Packaging films containing coextruded polyester and nylon layers

BACKGROUND OF THE INVENTION

0001The present invention relates to multilayer thermoformable structures for packaging film applications. Particularly, the invention relates to polyester and nylon structures formed into packaging films.

0002Multilayer thermoforming structures formed into flexible films are used to package food and medicinal articles, to protect the articles against external contamination and abuse, and to provide an attractive package for the article for its eventual sale.

0003There is great commercial interest in the packaging industry for a film structure, which provides superior mechanical strength, better optical and gas barrier properties, and improved thermoformability.

SUMMARY OF THE INVENTION

0004The present invention is directed to a multilayer thermoformable structure according to claim 1 comprising a first layer of polyester; a second layer of an adhesive; a third nylon layer consisting essentially of a nylon blend wherein the blend contains no more than about 29% (wt.) of amorphous nylon; and where the first layer, the second layer and the third layer are formed into a flexible film by a coextrusion process. Films which combine different layers into a single structure may be made by slot cast coextrusion or single-bubble blown coextrusion. The flat die or slot cast process includes extruding a polymer material through a die on to a chilled roll and winding the film onto a roll for further processing. In the single-bubble blown coextrusion process, polymer material is forced through a die and around a mandrel, and then emerges in tubular form. The tube or bubble is expanded by blowing air through the center of the mandrel to a desired thickness and, then rapidly cooled or quenched. Films made by either the slot cast or single-bubble blown method, as described hereinabove, are nonoriented as opposed to manufacturing methods which induce high levels of orientation in films such as the double-bubble or the tenter frame process.

0005Optionally the first and third layers directly contact opposing sides of the second layer.

0006In one embodiment, the first, second and third layered structure is used to form a flexible seven-layered film.

0007Suitable films of the present invention may be characterized as being nonoriented and/or as having a percent elongation at break at room temperature greater than about 250 in either or both the machine (MD) direction and the transverse direction (TD), and/or as having a heat shrinkage value less than about 5% at 90°C (MD and TD).

BRIEF DESCRIPTION OF THE DRAWINGS

0008<ul id="ul0001" list-style="none" compact="compact"><li><figref idref="f0001">FIG. 1</figref> is a cross-sectional view of a multilayer structure having three layers according to the present invention.</li><li><figref idref="f0002">FIG. 2</figref> is a cross-sectional view of a multilayer structure having seven layers according to the present invention.</li><li><figref idref="f0003">FIG. 3</figref> is a cross-sectional view of a multilayer structure having an alternative seven layers according to the present invention.</li><li><figref idref="f0004">FIG. 4</figref> is a cross-sectional view of a multilayer structure having another alternative seven layers according to the present invention.</li></ul>

DETAILED DESCRIPTION OF THE INVENTION

0009With reference to the drawings, there is seen in <figref idref="f0001">FIG. 1</figref> a three-layer multilayer structure 10 having a first layer 11, a second layer 12, and a third layer 13 formed into a film by coextrusion. First layer 11 of multilayer structure 10 comprises a polyester; a second layer 12 of an adhesive; and a third layer 13 comprising a nylon blend wherein the third layer contains no more than 29% (wt.) of amorphous nylon.

0010In <figref idref="f0002">FIG. 2</figref>, a seven-layer multilayer structure 20 is shown having a first layer 21, a second layer 22, a third layer 23, a fourth layer 24, a fifth layer 25, a sixth layer 26, and a seventh layer 27. Multilayer structure 20 may have a first layer 21 comprising polyester; a second layer 22 and fifth layer 25 each comprising an adhesive; a third layer 23 and fifth layer 25 comprising a nylon blend wherein the third layer contains no more than 29% (wt.) of amorphous nylon; a fourth layer 24 comprising an oxygen barrier or optionally, an adhesive; and a seventh layer 27 comprising a sealant.

0011In <figref idref="f0003">FIG. 3</figref>, a seven-layer multilayer structure 30 is shown having a first layer 31, a second layer 32, a third layer 33, a fourth layer 34, a fifth layer 35, a sixth layer 36, and a seventh layer 37. Structure 30 may have a first layer comprising polyester; a second layer 32, a third layer 33 and a sixth layer 36 each comprising an adhesive; a fourth layer 34 comprising a nylon blend wherein the third layer contains no more than 29% (wt.) of amorphous nylon; a fifth layer 35 comprising an oxygen barrier; and a seventh layer comprising a sealant.

