WO2021074931A1 - Uv printable biaxially oriented polypropylene film and a method of manufacturing thereof - Google Patents

Uv printable biaxially oriented polypropylene film and a method of manufacturing thereof Download PDF

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Publication number
WO2021074931A1
WO2021074931A1 PCT/IN2020/050891 IN2020050891W WO2021074931A1 WO 2021074931 A1 WO2021074931 A1 WO 2021074931A1 IN 2020050891 W IN2020050891 W IN 2020050891W WO 2021074931 A1 WO2021074931 A1 WO 2021074931A1
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WIPO (PCT)
Prior art keywords
polypropylene
film
bopp
printing
polypropylene film
Prior art date
Application number
PCT/IN2020/050891
Other languages
French (fr)
Inventor
Amit Kumar Uppal
Madhukar AGGARWAL
Original Assignee
Max Speciality Films Ltd.
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Publication date
Application filed by Max Speciality Films Ltd. filed Critical Max Speciality Films Ltd.
Publication of WO2021074931A1 publication Critical patent/WO2021074931A1/en

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
    • C08J7/04—Coating
    • C08J7/0427—Coating with only one layer of a composition containing a polymer binder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
    • B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
    • B29C55/10—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial
    • B29C55/12—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial biaxial
    • B29C55/14—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial biaxial successively
    • B29C55/143—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial biaxial successively firstly parallel to the direction of feed and then transversely thereto
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    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B32B25/04—Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B25/08—Layered products comprising a layer of natural or synthetic rubber comprising rubber 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
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    • B32B25/16—Layered products comprising a layer of natural or synthetic rubber comprising polydienes homopolymers or poly-halodienes homopolymers
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    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
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    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/02—Synthetic macromolecular particles
    • B32B2264/0214—Particles made of materials belonging to B32B27/00
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    • C08J2475/00—Characterised by the use of polyureas or polyurethanes; Derivatives of such polymers
    • C08J2475/04—Polyurethanes

Definitions

  • the present invention relates to a biaxially oriented polypropylene (BOPP) film.
  • the invention relates to a process for producing biaxially oriented polypropylene film and the product obtained thereof.
  • Biaxially oriented polypropylene (BOPP) films are used in a wide range of applications such as packaging, tapes, capacitor films, decorative, labelling applications and the like.
  • the fact that the Biaxially oriented polypropylene (BOPP) films exhibit good stiffness, high elasticity and strength, along with useful optical properties such as low haze and high gloss, and certain moisture barrier properties makes them the preferred choice across such diverse industries.
  • BOPP films can be also subjected to various treatments such as corona, flame, etc. in order enhance their printability. They also provide suitable substrates for organic/ inorganic coatings that can enable and enhance certain gas and moisture barrier properties. They can also be used to derive high heat seal/hermetic strength to provide a heat sealable layer for enclosure seal forming applications.
  • the present invention provides for a novel manufacturing process of producing biaxially oriented polypropylene (BOPP) films with enhanced mechanical properties and improved adhesion using inline coating process.
  • the present invention describes a manufacturing process for producing biaxially oriented polypropylene film utilized for labeling applications and the BOPP film obtained therefrom.
  • the invention discloses a process for making a biaxially oriented polypropylene (BOPP) film having improved adhesion to UV printing inks, the process comprising: orienting a substrate polypropylene film in a machine direction orientation (MDO) to obtain an uniaxially oriented polypropylene film; Inline coating at least one surface of the uniaxially oriented polypropylene film with an acrylic and/or polyurethane (PU) dispersion coating to obtain a coated polypropylene film; and orienting the coated polypropylene film in a transverse direction orientation (TDO) to obtain a biaxially oriented polypropylene film, wherein the acrylic and/or polyurethane dispersion coating comprises 20-23% (wt/wt) of A-2092, 5-16% (wt/wt) of RU- 92208, 1-2% (wt/wt) IPA, 59-74% (wt/wt) of demineralized water, and wherein at
  • the substrate polypropylene film is obtained by extruding a raw material comprising at least a polypropylene resin selected from the group consisting of: homopolymers of polypropylene, copolymers of polypropylene, terpolymer of polypropylene, and/or combination thereof.
  • the raw material further comprising at least one additive selected from the group consisting of organic antiblock e.g. AB6060PPR or AB 6059 PPR of Contab, inorganic antiblock additive e.g.
  • PBT polybutylene terephthalate
  • At least one surface of the uniaxially oriented polypropylene film is modified with polymer selected from the group consisting of maleic anhydride (MA) grafted polymer, PP Homopolymer, High isotactic Polypropylene, Co-polymers. Modification is done by blending these selected grades with PP Homopolymer in 20 - 80% or Skin layer can also be designed using 100% of above mentioned polymers.
  • MA maleic anhydride
  • At least one surface of the uniaxially oriented polypropylene film is further modified with addition of additive selected from the group consisting of: anti-blocking additive, anti-static additive, slip additive, cross linking additive or a combination thereof in small amount ranging from 0.5% to 5%.
  • additive selected from the group consisting of: anti-blocking additive, anti-static additive, slip additive, cross linking additive or a combination thereof in small amount ranging from 0.5% to 5%.
  • at least one surface of the uniaxially oriented polypropylene film is exposed to corona treatment before Inline coating at least one surface of the uniaxially oriented polypropylene film with the acrylic and/or polyurethane dispersion coating.
  • the BOPP can be used for labeling applications is selected from the group consisting of Pressure-sensitive adhesive (PSA) labeling, In-mould labeling (IML).
  • PSA Pressure-sensitive adhesive
  • IML In-mould labeling
  • the BOPP film can be printed using techniques selected from the group consisting of UV flexo printing, UV offset printing, Letter press printing, water based flexo printing, solvent based printing, digital printing, ink-jet printing [0016]
  • the BOPP film for labeling applications produced therefrom can be transparent, White Cavitated, solid white or metalized.
  • a biaxially oriented polypropylene (BOPP) film having improved adhesion to UV printing inks comprises a substrate polypropylene film; and an acrylic and/or polyurethane dispersion coating layer comprising 20- 23% (wt/wt) of A-2092, 5-16% (wt/wt) of RU-92208, 1-2% (wt/wt) IPA, 59-74% (wt/wt) of demineralized water, wherein the acrylic and/or polyurethane dispersion coating layer is inline coated on at least one surface of the substrate polypropylene film.
  • the substrate polypropylene film is oriented in machine direction orientation and in transverse direction orientation.
  • the BOPP film has enhanced adhesion to various type of printing inks including UV inks and enhanced mechanical properties like Tensile strength, Elongation, Elastic Modulus, Linear shrinkage etc.
  • the BOPP film comprising a substrate polypropylene film, wherein at least one surface of the substrate polypropylene film is inline coated with an acrylic and/or polyurethane dispersion coating.
  • the substrate polypropylene film comprises an upper skin layer, a core layer, and a lower skin layer.
  • the substrate polypropylene film comprises a core layer, at least one skin layer, and optionally at least one tie layer.
  • the substrate polypropylene film comprises an upper skin layer, an upper tie layer, a core layer, a lower tie layer, and a lower skin layer.
