer 550 is generally an ink applied to the first surface of the paper 512 and may include various images, logos, and / or text generally associated with flexible packaging. The first outer surface of the paper 512 may include an over lacquer or other coating applied to the surface and / or optionally over the printed indicia layer 550. The second surface of the paper 514 is aligned to be directly adjacent to the adhesive layer 540 with theadhesive layer 540 between the second surface of the paper 514 and vacuum deposited barrier layer 520. The vacuum deposited barrier layer 520 is formed upon a first surface of the sealing layer 532 with this first surface of the sealing layer 532 comprising a material generally selected to provide a very smooth, high gloss surface. In some embodiments, this sealing layer 530 comprises a metallocene catalyzed linear low density polyethylene (mLLDPE) to achieve the preferred surface characteristics of the first surface of the sealing layer 532. The sealing layer 530 further defines a second outer surface 504 of the packaging film 500, wherein this second outer surface 504 is utilized as a package interior surface and may be sealed upon itself to form an enclosed package interior.

[0062] As indicated earlier the high barrier packaging film is formed from the securing of the paper portion to a multilayer film having the sealing layer whereupon the barrier layer is formed. Referring now to FIG. 6, a multilayer film 10 is shown. The multilayer film 10 is generally constructed as a base film comprising one or more base layers 12 positioned adjacent to a sealing layer 14. The sealing layer 14 includes a sealing layer exposed surface 15 aligned opposite the one or more base layers 12 and generally providing a very smooth and glossy surface to enable the later formation of a barrier layer upon it. The one or more base layers 12 and the sealing layer 14 may be formed from polyethylene-based blown film with a thickness of about 1 .5 mils. Alternately, the one or more base layers 12 may be formed from a polypropylene-based film with a polyethylene-based sealing layer 14 in a blown film structure with a thickness of about 1 .5 mils. To enable for delamination as is necessary and further described below, the one or more base layers are specifically constructed and selected to allow for a controlled separation of the one or more base layers 12 at the interface of the sealing layer 14 after final assembly.Accordingly, in some embodiments it is preferred that the specific layer of the one or base layers 12 contacting the sealing layer 14 is a blend of nylon. One such useful blend is combination of about 70% polyamide (PA) blended with 30% polyethylene (PE). This blend ensures a high enough bond strength to allow for later processing and delamination when desired. In further embodiments, and in situations where the use of nylon is disfavored, the specific layer of the one or more base layers 12 contacting the sealing layer 14 is a polypropylene homopolymer layer.

[0063] Referring now to FIG. 7 a multilayer barrier film 20 is shown. Multilayer barrier film 20 includes one or more base layers 22, a sealing layer 24, and avacuum deposited barrier layer 26. Multilayer barrier film 20 is a metalized version of multilayer film 10 shown in FIG. 6. Accordingly, multilayer barrier film 20 represents a base film structure having barrier properties that is later secured to a paper. Vacuum deposited barrier layer 26 is a metalized layer as discussed in previous embodiments hereof.

[0064] Referring now to FIG. 8 an intermediate structure 30 that is further processed to form the high barrier paper packaging film is shown in cross-section. Intermediate structure 30 comprises one or more base layers 32, sealing layer 34, barrier layer 36, and paper 38. Accordingly, intermediate structure 30 provides the addition of paper 38 to the embodiment as shown in FIG. 7. To form the resultant high barrier paper packaging film of the present disclosure, intermediate structure 30 is further processed by removing at least a portion of the one or more base layers 32. The removal of the one or more base layers 32 provides a structure of the paper 38, the barrier layer 36, and the sealing layer 34. Accordingly, the use and specific composition of the at least one or more base layers 32 in the construction of the high barrier paper packaging film enables for the formation of a relatively thin sealing layer having a barrier layer and a sufficient amount of paper 38 to ensure that paper and / or fiber amounts are maintained at an amount of about above 80% by weight of the final structure.