0012In <figref idref="f0004">FIG. 4</figref>, a seven-layer multilayer structure 40 is shown having a first layer 41, a second layer 42, a third layer 43, a fourth layer 44, a fifth layer 45, a sixth layer 46, and a seventh layer 47. The structure 40 may have a first layer 41 comprising a polyester; a second layer 42, a fourth layer 44, and sixth layer 46 each comprising an adhesive; a third layer 43 comprising a homopolymer or copolymer of a polyolefin; a fifth layer of a nylon blend wherein the third layer contains no more than 29% (wt.) of amorphous nylon; and a seventh layer 47 comprising a sealant.

0013As used herein, the term "polyester" refers to a synthetic homopolymers and copolymers having ester linkages between monomer units which may be formed by condensation polymerization methods. Polymers of this type are preferable aromatic polyesters and more preferable, homopolymers and copolymers of poly (ethylene terephthalate), poly (ethylene naphthalate) and blends thereof. Suitable aromatic polyesters may have an intrinsic viscosity between 0.60 to 1.0, preferably between 0.60 to 0.80.

0014With reference to multilayer structure 10, the first layer 11 provides superior dimensional stability to the film during the thermoforming process and can serve as a surface layer in the film structure. The thickness of the first layer may be greater than or less than less than 127 µm (5 mils) or less than 76 µm (3 mils) and is typically between about 6.35 µm (0.25 mils) to about 127 µm (5 mils), preferably between about 6.35 µm (0.25 mils) to about 76 µm (3.0 mils). Examples of preferred polyesters are available under the trademarks EASTAPAK® PET Polyester 9663, EASTPAK® Polymer 9921 and EASTAR® Copolyester 6763, all from Eastman Chemical Company, Kingsport, Tennessee, U.S.A.

0015Second layer 12 is an adhesive material e.g. selected from the group consisting of a modified or unmodified homopolymer or copolymer especially ethylene copolymers, alkyl acrylates such as methyl acrylate, ethyl acrylate, n-butyl acrylate, or vinyl esters such as ethylene vinyl acetate, especially ethylene vinyl acetate copolymers, ethylene-alpha olefin (EAO), olefin and blends thereof.

0016"Olefin" is used herein broadly to include polymers such as polyethylene, ethylene copolymers having a small amount of a copolymer such as vinyl acetate, ethylene-alpha olefin copolymers (LLDPE), polypropylene, polybutene, and other polymeric resins falling in the "olefin" family classification.

0017As used herein, the term "modified" refers to a chemical derivative e.g. one having any form of anhydride functionality, such as anhydride of maleic acid, crotonic acid, citraconic acid, itaconic acid, fumaric acid, etc., whether grafted onto a polymer, copolymerized with a polymer, or blended with one or more polymers, and is also inclusive of derivatives of such functionalities, such as acids, esters, and metal salts derived therefrom.

0018One of the primary functions served by second layer 12 is as a bonding layer, i.e., to bond first layer 11 with third layer 13. Preferably the first and third layers directly contact opposing sides of the second layer, but optionally one or more additional layers may be coextruded between the first and third layers as long as these intermediate layers in conjunction with the adhesive lamination have sufficient adherence and corresponding delamination resistance for the intended use e.g. as a thermoformable film. The thickness of the second layer is between about 3.75 µm (0.15 mils) to about 127 µm (5.0 mils), preferably between about 75 µm (0.3 mils) to about 10 µm (0.4 mils). Examples of suitable commercially available adhesives are sold by Rohm and Haas, Philadelphia, Pennsylvania, U.S.A. under the trademark TYMOR® 72X06; Mitsui Petrochemical Industries, Ltd. of Tokyo, Japan, under the trademark ADMER^TM SF700; and DuPont Chemical Company, Wilmington, Delaware, U.S.A. under the trademark BYNEL® 41E687.

0019The third layer 13 comprises a nylon blend. Suitable nylons include nylon homopolymers and copolymers such as those selected form the group consisting of nylon 4,6 (poly(tetramethylene adipamide)), nylon 6 (polycaprolactam), nylon 6,6 (poly(hexamethylene adipamide)), nylon 6,9 (poly(hexamethylene nonanediamide)), nylon 6,10 (poly(hexamethylene sebacamide)), nylon 6,12 (poly(hexamethylene dodecanediamide)), nylon 6/12 (poly(caprolactam-co-dodecanediamide)), nylon 6,6/6 (poly(hexamethylene adipamide-<i>co</i>-caprolactam)), nylon 11 (polyundecanolactam), nylon 12 (polyauryllactam) and alloys or mixtures thereof.

