Metallized Barrier Material

Abstract

A metallized barrier material comprising a base material, a metallized layer and a protective coating. The base material has a first surface and a second surface. The metallized layer is vapor deposited on the first surface of the base material to a desired optical density. The protective coating is applied to the metallized layer, wherein the protective coating comprises a butyl methacrylate or a combination of an epoxy component and an acrylic component wherein the epoxy component has an EEW of less than 800.

What is claimed is: 
     
         1 . A metallized barrier material comprising:
 a base material having a first surface and a second surface;   a metallized layer vapor deposited on the first surface of the base material to a desired optical density;   a protective coating applied to the metallized layer, wherein the protective coating comprises a butyl methacrylate or a combination of an epoxy component and an acrylic component wherein the epoxy component has an EEW of less than 800.   
     
     
         2 . The metallized barrier material of  claim 1  wherein the base material comprises one of a cellulosic based material or a biopolymer, a second protective coating applied to the first surface of the base material between the first surface of the base material and the metallized layer, in at least one layer. 
     
     
         3 . The metallized barrier material of  claim 2  further comprising a third protective coating applied to the second surface of the base material. 
     
     
         4 . The metallized barrier material of  claim 2  wherein the biopolymer comprises one of the group consisting of PLA, PHA, thermoplastic starch, and blends thereof. 
     
     
         5 . The metallized barrier material of  claim 2  wherein the butyl methacrylate comprises one of the group consisting of a normal, iso and copolymer butyl methacrylate. 
     
     
         6 . The metallized barrier material of  claim 2  wherein the acrylic component of the combination acrylic and epoxy protective coating comprises one of a butyl methacrylate, methyl methacrylate or an acrylic copolymer and the epoxy component of the combination acrylic and epoxy protective coating comprises a bisphenol A epoxy. 
     
     
         7 . The metallized barrier material of  claim 2  wherein the acrylic component of the combination acrylic and epoxy protective coating comprises a glycidyl acrylic copolymer and the epoxy component of the combination acrylic and epoxy protective coating comprises a Tris(4-hydroxyphenyl)methane triglycidyl ether. 
     
     
         8 . The metallized barrier material of  claim 2  wherein the optical density of the metallized layer comprises 2.5 to 3.5. 
     
     
         9 . The metallized barrier material of  claim 1  wherein the base material comprises one of the group consisting of: PET, OPP, PE and blends thereof. 
     
     
         10 . The metallized barrier material of  claim 1  wherein the epoxy component has an EEW of less than 600. 
     
     
         11 . The metallized barrier material of  claim 1  wherein the butyl methacrylate comprises one of the group consisting of a normal, iso and copolymer butyl methacrylate. 
     
     
         12 . The metallized barrier material of  claim 1  wherein the acrylic component of the combination acrylic and epoxy protective coating comprises one of a butyl methacrylate, methyl methacrylate or an acrylic copolymer and the epoxy component of the combination acrylic and epoxy protective coating comprises a bisphenol A epoxy. 
     
     
         13 . The metallized barrier material of  claim 1  wherein the acrylic component of the combination acrylic and epoxy protective coating comprises a glycidyl acrylic copolymer and the epoxy component of the combination acrylic and epoxy protective coating comprises a Tris(4-hydroxyphenyl)methane triglycidyl ether. 
     
     
         14 . The metallized barrier material of  claim 1  wherein the desired optical density of the metallized layer comprises 2.5 to 3.5. 
     
     
         15 . A method of making a metallized barrier material comprising the steps of:
 providing a base material having a first surface and a second surface;   vapor depositing a metallized layer on the first surface of the base material, to a desired optical density;   formulating, in a solvent, a protective coating comprising a butyl methacrylate or a combination of an epoxy component and an acrylic component wherein the epoxy component has an EEW of less than 800;   applying the protective coating in a solvent onto the metallized layer; and   evaporating the solvent.   
     
     
         16 . The method of  claim 15  wherein the base material comprises one of a cellulosic based material or biopolymer, the method further comprising the step of:
 applying a second protective coating to the first surface of the base material before vapor depositing the metallized layer. 
 
     
     
         17 . The method of  claim 16  wherein the step of applying a second protective coating comprises the steps of:
 applying a first layer of the second protective coating to the first surface of the base material before vapor depositing the metallized layer; and 
 applying a second layer of the second protective coating to the first layer of the second protective coating before vapor depositing the metallized layer. 
 
     
     
         18 . The method of  claim 16  further comprising the step of applying a third protective coating to the second surface of the base material. 
     
     
         19 . The method of  claim 15  further comprising the step of:
 adhering the metallized barrier material to a second substrate. 
 
     
     
         20 . The method of  claim 19  wherein the second substrate comprises a cellulosic based material.