  • the core layer comprises homo polypropylene, polypropylene based elastomer or terpolymer.
  • At least one skin layer comprises polymer selected from the group consisting of homo polypropylene, high isotatic polypropylene, Grafted polypropylene, polypropylene Copolymer, polypropylene based elastomer, Ethylene-vinyl alcohol co-polymer or a combination thereof
  • the surface layer of the biaxially oriented polypropylene film of the present invention is formulated using suitable maleic anhydride (MA) grafted polymer along with specifically selected antiblock having fine particle size of 2 micron such as, but not limited to, AB 6059 PP and AB 6095 PP of Constab to have better anchorage with hybrid coating formulation based on acrylic polyurethane and ethylene acrylic acid.
  • MA maleic anhydride
  • the tie layer comprising homo polypropylene, PP based elastomer or a combination thereof.
  • the BOPP film comprises FDA approved cross linking additives, thereby the PSA label films can be used for Food and pharmaceutical applications.
  • the process of making BOPP film of the present invention can also be applied to metallized Pressure Sensitive Adhesive (PSA) labels.
  • PSA Pressure Sensitive Adhesive
  • the inline coating may be performed before or after the film leaves the machine direction orientation (MDO) unit but before it enters the transverse direction orientation (TDO) unit.
  • MDO machine direction orientation
  • TDO transverse direction orientation
  • FIG. 1 shows a manufacturing unit comprising various sub-units involved in the preparation of BOPP film according to the various embodiments of the present invention.
  • one embodiment or “an embodiment” means that a particular feature, structure, material, or characteristic described in connection with the embodiment is included in at least one embodiment of the disclosure.
  • each aspect includes only a few embodiments. Different embodiments from different aspects may be combined or practiced separately, to design a customized process or product depending upon application requirements. Many different combinations and sub-combinations of a few representative processes or structures shown within the broad framework of this invention, that may be apparent to those skilled in the art but not explicitly shown or described, should not be construed as precluded.
  • This disclosure is generally directed to products and methods describing a “BOPP film for labeling applications” or “UV printable BOPP film”, exhibiting improved adhesion and enhanced mechanical properties.
  • Reference to “layer” or “film” as used herein refers to a structure of a single polymer type or a blend of polymers.
  • BOPP film refers to a Biaxially Oriented Polypropylene Film which are produced by stretching polypropylene film in both machine direction and transverse direction. These films are preferred substrate for food packaging globally. These films exhibit a wide range of characteristics including their inherent moisture barrier properties, seal ability, high clarity and graphic reproduction.
  • corona treated refers to a surface treatment technique used to modify the surface properties.
  • the corona treatment is done to improve adhesive property of the desired layer/surface.
  • a low temperature corona discharge plasma is utilized for the modification of surface properties.
  • the corona discharge is an electrical discharge brought about by the ionization of a fluid such as air surrounding a conductor that is electrically charged.
  • the generation of corona plasma is done by the application of high voltage to an electrode having a sharp tip.
  • the plasma is formed at the tip of electrode.
  • a linear array of electrodes is utilized quite often to create a curtain of corona plasma.
  • the corona plasma curtain allows the passage of materials such as plastics, cloth, or paper through the corona plasma curtain to impart changes in the surface energy of the material.
  • anti-static additive refers to additives which are used to reduce or eliminate the static build up on a film by reducing the resistivity of the film. Anti-static additives can be internal and external. Internal additives are added into the composition of the polymeric layer to overcome the static issues, e.g., Electrostatic discharge, dust attraction etc., while the external additives are coated on the surface of film by spraying or immersion methods.
  • slip additive refers to agents which are used to reduce the friction coefficient of the polymeric layer while maintaining the optic properties of the film, e.g. Clarity and transparency of the film.
  • anti-block additive refers to additives which are used to minimize the interaction between two layers.
  • Suitable anti-blocking additive include, but are not limited to, starches, modified starches, crosslinked polyvinylpyrrolidone, crosslinked cellulose, microcrystalline cellulose, silica, metallic oxides, calcium carbonate, talc, mica, stearic acid and metal salts thereof, for example, magnesium stearate.
  • Preferred materials are starches, modified starches and silica.
  • the present invention relates to manufacturing process for producing biaxially oriented polypropylene film with enhanced adhesion to UV printing inks and the BOPP film obtained thereof.
  • the BOPP film according to the present invention is a UV Printable biaxially oriented polypropylene film coated through Inline coating process.
  • the substrate layer of the film is corona treated, followed by coating with an acrylic and/or polyurethane dispersion using inline coating method.
  • the acrylic and/or polyurethane dispersion coating comprises 20-23% (wt/wt) of A-2092, 5-16% (wt/wt) of RU-92208, 1-2% (wt/wt) IPA, 59-74% (wt/wt) of demineralized water.
  • the invention discloses a process for the making a biaxially oriented polypropylene (BOPP) film for labeling applications, wherein the process comprises: • extruding the raw material comprising polypropylene resin to derive substrate polypropylene film,
  • the present invention also provides for an In line Coated UV Printable BOPP film for labeling applications with improved adhesion to a large number of printing inks or lamination adhesives, not limited to, UV inks, solvent and water based ink systems.
  • the BOPP film of the present invention is a multilayered film which is manufactured by using a co-extrusion process followed by a biaxial orientation process.
  • the co-extrusion process involves the usage of multiple extruders to form multilayer flat films.
  • Biaxial orientation is the stretching of films in two perpendicular directions. Biaxial orientation improves the tensile strength, impact strength, tear strength, optical and barrier properties, stiffness and resistance to crazing.
  • the BOPP film of the present invention is a three- layered structure which comprises a skin layer, a core layer and a skin layer.
  • the BOPP film of the present invention is a five- layered structure which comprises a skin layer, a tie layer, a core layer, a tie layer, and a skin layer.
  • the biaxially oriented polypropylene film can be used for Pressure-sensitive adhesive (PSA) label and In-mould labeling (IML) applications.
  • PSA Pressure-sensitive adhesive
  • IML In-mould labeling
  • the invention provides for an In line Coated UV Printable BOPP for pressure sensitive labels for transparent, white cavitated, white solid and metallised films.
  • the Inline coating method is generally employed for the coating of polyester films.
  • the present invention provides for improved biaxially oriented polypropylene films with process parameters suitable to carry out the inline coating process. Generally, the film coated surface deteriorates when the film is stretched in the transverse direction after the inline coating process.
  • the novel manufacturing process according to the present invention ensures that after the Inline coating of the film is done and there are no damages on the surface of the film when it is stretched in the transverse direction.
  • the invention provides for a cost effective method of producing biaxially oriented polypropylene film and an economical BOPP film obtained thereof with improved inline coating and thereby enhanced adhesion to a large number of printing inks or lamination adhesives, not limited to, UV inks, solvent and water based ink systems.
  • the biaxially oriented polypropylene (BOPP) film of the present invention is suitable for printing including UV flexo printing, UV offset printing, Letter press printing, water based flexo printing, solvent based printing, digital printing, ink-jet printing and the like.
  • a biaxially oriented polypropylene (BOPP) film having improved adhesion to various types of printing inks, including UV inks and enhanced mechanical properties like tensile strength and elastic modulus is disclosed.
