Recyclable film for thermoforming

Abstract

Recyclable films having at least a first layer containing a high-density polyethylene, a second layer containing a high-density polyethlene and a hydrocarbon resin, and a third layer containing a high-density polyethylene may be used for thermoforming packaging components. The film structure is advantageous as it can be more easily thermoformed than traditional high-density poly-ethylene films and can maintain the shape taken during thermoforming, exhibiting minimal warping or shrinking.

1 . A thermoformable base film comprising:
 a first layer comprising a high-density polyethylene and a polyethylene having a density less than 0.92 g/cm 3 ,   a second layer comprising a high-density polyethylene and a hydrocarbon resin, and   a third layer comprising a high-density polyethylene,   wherein the first layer and the third layer each form a surface of the thermoformable base film.   
     
     
         2 . A thermoformable base film according to  claim 1 , wherein the thermoformable base film has a melt flow rate that is at least 20% greater than a thermoformable base film that is identical with the exception that the film is free from hydrocarbon resin. 
     
     
         3 . A thermoformable base film according to  claim 1 , wherein the thermoformable base film is essentially free from polyester, ethylene vinyl alcohol copolymer and polyamide. 
     
     
         4 . The thermoformable base film according to  claim 1 , wherein the polyethylene having a density of less than 0.92 g/cm 3  of the first layer further is a linear low-density polyethylene, a metallocene catalyzed linear low-density polyethylene, an ethylene-based plastomer or a low-density polyethylene. 
     
     
         5 . (canceled) 
     
     
         6 . The thermoformable base film according to  claim 1 , further comprising an oxygen barrier layer comprising an ethylene vinyl alcohol copolymer, wherein the oxygen barrier layer is located between the first layer and the third layer. 
     
     
         7 . The thermoformable base film according to  claim 1 , further comprising a center layer comprising an ethylene vinyl acetate copolymer and wherein the thermoformable base film is palindromic. 
     
     
         8 . A thermoformable base film comprising:
 a first layer comprising from 50 weight % to 99 weight % of a high-density polyethylene and from 0.5 weight % to 50 weight % of a polyethylene having a density less than 0.92 g/cm 3 ,   a second layer comprising a high-density polyethylene and between 2.5 weight % and 30 weight % hydrocarbon resin, and   a third layer comprising a high-density polyethylene,   wherein the second layer is located between the first layer and the third layer, and wherein after thermoforming, the thermoformable base film maintains the shape taken during thermoforming.   
     
     
         9 . The thermoformable base film according to  claim 8 , wherein the thermoformable base film has a thermoforming temperature operating window of at least 6° C. 
     
     
         10 . The thermoformable base film according to  claim 8 , further comprising a fourth layer comprising a high-density polyethylene and an inorganic particle, wherein the inorganic particle is present in the fourth layer at a level of at least 10% by weight of the fourth layer and wherein the fourth layer is between the first layer and the third layer. 
     
     
         11 . The thermoformable base film according to  claim 10 , wherein the inorganic particle is calcium carbonate. 
     
     
         12 . The thermoformable base film according to  claim 10 , wherein the overall density of the thermoformable base film is less than 1.0 g/cm 3 . 
     
     
         13 . The thermoformable base film according to  claim 8 , wherein the hydrocarbon resin is present from 5% to 10% by weight with respect to the thermoformable base film and wherein the melt index of the thermoformable base film is between 1.7 and 2.3 g/10 min (190° C., 2160 g). 
     
     
         14 . The thermoformable base film according to  claim 8 , wherein the thermoformable base film is essentially free from polyester, ethylene vinyl alcohol copolymer and polyamide. 
     
     
         15 . A thermoformable base film comprising:
 a first layer comprising a polyethylene,   a second layer comprising a high-density polyethylene and a hydrocarbon resin,   a third layer comprising a high-density polyethylene, and   a fourth layer comprising a high-density polyethylene and an inorganic particle,   wherein the inorganic particle is present in the fourth layer at a level of at least 10% by weight of the fourth layer and wherein the fourth layer is between the first layer and the third layer, and   wherein the second layer is located between the first layer and the third layer,   wherein the second layer has a thickness that is from 25% to 90% of the total thickness of the thermoformable base film.   
     
     
         16 . (canceled) 
     
     
         17 . (canceled) 
     
     
         18 . (canceled) 
     
     
         19 . (canceled) 
     
     
         20 . (canceled) 
     
     
         21 . (canceled) 
     
     
         22 . A thermoformed base comprising:
 the thermoformable base film according to  claim 15 ,   at least one cavity, and   a flange surrounding each of the cavities.   
     
     
         23 . (canceled) 
     
     
         24 . A packaged product comprising:
 the thermoformed base according to  claim 22 ,   a lid packaging component, and a product,   wherein the lid packaging component is hermetically sealed to the flange of the thermoformed base and the product is enclosed in the at least one cavity of the thermoformed base.   
     
     
         25 . (canceled) 
     
     
         26 . (canceled) 
     
     
         27 . The packaged product according to  claim 24 , wherein the thermoformed base and the lid packaging component are recyclable in the same recycle process. 
     
     
         28 . The packaged product according to  claim 27 , wherein the thermoformed base and the lid packaging component are recyclable in a high-density polyethylene recycle process. 
     
     
         29 . The packaged product according to  claim 24 , wherein the at least one cavity of the thermoformed base may be depressed manually, and the product may be pushed through the lid packaging component for product dispensing. 
     
     
         30 . The packaged product according to  claim 24 , wherein the lid packaging component comprises:
 a first exterior layer comprising a high-density polyethylene and an inorganic particle,   a first interior layer comprising a high-density polyethylene, a nucleating agent and optionally a hydrocarbon resin, and   a second exterior layer comprising a polyethylene-based material.   
     
     
         31 . (canceled)