Sustainable barrer 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 packaging structure comprising:
a cap layer which comprises post-consumer resin;
at least one additional layer adjacent the cap 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 layer adjacent the barrier coating opposite the at least one additional layer.
2. The packaging structure of claim 1 , wherein the alloy additionally comprises between 50% and 70% regrind and virgin polyethylene terephthalate, virgin polyolefin, and virgin compatibilizer.
3. The packaging structure of claim 1 , wherein the alloy additionally comprises up to 60% regrind and virgin polyethylene terephthalate, virgin polyolefin, and virgin compatibilizer.
4. The packaging structure of claim 1 additionally comprising a second additional layer adjacent the first additional layer which comprises an alloy of polyethylene terephthalate, a polyolefin, and at least one compatibilizer, and wherein the barrier coating is adjacent the second additional layer.
5. The packaging structure of claim 1 , wherein the polyolefin comprises high density polyethylene.
6. The packaging structure of claim 5 , wherein the alloy comprises, by weight, between 50% and 60% high density polyethylene, between 35% and 45% polyethylene terephthalate, and between 2% and 6% compatibilizer.
7. The packaging structure of claim 5 , wherein the packaging structure comprises, by weight, between 50% and 60% high density polyethylene, between 34% and 37% polyethylene terephthalate, and between 4% and 6% compatibilizer.
8. The packaging structure of claim 1 , wherein the polyethylene terephthalate comprises post-consumer resin polyethylene terephthalate.
9. The packaging structure of claim 1 , wherein the cap layer is disposed on an interior of the packaging structure.
10. The packaging structure of claim 1 , wherein the cap layer is a food contact layer.
11. The packaging structure of claim 1 , wherein the post-consumer resin of the cap layer comprises high density polyethylene.
12. The packaging structure of claim 1 , wherein the post-consumer resin of the cap layer comprises high density polyethylene, polyethylene terephthalate, and a compatibilizer.
13. The packaging structure of claim 12 , wherein the post-consumer resin of the cap layer comprises, by weight, between 50% and 60% high density polyethylene, between 30% and 40% polyethylene terephthalate, and between 2% and 5% compatibilizer.
14. The packaging structure of claim 12 , wherein the post-consumer resin of the cap layer comprises, by weight, between 30% and 40% high density polyethylene, between 60% and 70% polyethylene terephthalate, and between 2% and 5% compatibilizer.
15. The packaging structure of claim 1 , wherein the compatibilizer comprises ethylene methyl acrylate, ethylene glycidyl methacrylate copolymer, ethylene/methyl acrylate/glycidyl methacrylate terpolymer, or a combination thereof.
16. The packaging structure of claim 1 , wherein the matrix of polyethyleneimine and polyvinyl alcohol does not comprise distinct layers of polyethyleneimine and polyvinyl alcohol.
17. The packaging structure of claim 1 , wherein at least one of the cap layer, the at least one additional layer, and the barrier coating additionally comprise a coloring agent.
18. The packaging structure of claim 1 , wherein the ratio of polyethyleneimine to polyvinyl alcohol is 1:5 or less.
19. The packaging structure of claim 1 , wherein the ratio of polyethyleneimine to polyvinyl alcohol is 1:4 or less.
20. The packaging structure of claim 1 , wherein the packaging structure has an oxygen transmission rate less than or equal to 0.03 cc/package/day.
21. The packaging structure of claim 1 , wherein the overlacquer comprises, by weight, between 10% and 40% vinyl acetate, and between 60% and 90% polyethylene.
22. The packaging structure of claim 1 , wherein the overlacquer comprises, by weight, 80% and 95% vinyl acetate, and between 5% and 20% polyethylene.
23. A formable sheet comprising:
a cap layer which comprises post-consumer resin;
at least one additional layer adjacent the cap layer which comprises an alloy of:
post-consumer resin 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 layer adjacent the barrier coating opposite the at least one additional layer.
24. A formed sheet formed from the formable sheet of claim 23 .
25. A thermoformed container thermoformed from the formable sheet of claim 23 .