Sustainable barrier containers and methods
In an embodiment, the invention comprises a packaging structure comprising a cap layer which comprises post-consumer resin, at least one additional layer adjacent the first layer which comprises an alloy of: polyethylene terephthalate; a polyolefin; and at least one compatibilizer; a barrier coating adjacent the at least one additional layer and opposite the cap layer, wherein the barrier coating comprises a matrix of polyethyleneimine and polyvinyl alcohol and an overlacquer about the barrier coating. The methods of the invention may include co-extruding the cap layer and an alloy layer to form a co-extrudate; optionally, melt adhering the co-extrudate to another alloy layer to form a melt-adhered sheet; intermixing a solution of polyethyleneimine, polyvinyl alcohol, and water to form a coating; applying the coating to the outermost alloy layer opposite the cap layer; drying the applied coating; applying an overlacquer about the coating; and drying the overlacquer.
1 . A method of making a packaging structure or formable sheet comprising:
co-extruding a first layer which comprises post-consumer resin and a second layer which comprises an alloy of:
polyethylene terephthalate;
a polyolefin; and
at least one compatibilizer, to form a co-extrudate;
intermixing a solution of polyethyleneimine, polyvinyl alcohol, and water to form a coating;
applying the coating to the second layer of the melt-adhered sheet;
drying the applied coating; and
applying an overlacquer to the dried coating.
2 . The method of claim 1 additionally comprising, before co-extruding the first layer and second layer, intermixing the polyethylene terephthalate, the polyolefin, and the at least one compatibilizer; and drying the intermixture.
3 . A method of making a packaging structure or formable sheet comprising:
co-extruding a first layer which comprises post-consumer resin and a second layer which comprises an alloy of:
polyethylene terephthalate;
a polyolefin; and
at least one compatibilizer, to form a co-extrudate;
melt adhering the co-extrudate to a third layer which comprises an alloy of:
polyethylene terephthalate;
a polyolefin; and
at least one compatibilizer, to form a melt-adhered sheet;
intermixing a solution of polyethyleneimine, polyvinyl alcohol, and water to form a coating;
applying the coating to the third layer of the melt-adhered sheet opposite the first layer and second layer;
drying the applied coating; and
applying an overlacquer to the dried coating.
4 . The method of claim 3 , wherein the polyolefin comprises high density polyethylene.
5 . The method of claim 3 , wherein the post-consumer resin of the first layer comprises high density polyethylene.
6 . The method of claim 3 , wherein the compatibilizer comprises ethylene methyl acrylate, ethylene glycidyl methacrylate copolymer, ethylene/methyl acrylate/glycidyl methacrylate terpolymer, or a combination thereof.
7 . The method of claim 3 , wherein the coating is applied to the entire surface of the third layer.
8 . The method of claim 3 , wherein the overlacquer is applied to the entire surface of the dried coating.
9 . The method of claim 3 additionally comprising, before co-extruding the first layer and second layer, intermixing the polyethylene terephthalate, the polyolefin, and the at least one compatibilizer; and drying the intermixture.
10 . The method of claim 3 , further comprising thermoforming the melt adhered sheet to define at least one cavity, and a flange surrounding the at least one cavity;
filling the at least one cavity with a water emulsion; and
adhering a lidding member along the flange.
11 . A method of making a packaging structure or formable sheet comprising:
intermixing a solution of polyethyleneimine, polyvinyl alcohol, and water to form a coating;
applying the coating to a first layer which comprises an alloy of:
polyethylene terephthalate;
a polyolefin; and
at least one compatibilizer, to form a coated first layer;
drying the applied coating;
co-extruding a second layer which comprises post-consumer resin and a third layer which comprises an alloy of:
polyethylene terephthalate;
a polyolefin; and
at least one compatibilizer, to form a co-extrudate; and
melt adhering the co-extrudate to the coated first layer such that the coating is disposed between the third layer and the first layer.
12 . The method of claim 11 , additionally comprising, before co-extruding the first layer and second layer, intermixing the polyethylene terephthalate, the polyolefin, and the at least one compatibilizer; and drying the intermixture.
13 . The method of claim 11 , further comprising:
thermoforming the melt adhered sheet, into a plurality of cavities, wherein each of the cavities define a flange about a perimeter of the cavity, and wherein the overlacquer defines an exterior of the packaging structure.
14 . The method of claim 11 , further comprising:
adhering a lidding member to the flange.
15 . The method of claim 11 , further comprising:
separating the plurality of cavities along the flange.
16 . The method of claim 11 , wherein the plurality of cavities are divided by cutting the flange.