[0065] Referring now to FIG. 9, an intermediate structure 40 representing an alternate embodiment of a structure that is further processed to form the high barrier paper packaging film is shown in cross-section. Intermediate structure 40 comprises one or more base layers 42, a sealing layer 44, a vacuum deposited barrier layer 46, a paper 48, and an adhesive layer 49 positioned between the vacuum deposited barrier layer 46 and the paper 48. Accordingly, intermediate structure 40 provides the addition of an adhesive layer 49 to the embodiment shown in FIG. 8. Intermediate structure 40 can generally be described as a laminate, wherein the multilayer barrier film comprising the at least one or more base layers 42, the sealing layer 44, and the vacuum deposited barrier layer 46 is secured to the paper 48 utilizing the adhesive layer 49. After the lamination is completed, similar to previous embodiments, intermediate structure 40 is further processed by removing at least a portion of the one or more base layers 42 to form the resultant high barrier paper packaging film of the present disclosure. The removal of the one or more base layers 42 provides a structure of the paper 48, adhesive layer 49, barrier layer 46, and sealing layer 44. Accordingly, the use and composition of theat least one or more base layers 42 in the construction of the high barrier paper packaging film forms a relatively thin sealing layer having a barrier layer and a sufficient amount of paper and / or fiber-based materials to ensure that paper and / or fiber amounts are maintained at an amount of about above 80% by weight of the final structure.

[0066] Referring now to FIG. 10, as discussed earlier, to produce the high barrier paper packaging film of the present disclosure a method of construction is provided through various processing steps in a method of construction 1000. In a first step 1002 a multilayer film comprising one or more base layers and a sealing layer with the sealing layer having a sealing layer exposed surface is provided. The multilayer film provided in step 1002 has the sealing layer with a thickness in a range of from about 2 micron to 15 micron and in some embodiments comprises a composition including greater than 90% polyolefin by weight. In a second step 1004 the sealing layer exposed surface is coated with a vacuum deposited barrier layer by a vacuum deposition process to produce a multilayer barrier film. The vacuum deposited barrier layer comprises a metal, a metal oxide, and / or inorganic oxide. At a third step 1006, a paper is attached to the vacuum deposited barrier layer of the multilayer barrier film produced at step 1004 to produce an intermediate structure. In some embodiments, the third step 1006 may be an adhesive lamination utilizing an adhesive layer positioned between the paper and the vacuum deposited barrier layer. In a fourth step 1008 the at least one or more base layers is removed from the intermediate structure produced at the third step 1006 to yield the high barrier paper packaging film of the present disclosure comprising the paper, the vacuum deposited barrier layer, and the sealing layer. To accomplish an easy removal of the at least one or more base layers at the interface between the sealing layer and the at least one or more base layers, the materials comprising the layers are specifically constructed and selected to allow for a controlled separation at this interface. In some embodiments, a nylon blend in the layer of the at least one base layers is positioned directly adjacent a polyethylene based sealing layer. In further embodiments, a polypropylene homopolymer layer is positioned in contact with the sealing layer to enable for controlled delamination at the preferred at least one base layer interface layer.

[0067] EXAMPLES

[0068] An exemplary multilayer film useful for a high barrier paper packaging film is shown in Table 1 below. The multilayer film of Table 1 is a 1 .5 mils thick blown filmhaving seven layers including an about 6 micron combined sealing layer. The double lines shown in Table 1 represent the interface between the sealing layer portion and base layer portion of the exemplary film. Accordingly, the Red and Yellow layers in Table 1 comprise the sealant and / or the sealing layer of the multilayer film with the remaining layers comprising the base layers.TABLE 1 : MULTILAYER FILM

[0069] An exemplary multilayer film useful for a high barrier paper packaging film is shown in Table 2 below. The multilayer film of Table 2 has an improved sealing layer with optimized sub-layers to provide better sealing when compared to the exemplary film of Table 1 . The multilayer film of Table 2 is also a 1 .5 mils thick blown film having seven layers including an about 6 micron combined sealing layer. The double lines shown in Table 2 represent the interface between the sealing layer portion and base layer portion of the exemplary film. Accordingly, the Red and Yellow layers in Table 2 comprise the sealant and / or the sealing layer of the multilayer film with the remaining layers comprising the base layers.TABLE 2: MULTILAYER FILM