0020The third layer comprises between about 100% (wt.) to about 71 % (wt.) of a nylon selected from the group consisting of nylon 4,6 (poly(tetramethylene adipamide)), nylon 6 (polycaprolactam), nylon 6,6 (poly(hexamethylene adipamide)), nylon 6,9 (poly(hexamethylene nonanediamide)), nylon 6,10 (poly(hexamethylene sebacamide)), nylon 6,12 (poly(hexamethylene dodecanediamide)), nylon 6/12 (poly(caprolactam-co-dodecanediamide)), nylon 6,6/6 (poly(hexamethylene adipamide-co-caprolactam)), nylon 11 (polyundecanolactam), nylon 12 (polyauryllactam) and alloys or mixtures thereof; blended with between about 0% (wt.) to about 29% (wt.) of an amorphous nylon.

0021The generic source-based nomenclature convention is used to name the hereinabove nylon polymers and copolymers. See, "<nplcit id="ncit0001" npl-type="s"><text>Generic Source-Based Nomenclature For Polymers," Pure Applied Chemistry, Vol. 73, No. 9, pp. 1511-1519 (International Union of Pure and Applied Chemistry 2001</text></nplcit>).

0022The third layer typically has a thickness between about 0.5 mils to about 4 mils, and preferably comprises between about 5% to about 20% of the total thickness for the first, second and third layers combined. Examples of commercially available nylons are sold under the trademark ULTRAMID® C35 or ULTRAMID® B36 from BASF, Mount Olive, New Jersey, U.S.A., and 66 ZYTEL® 42A NC010 from DuPont Chemical Company, Wilmington, Delaware, U.S.A. A commercial example of an amorphous nylon is sold under the trademark SELAR® PA 3426 from DuPont Chemical Company, Wilmington, Delaware, U.S.A.

0023As used herein, the term "amorphous nylon" refers to nylons with an absence of a regular three-dimensional arrangement of molecules or subunits of molecules extending over distances, which are large relative to atomic dimensions. However, regularity of structure exists on a local scale. See, "<nplcit id="ncit0002" npl-type="b"><text>Amorphous Polymers," Encyclopedia of Polymer Science and Engineering, 2nd Ed., pp. 789-842 (J. Wiley &amp; Sons, Inc. 1985</text></nplcit>). In particular, the term "amorphous polyamide" as used with respect to the present invention refers to a material recognized by one skilled in the art of differential scanning calorimetry (DSC) as having no measurable melting point (less than 0.5 cal/g) or no heat of fusion as measured by DSC using ASTM 3417-83. Such nylons include those amorphous nylons prepared from condensation polymerization reactions of diamines with diacarboxylic acids. For example, an aliphatic diamine is combined with an aromatic dicarboxylic acid, or an aromatic diamine is combined with an aliphatic dicarboxylic acid to give suitable amorphous nylons.

0024The first, second and third layers are combined into a multilayer film by single-bubble blown or slot cast extrusion. When polymers are extruded into mono or multilayer films using cast methods such as the slot cast method, "gauge bands" tend to form; which are narrow strips of thicker extrudate running continuously in the machine direction. Gauge bands accumulate as the film is wound onto a roll, which accentuates the variations in film thickness and ultimately results in an undesirable film. For this reason, it is preferred that the multilayer structure of the present invention is coextruded into a multilayer film by the single-bubble blown method. As used herein, the term "coextruded" refers to the process of extruding two or more materials through a single die with two or more orifices arranged so that the extrudates merge and weld together into a film structure before chilling and solidifying, e.g., via water, chilled metal, or air quenching. In accordance with the present invention, the preferred film is nonoriented.

0025Multilayered structure 10 is formed into a flexible film by a coextrusion process; and preferably by a single-bubble blown or slot cast coextrusion process, most preferably by a single-bubble blown film process.

0026In accordance with the present invention, the multilayered structure 10 with three layers formed into a flexible film has a thickness less than 406 µm (16 mils), more preferably less than 254 µm (10 mils), and most preferably, from 76 µm (3 mils) to 178 µm (7 mils). In the present invention, the multilayered structure 20 with seven layers formed into a flexible film has a thickness less than 406 µm (16 mils), more preferable less than 254 µm (10 mils), and most preferably, from 76 µm (3 mils) to 178 µm (7 mils).

0027Further, the multilayered structure 10 formed into a flexible film has a heat as measured in accordance with the Heat Shrinkage Test method. The shrinkage value of less than 5% at 90°C; preferably less than 2% at 90°CHeat Shrinkage Test is defined to be values obtained by measuring unrestrained shrink at 90°C. for five seconds. Four test specimens are cut to 10 cm. in the machine direction by 10 cm. in the transverse direction. Each specimen is completely immersed for 5 seconds in a 90°C. water bath (or other specified nonreactive liquid). The distance between the ends of the shrunken specimen is measured. The difference in the measured distance for the shrunken specimen and the original 10 cm. is multiplied by ten to obtain the percent of shrinkage for the specimen for each direction. The M.D. shrinkage for the four specimens is averaged for the machine direction shrinkage value of the given film sample, and the T.D. shrinkage for the four specimens is averaged for the transverse direction shrinkage value.

