Retortable packaging film with having seal/product-contact layer containing blend of polyethylenes and skin layer containing propylene-based polymer blended with polyethylene

Abstract

A retortable multilayer packaging film comprises a crosslinked first layer which serves as an outer heat seal/product contact layer, and a crosslinked second layer which serves as an outer heat seal/skin layer. The crosslinked first outer heat seal/product contact layer comprises a blend of a homogeneous ethylene/alpha-olefin copolymer and a heterogeneous ethylene/alpha-olefin copolymer and/r a propylene/ethylene copolymer having a melting point of from about 110° C. to about 150° C. and having up to 4.9 weight percent ethylene mer. The crosslinked outer heat seal/skin layer comprises a blend of: an isotactic propylene-based polymer, and a homogeneous ethylene/C 4-8 alpha-olefin copolymer having a density of from about 0.86 g/cc to about 0.91 g/cc. The invention also pertains to packaging articles made from the film, packaged products utilizing the film in the package, and a packaging process utilizing the film

1 - 21 . (canceled) 
   
   
       22 . A process of preparing a retorted packaged product, comprising:
 (A) placing a product in a packaging article comprising a multilayer packaging film heat sealed to itself, the multilayer packaging film comprising:
 (1) a crosslinked first layer which serves as an outer heat seal and product contact layer, the first layer comprising a blend of:
 (a) at least one member selected from the group consisting of:
 (i) a homogeneous ethylene/octene copolymer having a density of from about 0.905 g/cc to about 0.93 g/cc; 
 (ii) a homogeneous ethylene/butene copolymer having a density of from about 0.90 g/cc to about 0.93 g/cc; and 
 (iii) a homogeneous ethylene/hexene copolymer having a density of from about 0.90 g/cc to about 0.93 g/cc; and 
 
 (b) at least one member selected from the group consisting of:
 (i) heterogeneous ethylene/alpha-olefin copolymer having a density of from about 0.92 g/cc to about 0.95 g/cc; and 
 (ii) propylene/ethylene copolymer having a melting point of from about 110° C. to about 150° C.; 
 
 
 (2) a crosslinked second layer which serves as an outer heat seal and skin layer, the second layer comprising a blend of
 (a) an isotactic propylene-based polymer; 
 (b) a homogeneous ethylene/C 4-8  alpha-olefin copolymer having a density of from about 0.86 g/cc to about 0.91 g/cc; 
 
   (B) sealing the article closed so that a packaged product is formed, in which the product is surrounded by the multilayer packaging film;   (C) heating the packaged product to a temperature of at least 220° F. for a period of at least 1 hour in the presence of pressurized steam, so that the product is retorted.   
   
   
       23 . The process according to  claim 22 , wherein the product comprises at least one member selected from the group consisting of chili, rice, beans, olives, beef, pork, fish, poultry, corn, eggs, tomatoes, and nuts. 
   
   
       24 . The process according to  claim 22 , wherein the packaged product is heated to a temperature of at least 230° F. for a period of at least about 75 minutes. 
   
   
       25 . The process according to  claim 24 , wherein the packaged product is heated to a temperature of at least 240° F. for a period of at least about 90 minutes. 
   
   
       26 . The process according to  claim 22 , wherein the multilayer packaging film further comprises an O 2 -barrier layer, and a grease-resistant layer between the second layer and the O 2 -barrier layer. 
   
   
       27 . The process according to  claim 26 , wherein the 02-barrier layer comprises at least one member selected from the group consisting of crystalline polyamide, amorphous polyamide, ethylene/vinyl alcohol copolymer, vinylidene chloride copolymer, and polyacrylonitrile. 
   
   
       28 . The process according to  claim 22 , wherein the crosslinked first layer comprises a blend of:
 (i) at least one member selected from the group consisting of:
 (a) a homogeneous ethylene/octene copolymer having a density of from about 0.91 g/cc to about 0.93 g/cc; and 
 (b) a homogeneous ethylene/butene copolymer having a density of from about 0.90 g/cc to about 0.91 g/cc; and 
   (ii) at least one member selected from the group consisting of:
 (a) a heterogeneous ethylene/alpha-olefin copolymer having a density of from about 0.92 g/cc to about 0.94 g/cc; and 
 (b) a propylene/ethylene copolymer having a melting point of from about 115° C. to about 125° C. 
   