[0070] An exemplary multilayer film useful for a high barrier paper packaging film is shown in Table 3 below. The multilayer film of Table 3 has an alternate at least one base layer portion comprising a polypropylene-based structure to provide a multibarrier film that is constructed without nylon to provide an alternate sustainable structure by using a majority of polyolefin-based polymers. The multilayer film of Table 3 is also a 1 .5 mils thick blown film having seven layers including an about 6 micron combined sealing layer. The double lines shown in Table 3 represent the interface between the sealing layer portion and base layer portion of the exemplary film. Accordingly, the Brown and Blue layers in Table 3 comprise the sealant and / or the sealing layer of the multilayer film with the remaining layers comprising the base layer.TABLE 3: MULTILAYER FILM

[0071] An exemplary multilayer film useful for a high barrier paper packaging film is shown in Table 4 below. The multilayer film of Table 4 is similar to Table 3 has an at least one base layer portion comprising a polypropylene-based structure to provide a multibarrier film that is constructed without nylon to provide a more sustainable structure by using a majority of polyolefin-based polymers. Compared to Table 3,the exemplary film of Table 4 includes an alternate ionomer-based sealing layer. The ionomer may be an ionomer of ethylene acid copolymer. The ionomer may be of the type having a melting point of 93°C and a melt index of 14g / 10 min according to ASTM D1238 or may be of the type having a melting point of 100°C and a melt index of 5.5g / 10 min according to ASTM D1238. The antiblock may be an antiblock compound comprising about 75 percent by weight of ethylene methacrylic acid copolymer (EMAA) or ethylene acrylic acid copolymer (EAA) and 25 percent by weight of antiblock additive. The multilayer film of Table 4 is also a 1 .5 mils thick blown film having seven layers including an about 6 micron combined sealing layer. The double lines shown in Table 4 represent the interface between the sealing layer portion and base layer portion of the exemplary film. Accordingly, the Brown and Blue layers in Table 4 comprise the sealant and / or the sealing layer of the multilayer film with the remaining layers comprising the base layer.TABLE 4: MULTILAYER FILM

[0072] The exemplary multilayer films of Table 1 and Table 2 were metalized upon the surface of the Red layer opposite the Yellow layer. The exemplary multilayer films of Table 3 and Table 4 were metalized upon the surface of the Blue layer opposite the Brown layer. The metallization upon the above indicated surfaces comprising mLLDPE, ionomer, and EA / PP random copolymer formed a multilayerbarrier film having an MVTR of 0.1 g / m2 / day. This transmission rate is comparable to a traditional metallized biaxially oriented polypropylene film.

[0073] HIGH BARRIER PAPER BASED FILM EMBODIMENTS

[0074] Embodiment A. A packaging film comprising:

[0075] a paper;

[0076] a sealing layer comprising a non-oriented polymer morphology and a sealing layer thickness in a range from 2 micron to 15 micron; and

[0077] a vacuum deposited barrier layer positioned between the paper and the sealing layer.

[0078] Embodiment B. The packaging film according to Embodiment A, wherein the packaging film has a composition including greater than 80% of the paper, by weight.

[0079] Embodiment C. The packaging film of Embodiment A, wherein the packaging film has a composition including greater than 80% recoverable fiber, by weight.

[0080] Embodiment D. The packaging film of Embodiment A, further comprising an adhesive layer positioned between the vacuum deposited barrier layer and the paper.

[0081] Embodiment E. The packaging film of Embodiment A, wherein the sealing layer comprises a composition including greater than 90% polyolefin, by weight.

[0082] Embodiment F. The packaging film of Embodiment A, wherein the paper is located at a first outer surface of the packaging film and the sealing layer is located at a second outer surface of the packaging film.

[0083] Embodiment G. The packaging film of Embodiment A, wherein:

[0084] the sealing layer further comprises a first surface and a second surface;

[0085] the vacuum deposited barrier layer is located on the first surface; and

[0086] the second surface of the sealing layer being an outer surface of the packaging film.

[0087] Embodiment H. The packaging film of Embodiment G, wherein the sealing layer comprises:

[0088] an inner sub-layer located at the first surface of the sealing layer; and

[0089] an outer sub-layer located at the second surface of the sealing layer.