0028It is also preferred that the multilayered structure 10 formed into a flexible film have a percent elongation at break at room temperature of greater than about 250 in either or both the machine direction and in the transverse direction. The percent elongation at break may be measured by following the procedure as outlined by ASTM D-882, Method A.

0029According to the present invention, the multilayered structure 10 may advantageously be formed into a flexible film containing less than 500 ppm of a transition-metal salt selected from the group consisting of manganese II, manganese III, iron II, iron III, cobalt II, cobalt III, nickel II, nickel III, copper I, copper II, rhodium II, rhodium III, rhodium IV, and ruthenium.

0030Small amounts of additives such as slip or anti-block agents, pigments, processing aids and the like can be included in any of the layers in the multilayered structure 10 or in any layers further added to this structure which is formed into a flexible film.

0031One noteworthy characteristic of the flexible films formed from multilayered structure 10 of this invention is they provide superior optical properties, i.e., high gloss. Gloss may be measured using the test method described by ASTM D-2457 at a 45° angle. According to the present invention, the multilayered structure 10 formed into a film has a gloss value greater than about 65 Hunter Units (HU).

0032Multilayer structure 10 may be used alone, i.e., as a three-layer film. For certain packaging applications, it may be beneficial to include the three-layer structure 10 as a substructure in a larger multilayer flexible film. In such a configuration, the larger multilayer film incorporating structure 10 as a substructure may advantageously possess properties and benefits resulting from the three-layer structure 10 as discussed above, but may also possess additional properties and benefits arising from the additional layers.

0033Larger multilayer film structures which incorporate structure 10 as a substructure may have at least one additional layer adhered to structure 10 by various methods known to those skilled in the art which include thermal lamination, adhesive lamination, coextrusion coating, coextrusion lamination.

0034Slot cast or single-bubble blown coextrusion of structure 10 with additional polymeric layers produces multilayer structure 20. Multilayer structure 20 formed into a flexible film includes a fourth layer 24, which may comprise a gas barrier or a second adhesive.

0035When the multilayer structure 20 includes a gas barrier as a fourth layer 24, it is preferable that the barrier be an oxygen barrier. Preferred oxygen barriers include ethylene vinyl alcohol copolymer, polyvinylidene chloride copolymers, polyacrylonitrile, acrylonitrile copolymer, and blends thereof. A more preferred oxygen barrier is an ethylene vinyl alcohol copolymer, which is commercially available under the trademark SOARNOL ET3803 obtained from The Nippon Synthetic Chemical Industry Company, Ltd. (Nippon Gohsei), Osaka, Japan.

0036A noteworthy characteristic of the flexible film formed from multilayered structure 20 where the fourth layer 24 is an oxygen barrier is that the film exhibits excellent barrier properties. Oxygen permeation resistance or barrier may be measured using the procedure of ASTM D-3985. Accordingly, the multilayered structure 10 formed into a flexible film where the fourth layer 24 is an oxygen barrier has an oxygen transmission rate less than about 15.5 cc/m² for 24 hours at 1 atmosphere.

0037When the multilayer structure 20 includes an adhesive as the fourth layer 24, the function of the fourth layer 24 is to bond layer 23 and layer 25 together. Suitable materials which can be used as an adhesive are selected from a group consisting of a modified or unmodified homopolymer or copolymer of alkyl acrylates such as methyl acrylate, ethyl acrylate, n-butyl acrylate, or vinyl esters such as vinyl acetate, especially ethylene vinyl acetate copolymers (EVA), ethylene-alpha olefin (EAO), olefin and blends thereof. Preferred adhesives are similar to those useful in the second layer and may include anhydride and/or rubber modified EVAs and EAOs.

0038Multilayer structure 20 formed into a flexible film preferably includes a fifth layer 25 comprises nylon or nylon blend. The fifth layer comprises a nylon selected form the group consisting of nylon 4,6 (poly(tetramethylene adipamide)), nylon 6 (polycaprolactam), nylon 6,6 (poly(hexamethylene adipamide)), nylon 6,9 (poly(hexamethylene nonanediamide)), nylon 6,10 (poly(hexamethylene sebacamide)), nylon 6,12 (poly(hexamethylene dodecanediamide)), nylon 6/12 (poly(caprolactam-co-dodecanediamide)), nylon 6,6/6 (poly(hexamethylene adipamide-co-caprolactam)), nylon 11 (polyundecanolactam), nylon 12 (polyauryllactam) and alloys or mixtures thereof.

