IE52177B1 - A multi-layer polymeric structure having a moisture sensitive polymeric layer - Google Patents

Description

The present invention relates to a multi-layer polymeric structure having a moisture sensitive polymeric layer.

Such multi-layer polymeric structures are 5 suitable for flexible and rigid packaging for food.

Flexible multi-layer films are used for pouches, bags, and wraps. Thicker multi-layer structures can be formed into shape-retaining containers in the shapes and sizes common for metal cans. Sufficient imperm10 eability to oxygen throughout the expected storage life of the packaged product is a necessity. Most economically practical polymers suitable for packaging purposes are relatively poor oxygen barriers. Consequently, an interior layer of a polymer impermeable to oxygen is desired. Among the favored candidate polymers for harrier layers are ethylenevinyl alcohol (EVOH) and polyvinyl alcohol (FVOH).

Both are excellent oxygen harriers, but both are quite moisture sensitive. Above a relatively modest moisture content, both rapidly begin to lose oxygen barrier quality. There are several opportunities for intrusion of moisture into the barrier layer from the packaged food itself, from storage in moist air and from water vapor present in commercial sterilisation processes.

The present invention aims to protect the moisture sensitive oxygen barrier layer from the adverse effects of moisture, and to maintain its water content at a low enough level so as to preserve the oxygen barrier qualities thereof adequately for a prolonged period.

According to the present invention, there is provided a multi-layer laminate structure for packaging, comprising an oxygen barrier polymer layer the oxygen permeability of which increases substantially upon moisture entering the polymer a water absorbing agent being dispersed in another polymeric layer of the structure which agent maintains an oxygen t permeability of the barrier polymer layer of no more than 1.35 ml per day per 100 sq. inches (645 cm ) when the pressure gradient is one atmosphere of oxygen per mil (0.025 mm) of thickness of said barrier polymer layer.

Also according to the present invention, there is provided a multi-layer laminate structure for packaging, comprising an oxygen barrier polymer layer the oxygen permeability of which increases substantially upon moisture entering the polymer, the barrier polymer layer being an interior layer of the structure and a water absorbing agent being incorporated in the structure, which agent maintains an oxygen permeability of the barrier polymer layer of no more than 1-35 ml per day per 100 sq. inches (645 cm ) when the pressure gradient is one atmosphere of oxygen per mil (0.025 mm) of thickness of said barrier polymer layer.

GB-A-1,199,843 discloses packaging materials specifically for packaging photographic films and proposes that certain black resin coating materials should contain desiccants to enable a packaging substrate to be opaquely coated in a manner avoiding the formation of holes, bubbles or other imperfections which render the S3177 packaging useless for light-sensitive materials. This patent neither addresses nor even recognises the moisture problem which the present invention solves and the problem the prior patent sought to overcome is self-evidently wholly different from that facing the present applicants.

GB-A-1,384,791 discloses a packaging laminate having an anhydrous polyvinyl alcohol (PVOH) oxygen barrier layer. This barrier layer is described as being associated with a polyurethane-based primer, the function of which is said to remove small amounts of water present in the PVOH during manufacture. Prom our experience, polyurethanes do not absorb significant amounts of water. Moreover, the commercially-available material cited in this patent as a suitable primer is not in fact a polyurethane, though it can be converted into one. The manufacturers of the cited commercially available material have stated that it is essentially unreactive with water, and certainly not nearly as reactive with water as a polyurethane.

The moisture-sensitive layer can be EVOH or PVOH and the water-absorbing agent can advantageously be contained in adhesive layers which bond the moisture sensitive layer to other layers of the structure. The said other layers can be outer layers and may be mainly responsible for conferring the necessary integrity or strength to the structure.

The invention is described in more detail below byway of example with reference to the accompanying drawings in which: Figure 1 is a graph of oxygen permeability as a function of water content for EVOH, 53177 Figure 2 is an enlarged cross-sectional view of a multi-layer polymeric structure, suitable for food packaging, to which this invention is applicable, Figure 3 is a graph of water content as a function of retort time for an EVOH layer in a multi-layer package, and Figure 4-7 are graphs, or isotherms, for various types of drying agents, illustrating the variation of drying ability of a desiccant with -the water activity or humidity of the surroundings.

