WO2017066779A1 - Metal coatings and co-extrusions - Google Patents

Metal coatings and co-extrusions Download PDF

Info

Publication number
WO2017066779A1
WO2017066779A1 PCT/US2016/057381 US2016057381W WO2017066779A1 WO 2017066779 A1 WO2017066779 A1 WO 2017066779A1 US 2016057381 W US2016057381 W US 2016057381W WO 2017066779 A1 WO2017066779 A1 WO 2017066779A1
Authority
WO
WIPO (PCT)
Prior art keywords
film
metallic
coating
gauge
oriented
Prior art date
Application number
PCT/US2016/057381
Other languages
French (fr)
Inventor
Mark W. Lockhart
Anand Sundararaman
Terry O. JENSEN
Daniel L. Hinman
Robert M. Sheppard
Original Assignee
Jindal Films Americas Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Jindal Films Americas Llc filed Critical Jindal Films Americas Llc
Publication of WO2017066779A1 publication Critical patent/WO2017066779A1/en

Links

Classifications

    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09DCOATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C09D5/38Paints containing free metal not provided for above in groups C09D5/00 - C09D5/36
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/022Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the choice of material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/09Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
    • B29C48/10Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels flexible, e.g. blown foils
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/15Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor incorporating preformed parts or layers, e.g. extrusion moulding around inserts
    • B29C48/151Coating hollow articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/16Articles comprising two or more components, e.g. co-extruded layers
    • B29C48/18Articles comprising two or more components, e.g. co-extruded layers the components being layers
    • B29C48/21Articles comprising two or more components, e.g. co-extruded layers the components being layers the layers being joined at their surfaces
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/06Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/16Layered products comprising a layer of synthetic resin specially treated, e.g. irradiated
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/18Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/18Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B32B27/205Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents the fillers creating voids or cavities, e.g. by stretching
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/28Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/30Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/30Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/306Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl acetate or vinyl alcohol (co)polymers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/32Layered products comprising a layer of synthetic resin comprising polyolefins
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/34Layered products comprising a layer of synthetic resin comprising polyamides
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/36Layered products comprising a layer of synthetic resin comprising polyesters
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04Interconnection of layers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04Interconnection of layers
    • B32B7/12Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00Layers arrangement
    • B32B2250/033 layers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00Layers arrangement
    • B32B2250/055 or more layers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00Layers arrangement
    • B32B2250/24All layers being polymeric
    • B32B2250/242All polymers belonging to those covered by group B32B27/32
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00Layers arrangement
    • B32B2250/40Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00Coating on the layer surface
    • B32B2255/10Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00Coating on the layer surface
    • B32B2255/20Inorganic coating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00Coating on the layer surface
    • B32B2255/20Inorganic coating
    • B32B2255/205Metallic coating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00Coating on the layer surface
    • B32B2255/28Multiple coating on one surface
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10Inorganic particles
    • B32B2264/101Glass
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10Inorganic particles
    • B32B2264/102Oxide or hydroxide
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10Inorganic particles
    • B32B2264/104Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10Inorganic particles
    • B32B2264/105Metal
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10Inorganic particles
    • B32B2264/107Ceramic
    • B32B2264/108Carbon, e.g. graphite particles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/40Properties of the layers or laminate having particular optical properties
    • B32B2307/402Coloured
    • B32B2307/4026Coloured within the layer by addition of a colorant, e.g. pigments, dyes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/40Properties of the layers or laminate having particular optical properties
    • B32B2307/406Bright, glossy, shiny surface
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/40Properties of the layers or laminate having particular optical properties
    • B32B2307/41Opaque
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/50Properties of the layers or laminate having particular mechanical properties
    • B32B2307/514Oriented
    • B32B2307/518Oriented bi-axially
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/50Properties of the layers or laminate having particular mechanical properties
    • B32B2307/538Roughness
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/50Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54Yield strength; Tensile strength
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/50Properties of the layers or laminate having particular mechanical properties
    • B32B2307/546Flexural strength; Flexion stiffness
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/50Properties of the layers or laminate having particular mechanical properties
    • B32B2307/584Scratch resistance
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/70Other properties
    • B32B2307/724Permeability to gases, adsorption
    • B32B2307/7242Non-permeable
    • B32B2307/7246Water vapor barrier
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/70Other properties
    • B32B2307/732Dimensional properties
    • B32B2307/734Dimensional stability
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/70Other properties
    • B32B2307/75Printability
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2439/00Containers; Receptacles
    • B32B2439/40Closed containers
    • B32B2439/46Bags
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2439/00Containers; Receptacles
    • B32B2439/70Food packaging
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2519/00Labels, badges