[0090] Embodiment I. The packaging film of Embodiment A, wherein the sealing layer thickness is in a range from 2 micron to 10 micron.

[0091] Embodiment J. A packaging film displaying high barrier properties, the packaging film comprising:

[0092] a paper comprising first surface and a second surface, the first surface of the paper located at a first outer surface of the packaging film;

[0093] a sealing layer, the sealing layer comprising a polyolefin polymer and a first surface defining a second outer surface of the packaging film;

[0094] a barrier layer, the barrier layer located on the sealing layer opposite the packaging film second outer surface; and

[0095] an adhesive layer, the adhesive layer bonding the barrier layer to the paper;

[0096] wherein the sealing layer comprises:

[0097] a sealing layer thickness in the range of from 2 micron to 15 micron;

[0098] an inner sub-layer defining the first surface of the sealing layer and comprising a first polyolefin; and

[0099] an outer sub-layer defining the second surface of the sealing layer and comprising a second polyolefin.

[0100] Embodiment K. The packaging film of Embodiment J, wherein the sealing layer is unoriented.

[0101] Embodiment L. The packaging film of Embodiment J, wherein the barrier layer comprises metal or metal oxide and has a thickness less than 0.1 microns.

[0102] Embodiment M. The packaging film of Embodiment J, wherein the first polyolefin is an ethylene vinyl alcohol copolymer, a cyclic olefin copolymer or a linear low-density polyethylene.

[0103] Embodiment N. The packaging film of Embodiment J, wherein the inner sublayer is free of anti-block particles.

[0104] Embodiment O. The packaging film of Embodiment J, wherein the second polyolefin is a polyethylene plastomer.

[0105] Embodiment P. The packaging film of Embodiment J, wherein the thickness of at least one of the inner sub-layer or the outer sub-layer is in a range from 1 micron to 10 micron.

[0106] Embodiment Q. The packaging film of Embodiment J, wherein the thickness of at least one of the inner sub-layer or the outer sub-layer is less than 5 micron.

[0107] Embodiment R. The packaging film of Embodiment J, further comprising a printed indicia layer located on the first surface of the paper.

[0108] Embodiment S. The packaging film of Embodiment J, wherein the second surface of the paper is uncoated.

[0109] Embodiment T. A method of producing a high barrier packaging film comprising the steps of:

[0110] providing a multilayer film comprising one or more base layers and a sealing layer, the sealing layer having a sealing layer exposed surface;

[0111] coating the sealing layer exposed surface of the multilayer film with a vacuum deposited barrier layer by a vacuum deposition process to produce a multilayer barrier film;

[0112] attaching a paper to the vacuum deposited barrier layer of the multilayer barrier film to produce an intermediate structure; and

[0113] removing the one or more base layers from the intermediate structure to yield the high barrier packaging film comprising the paper, the vacuum deposited barrier layer, and the sealing layer;

[0114] wherein the multilayer film is unoriented; and

[0115] the paper is located at a first outer surface of the high barrier packaging film and the sealing layer is located at a second outer surface of the high barrier packaging film.

[0116] Embodiment U. The method of Embodiment T, wherein attaching the paper to the vacuum deposited barrier layer of the multilayer barrier film to produce the intermediate structure is by an adhesive lamination process.

[0117] Embodiment V. The method of Embodiment U, wherein the high barrier packaging film further comprises an adhesive layer located between the paper and the vacuum deposited barrier layer.

[0118] Embodiment W. The method of Embodiment T, wherein the sealing layer comprises:

[0119] a sealing layer thickness in the range of from about 2 micron to 15 micron;

[0120] an inner sub-layer defining a first surface of the sealing layer and comprising a first polyolefin; and

[0121] an outer sub-layer defining a second surface of the sealing layer and comprising a second polyolefin.

Claims

CLAIMSWhat is claimed is:1 . A packaging film comprising: a paper; a sealing layer comprising a non-oriented polymer morphology and a sealing layer thickness in a range from 2 micron to 15 micron; and a vacuum deposited barrier layer positioned between the paper and the sealing layer.