Vinyl alcohol polymers and copolymers are excellent oxygen harrier materials, as noted above.

Substantially fully hydrolyzed ethjrlene-vinyl alcohol copolymers (EVOH) have rheological properties which allow them to be coextruded with common packaging polymers, and so EVOH represents preferred polymeric material for use as an oxygen barrier layer in both rigid and flexible multi-layer polymeric structures for packaging. EVOH is a relatively expensive polymer, costing ns much as ei^it times the cost of polymers commonly used in packaging. Its cost dictates the use of a very thin layer of EVOH.

A layer of dry EVOH less than one one-thousandth of an inch (1 mil) or 0.025 mm can provide sufficient protection from oxygen to permit storage of some foods for more than one year.

EVOH and PVOH are moisture sensitive polymers.

The oxygen barrier quality of an EVOH or PVOH layer is degraded by the presence of moisture in the layer. Figure 1 is a plot of oxygen permeability of EVOH as a function of moisture or water content. The oxygen permeability is presented in cubic centimeters per day for a film area of 100 square inches (645 cm) at a pressure gradient of one atmosphere 02 per mil (0.025 ran) of film thickness, that is; co«mil 09 permeability --λ ........ 100 in «day·atm The moisture or water content is presented as the weight percentage of water in the EVOH and is also presented as water activity. Water activity is most simply defined as the water vapor pressure exerted by a substance divided by the vapor pressure 2θ of pure water at the same temperature and pressure.

When expressed as a percentage, water activity is often called relative humidity. A strict thermodynamic definition of water activity is discussed in such standard texts as Thermodynamics by Lewis and Randall (1923). It should be noted that oxygen permeability i3 plotted on a logarithmic scale in Figure 1. There 1b a tenfold increase in permeability between a water content of about 3 percent and 7 percent and over a hundredfold increase between about 3 percent and 12 percent. Thus, a moisture content in excess of about 7 percent causes rapid degradation of the oxygen barrier quality of the EVOH. Food packaging economics favor an oxygen permeability of 0.1 or less, again expressed in the above described units. The cost of EVOH dictates the use of thin layers when very small quantities of water cause a significant increase in water activity. This causes the oxygen permeability to exceed desired limits. EVOH is hydrophilic and extracts moisture from the surroundings.

To protect the EVOH layer from moisture, it is buried between inner and outer layers of moisture barrier polymers such as polyethylene, polypropylene, or blends of the two. Figure 2 is an enlarged cross-sectional view of a typical multi-layer container wall. The polyolefin structural layers 1 and 2 are adhered to the EVOH oxygen barrier layer 3 by adhesive layers 4 and 5. The adhesive layers 4, 5 may be a modified polyolefin such as those sold under the name Plexar (Trade Mark) by Chenplex Corp, of Bolling Meadows, Illinois. Suitable EVOH polymeric materials having vinyl alcohol contents of approximately 70 mole percent are sold under the name EVAL by Kuraray Chemical Co., Ltd., and also by Nippon Goshei Co. Ltd. under the names GLD and GLE. Polyolefins are good moisture barriers at and below expectable normal ambient temperatures and thus serve to insulate the interior EVOH layer from moisture. However, at elevated temperatures polyolefins increasingly become more permeable to moisture. Many foods are retorted in the package or container to achieve commercial sterility. The ability to subject a filled food package to retort conditions of 250°F (121°C) or more for one half-hour or more in the presence of steam or water (under pressure) is a practical necessity. Retort conditions significantly increase the moisture permeability of polyolefins and allow moisture to enter the EVOH layer. Return of the package to room temperature restores the moisture impermeability of the polyolefin, thereby entrapping the moisture in the EVOH layer. The amount of moisture thus entrapped easily can exceed a water content of about 7 percent (water activity of about 0.9 at room temperature) thereby resulting in an oxygen harrier quality inadequate for many purposes. ι Figure 3 records the moisture absorbed by an EVOH layer buried in polyolefin inner and outer layers of a multi-layer rigid container of can shape. The water content is plotted as a function of time in a retort at 250°F (121°C). It can be observed that a all retort times above less than one half-hour, the water content is in excess of that (approximately 7X) which provides an oxygen permeability less than 0.1.