Definitions

  • the disclosure relates to metal coatings on co-extruded, multilayered films, processes applied thereto, products made therefrom such as bags, tags, packages, labels, and other structures, and uses thereof, such as to contain foods, beverages, and other articles or other finished products uses, such as those stated hereinbelow.
  • Metallic films may be obtained by chemical or vapor deposition of metal on suitable receptive substrates. However, these metallic films typically have poor ink printability, ink adhesion and surface-resistance. A second step occurs that applies a top- topcoat to permit surface printability and/or scratch-resistance is applied inline or offline during or after the metallization process respectively. Or, the metal layer may be buried by lamination under a printable film.
  • the film may be modified to include a matte skin or have a metallic surface that is further coated with a matte coating.
  • a metallic film that may include a multilayered film, optionally being oriented and having optionally having one or more additives, metallized layers, primers, coatings, sealants, treated layers, or combinations thereof. Further, the metallic film may include a metal coating applied to at least one outer surface of the multi-layered film, wherein the metal coating comprises a selected combination of size and type of one or more metal pigments, wherein the selected combination is for turning an appearance ranging from matte to sheen for the metallic film, whereby the metal coating is a substitute for a coating applied to a metallized layer.
  • a coextruded, oriented, multilayered film may include a core flanked by skin layers comprising polyethylene or polypropylene copolymer, optionally comprising tie layers between the core and the skin layers, and optionally comprising additives. Further, the coextruded, oriented, multilayered film may include one or more metal pigments and cavitaring agents in at least one of the core and the tie layers, whereby both sides of the coextruded, oriented, multilayered film have a metallic appearance.
  • a coextruded, oriented, multilayered film may include a core flanked by tie layers, and the tie layers flanked by skin layers, wherein all layers comprise polypropylene.
  • Hie coextruded, oriented, multilayered film may also include one or more metal pigments and carbon black in the core, and one or more tie layers located on a first side of the core comprises a whitening agent, whereby a first side of the coextruded, oriented, multilayered film has a metallic appearance and a second side of the coextruded, oriented, multilayered film has a white appearance.
  • This disclosure generally relates to methods, compositions, and structures, such as packages, bags, tags, labels, roll to roll wrap around labels, horizontal-form-fill-and-seal (“HFFS”) containers, vertical-form-fiU-and-seal (“VFFS”) containers, lids, sachets, stand-up pouches, overwraps, and so forth (i.e., collectively, "applications") associated with multilayercd films having optionally printable, metal coatings as an alternative or addition to standard metallization, e.g., vacuum-deposited metal on a biaxially oriented polypropylene (“BOPF') multilayered film.
  • HFFS horizontal-form-fill-and-seal
  • VFFS vertical-form-fiU-and-seal
  • applications associated with multilayercd films having optionally printable, metal coatings as an alternative or addition to standard metallization, e.g., vacuum-deposited metal on a biaxially oriented polypropylene (“BOPF') multilayered
  • This disclosure's type of labels may vary and appear on goods that include, for example: Arnold PalmerTM-type drinks, where the label has metal or metal foil; roll-to-sheet, hot-melt-applied, wrap-around labels; magazine feed labels; labels on waters, beer, wine and other beverages, foods, hair care items, cosmetics, aerosol cans; replace hot and cold foil stamping; pressure-sensitive labels; tire labels; block-out labels; any label that is for hot or cold foil applications; or applications where current label has a gun- metal appearance.
  • appearances may range anywhere from matte to sheen and from smooth to rough, e.g., brushed.
  • the disclosed metal coatings may be used in applications for the food or non-food industries, particularly in view of the point that the metal coating(s) may impede water-vapor transmission, i.e., improved barrier properties.
  • the metal coatings' print layer may be receptive to various print applications, including, for example, UV-flexo inks, UV screen inks, UV letterpress inks, and solvent- based or water-based inks, and may be laser-printed, inkjet-printed with code date, or thermal-transfer-ribbon-printed.
  • a multilayered film may have an A/B/C structure comprising at least a "core layer” "C,” optional “tie layer(s)” “B,” and “skin layer(s)” "A” with a tie layer between the core and skin layers.
  • the layers impart protection/cavities/color and can desirably be co-extruded layers of polymer or polymer mixtures.
  • the multilayered films may include processing aids or one or more additives such as opacifying agent, coloring agents, inks, pigments, cavitating agents, slip agents, anti-static agents, anti-block agents, void-initiating materials, fillers, and combinations thereof, so as to produce a translucent or opaque film, as desired.
  • processing aids or one or more additives such as opacifying agent, coloring agents, inks, pigments, cavitating agents, slip agents, anti-static agents, anti-block agents, void-initiating materials, fillers, and combinations thereof.
  • CaCOj as a cavitating agent
  • any of a number of other cavitating agents may be used in addition or in place of CaCCb, such as polybutylene terephthalates (“PBT”), glass beads, cyclic olefin polymers and/or cyclic olefin copolymers (“COC”), zeolites, etc., and combinations thereof.
  • PBT polybutylene tere
  • polymer may be used to refer to homopolymers, copolymers, interpolymers, terpolymers, etc., wherein such polymers may vary in density, stereoregularity, method of production (e.g., catalytic or not), and other chemical and physical properties.
  • the multilayered films may or may not be uniaxially or biaxially oriented.
  • Orientation in the direction of extrusion is known as machine direction (“MD") orientation.
  • Orientation perpendicular to the direction of extrusion is known as transverse direction (“TD") orientation.
  • Orientation may be accomplished by stretching or pulling a film first in the MD followed by the TD.
  • Orientation may be sequential or simultaneous, depending upon the desired film features.
  • Orientation ratios are commonly from between about three to about six times the extruded width in the MD and between about four to about ten times the extruded width in the TD.
  • Blown films may be oriented by controlling parameters such as take up and blow up ratio. Cast films may be oriented in the MD direction by take up speed, and in the TD through use of tenter equipment. Blown films or cast films may also be oriented by tenter- frame orientation subsequent to the film extrusion process, in one or both directions. Typical commercial orientation processes are BOPP tenter process and Linear Motor Simultaneous Stretching ("LISIM”) technology.
  • One or both of the outer exposed surfaces of the multilayered films may be surface-treated to increase the surface energy of the film to render the film receptive to metallization, coatings, printing inks, and/or lamination. The surface treatment may be carried out according to one of the methods known in the art. Exemplary treatments include, but are not limited to, corona-discharge, flame, plasma, chemical, by means of a polarized flame, or otherwise.
  • the film may first be surface treated, for example, by corona treatment, and then be treated again in the coating line, for example, by flame treatment, immediately prior to being coated.
  • the film may first be surface treated, for example, by flame treatment, and then be treated again in the metallization chamber, for example, by plasma treatment, immediately prior to being metallized.
  • Metallized films may be obtained by chemical or vapor deposition of appropriate metal ingot on suitable substrates like BOPP or biaxially oriented polyester film (“BOPET”) films.
  • BOPET biaxially oriented polyester film
  • the metallized layer is one of the outer skin and/or sealant layers.
  • the surface of a core layer may be metallized.
  • Such layers may be metallized using conventional methods, such as vacuum deposition, of a metal layer such as aluminum, copper, silver, chromium, or mixtures thereof from an oxide or otherwise of such metals.
  • These metallized films have poor ink printability, ink adhesion and surface scratch or resistance.
  • a second step may involve top- coating the metallized surface to enhance the surface printability and scratch resistance, whereby the top-coating is applied inline or offline and either during or after the metallization process.
  • the film's metallized layer may be buried by lamination under a printable film. Nevertheless, tuning the metallic appearance of the film is challenging in order to obtain different metallic shades. For instance, high-sheen films may have a negative effect under light due to reflection, and, thereby, resulting in poor product identification.
  • the multi layered film is modified to include a matte skin, and/or the metallized surface is further coated with a matte coating.
  • One example embodiment of the disclosed composition, methods and structures includes a multilayered film having a brushed-metal appearance with remarkable opacity and radiant-energy barriers, including, for instance, in the UV and IR spectra.
  • the disclosed composition, methods and structures may produce a printable metallic film in a single step so as to replace the conventional two-step vacuum metallization and coating steps.
  • one or more metallic pigments wherein the metal may be aluminum, copper, nickel, zinc, silver, gold, alloy, etc., may be dispersed in a coating (i.e., a mixture) that is compatible with metallic pigments, and applied, for example, to at least one outer surface of a film, be it multilayered or not.
  • a coating i.e., a mixture
  • Using different types of pigment(s), varying the particle size(s) of the pigment(s), or combinations of the foregoing may tune or alter the metallic appearance of the multilayered film. Larger particle sizes may provide higher sheen and smaller particle size provides more matte or gray shades.
  • the coating's composition may be tailored to the end-use application based on the choice of the aluminum pigments size and type.
  • a metal pigment may have particle size varying, for instance, in a range from 1 ⁇ to 100 ⁇ . In other embodiments, the pigment particle size may be within the range of S ⁇ to SO ⁇ , or even 7 ⁇ to 35 ⁇ .
  • the metal pigment itself, may be of milled-grade flake, such as cornflake, rounded silver dollar, thick tuff flake, ultra-thin, vacuum-metallized flake, any other flakes, or combinations thereof.
  • the metal pigments may be of a leafing type, whereby the metallic pigments may orient at the wet coating-air interface, or of a non-leafing type, whereby the metallic pigments are distributed throughout the bulk of the coating layer.
  • the chemical properties are critical for its application in different coating or resin systems, e.g., solvent-borne or waterborne.
  • unstablized or bare aluminum in a pigment may react vigorously with water to form aluminum hydroxide, Al(OH)3( S ), hydrogen, H3 ⁇ 4 g ), and heat.
  • This decomposition reaction results in the loss of the aluminum's metallic appearance due to the formation of a much grayer darker of Al(OH)3 (S ).
  • Passivation of aluminum pigments may improve the durability of the pigments and their aesthetic effects in waterborne coatings.
  • organophosphorous compounds or other inorganic passivators such as chromium oxides, zinc oxides, or silicon oxides, are used during the passivation of metallic-effect pigments.
  • the aluminum pigment may be supplied as pre-passivated from a vendor or may be passivated in- house before formulating into the coating.
  • the unstablized or bare pigment may be either passivated in situ with appropriate additives in waterborne coating systems or used directly in appropriate solvent-borne coating system(s).
  • orientation or laydown of the metal pigment is critical for a smooth metallic appearance of the film. For instance, uniform horizontal or parallel alignment of the metal pigment to the substrate improves a smooth, metallic appearance. Alternatively, a non- uniform alignment of the metallic pigments results in a greyish, uneven, metallic appearance.
  • the multilayered film may have a structure as shown in Figure 1.
  • the metallic coating may be applied using a gravure coater, rod coater, slot die technique, spray technique or otherwise.
  • the dry coating thickness may range, for example, from between 0.03 g/m 2 through 50 g/m 2 , or in the range from between 0.15 g/m 2 through 15.5 g/m 2 , or yet in the range from between 0.6 g/m 2 through 8 g/m 2 .
  • the properties of the metallic coating layer may be modified by changing the coating component(s). For instance, using a print-receptive component may generate a multilayered film with a metallic film coating that is printable.
  • Example resins of the print- receptive components include, but are not limited to epoxy acrylates, polyurethane acrylates, and/or polyester acrylates.
  • combining the metallic pigments in the metallic coating layer with a hard, cross-linked coating may enhance the scratch resistance of the metallic coated, multilayered film (collectively, a "scratch- resistance coating”).
  • using coating component(s) that impart barrier polymer will result in a metallic coated, multilayered film with barrier properties (collectively, a "barrier coating").
  • combining the metallic pigments in the metallic coating layer with a soft-touch coating may provide a metallic coated, multilayered film with soft touch properties.
  • the metallic pigments may include a coating that is receptive to digital printing that provides a matte, metallic appearance (i.e., a natural look) to the digital-printable surface, e.g., a type of printable coating.
  • embodiments may include other pigments with the aluminum flakes such as a carbon black pigment incorporated with the metallic pigment to provide additional hiding and opacity.
  • an organic yellow or red pigment can be incorporated with the aluminum metallic pigment to provide rich gold or red metallic appearance.
  • the metallic appearance of the film may be tuned from high sheen to a dull, subdued, brushed metal look by choosing the pigment, coating, and combinations thereof.
  • the disclosed, metallic film could have a metal coatings with some or all of the example types of coating functionalities, e.g., printable, scratch-resistance, barrier, soft-touch, sealability, low coefficient of friction, etc.
  • the remainder of the multilayered film i.e., "base film”
  • the base film may vary, and include, but is not limited to films having core, tie, and/or skin layers comprising polymers, such as polypropylene, polyester, nylon, polyethylene, polyamide, polylactic acid etc.
  • the base film may include a clear or cavitated BOPP, BOPET, biaxially oriented polyethylene film (BOPE), or combinations thereof.
  • the base film may be monoaxially oriented or non-oriented.
  • FIG. 2 shows an example embodiment of the multilayered aspect of the base film.
  • This exemplary S-layered base film includes outermost skin layers, which may have specific properties like printability, sealability, low co-efficient of friction, barrier properties, otherwise and combinations of the foregoing.
  • the skin layer on one side i.e., skin layer- 1 or skin layer 2 or both sides (i.e., skin layer 1 and skin layer 2) may include a layer of low density polyethylene (LDPE), liner low density polyethylene (LLDPE), medium density polyethylene (MDPE), high density polyethylene (HDPE), and combinations thereof.
  • LDPE low density polyethylene
  • LLDPE liner low density polyethylene
  • MDPE medium density polyethylene
  • HDPE high density polyethylene
  • one or more of the skin, tie and/or core layers may have a barrier layer, which may include, for example, ethylene vinyl alcohol (“EVOH”), polyvinylidene chloride (“PVDC”), nylon, acrylonitrile, etc.
  • a barrier layer may include, for example, ethylene vinyl alcohol (“EVOH”), polyvinylidene chloride (“PVDC”), nylon, acrylonitrile, etc.
  • one or more barrier layers may be placed between the tie layers and the skin(s) and/or the core.
  • the outer skin layers of the multilayered films may be primed, treated, and/or metallized.
  • the barrier layer(s) may be physical vapor deposited (PVD) or chemical vapor deposited (CVD) to the appropriate skin layer- 1 and/or skin layer-2.
  • the vapor deposited layer may be an aluminum (AT) layer, aluminum oxide (AIO*) layer, and/or silicon oxide (SiO x ) layer.
  • the skin, tie or core may have a cavitated structure and/or contain Ti0 2 particles to render the multilayered film opaque, such as to the point of being white.
  • any of the layers of the multilayered films may include one or more additives.
  • the thickness of the film is only limited by the coatings application process and the end-use application of the metallic coated, multilayered film Examples of thickness of the film may be between 12 ⁇ and 55 ⁇ , but much greater or lesser thicknesses may be formed.
  • these embodiments may have a structure as shown in Figure 3. That is, instead of only one or more front side metallic coating(s), wherein each coating layer is of the same or different composition, as shown and discussed with relation to Figures 1 and 2, the base film may also include back side metallic coating(s), wherein each coating layer is of the same or different composition. Otherwise, all of the foregoing description equally applies to two-sided, metallic-coated, multilayer films.
  • Figure 3 may include a host of different components, layers, coatings, additives, primers, sealants, treatments, and so forth, as well as having thicknesses on the same level or otherwise, and undergoing one or more of the previously discussed coating processes or otherwise to apply the back-side coating(s).
  • the metallic coating layer may be top coated with a second clear coating layer, also referred to as a "top coat-1" in Figure 4.
  • the top coat-1 may have different properties such as printability, scalability, low co-efficient of friction, barrier layers, otherwise, and combinations thereof. Further, since the metallic coating layer is underneath top coat-1, this structure provides additional surface scratch or mar resistance to the metallic coating layer.
  • the back side of the top-coated, metallic coated, multilayered film may be coated with a second coating that may have metallic pigments, provide clear coating, otherwise and combinations thereof.
  • the backside coating may have different properties such as printability, scalability, low co-efficient of friction, barrier properties, otherwise, and combinations thereof.
  • this layer can be further top-coated with a second clear coating, also referred to as a top coat-2 in Figure 5.
  • the base film and other layers, as well as optional tie layer(s), metallic coating(s), and so form may contain the same or different polymers and additives, and undergo the same or different treatments, primers, metallizing, and so forth as discussed earlier in mis application.
  • the metallic pigments suitable for extrusion may be blended with different resin types, such as a polypropylene, polyester, nylon, polyethylene, polyamide, polylactic acid, etc., and extruded to generate a film with metallic, matte metallic appearance or silver glossy appearance.
  • metallic pigments such as those that may undergo extrusion, may be incorporated into core layer, tie layer(s), skin layer(s) and combinations thereof.
  • the metallic pigment may be incorporated into the core layer of coextruded structure, in line with the structure shown at Figure 6A.
  • skin layers can have specific properties like printability, sealability, low co-efficient of friction, or barrier layer.
  • Additional and alternative embodiments may incorporate the extrudable metallic pigments into the core layer, tie layer(s), skin layer(s) and combinations thereof.
  • embodiments may include carbon black pigment incorporated with the metallic pigment to provide additional hiding and opacity.
  • FIG. 6B Another example structure for the disclosed films is illustrated in Figure 6B.
  • Its skin layer 1 is a LLDPE, such as Dowlex 2027G, with a poly gauge of 3.2 gauge.
  • the tie layer-1 may be an extrusion blended mixture of a polypropylene homopolymer, such as ExxonMobil 4912, and extrusion grade aluminum pigment, such as Sparkle Silvet 960-30-E1 from Silberline.
  • the aluminum content in the tie layer is 4%, but may vary in other embodiments.
  • the poly gauge of the tie layer-1 is 16.2 gauge in one example embodiment, but may vary in other example embodiments.
  • the core layer may be a mixture of a PP homopolymer ExxonMobil 4912 and Ampacet 403250 Pearl 2A MB containing calcium carbonate (CaC(3 ⁇ 4) blended in 82:18 ratio, but either or both types of PP and cavitation agent as well as ratios may vary in other embodiments.
  • the poly gauge of the core layer is 49.4 gauge, but may vary in other example embodiments.
  • the tie layer-2 may be an extrusion blended mixture of a polypropylene homopolymer, such as ExxonMobil 4912, and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30-E1 from Silberline.
  • the aluminum content in the tie layer is 4% in this example embodiment, but may vary in other embodiments.
  • the poly gauge of the tie layer-2 is 16.2 gauge, but may vary in other example embodiments.
  • the skin layer-2 may be a blend of 86.5% ExxonMobil HD6704.18, 10% Schulman S45, 1% Spartech Polycom A27527, and 2.5% Schulman MB0353-STAB, but may vary in other example embodiments.
  • the poly gauge of the tie layer-2 is 5.0 gauge, but may vary in other example embodiments.
  • the presence of the LLDPE skin layer may provide improved printability as illustrated in Table 2.
  • the presence of aluminum in the aluminum pigment in tie layers- 1 and 2 may provide the "metallic look" on both sides of the film for a two-sided, "metallic look" film.
  • tie layers- 1 and 2 also may provide increased opacity.
  • the presence of calcium carbonate in the polypropylene core provides cavitation, which may result in a white core and impart increased opacity to the film.
  • Skin layer-2 having an HDPE skin may provide cold-seal applications to the film.
  • the yield of the film is determined by ASTM D4321 test method and is 35567 in 2 /lb.