0039Preferably, the fifth layer is a blend between about 100% (wt.) to about 71 % (wt.) of a nylon selected form the group consisting of nylon 4,6 (poly(tetramethylene adipamide)), nylon 6 (polycaprolactam), nylon 6,6 (poly(hexamethylene adipamide)), nylon 6,9 (poly(hexamethylene nonanediamide)), nylon 6,10 (poly(hexamethylene sebacamide)), nylon 6,12 (poly(hexamethylene dodecanediamide)), nylon 6/12 (poly(caprolactam-co-dodecanediamide)), nylon 6,6/6 (poly(hexamethylene adipamide-<i>co</i>-caprolactam)), nylon 11 (polyundecanolactam), nylon 12 (polyauryllactam) and alloys or mixtures thereof; and between about 0% (wt.) to about 29% (wt.) of an amorphous nylon.

0040Examples of commercially available nylons are sold under the trademark ULTRAMID® C35 and ULTRAMID® B36 from BASF, Mount Olive, New Jersey, U.S.A., and 66 ZYTEL® 42A NC010 from DuPont Chemical Company, Wilmington, Delaware, U.S.A. A commercial example of an amorphous nylon is sold under the trademark SELAR® PA 3426 from DuPont Chemical Company, Wilmington, Delaware, U.S.A.

0041Multilayer structure 20 formed into a flexible film may further comprise a sixth layer 26 being an adhesive. The sixth layer 26 functions as an adhesive for bonding layer 25 and layer 27 together. Suitable materials as an adhesive are selected from a a group consisting of a modified or unmodified homopolymer or copolymer of alkyl acrylates such as methyl acrylate, ethyl acrylate, n-butyl acrylate, or vinyl esters such as vinyl acetate, especially ethylene vinyl acetate copolymers (EVA), ethylene-alpha olefin (EAO), olefin and blends thereof. Preferred adhesives are similar to those useful in the second layer and may include anhydride and/or rubber modified EVAs and EAOs.

0042An example of a commercially available material is sold under the trademark BYNEL® 41E687 from DuPont Chemical Company, Wilmington, Delaware, U.S.A. When layers are being laminated together as part of the structure containing the required coextrusion then the adhesive to adher the laminate of one or more added layers may also be chosen from chemical adhesives such as urethane or isocynate adhesives.

0043Multilayer structure 20 formed into a flexible film preferably includes a seventh layer 27 comprising a sealant. As used herein, the term "sealant" refers to a layer which is heat sealable to itself, i.e., be 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. Advantageously, the bond interface must be sufficiently thermally stable to prevent gas or liquid leakage therethrough.

0044Examples of suitable materials for the seventh layer 27 in the multilayered structure 20 include a sealant selected from a group consisting of an ionomer, heterogeneous ethylene alpha olefin copolymer, a homogeneous ethylene alpha olefin copolymer, ethylene vinyl acetate copolymer, ethylene methyl acrylate copolymer, ethylene propylene copolymer, polybutylene homopolymer or copolymer, and blends thereof.

0045The invention will now be further described in the following examples.

EXAMPLES 1 TO 4

0046It is to be understood, the present invention is not restricted to the following examples within the scope of the invention.

0047In all the following examples, all film structures were produced using a single-bubble coextrusion apparatus and method. The single-bubble blown film apparatus includes a multi-manifold circular die head for bubble blown film through which the film composition is forced and formed into a cylindrical bubble. The bubble is immediately quenched e.g., via cooled water bath, solid surface and/or air, and then ultimately collapsed and formed into a film.

Example 1

0048For Example 1, the first layer 11 comprises polyester and polyester additives, which are dried prior to being mixed together. The polyester comprises a copolymer of polyester terephthalate having a reported density of about 1.27 g/cm³, an inherent viscosity of 0.70, a 45° gloss of 108 Hunter Units (HU) and is available under the trademark EASTAR Copolyester 6763 from Eastman Chemical Company, Kingsport, Tennessee, U.S.A. A second layer 12 is an adhesive resin having a density of 0.941 g/ cm³, melt flow index of 5.0 g/10 minutes, a Vicat softening point of 48 °C, and is available under the trademark TYMOR® 72X06 from Rohm and Haas Company, Philadelphia, Pennsylvania, U.S.A. Third layer 13 is a mixture of nylon 6 having a density of 1.12 g/cm³, a melting point of a 220 °C, a recrystallization temperature (as measured by deferential scanning calorimetry (DSC)) of 176 °C, being available under the trademark ULTRAMID® B36 from BASF Corporation, Mount Olive, New Jersey, U.S.A.; and an amorphous nylon having a density of 1.19 g/cm³, a glass transition temperature of 127 °C, a heat deflection temperature at 66 psi of 126 °C, and is sold under the trademark SELAR® PA 3426 by DuPont Chemical Company, Wilmington, Delaware, U.S.A.