  • the BOPP film of the invention comprises a substrate polypropylene film, wherein at least one surface of the substrate polypropylene film is inline coated with an acrylic and/or polyurethane dispersion coating.
  • the surface layer on which the coating to be done is specifically modified by adding maleic anhydride (MA) grafted polymer to the surface layer, to have better anchorage with hybrid coating formulation based on acrylic polyurethane and ethylene acrylic acid.
  • Surface layer design is not limited to the use of maleic anhydride (MA) grafted polymer but it can be formulated using PP Homopolymer, High isotactic Polypropylene, Co-polymers.
  • the surface layer is incorporated with specific sized antiblock additives so that the appropriate antiblocking can be achieved without affecting the bond between the surface layer and the coating formulation.
  • the BOPP film can be transparent, White Cavitated or solid white. Accordingly, the base layer is formulated using Ti02, Calcium carbonate (CaC03) and PBT resin to provide the necessary whiteness and Cavitation.
  • the BOPP film is formulated with desired amounts of certain antistatic and slip additives to provide the required antistatic and slip properties required for the easy and trouble free converting during label converting etc
  • the BOPP film according to the present invention comprises FDA approved cross linking additives, thereby the PSA label films can be used for Food and pharmaceutical applications.
  • the process of In line coating the BOPP film of the present invention can also be applied to metallized PSA labels.
  • the present invention provides a metalized BOPP film wherein the metalized BOPP film may have a skin layer comprising of a butene or ethylene base co-polymer and Maleic anhydride grafted polypropylene.
  • the BOPP film is prepared using the manufacturing unit shown in FIG. 1.
  • the manufacturing unit comprises the various sub-units such as Feeder/hopper section (1), main extruder section (2), first co-extruder (4) and a second co-extruder (5), T-die section (6) , chill roll (7), water bath (8), machine direction orientation (MDO) unit (9), inline coating unit (13) , transverse direction orientation (TDO) section (14), winder (17) and the pull roll section (15).
  • the machine direction orientation (MDO) unit (9) comprises a set of preheating rollers (10), machine direction stretching rollers (11) and annealing rollers (12).
  • the method of manufacturing involves the use of Feeder section (1) for transferring the raw BOPP resin composition material to a co-extrusion unit.
  • the co-extrusion unit comprises of a main extruder (2), first co-extruder (4) and a second co-extruder (5).
  • the main extruder (2) can be a screw-type extruder with a screw drive (3).
  • screw extruders are used in the present invention, however, other suitable extruders, for example, twin-screw extruder, piston extruder, ram extruder, etc, as obvious to a person skilled in the art, can also be used.
  • the raw BOPP resin composition material is subjected to heat, shear and pressure to bring about the melting of the raw materials.
  • the thickness of different layers of the BOPP films is controlled by the relative speeds and sizes of the main extruder (2), first co-extruder (4), and second co-extruder (5).
  • the main extruder (2), first co-extruder (4) and second co-extruder (5), are maintained at a temperature ranging from about 220° C to about 260° C. Any number of co-extruders can be used depending on the number of layers required.
  • the melted molten material is then transferred to the T-die section (3). In the T-die section
  • the film from the molten BOPP material and/or co-extruded material is prepared.
  • the T-die (6) is kept at a temperature of about 240° C to 250° C.
  • the T-die (6) is used here as an exemplary die, however, other suitable dies available in the market and obvious to a person skilled in the art, can also be utilized.
  • the film thus formed is cooled and quenched using chill roll (7) and water bath (8).
  • the chill roller (7) and water bath (8) are maintained at a temperature of about 25-42 0 C.
  • the film is transferred to the machine direction orientation (MDO) unit (9).
  • MDO machine direction orientation
  • the film is preheated by passing through set of rollers and it is then stretched longitudinally using rollers arranged in series.
  • the set of preheating rollers (10) are maintained at a temperature ranging from about 100° C to 150° C.
  • the film passes over the machine direction stretching rollers (11).
  • the temperature of the machine direction stretching rollers (11) are kept at about 70° C to 90° C.
  • the film passes over the annealing rollers (12), which are maintained at a temperature of about 100° C to 120 0 C.
  • the stretching in machine direction orientation (MDO) unit (9) reduces the thickness of the film and enhances its mechanical properties.
  • the film is annealed and transferred to the inline coating unit (13).
  • the annealed film from the MDO unit on entering the inline coating unit (13) is subjected to corona treatment on its surface, followed by coating with the acrylic and/or polyurethane dispersion in the inline coating unit (13).
  • Acrylic and/or polyurethane based coating enhances the metal adhesion, oxygen transmission rate (OTR) and water vapor transmission rate (WVTR), luster and other optical properties of the film.
  • the coated film then enters the TDO section (14), where it is first preheated by passing through set of rollers and then stretched in transverse direction via the tenter frame section and finally the film is winded on the winder (17) via the pull roll section (15).
  • the preheating zone is maintained at a temperature ranging from about 160 0 C to 180° C.
  • the preheated film is then stretched in a transverse direction with the help of chain clips or jaws (not shown). In a preferred embodiment, the chain clips or jaws are kept at a temperature of about 158 0 C/ fan speed about 90%.
  • the film is then transferred to a set of annealing rollers (not shown). In a preferred embodiment, the annealing rollers are maintained at a temperature ranging from about 160 0 C to 165 0 C/ fan speed about 80%. This transverse direction orientation further decreases the film - thickness and enhances its mechanical properties.
  • MDSR may be defined as the length of a portion of the film after stretching divided by the initial length of that portion.
  • TDSR may be defined as the width of a portion of the film after stretching divided by the initial width of that portion.
  • MDSR/TDSR ratio for the above-mentioned BOPP films is 4.2 to 5.5/ 8.5 to 10.
  • the inline coating unit (13) is situated before machine direction orientation (MDO) unit (9), i.e the inline coating is performed before the film enters the machine direction orientation (MDO) unit (9).
  • the raw material comprises homopolymers or copolymers of polypropylene, organic antiblock e.g. AB6060PPR or AB 6059 PPR of Contab, inorganic antiblock additive e.g.
  • processing aids e.g EIN 25005 of 3M, titanium dioxide like WHITE 70 of Ampacet, Calcium Carbonate like PEARL 70 of Ampacet or PF 97/PF97NTS of A Schulman, polybutylene terephthalate(PBT) e.g PEARL 81 of
  • the biaxially oriented polypropylene (BOPP) film according to the present invention has excellent ink adhesion on the coated surface suitable for a broad range of ink systems, but not limited to, UV curing inks for flexo or offset printing process.
  • the corona treated film surface according to the present invention provides for excellent adhesive anchorage. Coating adhesion is maintained in hot and cold-water immersion without clouding.
  • the method of the present invention provides for a biaxially oriented polypropylene (BOPP) film with enhanced blocking resistance due to the optimal ratios of the acrylic system in the formulation without the addition of any anti-blocking additives.
  • the invention provides for a five- layer arrangement of the substrate layer instead of the conventional three layers.
  • the BOPP film accordingly may comprise a five-layered structure which further comprises an upper skin layer, an upper tie layer, a core layer, a lower tie layer, and a lower skin layer.