   
   
       29 . The process according to  claim 22 , wherein the crosslinked first layer further comprises a slip agent and an anti-blocking agent, and the crosslinked second layer further comprises a slip agent and an anti-blocking agent. 
   
   
       30 . The process according to  claim 22 , wherein the isotactic propylene-based polymer comprises homogeneous propylene/ethylene copolymer having a density of from about 0.88 g/cc to about 0.90 g/cc, and the homogeneous ethylene/C 4-8  alpha-olefin copolymer comprises homogeneous ethylene/butene copolymer having a density of from about 0.88 g/cc to about 0.905 g/cc. 
   
   
       31 . The process according to  claim 22 , wherein the crosslinked second layer further comprises a slip agent and an antiblocking agent. 
   
   
       32 . The process according to  claim 23 , further comprising a tie layer between the O 2 -barrier layer and the crosslinked second layer. 
   
   
       33 . The process according to  claim 32 , further comprising a grease-resistant layer between the O 2 -barrier layer and the crosslinked first layer. 
   
   
       34 . The process according to  claim 33 , wherein the grease-resistant layer also functions as a tie layer between the O 2 -barrier layer and the crosslinked first layer. 
   
   
       35 . The process according to  claim 33 , further comprising a first high temperature abuse layer between the crosslinked first layer and the O 2 -barrier layer, and a second high temperature abuse layer between the crosslinked second layer and the O 2 -barrier layer. 
   
   
       36 . The process according to  claim 35 , further comprising a first low temperature abuse layer between the grease-resistant layer and the O 2 -barrier layer, and a second low temperature abuse layer between the O 2 -barrier layer and the skin layer. 
   
   
       37 . The process according to  claim 36 , wherein:
 (A) the grease-resistant layer comprises at least one member selected from the group consisting of.
 (i) a crystalline anhydride-grafted C 2-3 /C 6-20  alpha-olefin copolymer having a density of from 0.93 g/cc to 0.97 g/cc, 
 (ii) a crystalline C 2-3 /butene copolymer having a density of at least 0.92 g/cc, 
 (iii) ionomer resin, and 
 (iv) ethylene/unsaturated acid copolymer; 
   the first high-temperature-abuse layer and the second high-temperature-abuse layer each comprise at least one semicrystalline polyamide selected from the group consisting of polyamide-6, polyamide-6,6, polyamide-6,9, polyamide-4,6, and polyamide-6,10;   the first low-temperature-abuse layer and the second low-temperature-abuse layer each comprise at least one member selected from the group consisting of olefin homopolymer, C 2-3 /C 3-20  alpha-olefin copolymer, and anhydride-grafted ethylene/alpha-olefin copolymer;   the tie layer comprises at least one member selected from the group consisting of anhydride grafted ethylene/alpha-olefin copolymer, ionomer resin, and ethylene/unsaturated acid copolymer.   
   
   
       38 . The process according to  claim 37 , wherein the semicrystalline polyamide in each of the high-temperature-abuse layers is in a blend with at least one polyamide selected from the group consisting of polyamide-6/6,6, polyamide-6,12, polyamide-6/6,9, polyamide-12, and polyamide-11. 
   
   
       39 . The process according to  claim 37 , further comprising at least one medium-temperature-abuse layer which comprises at least one polyamide selected from the group consisting of polyamide-6/6,6, polyamide-6,12, polyamide-6/6,9, polyamide-12, and polyamide-11. 
   
   
       40 . The process according to  claim 22 , wherein the packaging article is a member selected from the group consisting of end-seal bag, side-seal bag, pouch, and casing. 
   
   
       41 . The process according to  claim 22 , wherein in the packaging article, the crosslinked first layer is heat-sealed to itself. 
   
   
       42 . The process according to  claim 22 , wherein in the packaging article, the crosslinked first layer is heat-sealed to the crosslinked second layer.