Water-absorbing agents, sometimes called desiccants, extract water from their surroundings.

We have determined that the incorporation of appropriate water-absorbing agents, hereinafter referred to as drying agents, in a multi-layer film structure can maintain an adequately low moisture content in a moisture sensitive layer. In particular, we have determined that the incorporation of drying agents in the adhesive layers 4, 5 adjacent to the barrier layer 3 of EVOH will preserve the oxygen barrier quality of EVOH by maintaining the water activity of the EVOH at a level below 0.8 or 0.9 (which corresponds to a water content of between 6 and 7 percent) to thereby keep the oxygen permeability below about 0.1.

Figure 4 is a generalized isotherm for hydrateforming drying agents such as sodium phosphate-dibasic and calcium chloride. The drying capacity (c, where c = wt. of water/wt. of agent) of the substance is plotted against the water activity (a) of the surroundings. When the surroundings are air, the water activity is usually expressed as relative humidity (R.H.). Ko water is taken up until the humidity or water activity reaches a value a-j_ at which the first hydrate forms. In the case of calcium chloride the first hydrate occurs at less than 2 percent R.H. (a <0.02). Water is taken up until point c·^ which represents completion of the first hydrate, Ko further water is taken up until the humidity or water activity reaches the value a2 where the second hydrate forms and takes up water to the point c2· This process continues through as many hydrates as the substance forms at which point (a_) the substance begins to dissolve and a saturated solution is formed. The saturated solution will then continue to take up water to the limit of saturation (c_) and beyond. s Figure 5 represents an isotherm of a drying agent which forms no hydrates. Common salt (KaCl) is typical of this class. Common salt will absorb no water at a humidity below about 75 percent. When the relative humidity reaches 75 percent, a saturated solution is formed which continues to take up water.

S3177 Figure 6 represents an isotherm of a v/ater soluble drying agent such as gelatin which absorbs water at all water activities. At high water activities it dissolves and the solution continues to take up water.

Figure 7 represents an isotherm of a water insoluble drying agent such as bentonite clay or silica gel which absorbs water at all water activities. No solution is formed with these agents and further adsorption ceasee when their intersticies are filled.

From the foregoing description of drying agents with reference to Figures 4 to 7» it can be observed that different materials act differently to extract water from their surroundings. Moreover, the absorption isotherm for a particular material depends upon temperature. Most available data are reported for room temperature. A particular material may act quite differently at elevated temperatures such as are encountered during retorting of foods. For example, although sodium phosphate-di-basic has three hydrates at room temperature, it forms none at 250°F (121°C).

Table I reports several drying agents which, at adequate loading (that is concentration in the ’ adhesive), resulted in favorable oxygen permeabilities 53177 I after at least a two hour retort at 250°F (121°C).

The agents were incorporated in the adhesive layers 4 and 5 of a multi-layer structure. Prior to use, the agents were comminuted in a Waring Blender and then screened. The agents and adhesive were compounded by melt blending with the adhesive polymeric material. The permeability data for the drying agents are averages of several determinations. The EVOH used was GED. The adhesive was Plexar III. The olefin was a high density polyethylene (HDPE).