  • the different ratios of acrylics / polyurethane coating according to the invention provide for better stretching efficiency and film formation characteristics as compared to the currently available films.
  • the addition of anti-foaming agents to the BOPP film formulation prevents the foaming issues during coating.
  • the addition of leveling agents to the film formulation brings about better leveling and dispersion.
  • the core layer comprises homo polypropylene, polypropylene based elastomer or terpolymer.
  • at least one skin layer comprises polymer selected from the group consisting of homo polypropylene, high isotatic polypropylene, Grafted polypropylene, polypropylene Copolymer, polypropylene based elastomer, Ethylene-vinyl alcohol co-polymer or a combination thereof
  • the tie layer comprising homo polypropylene, PP based elastomer or a combination thereof.
  • the biaxially oriented polypropylene (BOPP) film according to the present invention can be a transparent PSA label film for printing and as well as water based adhesive bonding or a metallized PSA label film for UV and other printing applications.
  • the biaxially oriented polypropylene (BOPP) film is cavitated BOPP film with a) Coating on glossy side for printing application and b) another product Adhesive bonding for ILC coating on Matte surface.
  • the biaxially oriented polypropylene (BOPP) film according to the present invention can therefore be used both for printing purposes, and also for adhesive anchorage with water based acrylic or hot melt adhesives.
  • the BOPP film produced in the above experiments was tested for Coating Grammage, Coating Tape test (Scotch tape 3M 610), Surface Treatment and UV ink adhesion test (Instrument: RK Flexiproof 100).
  • the UV ink adhesion was tested for printing immediate after coating, printing after 24 hours of coating and printing after One week of coating, using UV printing inks selected from Flexocure Force PR-Cyan, Flexocure Force Ivory-white, and Flexocure Force PR-Yellow.
  • Tablel shows the parameters tested for BOPP film produced in experiments 1-12.

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Abstract

The invention relates to a biaxially oriented polypropylene (BOPP) film having improved adhesion to UV printing inks. The invention also discloses a process for making the said biaxially oriented polypropylene (BOPP) film comprising the inline coating process. The BOPP film has enhanced adhesion to various type of printing inks including UV inks and enhanced mechanical properties like Tensile strength, Elongation, Elastic Modulus, Linear shrinkage etc. The BOPP film can be utilized for various labeling applications.

Description

UV PRINTABLE BIAXIALLY ORIENTED POLYPROPYLENE FILM AND A METHOD
OF MANUFACTURING THEREOF
FIELD OF INVENTION
[001] The present invention relates to a biaxially oriented polypropylene (BOPP) film. In particular, the invention relates to a process for producing biaxially oriented polypropylene film and the product obtained thereof.
CROSS-REFERENCE TO RELATED APPLICATIONS
[002] This application claims the benefit of Indian Provisional Application No 201911042400, filed October 18, 2019, the contents of which are incorporated herein by reference in its entirety. BACKGROUND OF THE INVENTION
[003] Biaxially oriented polypropylene (BOPP) films, are used in a wide range of applications such as packaging, tapes, capacitor films, decorative, labelling applications and the like. The fact that the Biaxially oriented polypropylene (BOPP) films exhibit good stiffness, high elasticity and strength, along with useful optical properties such as low haze and high gloss, and certain moisture barrier properties makes them the preferred choice across such diverse industries.
[004] Along with these properties for BOPP films to offer e.g. excellent printability, BOPP films can be also subjected to various treatments such as corona, flame, etc. in order enhance their printability. They also provide suitable substrates for organic/ inorganic coatings that can enable and enhance certain gas and moisture barrier properties. They can also be used to derive high heat seal/hermetic strength to provide a heat sealable layer for enclosure seal forming applications.
[005] For the desired use of the BOPP films it is often challenging to ensure the optimal mechanical properties such as high modulus of elasticity, stiffness, sufficient strength and low shrinkage, along with adhesion feasibility for a broad range of ink systems. Therefore, it is imperative to ensure appropriate mechanical properties along with good adhesion aspects. [006] Accordingly, the present invention provides for a novel manufacturing process of producing biaxially oriented polypropylene (BOPP) films with enhanced mechanical properties and improved adhesion using inline coating process.
SUMMARY OF THU INVENTION [007] The present invention describes a manufacturing process for producing biaxially oriented polypropylene film utilized for labeling applications and the BOPP film obtained therefrom.
[008] According to an aspect, the invention discloses a process for making a biaxially oriented polypropylene (BOPP) film having improved adhesion to UV printing inks, the process comprising: orienting a substrate polypropylene film in a machine direction orientation (MDO) to obtain an uniaxially oriented polypropylene film; Inline coating at least one surface of the uniaxially oriented polypropylene film with an acrylic and/or polyurethane (PU) dispersion coating to obtain a coated polypropylene film; and orienting the coated polypropylene film in a transverse direction orientation (TDO) to obtain a biaxially oriented polypropylene film, wherein the acrylic and/or polyurethane dispersion coating comprises 20-23% (wt/wt) of A-2092, 5-16% (wt/wt) of RU- 92208, 1-2% (wt/wt) IPA, 59-74% (wt/wt) of demineralized water, and wherein at least one surface of the uniaxially oriented polypropylene film is modified with a polymer before the inline coating with the acrylic and/or polyurethane dispersion coating.
[009] According to another aspect of the invention, the substrate polypropylene film is obtained by extruding a raw material comprising at least a polypropylene resin selected from the group consisting of: homopolymers of polypropylene, copolymers of polypropylene, terpolymer of polypropylene, and/or combination thereof.
[0010] According to yet another aspect of the invention, the raw material further comprising at least one additive selected from the group consisting of organic antiblock e.g. AB6060PPR or AB 6059 PPR of Contab, inorganic antiblock additive e.g. HOBLOCK-IO/SKIBLOCK of Ampacet or AB 6095 PP, anti-static additive like AT 4130PP or AT 4061 PP of Contstab, processing aids e.g EIN 25005 of 3M, titanium dioxide like WHITE 70 of Ampacet, Calcium Carbonate like PEARL 70 of Ampacet or PF 97/PF97NTS of A Schulman, polybutylene terephthalate(PBT) e.g PEARL 81 of Ampacet or HIGH GLOSS COMPOUND of Plastiblends or a combination thereof. [0011] According to yet another aspect of the invention, at least one surface of the uniaxially oriented polypropylene film is modified with polymer selected from the group consisting of maleic anhydride (MA) grafted polymer, PP Homopolymer, High isotactic Polypropylene, Co-polymers. Modification is done by blending these selected grades with PP Homopolymer in 20 - 80% or Skin layer can also be designed using 100% of above mentioned polymers.
[0012] According to yet another aspect of the invention, at least one surface of the uniaxially oriented polypropylene film is further modified with addition of additive selected from the group consisting of: anti-blocking additive, anti-static additive, slip additive, cross linking additive or a combination thereof in small amount ranging from 0.5% to 5%. [0013] According to yet another aspect of the invention, at least one surface of the uniaxially oriented polypropylene film is exposed to corona treatment before Inline coating at least one surface of the uniaxially oriented polypropylene film with the acrylic and/or polyurethane dispersion coating.