  • the optical gauge of the film is 32.3 micrometers (1.27 mils).
  • the light transmittance of the film was determined by ASTM D1003 test method and is 26.3%.
  • Skin layer-1 may be a LLDPE such as Dowlex 2027G.
  • the poly gauge of this skin layer-1 was increased S.O gauge to improve processability.
  • Tie layer- 1 may be an extrusion blended mixture of a polypropylene homopolymer, such as ExxonMobil 4912, and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30- El from Silberline.
  • the aluminum content in the tie layer is 4% but may vary in other example embodiments.
  • the poly gauge of the tie layer-1 is 16.2 gauge.
  • the core layer may be a mixture of a PP homopolymer, such as ExxonMobil 4912 and Ampacet 403250 Pearl 2A MB containing calcium carbonate (CaC(3 ⁇ 4) from Ampacet blended in 82:18 ratio, but the PP, cavitating agent, and ratio may differ in other example embodiments.
  • the poly gauge of the core layer is 49.4 gauge.
  • Tie layer-2 may be an extrusion blended mixture of a PP homopolymer, such as ExxonMobil 4912, and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30-E1 from Silberline, but the PP and metallic pigment may differ in other example embodiments.
  • the aluminum content in the tie layer is 4% but may vary in other example embodiments.
  • the poly gauge of tie layer-2 is 16.2 gauge.
  • Skin layer-2 may be a blend of 86.5% ExxonMobil HD6704.18, 10% Schulman S45, 1% Spartech Polycom A27527, and 2.5% Schulman MB0353-STAB.
  • the poly gauge of the skin layer-2 is 5.0 gauge.
  • the presence of the LLDPE skin layer may provide improved printability as illustrated in Table 2.
  • Aluminum in the aluminum pigment in tie layers- 1 and 2 may provide the "metallic look" on both sides of the film for a two-sided, "metallic look" film. Additionally, the aluminum also may provide increased opacity.
  • Calcium carbonate in the polypropylene core may provide cavitation, which may result in a white core and impart increased opacity to the film.
  • Skin layer-2 having HDPE may provide cold-seal applications.
  • the yield of the film is determined by ASTM D4321 test method and is 34246 in 2 /lb.
  • the optical gauge of the film is 34.3 micrometers (1.35 mils).
  • the light transmittance of the film was determined by ASTM D1003 test method and is 27.8%.
  • Skin layer-1 may be a LLDPE such as Dowlex 2027G with a poly gauge of 3.2 gauge.
  • Tie layer-1 may be an extrusion blended mixture of a PP homopolymer, such as ExxonMobil 4912, and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30-E1 from Silberline, but the PP and metallic pigment may differ in other example embodiments.
  • the aluminum content in the tie layer is 8%, but may vary in other example embodiments.
  • the poly gauge of the tie layer-1 is 16.2 gauge.
  • the core layer may be a mixture of a PP homopolymer, such as ExxonMobil 4912 and Ampacet 4032S0 Pearl 2A MB containing calcium carbonate (CaCO ? ) from Ampacet blended in 82:18 ratio, but the PP, cavitating agent, and ratio may differ in other example embodiments.
  • the poly gauge of the core layer is 49.4 gauge.
  • Tie layer-2 may be an extrusion blended mixture of a polypropylene homopolymer, such as ExxonMobil 4912, and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30-E1 from Silberline, but the PP and metallic pigment may differ in other example embodiments.
  • the aluminum content in the tie layer is 8%, but may vary in other example embodiments.
  • the poly gauge of tie layer-2 is 16.2 gauge.
  • Skin layer-2 may be a blend of 86.5% ExxonMobil HD6704.18, 10% Schulman S45, 1% Spartech Polycom A27S27, and 2.5% Schulman MB0353-STAB, but the blend's components and ratios may different in other embodiments.
  • the poly gauge of the skin layer-2 is 5.0 gauge.
  • Aluminum in the aluminum pigment in tie layers- 1 and 2 may provide the "metallic look" on bom sides of the film for a two-sided, "metallic look" film. Additionally, the aluminum also may provide increased opacity dependent on the aluminum loading in the tie layer.
  • the light transmittance of the film decreased from 26.3 to 18.4.
  • Calcium carbonate in the polypropylene core may provide cavitation, which may result in a white core and impart increased opacity to the film.
  • Skin layer-2 having HDPE may provide cold-seal applications.
  • the yield of the film is determined by ASTM D4321 test method and is 34353 in 2 Ab.
  • the optical gauge of the film is 36.6 micrometers (1.44 mils).
  • the light transmittance of the film was determined by ASTM D1003 test method and is 18.4%. While the higher aluminum loading in the tie layer resulted in improved opacity it however resulted in decreased film optics due to blister and void formation arising due to incompatibility of aluminum flakes at higher concentration in the polypropylene matrix.
  • Skin layer- 1 is a copolymer of polypropylene such as Total 8573HB with an antiblock content of lOOOppm and a poly gauge of S.O gauge.
  • the polypropylene skin provides improved compatibility with the tie layer and hence improved processability.
  • Tie layer- 1 may be an extrusion blended mixture of a polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30- E1 from Silberline.
  • the aluminum content in the tie layer is 8%, but may vary in other example embodiments.
  • the poly gauge of the tie layer- 1 may be 16.2 gauge.
  • the core layer may be mixture of a polypropylene homopolymer, such as Exxon Mobil 4912, and Ampacet 403250 Pearl 2A MB containing calcium carbonate (CaCCb) from Ampacet blended in 82:18 ratio, but the PP, cavitating agent, and ratio may differ in other example embodiments.
  • the poly gauge of the core layer may be 49.4 gauge.
  • Tie layer-2 may be an extrusion blended mixture of a polypropylene homopolymer, such as Exxon Mobil 4912, and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30-E1 from Silberline, but the PP and metallic pigment differ in other example embodiments.
  • the aluminum content in the tie layer is 8%, but may vary in other example embodiments.
  • the poly gauge of the tie layer-2 may be 16.2 gauge.
  • Skin layer-2 may be a blend of 86.5% ExxonMobil HD6704.18, 10% Schulman S45, 1% Spartech Polycom A27527, and 2.5% Schulman MB0353-STAB.
  • the poly gauge of the skin layer-2 may be 5.0 gauge.
  • Aluminum in the aluminum pigment in tie layers- 1 and 2 may provide the "metallic look" on both sides of the film for a two-sided, "metallic look" film. Additionally, aluminum also may provide increased opacity.
  • Hie calcium carbonate in the polypropylene core may provide cavitation, which may result in a white core and impart increased opacity to the film Skin layer-2 having an HDPE skin may provide cold-seal applications.
  • the yield of the film was determined by ASTM D4321 test method and is 36487 in 2 /lb.
  • the optical gauge of the film is 38.1 micrometer (1.S0 mils).
  • the light transmittance of the film was determined by ASTM D1003 test method and is 18.23%. While the higher aluminum loading in the tie layer resulted in improved opacity it however resulted in decreased film optics due to blister and void formation arising due to incompatibility of aluminum flakes at higher concentration in the polypropylene matrix.
  • Skin layer- 1 may be a copolymer of PP, such as Total 8S73HB, with an antiblock content of 1000 ppm.
  • the poly gauge of skin layer- 1 may be S.O gauge.
  • Tie layer- 1 is an extrusion blended mixture of a polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30-E1 from Silberline.
  • the aluminum content in the tie layer is 2%, but may vary in other example embodiments.
  • the poly gauge of the tie layer-1 is 16.2 gauge.
  • the core layer may be mixture of a polypropylene homopolymer, such as ExxonMobil 4912 and Ampacet 403250 Pearl 2 A MB containing calcium carbonate (CaCC ⁇ ) from Ampacet blended in 82:18 ratio, but the PP, cavitating agent, and ratio may differ in other example embodiments.
  • the poly gauge of the core layer may be 49.4 gauge or other gauges in other example embodiments.
  • the tie layer-2 may be an extrusion blended mixture of a polypropylene homopolymer, such as Exxon Mobil 4912 and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30-E1 from Silberline.
  • aluminum pigment In addition or in the alternative to this example aluminum pigment, other aluminum pigment(s), other pigments having different metal(s) than aluminum, or combinations thereof may be used in alternative example embodiments in this structure or other structures.
  • the aluminum content in the tie layer is 2% but may vary in other example embodiments.
  • the poly gauge of tie layer-2 may be 16.2 gauge or a different gauge.
  • Skin layer-2 may be a blend of 86.5% ExxonMobil HD6704.18, 10% Schulman S45, 1% Spartech Polycom A27527, and 2.5% Schulman MB0353-STAB.
  • the poly gauge of skin layer-2 may be 5.0 gauge.
  • the aluminum present in the aluminum pigment in tie layers- 1 and 2 may provide the "metallic look" on both sides of the film for a two-sided, "metallic look” film. Additionally, aluminum pigment also may provide increased opacity. The presence of calcium carbonate in the polypropylene core may provide cavitation, which may result in a white core and impart increased opacity to the film. Skin layer-2 having an HDPE skin may provide cold-seal applications. The yield of the film was determined by ASTM D4321 test method and is 35299 in 2 /lb. The optical gauge of the film is 32.3 micrometers (1.27 mils). The light transmittance of the film was determined by ASTM D1003 test method and is 36.37%. While the lower aluminum loading in the tie layer resulted in decreased opacity it however resulted in better film optics.
  • Skin layer-1 may be a copolymer of polypropylene, such as Total 8573HB, with an antiblock content of 1000 ppm.
  • the poly gauge of skin layer-1 may be 5.0 gauge.
  • Tie layer-1 is an extrusion blended mixture of a polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30-E1 from Silberline.
  • the aluminum content in the tie layer is 2% but may vary in other example embodiments.
  • the poly gauge of the tie layer-1 was raised to 25 gauge to increase the opacity of the film.
  • the core layer may be mixture of a polypropylene homopolymer, such as ExxonMobil 4912 and Ampacet 403250 Pearl 2A MB containing calcium carbonate (CaC(3 ⁇ 4) from Ampacet blended in 82:18 ratio, but the PP, cavitating agent, and ratio may differ in other example embodiments.
  • the poly gauge of the core layer may be 35 gauge or other gauges in other example embodiments.
  • the tie layer-2 may be an extrusion blended mixture of a polypropylene homopolymer, such as Exxon Mobil 4912 and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30-E1 from Silberline.
  • the aluminum content in the tie layer is 2% but may vary in other example embodiments.
  • the poly gauge of tie layer-2 was increased to 25 gauge to increase the opacity of the film.
  • Skin layer-2 may be a blend of 86.5% ExxonMobil HD6704.18, 10% Schulman S45, 1% Spartech Polycom A27527, and 2.5% Schulman MB0353-STAB.
  • the poly gauge of skin layer-2 may be 5.0 gauge.
  • the aluminum present in the aluminum pigment in tie layers- 1 and 2 may provide the "metallic look" on both sides of the film for a two-sided, "metallic look” film. Additionally, aluminum pigment also may provide increased opacity. The presence of calcium carbonate in the polypropylene core may provide cavitation, which may result in a white core and impart increased opacity to the film. Skin layer-2 having an HDPE skin may provide cold-seal applications. The yield of the film was determined by ASTM D4321 test method and is 35142 in 2 /lb. The optical gauge of the film is 32.8 micrometers (1.29 mils). The light transmittance of the film was determined by ASTM D1003 test method and is 35.6%. While the tie layer thickness was increased to 25 gauge for 6G compared to 16.2 gauge for 6F, the light transmittance of the film decreased only from 36.37% to 35.6%.
  • the structure of a film is illustrated in Figure 6H.
  • carbon black was added to the layer containing the aluminum pigment, which may equally be a different metallic pigment in other example embodiments.
  • Schulman carbon black 4645 resin was obtained from A. Schulman at 35% masterbatch and diluted further with ExxonMobil 4912 polypropylene resin to obtain 2.8% carbon black blend.
  • Skin layer-] may be a copolymer of polypropylene, such as Total 8573HB, with an antiblock content of 1000 ppm.
  • the poly gauge of skin layer- 1 may be 5.0 gauge.
  • Tie layer- 1 is a blend of polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment such as Sparkle Silvet 960-30-E1 from Silberline, and 2.8% carbon black blend.
  • the aluminum content in the tie layer is 2% and the carbon black content is 0.28%, but may vary in other example embodiments.
  • the poly gauge of the tie layer-1 was 16.2 gauge.
  • the core layer may be mixture of a polypropylene homopolymer, such as ExxonMobil 4912 and Ampacet 403250 Pearl 2A MB containing calcium carbonate (CaC(3 ⁇ 4) from Ampacet blended in 82:18 ratio or in other ratios and/or having different polymeric and/or cavitating agent components in various other embodiments.
  • the poly gauge of the core layer may be 49.4 gauge or other gauges in other example embodiments.
  • Tie layer-2 is a blend of polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment such as Sparkle Silvet 960-30-E1 from Silberline, and 2.8% carbon black blend.
  • the aluminum content in the tie layer is 2% and the carbon black content is 0.28%, but may vary in other example embodiments.
  • the poly gauge of the tie layer-2 was 16.2 gauge.
  • Skin layer-2 may be a blend of 86.5% ExxonMobil HD6704.18, 10% Schulman S45, 1% Spartech Polycom A27527, and 2.5% Schulman MB0353-STAB.
  • the poly gauge of skin layer-2 may be 5.0 gauge.
  • the aluminum present in the aluminum pigment in tie layers- 1 and 2 may provide the "metallic look" on both sides of the film for a two-sided, "metallic look" film. Additionally, aluminum pigment also may provide increased opacity.
  • the addition of carbon black will further enhance the opacity of the film
  • the presence of calcium carbonate in the polypropylene core may provide cavitation, which may result in a white core and impart increased opacity to the film.
  • Skin layer-2 having an HDPE skin may provide cold-seal applications.
  • the yield of the film was determined by ASTM D4321 test method and is 32663 in 2 /lb.
  • the optical gauge of the film is 37.8 micrometers (1.49 mils).
  • the light transmittance of the film was determined by ASTM D1003 test method and is 25.4%.
  • the structure of a film is illustrated in Figure 61.
  • the thickness of tie layer 1 and 2 was increased to 20 gauge.
  • the thickness of the core layer was decreased to 40 gauge.
  • Carbon black was added to the layer containing the aluminum pigment.
  • Schulman carbon black 4645 resin was obtained from A. Schulman at 35% masterbatch and diluted further with ExxonMobil 4912 polypropylene resin to obtain 2.8% carbon black blend.
  • Skin layer- 1 may be a copolymer of polypropylene, such as Total 8573HB, with an antiblock content of 1000 ppm.
  • the poly gauge of skin layer-1 may be 5.0 gauge.
  • Tie layer-1 is a blend of polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment such as Sparkle Silvet 960-30-E1 from Silberline, and 2.8% carbon black blend.
  • the aluminum content in the tie layer is 2% and the carbon black content is 0.28%, but may vary in other example embodiments.
  • the poly gauge of the tie layer-1 was raised to 20 gauge to increase the opacity of the film.
  • the core layer may be mixture of a polypropylene homopolymer, such as ExxonMobil 4912 and Ampacet 403250 Pearl 2A MB containing calcium carbonate (CaCCh) from Ampacet blended in 82:18 ratio or in other ratios and/or with other polymeric and/or cavitating agent components in various other embodiments.
  • the poly gauge of the core layer may be 40 gauge or other gauges in other example embodiments.
  • Tie layer-2 is a blend of polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment such as Sparkle Silvet 960-30-E1 from Silberline, and 2.8% carbon black blend.
  • the aluminum content in the tie layer is 2% and the carbon black content is 0.28%, but may vary in other example embodiments.
  • the poly gauge of the tie layer-1 was raised to 20 gauge to increase the opacity of the film.
  • Skin layer-2 may be a blend of 86.5% ExxonMobil HD6704.18, 10% Schulman S45, 1% Spartech Polycom A27527, and 2.5% Schulman MB0353-STAB.
  • the poly gauge of skin layer-2 may be 5.0 gauge.
  • the aluminum present in the aluminum pigment in tie layers- 1 and 2 may provide the "metallic look" on both sides of the film for a two-sided, "metallic look" film. Additionally, aluminum pigment also may provide increased opacity. The addition of carbon black will further enhance the opacity of the film.
  • the presence of calcium carbonate in the polypropylene core may provide cavitation, which may result in a white core and impart increased opacity to the film
  • Skin layer-2 having an HDPE skin may provide cold-seal applications.
  • the yield of the film was determined by ASTM D4321 test method and is 34000 in 2 /lb.
  • the optical gauge of the film is 32.0 micrometers (1.26 mils).
  • the light transmittance of the film was determined by ASTM D1003 test method and is 23.5%. While the tie layer thickness was increased to 20 gauge for example 61 compared to 16.2 gauge for example 6H, the light transmittance of the film decreased only from 25.4% to 23.5%.
  • the structure of a film is illustrated in Figure 6J.
  • carbon black was added to the layer containing the aluminum pigment.
  • Schulman carbon black 4645 resin was obtained from A. Schulman at 35% masterbatch and diluted further with ExxonMobil 4912 polypropylene resin to obtain 2.8% carbon black blend.
  • Skin layer- 1 may be a copolymer of polypropylene, such as Total 8573HB, with an antiblock content of 1000 ppm.
  • the poly gauge of skin layer- 1 may be 5.0 gauge.
  • Tie layer- 1 is a blend of polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment such as Sparkle Silvet 960-30-E1 from Silberline, and 2.8% carbon black blend.
  • the target aluminum content in the tie layer is 4% and the target carbon black content is 0.56% but may vary in other example embodiments.
  • the poly gauge of the tie layer- 1 was 16.2 gauge.
  • the core layer may be mixture of a polypropylene homopolymer, such as ExxonMobil 4912 and Ampacet 403250 Pearl 2A MB containing calcium carbonate (CaC(3 ⁇ 4) from Ampacet blended in 82:18 ratio or in other ratios in various other embodiments.
  • the poly gauge of the core layer may be 49.4 gauge or other gauges in other example embodiments.
  • Tie layer-2 is a blend of polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment such as Sparkle Silvet 960-30- El from Silberline, and 2.8% carbon black blend.
  • the target aluminum content in the tie layer is 4% and the target carbon black content is 0.56% but may vary in other example embodiments.
  • the poly gauge of the tie layer-2 was 16.2 gauge.
  • Skin layer-2 may be a copolymer of polypropylene, such as Total 8573HB, with an antiblock content of 1000 ppm.
  • the poly gauge of skin layer-2 may be S.O gauge.
  • the aluminum present in the aluminum pigment in tie layers- 1 and 2 may provide the "metallic look" on both sides of the film for a two-sided, "metallic look” film. Additionally, aluminum pigment also may provide increased opacity. The addition of carbon black will further enhance the opacity of the film. The presence of calcium carbonate in the polypropylene core may provide cavitation, which may result in a white core and impart increased opacity to the film.
  • the yield of the film was determined by ASTM D4321 test method and is 36065 in 2 /lb.
  • the optical gauge of the film is 44.2 micrometers (1.74 mils).
  • the light transmittance of the film was determined by ASTM D1003 test method and is 13.7%.
  • the structure of a film is illustrated in Figure 6K.
  • carbon black was added to the layer containing the aluminum pigment.
  • Schulman carbon black 4645 resin was obtained from A. Schulman at 35% masterbatch and diluted further with ExxonMobil 4912 polypropylene resin to obtain 2.8% carbon black blend.
  • Skin layer- 1 may be a copolymer of polypropylene, such as Total 8573HB, with an antiblock content of 1000 ppm.
  • the poly gauge of skin layer- 1 may be 5.0 gauge.
  • Tie layer- 1 is a blend of polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment such as Sparkle Silvet 960-30-E1 from Silberline, and 2.8% carbon black blend.
  • the aluminum content in the tie layer is 3.23% and the carbon black content is 0.53% but may vary in other example embodiments.
  • the poly gauge of the tie layer- 1 was 16.2 gauge.
  • the core layer may be mixture of a polypropylene homopolymer, such as ExxonMobil 4912 and Ampacet 403250 Pearl 2A MB containing calcium carbonate (CaCCh) from Ampacet blended in 82:18 ratio or in other ratios in various other embodiments.
  • the poly gauge of the core layer may be 49.4 gauge or other gauges in other example embodiments.
  • Tie layer-2 is a blend of polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment such as Sparkle Silvet 960-30- El from Silberline, and 2.8% carbon black blend.
  • the aluminum content in the tie layer is 3.23% and the carbon black content is 0.53% but may vary in other example embodiments.
  • the poly gauge of the tie layer-2 was 16.2 gauge.
  • Skin layer-2 may be a copolymer of polypropylene, such as Total 8S73HB, with an antiblock content of 1000 ppm.
  • the poly gauge of skin layer-2 may be S.O gauge.
  • the aluminum present in the aluminum pigment in tie layers- 1 and 2 may provide the "metallic look" on both sides of the film for a two-sided, "metallic look” film. Additionally, aluminum pigment also may provide increased opacity. The addition of carbon black will further enhance the opacity of the film. The presence of calcium carbonate in the polypropylene core may provide cavitation, which may result in a white core and impart increased opacity to the film.
  • the yield of the film was determined by ASTM D4321 test method and is 30239 in 2 /lb.
  • the optical gauge of the film is 33.0 micrometers (1.3 mils).
  • the light transmittance of the film was determined by ASTM D1003 test method and is 16.4%.
  • FIG. 6L a structure of a film is illustrated in Figure 6L.
  • the structure is designed to have 1 side metallic appearance and other side white appearance.
  • Skin layer- 1 is a copolymer of polypropylene such as Total 8573HB with an antiblock content of lOOOppm and a poly gauge of 6.4 gauge.
  • the polypropylene skin provides improved compatibility with the tie layer and hence improved processability.