0049In Example 1, in accordance with the present invention, a multilayer thermoformable structure is formed into a film by the following procedure:

0050Each layer is melt plastified in a separate extruder connected to an annular coextrusion die from which the heat plastified layers are coextruded forming a tube or bubble. The bubble has a first layer, a second layer and a third layer. The first and third layers are directly attached to opposing sides of the second core layer.

0051For each layer, the resin or resin mixture are fed from a hopper into an attached single screw extruder where the resin or resin mixture are heat plastified and extruded through a three layer coextrusion die into a tube or single-bubble. The extruder barrel temperature for the first layer is 500°F. (260°C.) and for the second and third layers is about 520°^F. (271°C.). The bubble is maintained at a width of less than 134.6 cm (53 inches). The extruded multilayer bubble is quenched against a cooled solid surface. The cooled bubble is flattened by passage through a pair of nip rollers and the resultant film of Example 1 has an average gauge of about 5 mils.

0052With reference to <figref idref="f0001">FIG. 1</figref>, a multilayered structure 10 is formed into a film in accordance with the present invention having the following three layers: <ul id="ul0002" list-style="none" compact="compact"><li>Layer 1: 97.5% Poly (ethylene terephthalate) + 1.5% anti-block additive + 1.0% slip agent (20% of total weight of layers 1-3).</li><li>Layer 2: Adhesive (55% of total weight of layers 1-3).</li><li>Layer 3: 85% Nylon 6 + 15% amorphous nylon (25% of total weight of layers 1-3).</li></ul>

EXAMPLES 2-4

0053For Example 2, first layer 21 comprises a homopolymer of polyester terephthalate having a reported crystalline density of about 1.4 g/cm³, an inherent viscosity of 0.80, a 45° gloss of 108 Hunter Units (HU) and is available under the trademark EASTAPAK Polymer 9921 from Eastman Chemical Company, Kingsport, Tennessee, U.S.A.

0054For Example 3-4, the first layer 21 comprised a polyester terephthalate copolymer and polyester additives, which are dried prior to being mixed together. The polyester terephthalate copolymer had a reported density of about 1.27 g/cm³, an inherent viscosity of 0.70, a 45° gloss of 108 Hunter Units (HU) and was available under the trademark EASTAR Copolyester 6763 from Eastman Chemical Company, Kingsport, Tennessee, U.S.A.

0055For Example 2-4, the second layer 22 and sixth layer 26 were identical adhesive material having a reported density of 0.88 g/cm3, a melt index at 190°C of 1.0 g/10 min. and was available under the trademark ADMER™ SF700 from Mitsui Petrochemical Industries, Ltd., Tokyo, Japan. Third layer 23 and fifth layer 25 were identical mixtures of nylon 6 having a density of 1.12 g/cm³, a melting point of a 220 °C, a recrystallization temperature (as measured by deferential scanning calorimetry (DSC)) of 176 °C, being available under the trademark ULTRAMID® B36 from BASF Corporation, Mount Olive, New Jersey, U.S.A.; and an amorphous nylon having a density of 1.19 g/cm³, a glass transition temperature of 127 °C, a heat deflection temperature at 455 KPa (66 psi) of 126°C, and is sold under the trademark SELAR® PA 3426 by DuPont Chemical Company, Wilmington, Delaware, U.S.A.

0056For Example 2-3, the fourth layer 24 comprised ethylene vinyl alcohol copolymer (EVOH) having a reported bulk density of 0.64-0.74 g/cm³, a relative density of 1.13-1.22 g/cm³, a melting point of 164-188°C, and was available under the trademark SOARNOL® ET3803 from the Nippon Synthetic Chemical Industry Company, Ltd. (Nippon Gohsei), Osaka, Japan.

0057In Example 4, the fourth layer 24 was an adhesive material having a density of 0.941 g/ cm³, melt flow index of 5.0 g/10 minutes, a Vicat softening point of 48 °C, and was available under the trademark TYMOR® 72X06 from Rohm and Haas Company, Philadelphia, Pennsylvania, U.S.A..

0058For Examples 2-4, the seventh layer 27 comprises a partial zinc salt of ethylene methacrylic acid copolymers having a density of 0.940 g/ cm³, a melt flow index at 190°C of 1.30 g/10 min., a Vicat softening point of 165°F. (73.9°C.), and was available under the trademark SURLYN® 1601 from DuPont Chemical Company, Wilmington, Delaware U.S.A.