[0014] According to yet another aspect of the invention, the BOPP can be used for labeling applications is selected from the group consisting of Pressure-sensitive adhesive (PSA) labeling, In-mould labeling (IML).
[0015] According to yet another aspect of the invention, the BOPP film can be printed using techniques selected from the group consisting of UV flexo printing, UV offset printing, Letter press printing, water based flexo printing, solvent based printing, digital printing, ink-jet printing [0016] According to yet another aspect of the invention, the BOPP film for labeling applications produced therefrom can be transparent, White Cavitated, solid white or metalized.
[0017] According to yet another aspect of the invention, there is provided a biaxially oriented polypropylene (BOPP) film having improved adhesion to UV printing inks comprises a substrate polypropylene film; and an acrylic and/or polyurethane dispersion coating layer comprising 20- 23% (wt/wt) of A-2092, 5-16% (wt/wt) of RU-92208, 1-2% (wt/wt) IPA, 59-74% (wt/wt) of demineralized water, wherein the acrylic and/or polyurethane dispersion coating layer is inline coated on at least one surface of the substrate polypropylene film.
[0018] According to yet another aspect of the invention, the substrate polypropylene film is oriented in machine direction orientation and in transverse direction orientation.
[0019] According to yet another aspect of the invention, the BOPP film has enhanced adhesion to various type of printing inks including UV inks and enhanced mechanical properties like Tensile strength, Elongation, Elastic Modulus, Linear shrinkage etc. [0020] The BOPP film comprising a substrate polypropylene film, wherein at least one surface of the substrate polypropylene film is inline coated with an acrylic and/or polyurethane dispersion coating.
[0021] According to yet another aspect, at least one surface of the substrate polypropylene film is corona treated. [0022] According to yet another aspect, the substrate polypropylene film comprises an upper skin layer, a core layer, and a lower skin layer.
[0023] According to yet another aspect, the substrate polypropylene film comprises a core layer, at least one skin layer, and optionally at least one tie layer.
[0024] According to yet another aspect, the substrate polypropylene film comprises an upper skin layer, an upper tie layer, a core layer, a lower tie layer, and a lower skin layer.
[0025] According to yet another aspect, the core layer comprises homo polypropylene, polypropylene based elastomer or terpolymer.
[0026] According to yet another aspect, at least one skin layer comprises polymer selected from the group consisting of homo polypropylene, high isotatic polypropylene, Grafted polypropylene, polypropylene Copolymer, polypropylene based elastomer, Ethylene-vinyl alcohol co-polymer or a combination thereof
[0027] According to yet another aspect, the surface layer of the biaxially oriented polypropylene film of the present invention is formulated using suitable maleic anhydride (MA) grafted polymer along with specifically selected antiblock having fine particle size of 2 micron such as, but not limited to, AB 6059 PP and AB 6095 PP of Constab to have better anchorage with hybrid coating formulation based on acrylic polyurethane and ethylene acrylic acid. [0028] According to yet another aspect of the present invention, the tie layer comprising homo polypropylene, PP based elastomer or a combination thereof.
[0029] According to another aspect, the BOPP film comprises FDA approved cross linking additives, thereby the PSA label films can be used for Food and pharmaceutical applications. [0030] According to yet another aspect, the process of making BOPP film of the present invention can also be applied to metallized Pressure Sensitive Adhesive (PSA) labels.
[0031] The inline coating may be performed before or after the film leaves the machine direction orientation (MDO) unit but before it enters the transverse direction orientation (TDO) unit.
BRIEF DESCRIPTION OF DRAWINGS [0032] Exemplary embodiments are illustrated in referenced figures. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than restrictive. [0033] FIG. 1 shows a manufacturing unit comprising various sub-units involved in the preparation of BOPP film according to the various embodiments of the present invention.
DETATEED DESCRIPTION OF THE INVENTION [0034] Aspects of the present invention are best understood by reference to the description set forth herein. All the aspects described herein will be better appreciated and understood when considered in conjunction with the following descriptions. It should be understood, however, that the following descriptions, while indicating preferred aspects and numerous specific details thereof, are given by way of illustration only and should not be treated as limitations. Changes and modifications may be made within the scope herein without departing from the spirit and scope thereof, and the present invention herein includes all such modifications.
[0035] Several aspects of the present invention are disclosed herein. It is to be understood that these aspects may or may not overlap with one another. Thus, part of one aspect may fall within the scope of another aspect, and vice versa. Each aspect is illustrated by several embodiments, each of which in turn, can include one or more specific embodiments. It is to be understood that the embodiments may or may not overlap with each other. Thus, part of one embodiment, or specific embodiments thereof, may or may not fall within the ambit of another, or specific embodiments thereof, and vice versa. [0036] Abroad framework of the principles will be presented by describing various embodiments of this invention using exemplary aspects. The terms "one embodiment" or "an embodiment" means that a particular feature, structure, material, or characteristic described in connection with the embodiment is included in at least one embodiment of the disclosure. For clarity and ease of description, each aspect includes only a few embodiments. Different embodiments from different aspects may be combined or practiced separately, to design a customized process or product depending upon application requirements. Many different combinations and sub-combinations of a few representative processes or structures shown within the broad framework of this invention, that may be apparent to those skilled in the art but not explicitly shown or described, should not be construed as precluded.
[0037] This disclosure is generally directed to products and methods describing a “BOPP film for labeling applications” or “UV printable BOPP film”, exhibiting improved adhesion and enhanced mechanical properties.
[0038] Definitions:
[0039] Reference to “layer” or “film” as used herein refers to a structure of a single polymer type or a blend of polymers.
[0040] Reference to “BOPP film” as used herein refers to a Biaxially Oriented Polypropylene Film which are produced by stretching polypropylene film in both machine direction and transverse direction. These films are preferred substrate for food packaging globally. These films exhibit a wide range of characteristics including their inherent moisture barrier properties, seal ability, high clarity and graphic reproduction.
[0041] Reference to "corona treated," as used herein refers to a surface treatment technique used to modify the surface properties. In polymeric films, the corona treatment is done to improve adhesive property of the desired layer/surface. A low temperature corona discharge plasma is utilized for the modification of surface properties. In this, the corona discharge is an electrical discharge brought about by the ionization of a fluid such as air surrounding a conductor that is electrically charged. The generation of corona plasma is done by the application of high voltage to an electrode having a sharp tip. The plasma is formed at the tip of electrode. A linear array of electrodes is utilized quite often to create a curtain of corona plasma. The corona plasma curtain allows the passage of materials such as plastics, cloth, or paper through the corona plasma curtain to impart changes in the surface energy of the material.
[0042] Reference to "anti-static additive," as used herein refers to additives which are used to reduce or eliminate the static build up on a film by reducing the resistivity of the film. Anti-static additives can be internal and external. Internal additives are added into the composition of the polymeric layer to overcome the static issues, e.g., Electrostatic discharge, dust attraction etc., while the external additives are coated on the surface of film by spraying or immersion methods. [0043] Reference to "slip additive," as used herein refers to agents which are used to reduce the friction coefficient of the polymeric layer while maintaining the optic properties of the film, e.g. Clarity and transparency of the film. [0044] Reference to "anti -block additive," as used herein refers to additives which are used to minimize the interaction between two layers. Suitable anti-blocking additive include, but are not limited to, starches, modified starches, crosslinked polyvinylpyrrolidone, crosslinked cellulose, microcrystalline cellulose, silica, metallic oxides, calcium carbonate, talc, mica, stearic acid and metal salts thereof, for example, magnesium stearate. Preferred materials are starches, modified starches and silica.