2. The packaging film of claim 1 , wherein the packaging film has a composition including greater than 80% of the paper, by weight.

3. The packaging film of claim 1 , wherein the packaging film has a composition including greater than 80% recoverable fiber, by weight.

4. The packaging film of claim 1 , further comprising an adhesive layer positioned between the vacuum deposited barrier layer and the paper.

5. The packaging film of claim 1 , wherein the sealing layer comprises a composition including greater than 90% polyolefin, by weight.

6. The packaging film of claim 1 , wherein the paper is located at the first outer surface of the packaging film and the sealing layer is located at the second outer surface of the packaging film.

7. The packaging film of claim 1 , wherein the sealing layer further comprises a first surface and a second surface; the vacuum deposited barrier layer is located on the first surface; and the second surface of the sealing layer being an outer surface of the packaging film.

8. The packaging film of claim 7, wherein the sealing layer comprises: an inner sub-layer located at the first surface of the sealing layer; and an outer sub-layer located at the second surface of the sealing layer.

9. The packaging film of claim 1 , wherein the sealing layer thickness is in a range from 2 micron to 10 micron.

10. A packaging film displaying high barrier properties, the packaging film comprising: a paper comprising first surface and a second surface, the first surface of the paper located at a first outer surface of the packaging film; a sealing layer, the sealing layer comprising a polyolefin polymer and a first surface defining a second outer surface of the packaging film; a barrier layer, the barrier layer located on the sealing layer opposite the packaging film second outer surface; and an adhesive layer, the adhesive layer bonding the barrier layer to the paper; wherein the sealing layer comprises: a sealing layer thickness in the range of from 2 micron to 15 micron; an inner sub-layer defining the first surface of the sealing layer and comprising a first polyolefin; and an outer sub-layer defining the second surface of the sealing layer and comprising a second polyolefin.1 1 . The packaging film of claim 10, wherein the sealing layer is unoriented.

12. The packaging film of claim 10, wherein the barrier layer comprises metal or metal oxide and has a thickness less than 0.1 microns.

13. The packaging film of claim 10, wherein the first polyolefin is an ethylene vinyl alcohol copolymer, a cyclic olefin copolymer or a linear low-density polyethylene.

14. The packaging film of claim 10, wherein the inner sub-layer is free of anti-block particles.

15. The packaging film of claim 10, wherein the second polyolefin is a polyethylene plastomer.

16. The packaging film of claim 10, wherein the thickness of at least one of the inner sub-layer or the outer sub-layer is in a range from 1 micron to 10 micron.

17. The packaging film of claim 10, wherein the thickness of at least one of the inner sub-layer or the outer sub-layer is less than 5 micron.

18. The packaging film of claim 10, further comprising a printed indicia layer located on the first surface of the paper.

19. The packaging film of claim 10, wherein the second surface of the paper is uncoated.

20. A method of producing a high barrier packaging film comprising the steps of: providing a multilayer film comprising one or more base layers and a sealing layer, the sealing layer having a sealing layer exposed surface; coating the sealing layer exposed surface of the multilayer film with a vacuum deposited barrier layer by a vacuum deposition process to produce a multilayer barrier film; attaching a paper to the vacuum deposited barrier layer of the multilayer barrier film to produce an intermediate structure; and removing the one or more base layers from the intermediate structure to yield the high barrier packaging film comprising the paper, the vacuum deposited barrier layer, and the sealing layer; wherein the multilayer film is unoriented; and the paper is located at a first outer surface of the high barrier packaging film and the sealing layer is located at a second outer surface of the high barrier packaging film.21 . The method of claim 20, wherein attaching the paper to the vacuum deposited barrier layer of the multilayer barrier film to produce the intermediate structure is by an adhesive lamination process.

22. The method of claim 21 , wherein the high barrier packaging film further comprises an adhesive layer located between the paper and the vacuum deposited barrier layer.

23. The method of claim 20, wherein the sealing layer comprises: a sealing layer thickness in the range of from about 2 micron to 15 micron; an inner sub-layer defining a first surface of the sealing layer and comprising a first polyolefin; and an outer sub-layer defining a second surface of the sealing layer and comprising a second polyolefin.

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