  • the tie layer -1 may be mixture of a polypropylene homopolymer, such as Exxon Mobil 4912, and Ampacet 403250 Pearl 2A MB containing calcium carbonate (CaC(3 ⁇ 4) from Ampacet and Ampacet 511094 containing titanium dioxide (Ti0 2 ) from Ampacet blended in 77:15:8 ratio; other PP, cavitating agents, and/or ratios are possible in other embodiments.
  • Hie tie layer thickness is 32.4 gauge.
  • the core layer may be an extrusion blended mixture of a polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30-E1 from Silberline and Schulman carbon black 464S. Schulman carbon black 4645 resin was obtained from A. Schulman at 35% mastcrbatch and diluted further with ExxonMobil 4912 polypropylene resin to obtain 2.8% carbon black blend.
  • the aluminum content in the core layer is 1.2% but may vary in other example embodiments.
  • the carbon black content in the core layer is 0.28%, but may vary in other example embodiments.
  • the poly gauge of the core layer may be 98.8 gauge.
  • Tie layer-2 may be a polypropylene homopolymer, such as Exxon Mobil 4912.
  • the poly gauge of the tie layer-2 may be 32.4 gauge.
  • Skin layer-2 may be a LLDPE such as Dowlex 2027G with a poly gauge of 10.0 gauge.
  • Aluminum in the aluminum pigment in core layer may provide the "metallic look" to one side of the film Additionally, aluminum blended with carbon black also may provide increased opacity.
  • the calcium carbonate and titanium dioxide in the polypropylene tie layer- 1 may provide cavitation, which may result in a white appearance to the second side of the film.
  • the LLDPE skin layer-2 may provide improved printability.
  • the yield of the film was detennined by ASTM D4321 test method and is 20783 in 2 /lb.
  • the optical gauge of the film is 56.1 micrometer (2.21 mils).
  • the light transmittance of the film was determined by ASTM D1003 test method and is 12.3%.
  • the addition of carbon black further enhance
  • a structure of a film is illustrated in Figure 6M.
  • the structure is designed to have 1 side metallic appearance and other side white appearance.
  • Skin layer- 1 is a copolymer of polypropylene such as Total 8573HB with an antiblock content of lOOOppm and a poly gauge of 5.0 gauge.
  • the polypropylene skin provides improved compatibility with the tie layer and hence improved processability.
  • the tie layer -1 may be mixture of a polypropylene homopolymer, such as Exxon Mobil 4912, and Ampacet 403250 Pearl 2A MB containing calcium carbonate (CaC(1 ⁇ 2) and Ampacet 511094 containing titanium dioxide (Ti(1 ⁇ 4) blended in 77:15:8 ratio.
  • the tie layer thickness is 10 gauge.
  • the core layer may be an extrusion blended mixture of a polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30-E1 from Silberline.
  • the aluminum content in the core layer is 2% but may vary in other example embodiments.
  • the poly gauge of the core layer may be 120 gauge.
  • Tie layer-2 may be a polypropylene homopolymer, such as Exxon Mobil 4912.
  • the poly gauge of the tie layer-2 may be 10 gauge.
  • Skin layer-2 is a copolymer of polypropylene such as Total 8573HB with an antiblock content of lOOOppm and a poly gauge of 5.0 gauge.
  • Aluminum in the aluminum pigment in core layer may provide the "metallic look" to one side of the film
  • the calcium carbonate and titanium dioxide in the polypropylene tie layer- 1 may provide cavitation, which may result in a white appearance to the second side of the film.
  • the yield of the film was determined by ASTM D4321 test method and is 23638 in 2 /lb.
  • the optical gauge of the film is 38.6 micrometer (1.52 mils).
  • the light transmittance of the film was determined by ASTM D1003 test method and is 22.4%.
  • a structure of a film is illustrated in Figure 6N.
  • the structure is designed to have 1 side metallic appearance and other side white appearance.
  • Skin layer-] is a copolymer of polypropylene such as Total 8573HB with an antiblock content of lOOOppm and a poly gauge of 5.0 gauge.
  • the polypropylene skin provides improved compatibility with the tie layer and hence improved processability.
  • the tie layer -1 may be mixture of a polypropylene homopolymer, such as Exxon Mobil 4912, and Ampacet 403250 Pearl 2A MB containing calcium carbonate (CaCO ? ) and Ampacet 511094 containing titanium dioxide (T1O 2 ) blended in 77:15:8 ratio.
  • the tie layer thickness is 10 gauge.
  • the core layer may be an extrusion blended mixture of a polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30-E1 from Silberline and Schulman carbon black 4645.
  • Schulman carbon black 4645 resin was obtained from A. Schulman at 35% masterbatch and diluted further with ExxonMobil 4912 polypropylene resin to obtain 2.8% carbon black blend.
  • the aluminum content in the core layer is 2% but may vary in other example embodiments.
  • the carbon black content in the core layer is 0.28%, but may vary in other example embodiments.
  • the poly gauge of the core layer may be 120 gauge.
  • Tie layer-2 may be a polypropylene homopolymer, such as Exxon Mobil 4912.
  • the poly gauge of the tie layer-2 may be 10 gauge.
  • Skin layer-2 is a copolymer of polypropylene such as Total 8573HB with an antiblock content of lOOOppm and a poly gauge of 5.0 gauge.
  • Aluminum in the aluminum pigment in core layer may provide the "metallic look" to one side of the film. Additionally, aluminum blended with carbon black also may provide increased opacity.
  • the calcium carbonate and titanium dioxide in the polypropylene tie layer- 1 may provide cavitation, which may result in a white appearance to the second side of the film.
  • the yield of the film was determined by ASTM D4321 test method and is 20722 in 2 /lb.
  • the optical gauge of the film is 46.1 micrometer (1.81 mils).
  • the light transmittancc of the film was determined by ASTM D1003 test method and is 5.29%.
  • the addition of carbon black further enhances
  • Table 1 shows test results from measuring water-based ink adhesion of films with different compositions. Notably, all coatings show 100% ink adhesion to different tape tests after treatment.
  • Table 2 shows test results from measuring UV-ink adhesion of same selected films with different compositions.
  • samples 6B and 6C with LLDPE skin shows good UV ink adhesion before and after treatment. All the other samples show poor to moderate UV ink adhesion before treatment. All the samples show improved UV ink adhesion after retreatment.
  • Further example embodiments include skin layers 1 and/or 2 optionally having specific surface properties, which are receptive to coating as shown in Figure 7.
  • the coating composition may be applied to either or both sides of the film.
  • the top coat-1 and/or 2 may have different properties such as printability, sealability, low co-efficient of friction, barrier layers, otherwise, and combinations thereof.
  • other example embodiments may include carbon black pigment incorporated with the metallic pigment to provide additional hiding and opacity.
  • a particular coating's composition may be guided by performance of the coating, its end-use, and/or its application. Particularized or desired coating laydown and adhesion may be observed only with special attention drawn towards optimizing the coating composition.
  • the pigment to binder ratio (P/B) is a parameter used to determine the coating adhesion.
  • the P/B ratio may be preferably within a range from 0.1 through 6, more preferably from 0.25 through 4, or most preferably from 0.42 through 2.5.
  • the pigment (P) to binder (Bl) ratio is 0.61 for "Coating 1" as provided in Example 1 shown in Table 3.
  • binder Bl is an acrylic emulsion NeoCryl FL-5095 from DSM Coating Resins
  • antiblock is an amorphous silica from Sylobloc 45 from Grace Davison
  • passivated aluminum pigment is Sil-O-Wet Premier 014NL-PA from Silberline Manufacturing Inc.
  • the coating as described in Table 3 was applied onto a 66 ⁇ , white, opaque, polyolefin film, such as Label-Lyte ® 150LL-302 available from Jindal Films Americas LLC.
  • the dry metal coating thickness is 2.5 g/m 2 .
  • the metallic coating shows acceptable coating laydown appearance and >99% coating adhesion with 600 and 610 tape test.
  • the coating adhesion tape test is performed immediately and 24 hours after coating.
  • the metal-coated film structures were then surface printed with water base (WB) ink and ultraviolet (UV) curable ink to determine the print performance of the coating compositions.
  • WB water base
  • UV ultraviolet
  • the ink adhesion was evaluated with 600 and 610 tape test.
  • Blending of a second binder (B2), which has an additional functionality to improve coating cohesive adhesion, may enhance the UV-ink adhesion performance.
  • the additional functionality is provided by incorporating a functional monomer in the polymer chain.
  • Such functional monomers include, but are not limited to, mono or multifunctional acids containing monomers, mono or multifunctional acids containing monomers metal salts, mono or multifunctional silanes containing monomers, mono or multifunctional amine, difunctional acrylic monomers including 1,4-butanediol diacrylate, 1,3-butanediol dimethacrylate, 1,4-butanediol dimethacrylate, copper ( ⁇ ) methacrylate carboxylic acid, trans- 1,4-cyclohcxanediol dimethacrylate, N.N'-cystaminebisacrylamide, 1,10-decanediol dimethacrylate, N,N'-diallylacrylamide, diethylene glycol diacrylate, diethylene glycol dimethacrylate, 2,2-dimethylpropanediol dimethacrylate, dipropylene glycol dimethacrylate, ⁇ , ⁇ ' -ethylene bisacrylamide, ethylene glycol diacrylate, ethylene glycol
  • the coating adhesion and/or the UV-ink adhesion may provide improved adhesion performance by blending a second binder with a different acid value between Bl and B2.
  • the optimized blending ratios of binders having different acid values are one way to optimize the acceptable coating adhesion and UV-ink adhesion performances of the coating.
  • the coating adhesion and UV-ink adhesion may provide improved performance by including a second binder with a different glass transition temperature (Tg).
  • Tg glass transition temperature
  • the optimized blending ratios of these different glass transition temperature (Tg) binders determine the acceptable coating adhesion and UV-ink adhesion performance of the coating.
  • the pigment to binder ratio is 0.61 for "Coating 2," and is provided as Example 2 in Table 4.
  • Binder Bl is an acrylic emulsion NeoCryl FL-5095 from DSM Coating Resins Inc.
  • binder B2 is Styrene acrylic emulsion NeoCryl A- 1094 from DSM Coating Resins Inc.
  • Example 2 provides an example coating formulation with improved UV-ink adhesion in accordance with this disclosure.
  • the parts per hundred (“PHR”) loading which determines the blending ratios of the two different binders and pigment to binder ratio, is important and may be adjusted, for instance, based on the fitness-for-use requirements and the type of coatings being used.
  • Table S below shows a list of metal coated variables produced with different binder ratios (B1/B2), pigment to binder ratios (P/B), dry aluminum (i.e., metal) coating weight and any additional dry top coating weight where applied.
  • Bl Binder 1, i.e., a 100% acrylic coating; in another example embodiment, Bl could be one or more styrene acrylic coatings, in other example embodiments, Bl could be one or more aliphatic or aromatic epoxy coatings, in yet another example, Bl could be one or more aliphatic or aromatic polyester coatings, in still another example, Bl could be one or more aliphatic or aromatic polyurethane coatings, and, in still yet another example, Bl could be one or more aliphatic or aromatic organo-silane coatings.
  • B2 Binder 2, i.e., a functionalized styrene acrylic having a high Tg coating to enhance cohesive adhesion; in another example embodiment, B2 could be one or more functionalized 100% acrylic coatings, in other example embodiments, B2 could be one or more aliphatic or aromatic epoxy coatings, in another example, B2 could be one or more aliphatic or aromatic polyester coatings, in yet another example, B2 could be one or more aliphatic or aromatic polyurethane coatings, and, in still yet another example, B2 could be one or more aliphatic or aromatic organo silane coatings.
  • B2 Binder 2, i.e., a functionalized styrene acrylic having a high Tg coating to enhance cohesive adhesion; in another example embodiment, B2 could be one or more functionalized 100% acrylic coatings, in other example embodiments, B2 could be one or more aliphatic or aromatic epoxy coatings, in another example, B2 could be one or more aliphatic or aromatic polyester coatings, in
  • B1/B2 physical property that is an empirical ratio indicative of acceptable adhesion (n.b. Bl provides good printability and B2 provides good cohesive coating adhesion)
  • P Pigment loading in PHR
  • P/B physical property that is an empirical ratio of (pigment + fillers) to binder, i.e., solids
  • Table 6 shows test results from measuring water-based ink adhesion of coatings with different compositions, wherein the difference may be identified based on the B1/B2 ratio. Notably, all coatings show 100% ink adhesion to different tape tests before and after treatment.
  • Table 6 shows test results from measuring UV-ink adhesion of coatings with different compositions.
  • the different coatings in the UV-ink system showed variation in performance based on different coating formulations.
  • using only the higher Tg styrene acrylic coating also showed poor UV-ink adhesion.
  • Blending binders Bl and B2 in 1:1 ratio, "Sample 1" also shows poor ink adhesion performance before treatment.
  • sample 3 with a B1:B2 blending ratio of 70:30 and “Sample 5" with a B1:B2 blending ratio of 90:10 reveal enhanced UV-ink adhesion performance of the metal-coated variables as seen in Table 7.
  • the metal coating is top coated with an additional print receptive coating resulting in good UV ink adhesion performance before and after treatment.
  • the compositions of the coating layer(s) may be modified with wax and antiblock loading based on the slip and coefficient of friction (COF) requirements.
  • Table 8 shows typical fitness-for-use (FFU) properties of the metallic coated film CMW "Sample 7", as illustrated in structure 1.
  • the aluminum coated film provides a typical opacity of 99%.
  • the metal coated film shows a light transmission of 5%, which is a 72% reduction compared to a similar structure with no aluminum pigment that has a typical value of 18% light transmission.
  • the superior opacity of the aluminum coated film facilitates the use of mis film in opaque labels applications. No additional colored or black ink, coating or adhesive is required to use this film as a block-out label or application.
  • the unique silver block-out film is a white, opaque design that may replace traditional matte metallic films obtained through vacuum metallization process.
  • the coated approach has exceptional graphic appeal, and may address security label needs as well as have a host of other applications, such as those previously discussed.
  • the coated aluminum silver label technology provides a broad range of surface print compatibility, including, but not limited to, UV flexo inks, UV screen, UV letterpress, solvent-based and water-based inks and can be laser-printed, inkjet-printed with code date, or thermal-transfer-ribbon-printed.
  • the film may have a white opaque adhesive side and silver print face that provides an excellent material for use in block-out/security, beverage, retail, equipment, name tags, food, health and beauty labels, and other applications.
  • packaging or other applications formed for food or non-food items may include a sealed bag/pouch made through use of machine-packaging equipment, such as HFFS, VFFS, and/or other pouch packaging machines.
  • the disclosed coated aluminum film also provides exceptional opacity.
  • the uncoated Label-Lyte ® 150LL-302 is the "control" film shown in Table 9.
  • coat weight of the aluminum metal coating dry film was varied in Example #1, Example #2, and Example #3.
  • the control base film is 66 ⁇ thick, has an opacity of 88%, and a light transmission of 19%.
  • Example #2 Applying a metal coating of dry film coat weight of 2.1 g/m 2 improved the film's opacity to 97.4% and reduced light transmission to 11.60.
  • Example #2 the dry coat weight of the metal coating dry film was increased to 2.43 g/m 2 . This improved the film's opacity to 98.7% with a reduction in light transmission to 6.54.
  • Example #3 the dry coat weight of the metal coating dry film was increased to 3.28 g/m 2 . This improved the film's opacity to 99.4% and reduced light transmission to 4.44%.
  • the opacity and light transmission can be manipulated and optimized for a specific block-out label requirement by manipulating the dry coat weight of the metal coating layer.
  • the opacity of the aluminum coated film facilitates the use of these metal coated films in opaque labels and block-out label applications.
  • Typical block-out labels involve additional process steps that, for example, require application of a black ink or other opaque-colored ink to produce a block-out label. This disclosure, however, provides a one-step process where the metal coatings provide high opacity in addition to surface printability.
  • radiant barrier film consists of a reflective material such as an aluminum foil.
  • aluminum foil is laminated to one or both sides of another material such as plastic film or Kraft paper that provides flexibility, strength, and durability.
  • Such radiation barrier films are then applied in the attics and a home's side walls to reduce IR and UV absorption resulting in better heat management.
  • aluminum metal coatings can be directly applied to the attic ceilings or a home's walls using a spray gun or other wet coating application techniques.
  • Such onsite application techniques are time- consuming, involve exposure to chemicals, and increase the probability of human error during coating application.
  • the disclosed coated aluminum metal film may be used as an alternative to above- mentioned shortcomings of existing barrier films and coatings.
  • metal film Example #3 as described above in Table 9, was tested as a solution to block IR and UV radiation absorption in attics and a home's side walls.
  • the attic is bifurcated in two equal parts, Al and A2.
  • the radiant barrier film was fixed to the interior of roof ceiling to the attic side Al.
  • the roof was then exposed to a 500 Watts quartz halogen lamp and the change in temperature inside the attic was measured by placing a temperature recorder inside the attic.
  • the temperature inside the attic was measured in real-time over a 1 hour period using an EL- USB-1 temperature data logger from Lascar Electronics.
  • Example #3 is film coated with 3.27g/m 2 metal coatings, and shows improved radiant-barrier performance compared to an attic with no radiant-barrier film.
  • each data point was recorded approximately every 3 minutes. For instance, after one hour of exposure to a 500 Watt quartz lamp, the maximum temperature reached with no radiant barrier layer is 78°C compared to 68°C by using Example #3 coated film. Using Example #3' further dropped the temperature inside the attic, wherein the maximum temperature was 48°C after one hour of exposure. As a comparison, a metal foil laminated to paper with a fiberglass intermediate layer was used as a control.
  • the metal foil paper laminated structure showed a maximum temperature in the attic of 51°C after one hour of exposure.
  • the coated metal foil was 10.2 ⁇ thick and laminated to paper having an average thickness of 83.5 ⁇ with an intermediate fiber glass layer having an average thickness of 9.S ⁇ .
  • Example #3 is approximately 4.23 ⁇ (3.27 g/m 2 ) metal coating applied to a 66 pm cavitated white film as listed in Table 10.
  • an appropriate metal coating film may be used for labels or packaging applications where improved water vapor or gas barrier properties are required.
  • the micrometer-sized aluminum flakes due to their high aspect ratio are oriented and stacked into a brick-like pattern in the bulk of the coating. This alignment of the flakes creates a tortuous path for water vapor or gas molecules to diffuse resulting in barrier performance improvement.
  • the effective barrier performance is controlled by the uniform alignment of the flakes and the density of the flakes in the coating layer.
  • the water vapor transmission rate (WVTR) of a 66 ⁇ thickness uncoated white opaque "control" film Label-Lyte ® 150LL-302 available from Jindal Films Americas LLC is 1.81 g/m 2 /day.
  • a metal coating with composition as described in Table 4 was applied onto the control film to obtain Example #3 in Table 11.
  • the thickness of the metal coated layer is 3.27 g/m 2 .
  • the WVTR barrier property of the film improved to 0.75 g/m /day.
  • the improvement in WVTR barrier is attributed to the decrease in the diffusion of the water vapor molecules due to metal coating thickness and the uniform alignment of the metal flakes in the metal coating as described above.
  • the smooth laydown of the metal coating can be determined visually and results in uniform alignment of the metal flakes in the coated layer.
  • This disclosure describes a one-step process where the metal coating provides improved moisture barrier properties in addition to surface printability and matte metallic appearance.
  • Binder Bl is an acrylic emulsion NeoCryl FL-5095 from DSM Coating Resins Inc.
  • binder B2 is styrene acrylic emulsion NeoCryl A-1094 from DSM Coating Resins Inc.
  • antiblock is amorphous silica from Sylobloc 45 from Grace Davison
  • passivated pigment is Aquavex AD 015 from Silberline Manufacturing Inc.
  • the dry film metal coating weight is 1.86 g/m 2 .
  • the resulting metal coated film provides a matte finish with low gloss appearance.
  • the gloss measured at different angles for the matte finish film is listed in Table 13 for Example #4 (not buffed).
  • Example #4' When this film is gently buffed, i.e., about 20 times or so, with a KimwipeTM, paper, wool, or textile fiber, then a high gloss film results Example #4' (Buffed).
  • the gloss measured for the buffed film Example #4' is listed below in Table 13.
  • the gloss at 45° and 60° are too high to detect by the glossmeter.
  • greater than two-fold increase in gloss is observed at 85° for the buffed Example #4' compared to the unbuffed Example #4, as shown in Table 13. Accordingly, the disclosure describes a process whereby the matte metal appearance may be tuned into a high-gloss finished film by surface-buffing phenomenon.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Materials Engineering (AREA)
  • Wood Science & Technology (AREA)
  • Organic Chemistry (AREA)
  • Laminated Bodies (AREA)