[0045] According to an embodiment, the present invention relates to manufacturing process for producing biaxially oriented polypropylene film with enhanced adhesion to UV printing inks and the BOPP film obtained thereof.
[0046] According to another embodiment of the invention, the BOPP film according to the present invention is a UV Printable biaxially oriented polypropylene film coated through Inline coating process. The substrate layer of the film is corona treated, followed by coating with an acrylic and/or polyurethane dispersion using inline coating method.
[0047] According to another embodiment of the invention, the acrylic and/or polyurethane dispersion coating comprises 20-23% (wt/wt) of A-2092, 5-16% (wt/wt) of RU-92208, 1-2% (wt/wt) IPA, 59-74% (wt/wt) of demineralized water.
[0048] According to yet another embodiment of the present invention, the invention discloses a process for the making a biaxially oriented polypropylene (BOPP) film for labeling applications, wherein the process comprises: • extruding the raw material comprising polypropylene resin to derive substrate polypropylene film,
• Orienting the substrate polypropylene film in the machine direction,
• Subjecting the substrate polypropylene film to corona treatment, · Coating the top surface of the corona treated substrate layer with acrylic and/or polyurethane
(PU) dispersion coating,
• Orienting the acrylic and/or polyurethane (PU) dispersion coated substrate layer coated in the transverse direction.
[0049] According to yet another embodiment, the present invention also provides for an In line Coated UV Printable BOPP film for labeling applications with improved adhesion to a large number of printing inks or lamination adhesives, not limited to, UV inks, solvent and water based ink systems.
[0050] According to yet another embodiment, the BOPP film of the present invention is a multilayered film which is manufactured by using a co-extrusion process followed by a biaxial orientation process. The co-extrusion process involves the usage of multiple extruders to form multilayer flat films. Biaxial orientation is the stretching of films in two perpendicular directions. Biaxial orientation improves the tensile strength, impact strength, tear strength, optical and barrier properties, stiffness and resistance to crazing.
[0051] According to yet another embodiment, the BOPP film of the present invention is a three- layered structure which comprises a skin layer, a core layer and a skin layer.
[0052] According to yet another embodiment, the BOPP film of the present invention is a five- layered structure which comprises a skin layer, a tie layer, a core layer, a tie layer, and a skin layer.
[0053] According to yet another embodiment of the present invention, the biaxially oriented polypropylene film can be used for Pressure-sensitive adhesive (PSA) label and In-mould labeling (IML) applications.
[0054] According to yet another embodiment of the present invention, the invention provides for an In line Coated UV Printable BOPP for pressure sensitive labels for transparent, white cavitated, white solid and metallised films. [0055] The Inline coating method is generally employed for the coating of polyester films. However, the present invention provides for improved biaxially oriented polypropylene films with process parameters suitable to carry out the inline coating process. Generally, the film coated surface deteriorates when the film is stretched in the transverse direction after the inline coating process. The novel manufacturing process according to the present invention ensures that after the Inline coating of the film is done and there are no damages on the surface of the film when it is stretched in the transverse direction.
[0056] According to yet another embodiment of the present invention, the invention provides for a cost effective method of producing biaxially oriented polypropylene film and an economical BOPP film obtained thereof with improved inline coating and thereby enhanced adhesion to a large number of printing inks or lamination adhesives, not limited to, UV inks, solvent and water based ink systems.
[0057] According to yet another embodiment, the biaxially oriented polypropylene (BOPP) film of the present invention is suitable for printing including UV flexo printing, UV offset printing, Letter press printing, water based flexo printing, solvent based printing, digital printing, ink-jet printing and the like.
[0058] According to yet another embodiment of the present invention, a biaxially oriented polypropylene (BOPP) film having improved adhesion to various types of printing inks, including UV inks and enhanced mechanical properties like tensile strength and elastic modulus is disclosed. The BOPP film of the invention comprises a substrate polypropylene film, wherein at least one surface of the substrate polypropylene film is inline coated with an acrylic and/or polyurethane dispersion coating.
[0059] The surface layer on which the coating to be done is specifically modified by adding maleic anhydride (MA) grafted polymer to the surface layer, to have better anchorage with hybrid coating formulation based on acrylic polyurethane and ethylene acrylic acid. Surface layer design is not limited to the use of maleic anhydride (MA) grafted polymer but it can be formulated using PP Homopolymer, High isotactic Polypropylene, Co-polymers. Also, the surface layer is incorporated with specific sized antiblock additives so that the appropriate antiblocking can be achieved without affecting the bond between the surface layer and the coating formulation. [0060] The BOPP film can be transparent, White Cavitated or solid white. Accordingly, the base layer is formulated using Ti02, Calcium carbonate (CaC03) and PBT resin to provide the necessary whiteness and Cavitation.
[0061] The BOPP film is formulated with desired amounts of certain antistatic and slip additives to provide the required antistatic and slip properties required for the easy and trouble free converting during label converting etc
[0062] The BOPP film according to the present invention comprises FDA approved cross linking additives, thereby the PSA label films can be used for Food and pharmaceutical applications.
[0063] The process of In line coating the BOPP film of the present invention can also be applied to metallized PSA labels. In one exemplary embodiment, the present invention provides a metalized BOPP film wherein the metalized BOPP film may have a skin layer comprising of a butene or ethylene base co-polymer and Maleic anhydride grafted polypropylene.
[0064] According to yet another embodiment, the BOPP film is prepared using the manufacturing unit shown in FIG. 1. the manufacturing unit comprises the various sub-units such as Feeder/hopper section (1), main extruder section (2), first co-extruder (4) and a second co-extruder (5), T-die section (6) , chill roll (7), water bath (8), machine direction orientation (MDO) unit (9), inline coating unit (13) , transverse direction orientation (TDO) section (14), winder (17) and the pull roll section (15). The machine direction orientation (MDO) unit (9) comprises a set of preheating rollers (10), machine direction stretching rollers (11) and annealing rollers (12). [0065] According to another embodiment of the present invention, the method of manufacturing involves the use of Feeder section (1) for transferring the raw BOPP resin composition material to a co-extrusion unit. The co-extrusion unit comprises of a main extruder (2), first co-extruder (4) and a second co-extruder (5). The main extruder (2) can be a screw-type extruder with a screw drive (3). Preferably screw extruders are used in the present invention, however, other suitable extruders, for example, twin-screw extruder, piston extruder, ram extruder, etc, as obvious to a person skilled in the art, can also be used. In the extruder section (2), the raw BOPP resin composition material is subjected to heat, shear and pressure to bring about the melting of the raw materials. The thickness of different layers of the BOPP films is controlled by the relative speeds and sizes of the main extruder (2), first co-extruder (4), and second co-extruder (5). The main extruder (2), first co-extruder (4) and second co-extruder (5), are maintained at a temperature ranging from about 220° C to about 260° C. Any number of co-extruders can be used depending on the number of layers required. [0066] The melted molten material is then transferred to the T-die section (3). In the T-die section
(6), the film from the molten BOPP material and/or co-extruded material is prepared. The T-die (6) is kept at a temperature of about 240° C to 250° C. The T-die (6) is used here as an exemplary die, however, other suitable dies available in the market and obvious to a person skilled in the art, can also be utilized. The film thus formed is cooled and quenched using chill roll (7) and water bath (8). In a preferred embodiment, the chill roller (7) and water bath (8) are maintained at a temperature of about 25-420 C.