0059In examples 2-4, one extruder was used for each layer. Each extruder was connected to an annular coextrusion die from which heat plastified resins were coextruded forming a tube or single-bubble having seven layers.

0060The resin or resin mixture was fed from a hopper into an attached single screw extruder where the heat plastified and extruded through a seven-layer coextrusion die into a tube or single-bubble. The extruder barrel temperature for the first layer was about 500°F. (260°C.); for the second layer 510 °F. (266 °C. ); and for the third through seventh layers, about 520 °F. (271 °C.). The bubble is maintained at a width of less than 134.6 cm (53 inches). The extruded multilayer bubble is quenched against a cooled solid surface. The cooled bubble is flattened by passage through a pair of nip rollers and the resultant film of Example 2-4 had an average gauge between 4 mil to 6 mil.

0061With reference to <figref idref="f0002">FIG. 2</figref>, a multilayered structure 20 was formed into a film in accordance with the present invention having the following seven layers:

Example 2

0062<ul id="ul0003" list-style="none" compact="compact"><li>Layer 21: Poly (ethylene terephthalate) (20% of total weight of layers 1-7).</li><li>Layer 22: Adhesive (13% of total weight of layers 1-7).</li><li>Layer 23: 85% Nylon 6 + 15% amorphous nylon (14% of total weight of layers 1-7).</li><li>Layer 24: Oxygen barrier (9% of total weight of layers 1-7).</li><li>Layer 25: 85% Nylon 6 + 15% amorphous nylon (14% of total weight of layers 1-7).</li><li>Layer 26: Adhesive (12% of total weight of layers 1-7).</li><li>Layer 27: Sealant (18% of total weight of layers 1-7).</li></ul> The film had a total thickness of about 127 µm (5 mils).

Example 3

0063<ul id="ul0004" list-style="none" compact="compact"><li>Layer 21: 98.5% Poly (ethylene terephthalate) + 1.0% anti-block additive + 0.5% slip agent (25% of total weight of layers 1-7).</li><li>Layer 22: Adhesive (11% of total weight of layers 1-7).</li><li>Layer 23: 85% Nylon 6 + 15% amorphous nylon (14% of total weight of layers 1-7).</li><li>Layer 24: Oxygen barrier (9% of total weight of layers 1-7).</li><li>Layer 25: 85% Polyamide 6 + 15% amorphous polyamide (14% of total weight of layers 1-7).</li><li>Layer 26: Adhesive (10% of total weight of layers 1-7).</li><li>Layer 27: Sealant (17% of total weight of layers 1-7).</li></ul> The film had a total thickness of about 101.6 µm (4 mils).

Example 4

0064<ul id="ul0005" list-style="none" compact="compact"><li>Layer 21: 97.5% Poly (ethylene terephthalate) + 1.5% anti-block additive + 1.0% slip agent (15% of total weight of layers 1-7).</li><li>Layer 22: Adhesive (11% of total weight of layers 1-7).</li><li>Layer 23: 85% Nylon 6+ 15% amorphous nylon (9% of total weight of layers 1-7).</li><li>Layer 24: Adhesive (9% of total weight of layers 1-7).</li><li>Layer 25: 85% Nylon 6 + 15% amorphous nylon (9% of total weight of layers 1-7).</li><li>Layer 26: Adhesive (21 % of total weight of layers 1-7).</li><li>Layer 27: Sealant (26% of total weight of layers 1-7).</li></ul> The film had a total thickness of about 101.6 (4 mils).