Abstract

Disclosed are methods, compositions and structures that, in one example embodiment, is a metallic film mat may include a multilayered film, optionally being oriented and having optionally having one or more additives, metallized layers, primers, coatings, sealants, treated layers, or combinations thereof. Further, the metallic film may include a metal, coating applied to at least one outer surface of the multi-layered film, wherein the metal coating comprises a selected combination of size and type of one or more metal pigments, wherein the selected combination is for turning an appearance ranging from matte to sheen for the metallic film, whereby the metal coating is a substitute for a coating applied to a metallized layer.

Description

METAL COATINGS AND CO-EXTRUSIONS
REFERENCE TO RELATED APPLICATION
[00011 The present application is a Patent Cooperation Treaty (PCT) application, which claims priority to both United States provisional patent application serial number 62/242,769 filed October 16, 2015 and United States provisional patent application serial number 62/318,589 filed April 5, 2016, both of which are hereby incorporated by this reference in their entireties. FIELD
[0002] The disclosure relates to metal coatings on co-extruded, multilayered films, processes applied thereto, products made therefrom such as bags, tags, packages, labels, and other structures, and uses thereof, such as to contain foods, beverages, and other articles or other finished products uses, such as those stated hereinbelow.
BACKGROUND
[0003] Metallic films may be obtained by chemical or vapor deposition of metal on suitable receptive substrates. However, these metallic films typically have poor ink printability, ink adhesion and surface-resistance. A second step occurs that applies a top- topcoat to permit surface printability and/or scratch-resistance is applied inline or offline during or after the metallization process respectively. Or, the metal layer may be buried by lamination under a printable film.
[0004] In addition, it is challenging to tune the metallic appearance of the film to obtain different metallic shades. For instance, high sheen films may result in poor product identification because incident light on the sheen may affect readability. As a result, to obtain a subdued or brushed metallic appearance, the film may be modified to include a matte skin or have a metallic surface that is further coated with a matte coating. These techniques, however, are complex and involve many steps, much time, and considerable costs. SUMMARY
[0005] Disclosed are methods, compositions and structures mat, in one example embodiment, is a metallic film that may include a multilayered film, optionally being oriented and having optionally having one or more additives, metallized layers, primers, coatings, sealants, treated layers, or combinations thereof. Further, the metallic film may include a metal coating applied to at least one outer surface of the multi-layered film, wherein the metal coating comprises a selected combination of size and type of one or more metal pigments, wherein the selected combination is for turning an appearance ranging from matte to sheen for the metallic film, whereby the metal coating is a substitute for a coating applied to a metallized layer.
[0006] In another embodiment, disclosed is a coextruded, oriented, multilayered film that may include a core flanked by skin layers comprising polyethylene or polypropylene copolymer, optionally comprising tie layers between the core and the skin layers, and optionally comprising additives. Further, the coextruded, oriented, multilayered film may include one or more metal pigments and cavitaring agents in at least one of the core and the tie layers, whereby both sides of the coextruded, oriented, multilayered film have a metallic appearance.
[0007] In yet another embodiment, disclosed is a coextruded, oriented, multilayered film that may include a core flanked by tie layers, and the tie layers flanked by skin layers, wherein all layers comprise polypropylene. Hie coextruded, oriented, multilayered film may also include one or more metal pigments and carbon black in the core, and one or more tie layers located on a first side of the core comprises a whitening agent, whereby a first side of the coextruded, oriented, multilayered film has a metallic appearance and a second side of the coextruded, oriented, multilayered film has a white appearance.
DETAILED DESCRIPTION
[0008] Below, directional terms, such as "above," "below," "upper," "lower," "front," "back," "top," "bottom," etc., are used for convenience in referring to the accompanying drawings. In general, "above," "upper," "upward," "top," and similar terms refer to a direction away the earth's surface, and "below," "lower," "downward," "bottom," and similar terms refer to a direction toward the earth's surface, but is meant for illustrative purposes only, and the terms are not meant to limit the disclosure.
[0009] This disclosure generally relates to methods, compositions, and structures, such as packages, bags, tags, labels, roll to roll wrap around labels, horizontal-form-fill-and-seal ("HFFS") containers, vertical-form-fiU-and-seal ("VFFS") containers, lids, sachets, stand-up pouches, overwraps, and so forth (i.e., collectively, "applications") associated with multilayercd films having optionally printable, metal coatings as an alternative or addition to standard metallization, e.g., vacuum-deposited metal on a biaxially oriented polypropylene ("BOPF') multilayered film. This disclosure's type of labels may vary and appear on goods that include, for example: Arnold Palmer™-type drinks, where the label has metal or metal foil; roll-to-sheet, hot-melt-applied, wrap-around labels; magazine feed labels; labels on waters, beer, wine and other beverages, foods, hair care items, cosmetics, aerosol cans; replace hot and cold foil stamping; pressure-sensitive labels; tire labels; block-out labels; any label that is for hot or cold foil applications; or applications where current label has a gun- metal appearance.
[0010] Depending on the composition and/or process, and the conditions for applying the metal coating(s) to the multilayered films, appearances may range anywhere from matte to sheen and from smooth to rough, e.g., brushed. In addition, the disclosed metal coatings may be used in applications for the food or non-food industries, particularly in view of the point that the metal coating(s) may impede water-vapor transmission, i.e., improved barrier properties. The metal coatings' print layer may be receptive to various print applications, including, for example, UV-flexo inks, UV screen inks, UV letterpress inks, and solvent- based or water-based inks, and may be laser-printed, inkjet-printed with code date, or thermal-transfer-ribbon-printed.
[0011] To familiarize with terminology used herein, a multilayered film may have an A/B/C structure comprising at least a "core layer" "C," optional "tie layer(s)" "B," and "skin layer(s)" "A" with a tie layer between the core and skin layers. Functionally, the layers impart protection/cavities/color and can desirably be co-extruded layers of polymer or polymer mixtures. The multilayered films may include processing aids or one or more additives such as opacifying agent, coloring agents, inks, pigments, cavitating agents, slip agents, anti-static agents, anti-block agents, void-initiating materials, fillers, and combinations thereof, so as to produce a translucent or opaque film, as desired. Although this following disclosure refers to CaCOj as a cavitating agent, in alternative embodiments, any of a number of other cavitating agents may be used in addition or in place of CaCCb, such as polybutylene terephthalates ("PBT"), glass beads, cyclic olefin polymers and/or cyclic olefin copolymers ("COC"), zeolites, etc., and combinations thereof.
[0012] As used herein, "polymer" may be used to refer to homopolymers, copolymers, interpolymers, terpolymers, etc., wherein such polymers may vary in density, stereoregularity, method of production (e.g., catalytic or not), and other chemical and physical properties.
[0013 J The multilayered films may or may not be uniaxially or biaxially oriented. Orientation in the direction of extrusion is known as machine direction ("MD") orientation. Orientation perpendicular to the direction of extrusion is known as transverse direction ("TD") orientation. Orientation may be accomplished by stretching or pulling a film first in the MD followed by the TD. Orientation may be sequential or simultaneous, depending upon the desired film features. Orientation ratios are commonly from between about three to about six times the extruded width in the MD and between about four to about ten times the extruded width in the TD.
[0014] Blown films may be oriented by controlling parameters such as take up and blow up ratio. Cast films may be oriented in the MD direction by take up speed, and in the TD through use of tenter equipment. Blown films or cast films may also be oriented by tenter- frame orientation subsequent to the film extrusion process, in one or both directions. Typical commercial orientation processes are BOPP tenter process and Linear Motor Simultaneous Stretching ("LISIM") technology. [0015] One or both of the outer exposed surfaces of the multilayered films may be surface-treated to increase the surface energy of the film to render the film receptive to metallization, coatings, printing inks, and/or lamination. The surface treatment may be carried out according to one of the methods known in the art. Exemplary treatments include, but are not limited to, corona-discharge, flame, plasma, chemical, by means of a polarized flame, or otherwise.
[0016] In some embodiments, the film may first be surface treated, for example, by corona treatment, and then be treated again in the coating line, for example, by flame treatment, immediately prior to being coated. In additional or alternative embodiments, the film may first be surface treated, for example, by flame treatment, and then be treated again in the metallization chamber, for example, by plasma treatment, immediately prior to being metallized.
[0017] Metallized films may be obtained by chemical or vapor deposition of appropriate metal ingot on suitable substrates like BOPP or biaxially oriented polyester film ("BOPET") films. Generally, when films are metallized, the metallized layer is one of the outer skin and/or sealant layers. However, if no skin or sealant layer is present, the surface of a core layer may be metallized. Such layers may be metallized using conventional methods, such as vacuum deposition, of a metal layer such as aluminum, copper, silver, chromium, or mixtures thereof from an oxide or otherwise of such metals. These metallized films have poor ink printability, ink adhesion and surface scratch or resistance. A second step may involve top- coating the metallized surface to enhance the surface printability and scratch resistance, whereby the top-coating is applied inline or offline and either during or after the metallization process. Alternatively, the film's metallized layer may be buried by lamination under a printable film. Nevertheless, tuning the metallic appearance of the film is challenging in order to obtain different metallic shades. For instance, high-sheen films may have a negative effect under light due to reflection, and, thereby, resulting in poor product identification. Hence, in order to obtain a subdued or brushed metallic appearance, the multi layered film is modified to include a matte skin, and/or the metallized surface is further coated with a matte coating. These techniques, however, involve multiple steps, are quite complex, and promote wasted time and expense. [0018] One example embodiment of the disclosed composition, methods and structures includes a multilayered film having a brushed-metal appearance with remarkable opacity and radiant-energy barriers, including, for instance, in the UV and IR spectra. Generally, the disclosed composition, methods and structures may produce a printable metallic film in a single step so as to replace the conventional two-step vacuum metallization and coating steps. More specifically, one or more metallic pigments, wherein the metal may be aluminum, copper, nickel, zinc, silver, gold, alloy, etc., may be dispersed in a coating (i.e., a mixture) that is compatible with metallic pigments, and applied, for example, to at least one outer surface of a film, be it multilayered or not.
[0019] Using different types of pigment(s), varying the particle size(s) of the pigment(s), or combinations of the foregoing may tune or alter the metallic appearance of the multilayered film. Larger particle sizes may provide higher sheen and smaller particle size provides more matte or gray shades.
[0020] The coating's composition may be tailored to the end-use application based on the choice of the aluminum pigments size and type. For instance, a metal pigment may have particle size varying, for instance, in a range from 1 μπι to 100 μηι. In other embodiments, the pigment particle size may be within the range of S μπι to SO μιη, or even 7 μπι to 35 μηι. The metal pigment, itself, may be of milled-grade flake, such as cornflake, rounded silver dollar, thick tuff flake, ultra-thin, vacuum-metallized flake, any other flakes, or combinations thereof. In addition, the metal pigments may be of a leafing type, whereby the metallic pigments may orient at the wet coating-air interface, or of a non-leafing type, whereby the metallic pigments are distributed throughout the bulk of the coating layer.
[0021 ] In addition to the foregoing physical characteristics, the chemical properties, such as the surface chemistry of the metal pigment or flake, are critical for its application in different coating or resin systems, e.g., solvent-borne or waterborne. For example, unstablized or bare aluminum in a pigment may react vigorously with water to form aluminum hydroxide, Al(OH)3(S), hydrogen, H¾g), and heat. This decomposition reaction results in the loss of the aluminum's metallic appearance due to the formation of a much grayer darker of Al(OH)3(S). [0022] Passivation of aluminum pigments may improve the durability of the pigments and their aesthetic effects in waterborne coatings. In some example embodiments, organophosphorous compounds or other inorganic passivators, such as chromium oxides, zinc oxides, or silicon oxides, are used during the passivation of metallic-effect pigments. Returning to passivation in waterborne coating systems, in various embodiments, the aluminum pigment may be supplied as pre-passivated from a vendor or may be passivated in- house before formulating into the coating. In other embodiments, the unstablized or bare pigment may be either passivated in situ with appropriate additives in waterborne coating systems or used directly in appropriate solvent-borne coating system(s).
[0023] Additionally, orientation or laydown of the metal pigment is critical for a smooth metallic appearance of the film. For instance, uniform horizontal or parallel alignment of the metal pigment to the substrate improves a smooth, metallic appearance. Alternatively, a non- uniform alignment of the metallic pigments results in a greyish, uneven, metallic appearance.
[0024] Turning now to example, specific embodiments, disclosed is a coating composition, method and structure for use in multilayered films or otherwise in various applications. The multilayered film may have a structure as shown in Figure 1. The metallic coating may be applied using a gravure coater, rod coater, slot die technique, spray technique or otherwise. The dry coating thickness may range, for example, from between 0.03 g/m2 through 50 g/m2, or in the range from between 0.15 g/m2 through 15.5 g/m2, or yet in the range from between 0.6 g/m2 through 8 g/m2.
Figure imgf000008_0001
[0025] The properties of the metallic coating layer may be modified by changing the coating component(s). For instance, using a print-receptive component may generate a multilayered film with a metallic film coating that is printable. Example resins of the print- receptive components) include, but are not limited to epoxy acrylates, polyurethane acrylates, and/or polyester acrylates. In another example embodiment, combining the metallic pigments in the metallic coating layer with a hard, cross-linked coating may enhance the scratch resistance of the metallic coated, multilayered film (collectively, a "scratch- resistance coating"). In yet another example embodiment, using coating component(s) that impart barrier polymer will result in a metallic coated, multilayered film with barrier properties (collectively, a "barrier coating"). And, further, in another example embodiment, combining the metallic pigments in the metallic coating layer with a soft-touch coating may provide a metallic coated, multilayered film with soft touch properties. In another example embodiment, the metallic pigments may include a coating that is receptive to digital printing that provides a matte, metallic appearance (i.e., a natural look) to the digital-printable surface, e.g., a type of printable coating. Yet further, embodiments may include other pigments with the aluminum flakes such as a carbon black pigment incorporated with the metallic pigment to provide additional hiding and opacity. In another embodiment an organic yellow or red pigment can be incorporated with the aluminum metallic pigment to provide rich gold or red metallic appearance. The metallic appearance of the film may be tuned from high sheen to a dull, subdued, brushed metal look by choosing the pigment, coating, and combinations thereof. The disclosed, metallic film could have a metal coatings with some or all of the example types of coating functionalities, e.g., printable, scratch-resistance, barrier, soft-touch, sealability, low coefficient of friction, etc. [0026 J The remainder of the multilayered film (i.e., "base film"), such as the layer shown in Figure 1, may vary, and include, but is not limited to films having core, tie, and/or skin layers comprising polymers, such as polypropylene, polyester, nylon, polyethylene, polyamide, polylactic acid etc. In one embodiment, the base film may include a clear or cavitated BOPP, BOPET, biaxially oriented polyethylene film (BOPE), or combinations thereof. In other embodiments, the base film may be monoaxially oriented or non-oriented.
[0027] Figure 2 shows an example embodiment of the multilayered aspect of the base film. This exemplary S-layered base film includes outermost skin layers, which may have specific properties like printability, sealability, low co-efficient of friction, barrier properties, otherwise and combinations of the foregoing. For instance, in one embodiment, the skin layer on one side (i.e., skin layer- 1 or skin layer 2) or both sides (i.e., skin layer 1 and skin layer 2) may include a layer of low density polyethylene (LDPE), liner low density polyethylene (LLDPE), medium density polyethylene (MDPE), high density polyethylene (HDPE), and combinations thereof. In another instance, one or more of the skin, tie and/or core layers may have a barrier layer, which may include, for example, ethylene vinyl alcohol ("EVOH"), polyvinylidene chloride ("PVDC"), nylon, acrylonitrile, etc. In other examples, one or more barrier layers may be placed between the tie layers and the skin(s) and/or the core. In additional and alternative embodiments, the outer skin layers of the multilayered films may be primed, treated, and/or metallized. In yet another example embodiment, the barrier layer(s) may be physical vapor deposited (PVD) or chemical vapor deposited (CVD) to the appropriate skin layer- 1 and/or skin layer-2. The vapor deposited layer, for example, may be an aluminum (AT) layer, aluminum oxide (AIO*) layer, and/or silicon oxide (SiOx) layer. In another instance the skin, tie or core may have a cavitated structure and/or contain Ti02 particles to render the multilayered film opaque, such as to the point of being white. In additional and alternative embodiments, any of the layers of the multilayered films may include one or more additives.
Figure imgf000010_0001
[0028] The thickness of the film is only limited by the coatings application process and the end-use application of the metallic coated, multilayered film Examples of thickness of the film may be between 12 μπι and 55 μηη, but much greater or lesser thicknesses may be formed.
[0029] Moving on to more examples of specific embodiments, these embodiments may have a structure as shown in Figure 3. That is, instead of only one or more front side metallic coating(s), wherein each coating layer is of the same or different composition, as shown and discussed with relation to Figures 1 and 2, the base film may also include back side metallic coating(s), wherein each coating layer is of the same or different composition. Otherwise, all of the foregoing description equally applies to two-sided, metallic-coated, multilayer films. That is, for example, various embodiments of Figure 3 may include a host of different components, layers, coatings, additives, primers, sealants, treatments, and so forth, as well as having thicknesses on the same level or otherwise, and undergoing one or more of the previously discussed coating processes or otherwise to apply the back-side coating(s).
Figure imgf000011_0001
[0031] The metallic coating layer may be top coated with a second clear coating layer, also referred to as a "top coat-1" in Figure 4. The top coat-1 may have different properties such as printability, scalability, low co-efficient of friction, barrier layers, otherwise, and combinations thereof. Further, since the metallic coating layer is underneath top coat-1, this structure provides additional surface scratch or mar resistance to the metallic coating layer.
[0032] The back side of the top-coated, metallic coated, multilayered film may be coated with a second coating that may have metallic pigments, provide clear coating, otherwise and combinations thereof. The backside coating may have different properties such as printability, scalability, low co-efficient of friction, barrier properties, otherwise, and combinations thereof. Further, if the back side coating has metallic coating, then this layer can be further top-coated with a second clear coating, also referred to as a top coat-2 in Figure 5. The base film and other layers, as well as optional tie layer(s), metallic coating(s), and so form, may contain the same or different polymers and additives, and undergo the same or different treatments, primers, metallizing, and so forth as discussed earlier in mis application.
Figure imgf000012_0001
[0033] In another instance the metallic pigments suitable for extrusion may be blended with different resin types, such as a polypropylene, polyester, nylon, polyethylene, polyamide, polylactic acid, etc., and extruded to generate a film with metallic, matte metallic appearance or silver glossy appearance. In yet another instance, metallic pigments, such as those that may undergo extrusion, may be incorporated into core layer, tie layer(s), skin layer(s) and combinations thereof. In another specific instance, the metallic pigment may be incorporated into the core layer of coextruded structure, in line with the structure shown at Figure 6A. In still another instance skin layers can have specific properties like printability, sealability, low co-efficient of friction, or barrier layer. Additional and alternative embodiments may incorporate the extrudable metallic pigments into the core layer, tie layer(s), skin layer(s) and combinations thereof. Yet further, embodiments may include carbon black pigment incorporated with the metallic pigment to provide additional hiding and opacity.
Figure imgf000012_0002
[0034] Another example structure for the disclosed films is illustrated in Figure 6B. Its skin layer 1 is a LLDPE, such as Dowlex 2027G, with a poly gauge of 3.2 gauge. The tie layer-1 may be an extrusion blended mixture of a polypropylene homopolymer, such as ExxonMobil 4912, and extrusion grade aluminum pigment, such as Sparkle Silvet 960-30-E1 from Silberline. The aluminum content in the tie layer is 4%, but may vary in other embodiments. The poly gauge of the tie layer-1 is 16.2 gauge in one example embodiment, but may vary in other example embodiments. The core layer may be a mixture of a PP homopolymer ExxonMobil 4912 and Ampacet 403250 Pearl 2A MB containing calcium carbonate (CaC(¾) blended in 82:18 ratio, but either or both types of PP and cavitation agent as well as ratios may vary in other embodiments. The poly gauge of the core layer is 49.4 gauge, but may vary in other example embodiments. The tie layer-2 may be an extrusion blended mixture of a polypropylene homopolymer, such as ExxonMobil 4912, and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30-E1 from Silberline. The aluminum content in the tie layer is 4% in this example embodiment, but may vary in other embodiments. The poly gauge of the tie layer-2 is 16.2 gauge, but may vary in other example embodiments. The skin layer-2 may be a blend of 86.5% ExxonMobil HD6704.18, 10% Schulman S45, 1% Spartech Polycom A27527, and 2.5% Schulman MB0353-STAB, but may vary in other example embodiments. The poly gauge of the tie layer-2 is 5.0 gauge, but may vary in other example embodiments. In this structure, the presence of the LLDPE skin layer may provide improved printability as illustrated in Table 2. The presence of aluminum in the aluminum pigment in tie layers- 1 and 2 may provide the "metallic look" on both sides of the film for a two-sided, "metallic look" film. Additionally, aluminum pigment in tie layers- 1 and 2 also may provide increased opacity. The presence of calcium carbonate in the polypropylene core provides cavitation, which may result in a white core and impart increased opacity to the film. Skin layer-2 having an HDPE skin may provide cold-seal applications to the film. The yield of the film is determined by ASTM D4321 test method and is 35567 in2/lb. The optical gauge of the film is 32.3 micrometers (1.27 mils). The light transmittance of the film was determined by ASTM D1003 test method and is 26.3%.
Figure imgf000014_0001