S2177 Table I Agent Weight Percent of Thickness, mil (mm) Oxygen Permea- Agent in Adhesive EVOH Ai dhesive bility Olefin none 0 1.6 (0.041) 2.6 (0.066) 15 1.6-2.5*** (0.381) C&C3.,} 23.4 1.6 2.6 17 <0.02 (0.431) NaCl 19.5 1.7 (0.045) 2.4 (0.061) 14.7 0.08 (0.373) nh4ci 20.2 1.7 2.8 (0.071) 15 0.05 Na2HP04 20.7 1.6 2.6 15 0.03 Na2HP04* 2.5 1.7 2.5 (0.063) 15 1.80*** Na2HP04* 10.5 1.7 2.5 15 0.02 Sucrose . 40 1.8 (0.046) 3.0 (0.076) 14.6 <0.02 (0.371) Sucrose 22.5 1.8 2.8 15 <0.02 Sucrose 5 1.8 2.5 15 0.20 18.3 1.8 2.9 (0.074) 14.5 <0.02 (0.368) kai(so4)2 24 1.6 2.3 (0.058) 14.7 0.02 MgSO4 21.7 1.6 2.6 14.4 <0.02 (0.366) KBr** 17.5 1.7 2.8 14.9 0.11 (0.378) 317 7 Table I (Continued) Agent Weight Percent of Agent in Adhesive Thickness, mil Oxygen Permea- bility (mm) Olefin EVOH Adhesive MgCl2 20 1.8 2.5 15 <;o.O2 (nh4)2so4 20.5 1.9 2.5 15 0.12 (0.048) NaNOj 20 1.6 2.5 15 <0.02 hh4e2P04 25.2 1.6 2.7 (0.068) 14-.7 0.11 NaCl+NH4Cl Na2HP04 10,10 1.7 2.7 15 0.03 + NH4C1 10,10 1.9 2.5 15 <0.02 * 3 hr. re.tort at 250°F (121°C) ** 2.25 hr. retort at 250°F (121°C) *** comparison Table II reports several other candidate materials which were not as effective as -those in 2o Table I. The structures were otherwise similar to those of Table I.

Table II Agent Weight Percent Agent in Adhesive Thickness, mil (mm) Oxygen Permea- bility EVOH Adhesive Olefin CaO 15 1.6 2.8 14.8 0.84 (0.041) (0.071) (0.376) KNO5 20.8 1.65 2.5 15 0.35 (0.042) (0.063) (0.381) CaSO^ 24.6 1.5 2.6 14.8 2.4*** (0.058) (0.066) molecular sieve (Linde 4A) 20 1.6 2.7 14.6 1.35 (0.068) (0.371) bentonite clay 20 1.7 (0.043) 2.8 14.8 0.51 Na2S04 20.6 1.6 2.5 14.6 0.99 *** comparison Some experimentation has been conducted with polyvinyl alcohol (PVOH). PVOH has a curve of oxygen permeability as a function of water activity which differs from that for, EVOH (compare with Figure 1 for EVOH). The oxygen permeability of PVOH increases rapidly at water activity above 0.6. Since glycerin is often used as a plasticizer in PVOH, and since glycerin affects that curve, drying agents should be selected which result in a water activity somewhat below 0.6.

In a structure similar to those of Table I, 17 percent provided an oxygen permeability below 0.02, whereas FVOIi alone had a permeability of 1·7 or higher.

A test was run using Dm·; Saranex -(Trade Mark) brand multi-layer film including a 0.8 mil inner layer of Saran - Trade Mark _ (vinylidine chloride-vinyl chloride copolymer) with and without retorting at 250°F (121°C) for 1.25 hours and with and without sucrose (the drying agent) in the adhesive layers.

The outer layers were each 15 mil (0.381 mm) HDEE.

The adhesive layer was 2.6 mils (0.066 mm) thick. The results are tabulated helowj Table III Oxygen Permsability non-retorted retorted without sucrose with sucrose 0.23 0.80 0.20 0.23 From Table III, it can be seen that the inclusion of sucrose as the drying agent provided a permeability after retorting as low as before retorting. Saran is not as effective an oxygen barrier as is EVOH.

Desirable drying agents should have. sufficient drying capacity (c) at the water activity above which EVOH loses Its oxygen barrier quality. Potassium nitrate is an example of a material which has no drying capacity at a water activity below about 0. 85 (see Pig. 1). Therefore, according to our investigation even the use of large quantities of this material will not provide the EVOH with an oxygen permeability better than 0.35, see Table II. Further, desirable drying agents should have sufficient drying capacity to protect the EVOH at reasonable quantities or loadings of the agent. Molecular sieves, calcium sulphate (Drierite) and bentonite clay are examples of candidate materials which, at reasonable loadings, result in relatively high oxygen permeability, still further, desirable drying agents generally should have more drying capacity at higher water activities than at lower water activities to avoid premature exhaustion. Calcium oxide is as'active at 0.01 (water activity) as it is at 0.9 and therefore soon exhausts its drying capacity, so that this agent is not suitable to provide for prolonged storage.