0065Table 1 shows a comparison of the amount of elongation in the machine direction and transverse direction for films having different thicknesses in a seven-layered structure. Table 2 shows a comparison of the amount of shrinkage in the machine direction and transverse direction for films having different thicknesses in a seven-layered structure. <tables id="tabl0001" num="0001"><table frame="topbot"><title>TABLE 1</title><tgroup cols="7" rowsep="0"><colspec colnum="1" colname="col1" colwidth="14mm" /><colspec colnum="2" colname="col2" colwidth="25mm" /><colspec colnum="3" colname="col3" colwidth="25mm" /><colspec colnum="4" colname="col4" colwidth="25mm" /><colspec colnum="5" colname="col5" colwidth="25mm" /><colspec colnum="6" colname="col6" colwidth="26mm" /><colspec colnum="7" colname="col7" colwidth="26mm" /><thead valign="top"><row rowsep="1"><entry namest="col1" nameend="col7" colsep="0" rowsep="0" align="center"><u>COMPARISON OF % ELONGATION FOR EXAMPLE 1</u></entry></row><row rowsep="1"><entry colsep="0" /><entry namest="col2" nameend="col3" colsep="0" align="center">76.2 µm (3 mil) Machine/Transverse</entry><entry namest="col4" nameend="col5" colsep="0" align="center">127 µm (5 mil) Machine/Transverse</entry><entry namest="col6" nameend="col7" colsep="0" align="center">254 µm (10 mil) Machine/Transverse</entry></row></thead><tbody><row><entry colsep="0" /><entry colsep="0" align="char" char=".">386.8</entry><entry colsep="0" align="char" char="." charoff="22">484.4</entry><entry colsep="0" align="char" char=".">519.6</entry><entry colsep="0" align="char" char="." charoff="22">575.0</entry><entry colsep="0" align="char" char=".">643.6</entry><entry colsep="0" align="char" char="." charoff="21">612.9</entry></row><row><entry colsep="0" /><entry colsep="0" align="char" char=".">469.1</entry><entry colsep="0" align="char" char="." charoff="22">434.1</entry><entry colsep="0" align="char" char=".">516.8</entry><entry colsep="0" align="char" char="." charoff="22">529.8</entry><entry colsep="0" align="char" char=".">630.8</entry><entry colsep="0" align="char" char="." charoff="21">600.4</entry></row><row><entry colsep="0" /><entry colsep="0" align="char" char=".">412.1</entry><entry colsep="0" align="char" char="." charoff="22">459.3</entry><entry colsep="0" align="char" char=".">513.4</entry><entry colsep="0" align="char" char="." charoff="22">579.2</entry><entry colsep="0" align="char" char=".">615.2</entry><entry colsep="0" align="char" char="." charoff="21">599.2</entry></row><row><entry colsep="0" /><entry colsep="0" align="char" char=".">429.3</entry><entry colsep="0" align="char" char="." charoff="22">458.7</entry><entry colsep="0" align="char" char=".">518.9</entry><entry colsep="0" align="char" char="." charoff="22">562.3</entry><entry colsep="0" align="char" char=".">637.1</entry><entry colsep="0" align="char" char="." charoff="21">639.0</entry></row><row><entry colsep="0" /><entry colsep="0" align="char" char=".">406.1</entry><entry colsep="0" align="char" char="." charoff="22">427.1</entry><entry colsep="0" align="char" char=".">484.0</entry><entry colsep="0" align="char" char="." charoff="22">551.8</entry><entry colsep="0" align="char" char=".">605.1</entry><entry colsep="0" align="char" char="." charoff="21">590.2</entry></row><row rowsep="1"><entry colsep="0" align="center">AVE</entry><entry colsep="0" align="char" char=".">420.7</entry><entry colsep="0" align="char" char="." charoff="22">452.7</entry><entry colsep="0" align="char" char=".">510.5</entry><entry colsep="0" align="char" char="." charoff="22">559.6</entry><entry colsep="0" align="char" char=".">626.4</entry><entry colsep="0" align="char" char="." charoff="21">608.3</entry></row></tbody></tgroup></table></tables><tables id="tabl0002" num="0002"><table frame="topbot"><title>TABLE 2</title><tgroup cols="3" rowsep="0"><colspec colnum="1" colname="col1" colwidth="27mm" /><colspec colnum="2" colname="col2" colwidth="30mm" /><colspec colnum="3" colname="col3" colwidth="35mm" /><thead valign="top"><row rowsep="1"><entry namest="col1" nameend="col3" colsep="0" rowsep="0" align="center"><u>COMPARISON OF % SHRINKAGE FOR EXAMPLE 1</u></entry></row><row rowsep="1"><entry colsep="0" align="center">Thickness</entry><entry colsep="0" align="center">Machine Direction</entry><entry colsep="0" align="center">Transverse Direction</entry></row></thead><tbody><row><entry colsep="0">76.2 µm (3 mil)</entry><entry colsep="0" align="char" char="." charoff="6">0.0%</entry><entry colsep="0" align="char" char="." charoff="6">0.0%</entry></row><row><entry colsep="0">127 µm (5 mil)</entry><entry colsep="0" align="char" char="." charoff="6">1.5 %</entry><entry colsep="0" align="char" char="." charoff="6">0.5 %</entry></row><row rowsep="1"><entry colsep="0">254 µm (10 mil)</entry><entry colsep="0" align="char" char="." charoff="6">1.0 %</entry><entry colsep="0" align="char" char="." charoff="6">0.0 %</entry></row></tbody></tgroup></table></tables>

0066Various features of the invention are particularly shown and described in connection with the illustrated embodiments of the invention. However, it must be understood that the particular arrangements do not limit, but merely illustrates, and the invention is to be given its fullest interpretation within the terms of the appended Claims.