[0035] In another example embodiment, the structure of the film is as illustrated in Figure 6C. Skin layer-1 may be a LLDPE such as Dowlex 2027G. As compared to Figure 6B, the poly gauge of this skin layer-1 was increased S.O gauge to improve processability. Tie layer- 1 may be an extrusion blended mixture of a polypropylene homopolymer, such as ExxonMobil 4912, and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30- El from Silberline. The aluminum content in the tie layer is 4% but may vary in other example embodiments. The poly gauge of the tie layer-1 is 16.2 gauge. The core layer may be a mixture of a PP homopolymer, such as ExxonMobil 4912 and Ampacet 403250 Pearl 2A MB containing calcium carbonate (CaC(¾) from Ampacet blended in 82:18 ratio, but the PP, cavitating agent, and ratio may differ in other example embodiments. The poly gauge of the core layer is 49.4 gauge. Tie layer-2 may be an extrusion blended mixture of a PP homopolymer, such as ExxonMobil 4912, and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30-E1 from Silberline, but the PP and metallic pigment may differ in other example embodiments. The aluminum content in the tie layer is 4% but may vary in other example embodiments. The poly gauge of tie layer-2 is 16.2 gauge. Skin layer-2 may be a blend of 86.5% ExxonMobil HD6704.18, 10% Schulman S45, 1% Spartech Polycom A27527, and 2.5% Schulman MB0353-STAB. The poly gauge of the skin layer-2 is 5.0 gauge. In this structure, the presence of the LLDPE skin layer may provide improved printability as illustrated in Table 2. Aluminum in the aluminum pigment in tie layers- 1 and 2 may provide the "metallic look" on both sides of the film for a two-sided, "metallic look" film. Additionally, the aluminum also may provide increased opacity. Calcium carbonate in the polypropylene core may provide cavitation, which may result in a white core and impart increased opacity to the film. Skin layer-2 having HDPE may provide cold-seal applications. The yield of the film is determined by ASTM D4321 test method and is 34246 in2/lb. The optical gauge of the film is 34.3 micrometers (1.35 mils). The light transmittance of the film was determined by ASTM D1003 test method and is 27.8%.
Figure imgf000015_0001
[0036J In another example embodiment, the structure of the film is as illustrated in Figure 6D. Skin layer-1 may be a LLDPE such as Dowlex 2027G with a poly gauge of 3.2 gauge. Tie layer-1 may be an extrusion blended mixture of a PP homopolymer, such as ExxonMobil 4912, and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30-E1 from Silberline, but the PP and metallic pigment may differ in other example embodiments. The aluminum content in the tie layer is 8%, but may vary in other example embodiments. The poly gauge of the tie layer-1 is 16.2 gauge. The core layer may be a mixture of a PP homopolymer, such as ExxonMobil 4912 and Ampacet 4032S0 Pearl 2A MB containing calcium carbonate (CaCO?) from Ampacet blended in 82:18 ratio, but the PP, cavitating agent, and ratio may differ in other example embodiments. The poly gauge of the core layer is 49.4 gauge. Tie layer-2 may be an extrusion blended mixture of a polypropylene homopolymer, such as ExxonMobil 4912, and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30-E1 from Silberline, but the PP and metallic pigment may differ in other example embodiments. The aluminum content in the tie layer is 8%, but may vary in other example embodiments. The poly gauge of tie layer-2 is 16.2 gauge. Skin layer-2 may be a blend of 86.5% ExxonMobil HD6704.18, 10% Schulman S45, 1% Spartech Polycom A27S27, and 2.5% Schulman MB0353-STAB, but the blend's components and ratios may different in other embodiments. The poly gauge of the skin layer-2 is 5.0 gauge. Aluminum in the aluminum pigment in tie layers- 1 and 2 may provide the "metallic look" on bom sides of the film for a two-sided, "metallic look" film. Additionally, the aluminum also may provide increased opacity dependent on the aluminum loading in the tie layer. For instance, increasing the aluminum content in the tie layer from 4% for variable 6B to 8% for variable 6D the light transmittance of the film decreased from 26.3 to 18.4. Calcium carbonate in the polypropylene core may provide cavitation, which may result in a white core and impart increased opacity to the film. Skin layer-2 having HDPE may provide cold-seal applications. The yield of the film is determined by ASTM D4321 test method and is 34353 in2Ab. The optical gauge of the film is 36.6 micrometers (1.44 mils). The light transmittance of the film was determined by ASTM D1003 test method and is 18.4%. While the higher aluminum loading in the tie layer resulted in improved opacity it however resulted in decreased film optics due to blister and void formation arising due to incompatibility of aluminum flakes at higher concentration in the polypropylene matrix.
Figure imgf000016_0001
[0037] Turning to another example embodiment, a structure of a film is illustrated in Figure 6E termed as sample E. Skin layer- 1 is a copolymer of polypropylene such as Total 8573HB with an antiblock content of lOOOppm and a poly gauge of S.O gauge. The polypropylene skin provides improved compatibility with the tie layer and hence improved processability. Tie layer- 1 may be an extrusion blended mixture of a polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30- E1 from Silberline. The aluminum content in the tie layer is 8%, but may vary in other example embodiments. The poly gauge of the tie layer- 1 may be 16.2 gauge. The core layer may be mixture of a polypropylene homopolymer, such as Exxon Mobil 4912, and Ampacet 403250 Pearl 2A MB containing calcium carbonate (CaCCb) from Ampacet blended in 82:18 ratio, but the PP, cavitating agent, and ratio may differ in other example embodiments. The poly gauge of the core layer may be 49.4 gauge. Tie layer-2 may be an extrusion blended mixture of a polypropylene homopolymer, such as Exxon Mobil 4912, and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30-E1 from Silberline, but the PP and metallic pigment differ in other example embodiments. The aluminum content in the tie layer is 8%, but may vary in other example embodiments. The poly gauge of the tie layer-2 may be 16.2 gauge. Skin layer-2 may be a blend of 86.5% ExxonMobil HD6704.18, 10% Schulman S45, 1% Spartech Polycom A27527, and 2.5% Schulman MB0353-STAB. The poly gauge of the skin layer-2 may be 5.0 gauge. Aluminum in the aluminum pigment in tie layers- 1 and 2 may provide the "metallic look" on both sides of the film for a two-sided, "metallic look" film. Additionally, aluminum also may provide increased opacity. Hie calcium carbonate in the polypropylene core may provide cavitation, which may result in a white core and impart increased opacity to the film Skin layer-2 having an HDPE skin may provide cold-seal applications. The yield of the film was determined by ASTM D4321 test method and is 36487 in2/lb. The optical gauge of the film is 38.1 micrometer (1.S0 mils). The light transmittance of the film was determined by ASTM D1003 test method and is 18.23%. While the higher aluminum loading in the tie layer resulted in improved opacity it however resulted in decreased film optics due to blister and void formation arising due to incompatibility of aluminum flakes at higher concentration in the polypropylene matrix.
Figure imgf000017_0001
[0038] In yet another example embodiment, the structure of a film is illustrated in Figure 6F. Skin layer- 1 may be a copolymer of PP, such as Total 8S73HB, with an antiblock content of 1000 ppm. The poly gauge of skin layer- 1 may be S.O gauge. Tie layer- 1 is an extrusion blended mixture of a polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30-E1 from Silberline. The aluminum content in the tie layer is 2%, but may vary in other example embodiments. The poly gauge of the tie layer-1 is 16.2 gauge. The core layer may be mixture of a polypropylene homopolymer, such as ExxonMobil 4912 and Ampacet 403250 Pearl 2 A MB containing calcium carbonate (CaCC^) from Ampacet blended in 82:18 ratio, but the PP, cavitating agent, and ratio may differ in other example embodiments. The poly gauge of the core layer may be 49.4 gauge or other gauges in other example embodiments. The tie layer-2 may be an extrusion blended mixture of a polypropylene homopolymer, such as Exxon Mobil 4912 and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30-E1 from Silberline. In addition or in the alternative to this example aluminum pigment, other aluminum pigment(s), other pigments having different metal(s) than aluminum, or combinations thereof may be used in alternative example embodiments in this structure or other structures. The aluminum content in the tie layer is 2% but may vary in other example embodiments. The poly gauge of tie layer-2 may be 16.2 gauge or a different gauge. Skin layer-2 may be a blend of 86.5% ExxonMobil HD6704.18, 10% Schulman S45, 1% Spartech Polycom A27527, and 2.5% Schulman MB0353-STAB. The poly gauge of skin layer-2 may be 5.0 gauge. The aluminum present in the aluminum pigment in tie layers- 1 and 2 may provide the "metallic look" on both sides of the film for a two-sided, "metallic look" film. Additionally, aluminum pigment also may provide increased opacity. The presence of calcium carbonate in the polypropylene core may provide cavitation, which may result in a white core and impart increased opacity to the film. Skin layer-2 having an HDPE skin may provide cold-seal applications. The yield of the film was determined by ASTM D4321 test method and is 35299 in2/lb. The optical gauge of the film is 32.3 micrometers (1.27 mils). The light transmittance of the film was determined by ASTM D1003 test method and is 36.37%. While the lower aluminum loading in the tie layer resulted in decreased opacity it however resulted in better film optics.
Figure imgf000018_0001
[0039] In yet another example embodiment, the structure of a film is illustrated in Figure 6G.
Skin layer-1 may be a copolymer of polypropylene, such as Total 8573HB, with an antiblock content of 1000 ppm. The poly gauge of skin layer-1 may be 5.0 gauge. Tie layer-1 is an extrusion blended mixture of a polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30-E1 from Silberline.
The aluminum content in the tie layer is 2% but may vary in other example embodiments.
The poly gauge of the tie layer-1 was raised to 25 gauge to increase the opacity of the film. The core layer may be mixture of a polypropylene homopolymer, such as ExxonMobil 4912 and Ampacet 403250 Pearl 2A MB containing calcium carbonate (CaC(¾) from Ampacet blended in 82:18 ratio, but the PP, cavitating agent, and ratio may differ in other example embodiments. The poly gauge of the core layer may be 35 gauge or other gauges in other example embodiments. The tie layer-2 may be an extrusion blended mixture of a polypropylene homopolymer, such as Exxon Mobil 4912 and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30-E1 from Silberline. In addition or in the alternative to this example aluminum pigment, other aluminum pigment(s), other pigments having different metal(s) than aluminum, or combinations thereof may be used in alternative example embodiments in this structure or other structures. The aluminum content in the tie layer is 2% but may vary in other example embodiments. The poly gauge of tie layer-2 was increased to 25 gauge to increase the opacity of the film. Skin layer-2 may be a blend of 86.5% ExxonMobil HD6704.18, 10% Schulman S45, 1% Spartech Polycom A27527, and 2.5% Schulman MB0353-STAB. The poly gauge of skin layer-2 may be 5.0 gauge. The aluminum present in the aluminum pigment in tie layers- 1 and 2 may provide the "metallic look" on both sides of the film for a two-sided, "metallic look" film. Additionally, aluminum pigment also may provide increased opacity. The presence of calcium carbonate in the polypropylene core may provide cavitation, which may result in a white core and impart increased opacity to the film. Skin layer-2 having an HDPE skin may provide cold-seal applications. The yield of the film was determined by ASTM D4321 test method and is 35142 in2/lb. The optical gauge of the film is 32.8 micrometers (1.29 mils). The light transmittance of the film was determined by ASTM D1003 test method and is 35.6%. While the tie layer thickness was increased to 25 gauge for 6G compared to 16.2 gauge for 6F, the light transmittance of the film decreased only from 36.37% to 35.6%.
Figure imgf000019_0001
[0040] In yet another example embodiment, the structure of a film is illustrated in Figure 6H. To increase the opacity of the film, carbon black was added to the layer containing the aluminum pigment, which may equally be a different metallic pigment in other example embodiments. Schulman carbon black 4645 resin was obtained from A. Schulman at 35% masterbatch and diluted further with ExxonMobil 4912 polypropylene resin to obtain 2.8% carbon black blend. Skin layer-] may be a copolymer of polypropylene, such as Total 8573HB, with an antiblock content of 1000 ppm. The poly gauge of skin layer- 1 may be 5.0 gauge. Tie layer- 1 is a blend of polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment such as Sparkle Silvet 960-30-E1 from Silberline, and 2.8% carbon black blend. The aluminum content in the tie layer is 2% and the carbon black content is 0.28%, but may vary in other example embodiments. The poly gauge of the tie layer-1 was 16.2 gauge. The core layer may be mixture of a polypropylene homopolymer, such as ExxonMobil 4912 and Ampacet 403250 Pearl 2A MB containing calcium carbonate (CaC(¾) from Ampacet blended in 82:18 ratio or in other ratios and/or having different polymeric and/or cavitating agent components in various other embodiments. The poly gauge of the core layer may be 49.4 gauge or other gauges in other example embodiments. Tie layer-2 is a blend of polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment such as Sparkle Silvet 960-30-E1 from Silberline, and 2.8% carbon black blend. The aluminum content in the tie layer is 2% and the carbon black content is 0.28%, but may vary in other example embodiments. The poly gauge of the tie layer-2 was 16.2 gauge. Skin layer-2 may be a blend of 86.5% ExxonMobil HD6704.18, 10% Schulman S45, 1% Spartech Polycom A27527, and 2.5% Schulman MB0353-STAB. The poly gauge of skin layer-2 may be 5.0 gauge. The aluminum present in the aluminum pigment in tie layers- 1 and 2 may provide the "metallic look" on both sides of the film for a two-sided, "metallic look" film. Additionally, aluminum pigment also may provide increased opacity. The addition of carbon black will further enhance the opacity of the film The presence of calcium carbonate in the polypropylene core may provide cavitation, which may result in a white core and impart increased opacity to the film. Skin layer-2 having an HDPE skin may provide cold-seal applications. The yield of the film was determined by ASTM D4321 test method and is 32663 in2/lb. The optical gauge of the film is 37.8 micrometers (1.49 mils). The light transmittance of the film was determined by ASTM D1003 test method and is 25.4%.
Figure imgf000021_0001
[0041] In yet another example embodiment, the structure of a film is illustrated in Figure 61. To further increase the opacity and processability of the film compared to example 6H, the thickness of tie layer 1 and 2 was increased to 20 gauge. To maintain the overall target thickness of the film, the thickness of the core layer was decreased to 40 gauge. Carbon black was added to the layer containing the aluminum pigment. Schulman carbon black 4645 resin was obtained from A. Schulman at 35% masterbatch and diluted further with ExxonMobil 4912 polypropylene resin to obtain 2.8% carbon black blend. Skin layer- 1 may be a copolymer of polypropylene, such as Total 8573HB, with an antiblock content of 1000 ppm. The poly gauge of skin layer-1 may be 5.0 gauge. Tie layer-1 is a blend of polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment such as Sparkle Silvet 960-30-E1 from Silberline, and 2.8% carbon black blend. The aluminum content in the tie layer is 2% and the carbon black content is 0.28%, but may vary in other example embodiments. The poly gauge of the tie layer-1 was raised to 20 gauge to increase the opacity of the film. The core layer may be mixture of a polypropylene homopolymer, such as ExxonMobil 4912 and Ampacet 403250 Pearl 2A MB containing calcium carbonate (CaCCh) from Ampacet blended in 82:18 ratio or in other ratios and/or with other polymeric and/or cavitating agent components in various other embodiments. The poly gauge of the core layer may be 40 gauge or other gauges in other example embodiments. Tie layer-2 is a blend of polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment such as Sparkle Silvet 960-30-E1 from Silberline, and 2.8% carbon black blend. The aluminum content in the tie layer is 2% and the carbon black content is 0.28%, but may vary in other example embodiments. The poly gauge of the tie layer-1 was raised to 20 gauge to increase the opacity of the film. Skin layer-2 may be a blend of 86.5% ExxonMobil HD6704.18, 10% Schulman S45, 1% Spartech Polycom A27527, and 2.5% Schulman MB0353-STAB. The poly gauge of skin layer-2 may be 5.0 gauge. The aluminum present in the aluminum pigment in tie layers- 1 and 2 may provide the "metallic look" on both sides of the film for a two-sided, "metallic look" film. Additionally, aluminum pigment also may provide increased opacity. The addition of carbon black will further enhance the opacity of the film. The presence of calcium carbonate in the polypropylene core may provide cavitation, which may result in a white core and impart increased opacity to the film Skin layer-2 having an HDPE skin may provide cold-seal applications. The yield of the film was determined by ASTM D4321 test method and is 34000 in2/lb. The optical gauge of the film is 32.0 micrometers (1.26 mils). The light transmittance of the film was determined by ASTM D1003 test method and is 23.5%. While the tie layer thickness was increased to 20 gauge for example 61 compared to 16.2 gauge for example 6H, the light transmittance of the film decreased only from 25.4% to 23.5%.
Figure imgf000022_0001
[0042] In yet another example embodiment, the structure of a film is illustrated in Figure 6J. To increase the opacity of the film, carbon black was added to the layer containing the aluminum pigment. Schulman carbon black 4645 resin was obtained from A. Schulman at 35% masterbatch and diluted further with ExxonMobil 4912 polypropylene resin to obtain 2.8% carbon black blend. Skin layer- 1 may be a copolymer of polypropylene, such as Total 8573HB, with an antiblock content of 1000 ppm. The poly gauge of skin layer- 1 may be 5.0 gauge. Tie layer- 1 is a blend of polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment such as Sparkle Silvet 960-30-E1 from Silberline, and 2.8% carbon black blend. The target aluminum content in the tie layer is 4% and the target carbon black content is 0.56% but may vary in other example embodiments. The poly gauge of the tie layer- 1 was 16.2 gauge. The core layer may be mixture of a polypropylene homopolymer, such as ExxonMobil 4912 and Ampacet 403250 Pearl 2A MB containing calcium carbonate (CaC(¾) from Ampacet blended in 82:18 ratio or in other ratios in various other embodiments. The poly gauge of the core layer may be 49.4 gauge or other gauges in other example embodiments. Tie layer-2 is a blend of polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment such as Sparkle Silvet 960-30- El from Silberline, and 2.8% carbon black blend. The target aluminum content in the tie layer is 4% and the target carbon black content is 0.56% but may vary in other example embodiments. The poly gauge of the tie layer-2 was 16.2 gauge. Skin layer-2 may be a copolymer of polypropylene, such as Total 8573HB, with an antiblock content of 1000 ppm. The poly gauge of skin layer-2 may be S.O gauge. The aluminum present in the aluminum pigment in tie layers- 1 and 2 may provide the "metallic look" on both sides of the film for a two-sided, "metallic look" film. Additionally, aluminum pigment also may provide increased opacity. The addition of carbon black will further enhance the opacity of the film. The presence of calcium carbonate in the polypropylene core may provide cavitation, which may result in a white core and impart increased opacity to the film. The yield of the film was determined by ASTM D4321 test method and is 36065 in2/lb. The optical gauge of the film is 44.2 micrometers (1.74 mils). The light transmittance of the film was determined by ASTM D1003 test method and is 13.7%.
Figure imgf000023_0001
[0043] In yet another example embodiment, the structure of a film is illustrated in Figure 6K. To increase the opacity of the film, carbon black was added to the layer containing the aluminum pigment. Schulman carbon black 4645 resin was obtained from A. Schulman at 35% masterbatch and diluted further with ExxonMobil 4912 polypropylene resin to obtain 2.8% carbon black blend. Skin layer- 1 may be a copolymer of polypropylene, such as Total 8573HB, with an antiblock content of 1000 ppm. The poly gauge of skin layer- 1 may be 5.0 gauge. Tie layer- 1 is a blend of polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment such as Sparkle Silvet 960-30-E1 from Silberline, and 2.8% carbon black blend. The aluminum content in the tie layer is 3.23% and the carbon black content is 0.53% but may vary in other example embodiments. The poly gauge of the tie layer- 1 was 16.2 gauge. The core layer may be mixture of a polypropylene homopolymer, such as ExxonMobil 4912 and Ampacet 403250 Pearl 2A MB containing calcium carbonate (CaCCh) from Ampacet blended in 82:18 ratio or in other ratios in various other embodiments. The poly gauge of the core layer may be 49.4 gauge or other gauges in other example embodiments. Tie layer-2 is a blend of polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment such as Sparkle Silvet 960-30- El from Silberline, and 2.8% carbon black blend. The aluminum content in the tie layer is 3.23% and the carbon black content is 0.53% but may vary in other example embodiments. The poly gauge of the tie layer-2 was 16.2 gauge. Skin layer-2 may be a copolymer of polypropylene, such as Total 8S73HB, with an antiblock content of 1000 ppm. The poly gauge of skin layer-2 may be S.O gauge. The aluminum present in the aluminum pigment in tie layers- 1 and 2 may provide the "metallic look" on both sides of the film for a two-sided, "metallic look" film. Additionally, aluminum pigment also may provide increased opacity. The addition of carbon black will further enhance the opacity of the film. The presence of calcium carbonate in the polypropylene core may provide cavitation, which may result in a white core and impart increased opacity to the film. The yield of the film was determined by ASTM D4321 test method and is 30239 in2/lb. The optical gauge of the film is 33.0 micrometers (1.3 mils). The light transmittance of the film was determined by ASTM D1003 test method and is 16.4%.
Figure imgf000024_0001
[0044] Turning to another example embodiment, a structure of a film is illustrated in Figure 6L. The structure is designed to have 1 side metallic appearance and other side white appearance. Skin layer- 1 is a copolymer of polypropylene such as Total 8573HB with an antiblock content of lOOOppm and a poly gauge of 6.4 gauge. The polypropylene skin provides improved compatibility with the tie layer and hence improved processability. The tie layer -1 may be mixture of a polypropylene homopolymer, such as Exxon Mobil 4912, and Ampacet 403250 Pearl 2A MB containing calcium carbonate (CaC(¾) from Ampacet and Ampacet 511094 containing titanium dioxide (Ti02) from Ampacet blended in 77:15:8 ratio; other PP, cavitating agents, and/or ratios are possible in other embodiments. Hie tie layer thickness is 32.4 gauge. The core layer may be an extrusion blended mixture of a polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30-E1 from Silberline and Schulman carbon black 464S. Schulman carbon black 4645 resin was obtained from A. Schulman at 35% mastcrbatch and diluted further with ExxonMobil 4912 polypropylene resin to obtain 2.8% carbon black blend. The aluminum content in the core layer is 1.2% but may vary in other example embodiments. The carbon black content in the core layer is 0.28%, but may vary in other example embodiments. The poly gauge of the core layer may be 98.8 gauge. Tie layer-2 may be a polypropylene homopolymer, such as Exxon Mobil 4912. The poly gauge of the tie layer-2 may be 32.4 gauge. Skin layer-2 may be a LLDPE such as Dowlex 2027G with a poly gauge of 10.0 gauge. Aluminum in the aluminum pigment in core layer may provide the "metallic look" to one side of the film Additionally, aluminum blended with carbon black also may provide increased opacity. The calcium carbonate and titanium dioxide in the polypropylene tie layer- 1 may provide cavitation, which may result in a white appearance to the second side of the film. The LLDPE skin layer-2 may provide improved printability. The yield of the film was detennined by ASTM D4321 test method and is 20783 in2/lb. The optical gauge of the film is 56.1 micrometer (2.21 mils). The light transmittance of the film was determined by ASTM D1003 test method and is 12.3%. The addition of carbon black further enhances the opacity of the film.
Figure imgf000025_0001
[0045] Turning to another example embodiment, a structure of a film is illustrated in Figure 6M. The structure is designed to have 1 side metallic appearance and other side white appearance. Skin layer- 1 is a copolymer of polypropylene such as Total 8573HB with an antiblock content of lOOOppm and a poly gauge of 5.0 gauge. The polypropylene skin provides improved compatibility with the tie layer and hence improved processability. The tie layer -1 may be mixture of a polypropylene homopolymer, such as Exxon Mobil 4912, and Ampacet 403250 Pearl 2A MB containing calcium carbonate (CaC(½) and Ampacet 511094 containing titanium dioxide (Ti(¼) blended in 77:15:8 ratio. The tie layer thickness is 10 gauge. The core layer may be an extrusion blended mixture of a polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30-E1 from Silberline. The aluminum content in the core layer is 2% but may vary in other example embodiments. The poly gauge of the core layer may be 120 gauge. Tie layer-2 may be a polypropylene homopolymer, such as Exxon Mobil 4912. The poly gauge of the tie layer-2 may be 10 gauge. Skin layer-2 is a copolymer of polypropylene such as Total 8573HB with an antiblock content of lOOOppm and a poly gauge of 5.0 gauge. Aluminum in the aluminum pigment in core layer may provide the "metallic look" to one side of the film The calcium carbonate and titanium dioxide in the polypropylene tie layer- 1 may provide cavitation, which may result in a white appearance to the second side of the film. The yield of the film was determined by ASTM D4321 test method and is 23638 in2/lb. The optical gauge of the film is 38.6 micrometer (1.52 mils). The light transmittance of the film was determined by ASTM D1003 test method and is 22.4%.
Figure imgf000026_0001