Sucrose at 5 percent and sodium phosphate-dibasic at 2.5 percent are examples of drying agents inadequate at insufficient loadings but which are effective at higher loadings (see Table I).

Many sugars are effective drying agents for multi-layer structures because they have high drying capacities at a water activity level which preserves the oxygen barrier quality of E70H. Some sugars, such as sucrose galactose, glucose and maltose, are more effective after heating. For example, sucrose when heated to 350°F (176.6°C) for up to 40 minutes becomes effective. Such heating occurs during melt blending with the polymer.

Considerations in selection of drying agents include the ability to compound the drying agent with the polymer and to process the compound at the temperature dictated by the polymer. Calcium chloride, while very effective as a drying agent, is difficult to process because it normally contains at least the first hydrate which forms below 2 percent R.H. When the polymer is extruded or otherwise melt processed, water of hydration in calcium chloride compounded therewith is driven off and causes bubbles to form in the polymer.

The quantity of drying agent required is in part dictated by the need to have the drying agent still active after retorting. Too small a quantity may exhaust its drying capacity. Generally, drying agents are less expensive than the polymer with which they are compounded which encourages high loading of the polymer with agent. However, excessive loading may cause various problems such as interference with the adhesion of the polymer to the other layers.

Studies were made comparing identical rigid multi-layer polyolefin containers having a 2.0 mil (0.051 mm) EVOH buried layer where one group of containers was retorted and the other not. After the containers reached moisture equilibrium, the oxygen permeability was measured. The oxygen permeability of those having a history of retorting was higher. This leads to the conclusion that the properties of EVOH are not entirely restored by extracting moisture. Thus, it appears that it is more desirable to prevent the intrusion of moisture into the EVOH during retorting than to extract the moisture subsequently. It can he concluded that drying agents which are active under retort conditions have advantages. Potassium carbonate, sodium nitrate and ammonium chloride are examples of agents which are active during retorting.

The term drying agent or Water absorbing agent includes mixtures of two or more agents and include mixtures of agents in which one member is more active during retorting than the other(s). .Some mixtures have demonstrated better performance than do the components of the mixture separately (see Table I). 53177 Rigid containers comprising inner and outer layers of a blend of polypropylene and polyethylene, adhesive layers of Plexar (modified polyolefin) and an innermost barrier layer of EVOH were formed in the shape of cans and a metal end was double seamed on the open end by conventional canning techniques. The containers were retorted for 2 hours at 250°F (121°C). The containers were stored at room temperature with 100 percent R.H. inside and 75 percent outside. Those containers having drying agents in the adhesive layer showed superior oxygen, barrier after storage. Drying agents are desirable even for containers not subject to retorting. Containers without drying agents, when stored under the above conditions, show a threefold increase in permeability after 100 days, whereas those having drying agents show no increase.

The structural layers outside the barrier and the adhesive layers serve as moisture barriers.

TJhere the structural layers are relatively thick (polyolefin layer about 15 mils (o.383nm) ) the rate of- moisture transmission is low, lessening the demands made upon the drying agent. Consequently, there is a wide range of adequate drying agent materials.

The thinner structural layers used in films, pouches, or bags transmit more moisture and, therefore, impose greater demands upon the drying agent. For non-retorted thin packages, the drying agents should have a relatively high drying capacity in the range from about 0.5 to 0.8 water activity. Sodium chloride, sodium phosphate-di-basic and ammonium chloride are good choices. For thin retorted packages, a drying agent which is relatively inactive under retort conditions, but has high drying capacity subsequent to i’etorting is desired. Sodium phosphate-di-basic is effective because it exhibits no hydrates at 250°F (121°C) but forms hydrates at room temperature. (See Figure 4). Although the drying agents have been employed in the adhesive layers adjacent to ihe barrier layer, it is apparent that the layer containing the drying agent can he separated from the barrier layer by an intervening layer if that intervening layer is thin enough to allow moisture passage, or if that layer is a moisture permeable material such as nylon.