[0067] After quenching, the film is transferred to the machine direction orientation (MDO) unit (9). In the MDO unit, at first the film is preheated by passing through set of rollers and it is then stretched longitudinally using rollers arranged in series. The set of preheating rollers (10) are maintained at a temperature ranging from about 100° C to 150° C. After preheating, the film passes over the machine direction stretching rollers (11). In a preferred embodiment, the temperature of the machine direction stretching rollers (11) are kept at about 70° C to 90° C. Subsequently, the film passes over the annealing rollers (12), which are maintained at a temperature of about 100° C to 1200 C. The stretching in machine direction orientation (MDO) unit (9) reduces the thickness of the film and enhances its mechanical properties.
[0068] After stretching, the film is annealed and transferred to the inline coating unit (13). The annealed film from the MDO unit on entering the inline coating unit (13) is subjected to corona treatment on its surface, followed by coating with the acrylic and/or polyurethane dispersion in the inline coating unit (13). Acrylic and/or polyurethane based coating enhances the metal adhesion, oxygen transmission rate (OTR) and water vapor transmission rate (WVTR), luster and other optical properties of the film.
[0069] The coated film then enters the TDO section (14), where it is first preheated by passing through set of rollers and then stretched in transverse direction via the tenter frame section and finally the film is winded on the winder (17) via the pull roll section (15). The preheating zone is maintained at a temperature ranging from about 160 0 C to 180° C. The preheated film is then stretched in a transverse direction with the help of chain clips or jaws (not shown). In a preferred embodiment, the chain clips or jaws are kept at a temperature of about 158 0 C/ fan speed about 90%. The film is then transferred to a set of annealing rollers (not shown). In a preferred embodiment, the annealing rollers are maintained at a temperature ranging from about 1600 C to 165 0 C/ fan speed about 80%. This transverse direction orientation further decreases the film - thickness and enhances its mechanical properties.
[0070] MDSR may be defined as the length of a portion of the film after stretching divided by the initial length of that portion. TDSR may be defined as the width of a portion of the film after stretching divided by the initial width of that portion. MDSR/TDSR ratio for the above-mentioned BOPP films is 4.2 to 5.5/ 8.5 to 10.
[0071] According to another embodiment of the present invention, the inline coating unit (13) is situated before machine direction orientation (MDO) unit (9), i.e the inline coating is performed before the film enters the machine direction orientation (MDO) unit (9). [0072] According to another embodiment of the invention, the raw material comprises homopolymers or copolymers of polypropylene, organic antiblock e.g. AB6060PPR or AB 6059 PPR of Contab, inorganic antiblock additive e.g. HOBLOCK-IO/SKIBLOCK of Ampacet or AB 6095 PP, anti-static additive like AT 4130PP or AT 4061 PP of Contstab, processing aids e.g EIN 25005 of 3M, titanium dioxide like WHITE 70 of Ampacet, Calcium Carbonate like PEARL 70 of Ampacet or PF 97/PF97NTS of A Schulman, polybutylene terephthalate(PBT) e.g PEARL 81 of Ampacet or HIGH GLOSS COMPOUND of Plastiblends and special grafted polypropylene to facilitate adhesion to coating base, special coating material which is stretchable and processable through TDO unit.
[0073] The biaxially oriented polypropylene (BOPP) film according to the present invention has excellent ink adhesion on the coated surface suitable for a broad range of ink systems, but not limited to, UV curing inks for flexo or offset printing process. The corona treated film surface according to the present invention provides for excellent adhesive anchorage. Coating adhesion is maintained in hot and cold-water immersion without clouding. [0074] Further, the method of the present invention provides for a biaxially oriented polypropylene (BOPP) film with enhanced blocking resistance due to the optimal ratios of the acrylic system in the formulation without the addition of any anti-blocking additives.
[0075] According to the embodiments of the present invention, the invention provides for a five- layer arrangement of the substrate layer instead of the conventional three layers. The BOPP film accordingly may comprise a five-layered structure which further comprises an upper skin layer, an upper tie layer, a core layer, a lower tie layer, and a lower skin layer.
[0076] The different ratios of acrylics / polyurethane coating according to the invention provide for better stretching efficiency and film formation characteristics as compared to the currently available films. The addition of anti-foaming agents to the BOPP film formulation prevents the foaming issues during coating. Also, the addition of leveling agents to the film formulation brings about better leveling and dispersion.
[0077] According to yet another embodiment, the core layer comprises homo polypropylene, polypropylene based elastomer or terpolymer. [0078] According to yet another embodiment, at least one skin layer comprises polymer selected from the group consisting of homo polypropylene, high isotatic polypropylene, Grafted polypropylene, polypropylene Copolymer, polypropylene based elastomer, Ethylene-vinyl alcohol co-polymer or a combination thereof
[0079] According to yet another embodiment, the tie layer comprising homo polypropylene, PP based elastomer or a combination thereof.
[0080] The biaxially oriented polypropylene (BOPP) film according to the present invention can be a transparent PSA label film for printing and as well as water based adhesive bonding or a metallized PSA label film for UV and other printing applications.
[0081] The biaxially oriented polypropylene (BOPP) film is cavitated BOPP film with a) Coating on glossy side for printing application and b) another product Adhesive bonding for ILC coating on Matte surface. [0082] The biaxially oriented polypropylene (BOPP) film according to the present invention can therefore be used both for printing purposes, and also for adhesive anchorage with water based acrylic or hot melt adhesives.
[0083] The invention is described in detail in the Experiments given below which are provided by way of illustration only and therefore should not be construed as a limitation to the present invention. These Experiments record variations in film characteristics in response to changes in the coating medium and base film recipes:
[0084] Experiment-01
Figure imgf000015_0001
[0085] It was observed that the surface of BOPP film had a hazy and patchy pattern, the coating stretchability was not upto the mark. The treatment strength was 46 dynes and results of UV printability not achieved.
[0086] Experiment-02
Figure imgf000015_0002
[0087] It was observed that the surface of BOPP film had a hazy and patchy pattern, the coating stretchability was upto the mark. The treatment strength was 40 dynes and results of UV printability partially achieved but coted film was very tacky. [0088] Experiment-03
Figure imgf000016_0001
[0089] It was observed that the surface of BOPP film had a hazy and patchy pattern, the coating stretchability was not upto the mark. The treatment strength was 42 dynes and results of UV printability not achieved [0090] Experiment-04
Figure imgf000016_0002
[0091] It was observed that the stretchability of coated layer good, clarity of surface good, no patchy pattern. Treatment strength was 42 dynes but results of UV printability not good.