[0046] Turning to another example embodiment, a structure of a film is illustrated in Figure 6N. The structure is designed to have 1 side metallic appearance and other side white appearance. Skin layer-] is a copolymer of polypropylene such as Total 8573HB with an antiblock content of lOOOppm and a poly gauge of 5.0 gauge. The polypropylene skin provides improved compatibility with the tie layer and hence improved processability. The tie layer -1 may be mixture of a polypropylene homopolymer, such as Exxon Mobil 4912, and Ampacet 403250 Pearl 2A MB containing calcium carbonate (CaCO?) and Ampacet 511094 containing titanium dioxide (T1O2) blended in 77:15:8 ratio. The tie layer thickness is 10 gauge. The core layer may be an extrusion blended mixture of a polypropylene homopolymer, such as ExxonMobil 4912 and an extrusion grade aluminum pigment, such as Sparkle Silvet 960-30-E1 from Silberline and Schulman carbon black 4645. Schulman carbon black 4645 resin was obtained from A. Schulman at 35% masterbatch and diluted further with ExxonMobil 4912 polypropylene resin to obtain 2.8% carbon black blend. The aluminum content in the core layer is 2% but may vary in other example embodiments. The carbon black content in the core layer is 0.28%, but may vary in other example embodiments. The poly gauge of the core layer may be 120 gauge. Tie layer-2 may be a polypropylene homopolymer, such as Exxon Mobil 4912. The poly gauge of the tie layer-2 may be 10 gauge. Skin layer-2 is a copolymer of polypropylene such as Total 8573HB with an antiblock content of lOOOppm and a poly gauge of 5.0 gauge. Aluminum in the aluminum pigment in core layer may provide the "metallic look" to one side of the film. Additionally, aluminum blended with carbon black also may provide increased opacity. The calcium carbonate and titanium dioxide in the polypropylene tie layer- 1 may provide cavitation, which may result in a white appearance to the second side of the film. The yield of the film was determined by ASTM D4321 test method and is 20722 in2/lb. The optical gauge of the film is 46.1 micrometer (1.81 mils). The light transmittancc of the film was determined by ASTM D1003 test method and is 5.29%. The addition of carbon black further enhances the opacity of the film.
Figure imgf000027_0001
[0047] In addition or in the alternative to the above example of the aluminum pigment, other aluminum pigment(s), other pigments having different metal(s) than aluminum, or combinations thereof may be used in alternative example embodiments in this structure or other structures. It is understood that Figures 6A-6N are merely exemplary of some structures, and differences in sources for each of the layers, gauges, transmittance, yields, opacities, metal(s) in the metallic pigment(s), and so forth are entirely possible in other example structures within the ambit of this disclose even though such as not discussed explicitly herein.
[0048] Further to understand the print performance of the films disclosed above water based ink testing and UV ink testing were performed on selected samples. Table 1 shows test results from measuring water-based ink adhesion of films with different compositions. Notably, all coatings show 100% ink adhesion to different tape tests after treatment.
Figure imgf000028_0001
Table 1
[0049] Table 2 shows test results from measuring UV-ink adhesion of same selected films with different compositions. Interestingly, samples 6B and 6C with LLDPE skin shows good UV ink adhesion before and after treatment. All the other samples show poor to moderate UV ink adhesion before treatment. All the samples show improved UV ink adhesion after retreatment.
Figure imgf000029_0001
Tapes = 3M Scotch tape 600-3/4 in width, 3M Scotch tape 610-1 in width, 3M Scotch tape 810-1 in width and a Scapa 1129 tape 25 mm width from Scapa. Approximately 6" in length is applied on the coated film and let to adhere for 1 minute. The tape is then pulled out.
Table 2
[0050] During the ink adhesion testing protocols for the data in Tables 1 and 2, each sample is evaluated with and without pre-print press corona treater. All print evaluations are performed on the skin layer- 1 unless indicated otherwise. The percent that is noted in each results column is the percentage of total power of the unit. Here, the unit was set at 60% of unit total power. A rationale for testing both with and without treatment is that since film offerings in label applications are laminated with an adhesive and silicone coated liner, then silicone may transfer from the liner to the print face of films. This is a common phenomenon in the market, and the converting and printing industry may respond with press re-treatment of the film's surface. In certain instances the treatment tends to help cross-link the silicone and improve ink adhesion. Because the market has become so accustomed to re-treating print surfaces, men testing bom with and without treatment was incorporated in the testing protocol.
[0051] Further example embodiments include skin layers 1 and/or 2 optionally having specific surface properties, which are receptive to coating as shown in Figure 7. The coating composition may be applied to either or both sides of the film. The top coat-1 and/or 2 may have different properties such as printability, sealability, low co-efficient of friction, barrier layers, otherwise, and combinations thereof. Additionally and alternatively, other example embodiments may include carbon black pigment incorporated with the metallic pigment to provide additional hiding and opacity.
Figure imgf000030_0001
[0052] A particular coating's composition may be guided by performance of the coating, its end-use, and/or its application. Particularized or desired coating laydown and adhesion may be observed only with special attention drawn towards optimizing the coating composition. For instance, the pigment to binder ratio (P/B) is a parameter used to determine the coating adhesion. To obtain a particular coating adhesion that one considers acceptable, the P/B ratio may be preferably within a range from 0.1 through 6, more preferably from 0.25 through 4, or most preferably from 0.42 through 2.5.
[0053] In one example, the pigment (P) to binder (Bl) ratio is 0.61 for "Coating 1" as provided in Example 1 shown in Table 3. Further, binder Bl is an acrylic emulsion NeoCryl FL-5095 from DSM Coating Resins, antiblock is an amorphous silica from Sylobloc 45 from Grace Davison, and passivated aluminum pigment is Sil-O-Wet Premier 014NL-PA from Silberline Manufacturing Inc. The coating as described in Table 3 was applied onto a 66 μιη, white, opaque, polyolefin film, such as Label-Lyte® 150LL-302 available from Jindal Films Americas LLC. The dry metal coating thickness is 2.5 g/m2. The metallic coating shows acceptable coating laydown appearance and >99% coating adhesion with 600 and 610 tape test. (Two tape types = 3M Scotch tape 600-3/4 in width, 3M Scotch tape 610-1 in width. Approximately 6" in length is applied on the coated film and let to adhere for 1 minute. The tape is then pulled out. The coating removed is then rated visually and subtracted from a possible 100% and is reported as coating adhesion % (100% is best; 0% = total coating removal). The coating adhesion tape test is performed immediately and 24 hours after coating.
Figure imgf000031_0001
[0054] The metal-coated film structures were then surface printed with water base (WB) ink and ultraviolet (UV) curable ink to determine the print performance of the coating compositions. The ink adhesion was evaluated with 600 and 610 tape test. (Two tape types = 3M Scotch tape 600-3/4 in width, 3M Scotch tape 610-1 in width. Approximately 6" in length is applied on the printed film and let to adhere for 1 minute. The tape is then pulled out. The ink removed is then rated visually and subtracted from a possible 100% and is reported as ink adhesion % (100% is best; 0% = total coating removal). Print trials performed with the Example 1 coated structure revealed acceptable water-based ink adhesion both before and after treatment (i.e., acceptable = > 95%, but an acceptability definition may differ for other persons in the art in an exercise of their discretion and/or needs). However, the UV-ink adhesion of this composition revealed unacceptable adhesion both before and after treatment (unacceptable = < 95%). [0055] Blending of a second binder (B2), which has an additional functionality to improve coating cohesive adhesion, may enhance the UV-ink adhesion performance. The additional functionality is provided by incorporating a functional monomer in the polymer chain. Examples of such functional monomers include, but are not limited to, mono or multifunctional acids containing monomers, mono or multifunctional acids containing monomers metal salts, mono or multifunctional silanes containing monomers, mono or multifunctional amine, difunctional acrylic monomers including 1,4-butanediol diacrylate, 1,3-butanediol dimethacrylate, 1,4-butanediol dimethacrylate, copper (Π) methacrylate carboxylic acid, trans- 1,4-cyclohcxanediol dimethacrylate, N.N'-cystaminebisacrylamide, 1,10-decanediol dimethacrylate, N,N'-diallylacrylamide, diethylene glycol diacrylate, diethylene glycol dimethacrylate, 2,2-dimethylpropanediol dimethacrylate, dipropylene glycol dimethacrylate, Ν,Ν' -ethylene bisacrylamide, ethylene glycol diacrylate, ethylene glycol dimethacrylate, ethylene glycol dimethacrylate, N,N'-hexamethylenebisacrylamide, 1,6-hexanediol diacrylate, 1,6-hexanediol dimethacrylate, magnesium acrylate carboxylic acid, Ν,Ν'-methylcnebisacrylamide, nonanediol dimethacrylate, 1,5-pentanediol dimethacrylate, 1,4-phenylene diacrylate, tetraethylene glycol dimethacrylate, methylene glycol diacrylate, triethylene glycol dimethacrylate, zinc dimethacrylate, multifunctional acrylic monomers including pentaerythritol triacrylate, 1,1,1-trimethylolpropane triacrylate, 1,1,1-trimethylolpropane trimethacrylate, 1,1,1-trimethylolpropane trimethacrylate, dipentaerythritol pentaacrylate, pentaerythritol tetraacrylate, epoxide containing monomers, anhydride containing monomers, and imide containing monomers.
[0056] Alternatively, the coating adhesion and/or the UV-ink adhesion may provide improved adhesion performance by blending a second binder with a different acid value between Bl and B2. The optimized blending ratios of binders having different acid values are one way to optimize the acceptable coating adhesion and UV-ink adhesion performances of the coating.
[0057] Furthermore, the coating adhesion and UV-ink adhesion may provide improved performance by including a second binder with a different glass transition temperature (Tg). The optimized blending ratios of these different glass transition temperature (Tg) binders determine the acceptable coating adhesion and UV-ink adhesion performance of the coating. [0058] In another example, the pigment to binder ratio is 0.61 for "Coating 2," and is provided as Example 2 in Table 4. Binder Bl is an acrylic emulsion NeoCryl FL-5095 from DSM Coating Resins Inc., binder B2 is Styrene acrylic emulsion NeoCryl A- 1094 from DSM Coating Resins Inc. that has a different acid value and glass transition temperature (Tg) as compared to NeoCryl FL-5095, antiblock is amorphous silica Sylobloc 45 from Grace Davison, and passivated pigment is Sil-O-Wet Premier 014NL-PA from Silberline Manufacturing Inc. Aluminum metal coating having the composition as described in Table 4 was applied onto the 66 micron white, opaque, polyolefin film, such as Label-Lyte® 150LL- 302 available from Jindal Films Americas LLC. The dry metal coating thickness is 2.5 g/m2. [0059] Example 2 provides an example coating formulation with improved UV-ink adhesion in accordance with this disclosure. The parts per hundred ("PHR") loading, which determines the blending ratios of the two different binders and pigment to binder ratio, is important and may be adjusted, for instance, based on the fitness-for-use requirements and the type of coatings being used.
Example 2:
Figure imgf000033_0001
[0060] Table S below shows a list of metal coated variables produced with different binder ratios (B1/B2), pigment to binder ratios (P/B), dry aluminum (i.e., metal) coating weight and any additional dry top coating weight where applied.
Figure imgf000034_0001
Bl = Binder 1, i.e., a 100% acrylic coating; in another example embodiment, Bl could be one or more styrene acrylic coatings, in other example embodiments, Bl could be one or more aliphatic or aromatic epoxy coatings, in yet another example, Bl could be one or more aliphatic or aromatic polyester coatings, in still another example, Bl could be one or more aliphatic or aromatic polyurethane coatings, and, in still yet another example, Bl could be one or more aliphatic or aromatic organo-silane coatings.
B2 = Binder 2, i.e., a functionalized styrene acrylic having a high Tg coating to enhance cohesive adhesion; in another example embodiment, B2 could be one or more functionalized 100% acrylic coatings, in other example embodiments, B2 could be one or more aliphatic or aromatic epoxy coatings, in another example, B2 could be one or more aliphatic or aromatic polyester coatings, in yet another example, B2 could be one or more aliphatic or aromatic polyurethane coatings, and, in still yet another example, B2 could be one or more aliphatic or aromatic organo silane coatings.
B1/B2 = physical property that is an empirical ratio indicative of acceptable adhesion (n.b. Bl provides good printability and B2 provides good cohesive coating adhesion) P = Pigment loading in PHR
B = total binder quantity in PHR = Bl + B2 or (Bl + B2 + ...Bn) where n number of different binders used to optimize the performance of the coating.
P/B = physical property that is an empirical ratio of (pigment + fillers) to binder, i.e., solids
[0061] Table 6 shows test results from measuring water-based ink adhesion of coatings with different compositions, wherein the difference may be identified based on the B1/B2 ratio. Notably, all coatings show 100% ink adhesion to different tape tests before and after treatment.
Figure imgf000035_0001
Table 6 [0062] Table 7 shows test results from measuring UV-ink adhesion of coatings with different compositions. Interestingly, the different coatings in the UV-ink system showed variation in performance based on different coating formulations. For instance, good print-receptive coatings, such as "Sample 6" (B 1=100%), produced poor ink adhesion with 600 tape before treatment. Comparatively, using only the higher Tg styrene acrylic coating also showed poor UV-ink adhesion. For example, "Sample 2" (B2=100%) showed poor ink adhesion with all of the tape tests before treatment. Blending binders Bl and B2 in 1:1 ratio, "Sample 1" also shows poor ink adhesion performance before treatment. However, "Sample 3" with a B1:B2 blending ratio of 70:30 and "Sample 5" with a B1:B2 blending ratio of 90:10 reveal enhanced UV-ink adhesion performance of the metal-coated variables as seen in Table 7. Further, "Sample 4" with an optimized blending ratio of 75:25 shows acceptable UV-ink adhesion (acceptable = > 95%) as seen in Table 7.
[0063] In another instance a metal coated film with poor UV ink adhesion performance with B1/B2 = 1.00 can be improved by top coating the metallic coating with a second print receptive coating. For example, in "Sample 7," the metal coating is top coated with an additional print receptive coating resulting in good UV ink adhesion performance before and after treatment. In additional example embodiments, the compositions of the coating layer(s) may be modified with wax and antiblock loading based on the slip and coefficient of friction (COF) requirements.
Figure imgf000037_0001
[0064] During the ink adhesion testing protocols for the data in Tables 6 and 7, each sample is evaluated with and without pre-print press corona treater. The percent mat is noted in each results column is the percentage of total power of the unit (i.e., here, the unit was set at 60% of unit total power). A rationale for testing both with and without treatment is the following: because film offerings in label applications are laminated with an adhesive and silicone coated liner, silicone may transfer from the liner to the print face of films. This is a common phenomenon in the market, and the converting and printing industry may respond with press re-treatment of the film's surface. In certain instances, the treatment tends to help cross-link the silicone and improve ink adhesion. Because the market has become so accustomed to retreating print surfaces (even of coated films), then testing both with and without treatment was incorporated in the testing protocol. [0065] Table 8 shows typical fitness-for-use (FFU) properties of the metallic coated film CMW "Sample 7", as illustrated in structure 1. The aluminum coated film provides a typical opacity of 99%. Further, the metal coated film shows a light transmission of 5%, which is a 72% reduction compared to a similar structure with no aluminum pigment that has a typical value of 18% light transmission. The superior opacity of the aluminum coated film facilitates the use of mis film in opaque labels applications. No additional colored or black ink, coating or adhesive is required to use this film as a block-out label or application.
[0066 J Low blocking tendency of a film demonstrates its FFU throughout the supply chain cycle. A film with low blocking tendency may unwind easily at high speeds without web breakages. The addition of metallic pigments to the coatings has no adverse effect on the blocking properties. For instance, the above disclosed film "Sample 7" has a blocking value of 5.7 g/in at accelerated testing conditions of (125 PSI, 82.1°F, RH 72.9%). Typical acceptable blocking values for similar printable commercial coated label films with no metal pigments are in the range of 5 to 10 g/in.
Figure imgf000039_0001
Table 8 [0067] In view of the foregoing discussion, the above-described invention provides films with aesthetic, functional performances. The unique silver block-out film is a white, opaque design that may replace traditional matte metallic films obtained through vacuum metallization process. The coated approach has exceptional graphic appeal, and may address security label needs as well as have a host of other applications, such as those previously discussed. The coated aluminum silver label technology provides a broad range of surface print compatibility, including, but not limited to, UV flexo inks, UV screen, UV letterpress, solvent-based and water-based inks and can be laser-printed, inkjet-printed with code date, or thermal-transfer-ribbon-printed. The film may have a white opaque adhesive side and silver print face that provides an excellent material for use in block-out/security, beverage, retail, equipment, name tags, food, health and beauty labels, and other applications.
[0068] In view of the foregoing, various bags and films may be formed from the above- described, metallic-coated, printable, flexible, multilayered films. For example, packaging or other applications formed for food or non-food items may include a sealed bag/pouch made through use of machine-packaging equipment, such as HFFS, VFFS, and/or other pouch packaging machines.
[0069] In addition to the matte metallic appearance and excellent print performance just discussed, the disclosed coated aluminum film also provides exceptional opacity. An aluminum metal coating having the composition, as described in Table 4, was applied onto the white, opaque, polyolefin film, such as Label-Lyte® 150LL-302 available from Jindal Films Americas LLC. The uncoated Label-Lyte® 150LL-302 is the "control" film shown in Table 9. In Table 9, coat weight of the aluminum metal coating dry film was varied in Example #1, Example #2, and Example #3. As shown in Table 9, the control base film is 66 μπι thick, has an opacity of 88%, and a light transmission of 19%. Applying a metal coating of dry film coat weight of 2.1 g/m2 improved the film's opacity to 97.4% and reduced light transmission to 11.60. In Example #2, the dry coat weight of the metal coating dry film was increased to 2.43 g/m2. This improved the film's opacity to 98.7% with a reduction in light transmission to 6.54. In Example #3, the dry coat weight of the metal coating dry film was increased to 3.28 g/m2. This improved the film's opacity to 99.4% and reduced light transmission to 4.44%. Further, as illustrated by opacity performances for Example #1, Example #2, and Example #3, the opacity and light transmission can be manipulated and optimized for a specific block-out label requirement by manipulating the dry coat weight of the metal coating layer. The opacity of the aluminum coated film facilitates the use of these metal coated films in opaque labels and block-out label applications. Typical block-out labels involve additional process steps that, for example, require application of a black ink or other opaque-colored ink to produce a block-out label. This disclosure, however, provides a one-step process where the metal coatings provide high opacity in addition to surface printability.
Figure imgf000041_0001
Table 9
[0070 J One of the intrinsic properties of aluminum is its high reflection of visible light, IR radiation and UV radiation. As a result, aluminum reflects 90% of radiated heat. Due to mis intrinsic behavior, aluminum is used in the construction of a radiant barrier films or coatings that are applied to the attics or a home's side walls for better heat management. Typically, radiant barrier film consists of a reflective material such as an aluminum foil. However, due to its poor flexibility, aluminum foil is laminated to one or both sides of another material such as plastic film or Kraft paper that provides flexibility, strength, and durability. Such radiation barrier films are then applied in the attics and a home's side walls to reduce IR and UV absorption resulting in better heat management. In another instance, aluminum metal coatings can be directly applied to the attic ceilings or a home's walls using a spray gun or other wet coating application techniques. Such onsite application techniques, however, are time- consuming, involve exposure to chemicals, and increase the probability of human error during coating application.
[0071] The disclosed coated aluminum metal film may be used as an alternative to above- mentioned shortcomings of existing barrier films and coatings. In one instance, metal film Example #3, as described above in Table 9, was tested as a solution to block IR and UV radiation absorption in attics and a home's side walls. A model Plexiglas house with the dimensions as listed in the Figure 8 below was constructed. The attic is bifurcated in two equal parts, Al and A2.
Figure imgf000042_0001
[0072] As shown in Figure 9, the radiant barrier film was fixed to the interior of roof ceiling to the attic side Al. The roof was then exposed to a 500 Watts quartz halogen lamp and the change in temperature inside the attic was measured by placing a temperature recorder inside the attic. The temperature inside the attic was measured in real-time over a 1 hour period using an EL- USB-1 temperature data logger from Lascar Electronics.
Figure imgf000043_0001
[0073] The structures in Table 10 were tested for their radiation-barrier performance.
Figure imgf000044_0001
[0074] As shown in the Figure 10, Example #3, as referenced in Table 10, is film coated with 3.27g/m2 metal coatings, and shows improved radiant-barrier performance compared to an attic with no radiant-barrier film. In Figure 10, each data point was recorded approximately every 3 minutes. For instance, after one hour of exposure to a 500 Watt quartz lamp, the maximum temperature reached with no radiant barrier layer is 78°C compared to 68°C by using Example #3 coated film. Using Example #3' further dropped the temperature inside the attic, wherein the maximum temperature was 48°C after one hour of exposure. As a comparison, a metal foil laminated to paper with a fiberglass intermediate layer was used as a control. The metal foil paper laminated structure showed a maximum temperature in the attic of 51°C after one hour of exposure. The coated metal foil was 10.2 μπι thick and laminated to paper having an average thickness of 83.5 μπι with an intermediate fiber glass layer having an average thickness of 9.S μιη. In comparison, Example #3 is approximately 4.23 μιη (3.27 g/m2) metal coating applied to a 66 pm cavitated white film as listed in Table 10.
Figure imgf000045_0001
[0075 J In addition to the above-disclosed applications, an appropriate metal coating film may be used for labels or packaging applications where improved water vapor or gas barrier properties are required. The micrometer-sized aluminum flakes due to their high aspect ratio are oriented and stacked into a brick-like pattern in the bulk of the coating. This alignment of the flakes creates a tortuous path for water vapor or gas molecules to diffuse resulting in barrier performance improvement. The effective barrier performance is controlled by the uniform alignment of the flakes and the density of the flakes in the coating layer. As illustrated in Table 11, the water vapor transmission rate (WVTR) of a 66 μπι thickness uncoated white opaque "control" film Label-Lyte® 150LL-302 available from Jindal Films Americas LLC is 1.81 g/m2/day. In one instance, a metal coating with composition as described in Table 4 was applied onto the control film to obtain Example #3 in Table 11. The thickness of the metal coated layer is 3.27 g/m2. As described in Table 11 below on applying a metal coating of dry film thickness 3.27 g/m2, the WVTR barrier property of the film improved to 0.75 g/m /day. The improvement in WVTR barrier is attributed to the decrease in the diffusion of the water vapor molecules due to metal coating thickness and the uniform alignment of the metal flakes in the metal coating as described above. The smooth laydown of the metal coating can be determined visually and results in uniform alignment of the metal flakes in the coated layer. This disclosure describes a one-step process where the metal coating provides improved moisture barrier properties in addition to surface printability and matte metallic appearance.
Figure imgf000046_0001
[0076] In another instance, metal coatings as described in Table 12 below with aluminum pigments in situ passivated by non-ionic surfactants were applied on biaxially oriented white opaque film Label-Lyte® 150LL-302 available from Jindal Films Americas LLC to produce Example #4 in Table 13. Binder Bl is an acrylic emulsion NeoCryl FL-5095 from DSM Coating Resins Inc., binder B2 is styrene acrylic emulsion NeoCryl A-1094 from DSM Coating Resins Inc., antiblock is amorphous silica from Sylobloc 45 from Grace Davison, and passivated pigment is Aquavex AD 015 from Silberline Manufacturing Inc. The dry film metal coating weight is 1.86 g/m2. The resulting metal coated film provides a matte finish with low gloss appearance. The gloss measured at different angles for the matte finish film is listed in Table 13 for Example #4 (not buffed). When this film is gently buffed, i.e., about 20 times or so, with a Kimwipe™, paper, wool, or textile fiber, then a high gloss film results Example #4' (Buffed). The gloss measured for the buffed film Example #4' is listed below in Table 13. For the buffed version, the gloss at 45° and 60° are too high to detect by the glossmeter. However, greater than two-fold increase in gloss is observed at 85° for the buffed Example #4' compared to the unbuffed Example #4, as shown in Table 13. Accordingly, the disclosure describes a process whereby the matte metal appearance may be tuned into a high-gloss finished film by surface-buffing phenomenon.
Figure imgf000047_0001
[0077] While the foregoing is directed to example embodiments of the disclosed invention, other and further embodiments may be devised without departing from the basic scope thereof, wherein the scope of the disclosed applications, compositions, structures, labels, and so forth are determined by one or more claims of at least one subsequently filed, non-provisional patent application.