While the foregoing specification is written in terms of multi-layer polymeric structures for food packaging, the invention is applicable to multilayer structures for other purposes where maintenance of barrier properties of a moisture sensitive layer 9.2 c is important.

Experiments have shown that barrier polymers other than EVOH, such as polyvinyl alcohol and Saran, when subjected to retorting, benefit from the presence of drying agents.

Claims (15)

1. A multi-layer laminate structure for packaging, comprising an oxygen barrier polymer layer the oxygen permeability of which increases substantially upon moisture entering the polymer, a water absorbing agent being dispersed in another polymeric layer of the structure which agent maintains an oxygen permeability of the barrier polymer layer of no more than 1.35 ml per day per 100 sq. inches (645 cm ) when the pressure gradient is one atmosphere of oxygen per mil (0.025 mm) of thickness of said barrier polymer layer.

2. A structure according to Claim 1, wherein the said agent has a substantial drying capacity at a water activity level up to 0.8 to 0.9.

3. A structure according to Claim 1, wherein the barrier polymer is ethylene-vinyl alcohol copolymer and the said agent has a substantial drying capacity at a water activity of about 0.8 to 0.9.

4. A structure according to Claim 1, wherein the said agent has a substantial drying capacity at a water activity level in the range of 0.5 to 0.8.

5. A structure according to Claim 1, wherein the barrier polymer is polyvinyl alcohol and the said agent has a substantial drying capacity at a water activity of about 0.6.

6. A structure according to Claim 1, 2 or 3, wherein the said agent has a substantial drying capacity at a water activity below about 0.85 and a greater drying capacity at this water activity level than at lower water activities.

7. A structure according to any one of Claims 1 to 6, wherein the said agent is dispersed in more than one Interior polymeric layer of the structure.

8. A structure according to Claim 7, wherein the barrier layer is adhered to exterior layers of a structural polymer by intermediate layers of an adherent polymer, the intermediate polyer layers containing the said agent.

9. A structure according to Claim 8, wherein the exterior layers are of polyolefin, and the intermediate layers are of adherent modified polyolefin.

10. A structure according to any one of Claims 1 to 9, wherein the said agent is capable of maintaining the oxygen permeability of the barrier polymer layer at 0.23 ml or below, per 100 sq. inches (645 cm ) per day when the pressure gradient is one atmosphere of oxygen per mil (0.025 mm) of thickness of the barrier polymer layer.

11. A structure according to Claim 10, wherein said agent is capable of maintaining the oxygen permeability of the barrier 2 polymer layer at 0.1 ml or less per 100 sq. inches (645 cm ) per day.

12. A structure according to any one of Claims 1 to 9, wherein the said agent is selected from calcium chloride, sodium chloride, sodium phosphate-di-basic, sodium sulfate, ammonium chloride, sucrose, potassium carbonate, potassium aluminium sulphate, magnesium sulphate, magnesium chloride, sodium nitrate, ammonium sulphate, ammonium phosphate-monobasic, potassium bromide and mixtures of two or more of the foregoing.

13. A multi-layer laminate structure for packaging, comprising an oxygen barrier polymer layer the oxygen permeability of which increases substantially upon moisture entering the polymer, the barrier polymer layer being an interior layer of the structure and a water absorbing agent being incorporated in the structure, which agent maintains an oxygen permeability of the barrier polymer layer of no more than 1.35 ml per day per 100 sq. inches (645 cm ) when the pressure gradient is one atmosphere of oxygen per mil (0.025 mm) of thickness of said barrier polymer layer.

14. A multi-layer laminate structure according to Claim 1, substantially as hereinbefore described.

15. A multi-layer laminate structure according to Claim 13, substantially as hereinbefore described.