[0092] Experiment-05
Figure imgf000016_0003
[0093] It was observed that the stretchability of coated layer good, clarity of surface good, no patchy pattern. Treatment strength was 42-44 dynes , results of UV printability was very good. Ageing results not upto the mark.
[0094] Experiment-06
Figure imgf000017_0001
[0095] It was observed that the stretchability of coated layer good, clarity of surface good, no patchy pattern. Treatment strength was 40 dynes, results of UV printability was very good. Ageing results well but facing some issues of roll blocking.
[0096] Experiment-07
Figure imgf000017_0002
[0097] It was observed that the stretchability of coated layer good, clarity of surface good, no patchy pattern. But coating layer was coming off with rape. Treatment strength was 42 dynes, results of UV printability not good.
[0098] Experiment-08
Figure imgf000017_0003
Figure imgf000018_0003
[0099] It was observed that the stretchability of coated layer good, clarity of surface good, no patchy pattern. Treatment strength was 46 dynes, results of UV printability was very good.
[00100] Experiment-9
Figure imgf000018_0001
[00101] It was observed that the stretchability of coated layer good, clarity of surface good, no patchy pattern. Treatment strength was 40 dynes, results of UV printability was very good. Ageing results well but facing some issues of roll blocking.
[00102] Experiment-10
Figure imgf000018_0002
[00103] It was observed that the stretchability of coated layer good, clarity of surface good, no patchy pattern. Treatment strength was 40 dynes, results of UV printability was very good. Ageing results well but facing some issues of roll blocking
[00104] Experiment-11
Figure imgf000018_0004
Figure imgf000019_0002
[00105] It was observed that the stretchability of coated layer good, clarity of surface good, no patchy pattern. Treatment strength was 40 dynes, results of UV printability was very good. Ageing results well. No blocking issues observed.
[00106] Experiment-12
Figure imgf000019_0001
[00107] It was observed that the stretchability of coated layer good, clarity of surface good, no patchy pattern. Treatment strength was 40 dynes, results of UV printability was very good. Ageing results well. No blocking issues observed.
[00108] The BOPP film produced in the above experiments was tested for Coating Grammage, Coating Tape test (Scotch tape 3M 610), Surface Treatment and UV ink adhesion test (Instrument: RK Flexiproof 100). The UV ink adhesion was tested for printing immediate after coating, printing after 24 hours of coating and printing after One week of coating, using UV printing inks selected from Flexocure Force PR-Cyan, Flexocure Force Ivory-white, and Flexocure Force PR-Yellow.
[00109] Table 1:
Figure imgf000020_0001
Tablel shows the parameters tested for BOPP film produced in experiments 1-12.
[00110] Although explanatory embodiments have been shown and described, it would be appreciated by those skilled in the art that the above embodiments cannot be construed to limit the present disclosure, and changes, amendments, alternatives, and modifications can be made in the embodiments without departing from spirit, principles and scope of the present disclosure.

Claims

Claims:
1. A process for making a biaxially oriented polypropylene (BOPP) film having improved adhesion to UV printing inks, the process comprising: orienting a substrate polypropylene film in a machine direction orientation (MDO) to obtain an uniaxially oriented polypropylene film;
Inline coating at least one surface of the uniaxially oriented polypropylene film with an acrylic and/or polyurethane (PU) dispersion coating to obtain a coated polypropylene film; and orienting the coated polypropylene film in a transverse direction orientation (TDO) to obtain a biaxially oriented polypropylene film, wherein the acrylic and/or polyurethane dispersion coating comprises 20-23% (wt/wt) of A-2092, 5-16% (wt/wt) of RU-92208, 1-2% (wt/wt) IPA, 59-74% (wt/wt) of demineralized water and at least one surface of the uniaxially oriented polypropylene film is modified with a polymer before the inline coating.
2. The process according to claim 1, wherein the substrate polypropylene film is obtained by extruding a raw material comprising at least a polypropylene resin selected from the group consisting of homopolymers of polypropylene, copolymers of polypropylene, terpolymer of polypropylene, and/or combination thereof.
3. The process according to claim 2, wherein the raw material further comprising at least one additive selected from the group consisting of organic anti-block additive, inorganic anti block additive, anti-static additive, processing aids, titanium dioxide, Calcium Carbonate, polybutylene terephthalate(PBT) and a combination thereof.
4. The process according to claim 1, wherein at least one surface of the uniaxially oriented polypropylene film is modified by adding at least one polymer selected from the group consisting of maleic anhydride (MA) grafted polymer, polypropylene Homopolymer, High isotactic Polypropylene, Co-polymers.
5. The process according to claim 1, wherein at least one surface of the uniaxially oriented polypropylene film is exposed to corona treatment before Inline coating with the acrylic and/or polyurethane dispersion coating.
6. The process according to claim 1, wherein the BOPP film can be printed using techniques selected from the group consisting of UV flexo printing, UV offset printing, Letter press printing, water based flexo printing, solvent based printing, digital printing, ink-jet printing.
7. The process according to claim 1, wherein the BOPP film produced therefrom can be a transparent, a white cavitated, a solid white or a metalized BOPP film.
8. Abiaxially oriented polypropylene (BOPP) film having improved adhesion to UV printing inks comprises: a substrate polypropylene film; and an acrylic and/or polyurethane dispersion coating layer comprising 20-23% (wt/wt) of A- 2092, 5-16% (wt/wt) of RU-92208, 1-2% (wt/wt) IPA, 59-74% (wt/wt) of demineralized water, and wherein the acrylic and/or polyurethane dispersion coating layer is inline coated on at least one surface of the substrate polypropylene film.
9. The BOPP film according to claim 8, wherein the substrate polypropylene film comprising at least a polypropylene resin selected from the group consisting of homopolymers of polypropylene, copolymers of polypropylene, terpolymer pf polypropylene, and/or combination thereof.
10. The BOPP film according to claim 8, wherein the substrate polypropylene film further comprising at least one additive selected from the group consisting of: organic antiblock additive, inorganic antiblock additive, anti-static additive, processing aids, titanium dioxide, Calcium Carbonate, polybutylene terephthalate(PBT) or a combination thereof.
11. The BOPP film according to claim 8, wherein at least one surface of the substrate polypropylene film is modified by adding polymer selected from the group consisting of maleic anhydride (MA) grafted polymer, PP Homopolymer, High isotactic Polypropylene, Co-polymers.
12. The BOPP film according to claim 8, wherein at least one surface of the substrate polypropylene film is corona treated.
13. The BOPP film according to claim 8, wherein the substrate polypropylene film comprises a core layer, at least one skin layer, and optionally at least one tie layer.
14. The BOPP film according to claim 14, wherein the core layer comprises homo polypropylene, polypropylene based elastomer or terpolymer; and at least one skin layer comprises polymer selected from the group consisting of: homo polypropylene, high isotactic polypropylene, Grafted polypropylene, polypropylene Copolymer, polypropylene based elastomer, butene or ethylene base co-polymer, Ethylene-vinyl alcohol co-polymer.
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CN115302911A (en) * 2022-07-12 2022-11-08 德阳市美妆庭纸业有限公司 Polypropylene film for rotary offset printing and photocuring ink

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