Claims

What is claimed is:
1. A metallic film, comprising:
a multilayered film, optionally being oriented and having optionally having one or more additives, metallized layers, primers, coatings, sealants, treated layers, or combinations thereof; and a metal coating applied to at least one outer surface of the multi-layered film, wherein the metal coating comprises a selected combination of size and type of one or more metal pigments, wherein the selected combination is for turning an appearance ranging from matte to sheen for the metallic film, whereby the metal coating is a substitute for a coating applied to a metallized layer.
2. The metallic film of claim 1, further comprising a selected laydown of the selected combination, wherein the selected laydown is for turning a texture ranging from smooth to rough for the metallic film.
3. The metallic film of claim 1, wherein the metal coating further comprises components for imparting printability, sealability, low coefficient of friction, scratch-resistance, barriers, soft-touch, and combinations thereof.
4. The metallic film of claim 1, wherein the size comprises a range between 1 and 100 μπι.
5. The metallic film of claim 1, wherein metal pigment in the metal coating is a leafing type or non-leafing type.
6. The metallic film of claim 1, wherein the one or more metal pigments comprise milled- grade flake, thick tuff flake, ultra-thin flake, any other flakes, or combinations thereof.
7. The metallic film of claim 1, wherein the metal pigment is passivated.
8. The metallic film of claim 1, wherein the metal coating comprises a dry-coating thickness in a range from 0.3 g/m2 through 50 g/m2.
9. The metallic film of claim 1, wherein the metal coating comprises a solvent-borne or waterborne coating.
10. The metallic film of claim 1, further comprising one or more coatings applied to the metal coating applied to at least one outer surface of the multi-layered film
11. The metallic film of claim 1, wherein the one or more metal pigments to binder ratio of the metal coating comprises within a range from 0.1 through 6.
12. The metallic film of claim 1, wherein the metallic film is a radiant-barrier.
13. A coextruded, oriented, multilayered film comprising:
a core flanked by skin layers comprising polyethylene or polypropylene copolymer, optionally comprising tie layers between the core and the skin layers, and optionally comprising additives; and one or more metal pigments and cavitating agents in at least one of the core and the tie layers, whereby both sides of the coextruded, oriented, multilayered film have a metallic appearance.
14. The coextruded, oriented, multilayered film of claim 13 comprising a light transmittance, even in presence of carbon black in the skin layers, of at least 18% when the skin layers comprise the polyethylene and at least 12% when the skin layers comprise the polypropylene copolymer.
15. The coextruded, oriented, multilayered film of claim 13comprising at least 85% water- based-curable ink adhesion of printing applied to the coextruded, oriented, multilayered film after corona re-treatment of the coextruded, oriented, multilayered film, and 100% ink adhesion of the printing applied to the coextruded, oriented, multilayered film after corona re-treatment.
16. The coextruded, oriented, multilayered film of claim 13 comprising at least 35% UV- based-curable ink adhesion of printing applied to the coextruded, oriented, multilayered film after corona re-treatment of the coextruded, oriented, multilayered film.
17. A coextruded, oriented, multilayered film comprising:
a core flanked by tie layers, and the tie layers flanked by skin layers, wherein all layers comprise polypropylene; one or more metal pigments and carbon black in the core; one or more tie layers located on a first side of the core comprises a whitening agent; whereby a first side of the coextruded, oriented, multilayered film has a metallic appearance and a second side of the coextruded, oriented, multilayered film has a white appearance.
18. Use of the multilayered film of claim 1 in a packaging, tagging, bagging, or labeling application.
PCT/US2016/057381 2015-10-16 2016-10-17 Metal coatings and co-extrusions WO2017066779A1 (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US201562242769P 2015-10-16 2015-10-16
US62/242,769 2015-10-16
US201662318589P 2016-04-05 2016-04-05
US62/318,589 2016-04-05

Publications (1)

Publication Number Publication Date
WO2017066779A1 true WO2017066779A1 (en) 2017-04-20

Family

ID=58518175

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2016/057381 WO2017066779A1 (en) 2015-10-16 2016-10-17 Metal coatings and co-extrusions

Country Status (1)

Country Link
WO (1) WO2017066779A1 (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110132536A (en) * 2019-05-20 2019-08-16 中国石油大学(华东) Sail body underwater emission experimental provision for supercavitation mechanism study
WO2020078858A1 (en) 2018-10-15 2020-04-23 Klöckner Pentaplast Gmbh Thermoformable composite film having a metallic appearance

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050288418A1 (en) * 2004-04-14 2005-12-29 Mayco Plastics, Inc. Article having a multilayer film including at least one layer containing metallic components and method of making the same
US20090280256A1 (en) * 2006-10-03 2009-11-12 Kansai Paint Co., Ltd. Aqueous metallic coating composition and method for forming a multilayer coating film
US20100143705A1 (en) * 2004-09-27 2010-06-10 E. I Du Pont De Nemours And Company Process For Producing Multi-Layer Coatings In Light Metallic Color Shades
US20150210867A1 (en) * 2012-08-07 2015-07-30 Nippon Paint Co., Ltd. Luster coating composition, method for producing multi layered coating film therewith, and multi layered coating film

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050288418A1 (en) * 2004-04-14 2005-12-29 Mayco Plastics, Inc. Article having a multilayer film including at least one layer containing metallic components and method of making the same
US20100143705A1 (en) * 2004-09-27 2010-06-10 E. I Du Pont De Nemours And Company Process For Producing Multi-Layer Coatings In Light Metallic Color Shades
US20090280256A1 (en) * 2006-10-03 2009-11-12 Kansai Paint Co., Ltd. Aqueous metallic coating composition and method for forming a multilayer coating film
US20150210867A1 (en) * 2012-08-07 2015-07-30 Nippon Paint Co., Ltd. Luster coating composition, method for producing multi layered coating film therewith, and multi layered coating film

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2020078858A1 (en) 2018-10-15 2020-04-23 Klöckner Pentaplast Gmbh Thermoformable composite film having a metallic appearance
DE102018125540B4 (en) 2018-10-15 2023-03-23 Klöckner Pentaplast Gmbh Thermoformable composite film with a metallic appearance
CN110132536A (en) * 2019-05-20 2019-08-16 中国石油大学(华东) Sail body underwater emission experimental provision for supercavitation mechanism study
CN110132536B (en) * 2019-05-20 2020-10-02 中国石油大学(华东) Navigation body underwater launching experimental device for research of supercavitation mechanism

Similar Documents

Publication Publication Date Title
CA2663507C (en) Metallized polymeric films
US6649279B2 (en) Monoweb metallized film suitable for direct surface printing
US10718046B2 (en) High-barrier, metal oxide films
EP2914430B1 (en) Coated metallized oriented polypropylene films
CA3011153A1 (en) Coated, oriented, linear, low-density, polyethylene films
US20150279245A1 (en) Part of a package
JP6969146B2 (en) Mirror label and its manufacturing method
US6649235B2 (en) Process for producing coated polymeric articles and the articles produced thereby
WO2017066779A1 (en) Metal coatings and co-extrusions
CN104070744A (en) Composite film and method for producing same
US20050019591A1 (en) Metallized films
JP2005314700A (en) White biaxially oriented polyester film and its production method
WO2010039376A1 (en) Film composition with controlled properties
US7279061B2 (en) Process for the production of improved metallized films
WO2010104626A1 (en) Coated polymer films
US11801670B2 (en) White, conformable films for pressure-sensitive-labeling applications
JP3952805B2 (en) Cosmetic material
CN109863025A (en) The metalized film of coating
JP6481947B2 (en) Metal laminated film and manufacturing method thereof
JP2001260266A (en) Barrier film and laminated material using the film
JP7482679B2 (en) Laminated tube laminate
WO2014053707A1 (en) A part of a package
JP2000167978A (en) Decoration steel sheet and manufacture thereof

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 16856426

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 16856426

Country of ref document: EP

Kind code of ref document: A1