# US 10,766,228 B2 · Coated film structures with an aluminum oxide intermediate layer > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,766,228 B2 - Document ID: US10766228B2 - Status: Granted - Kind: B2 - Application number: 15/858,233 - Filed: 2017-12-29 - Published: 2018-07-05 - Granted: 2020-09-08 - Earliest claimed: 2016-12-30 - Assignees: Michelman, Inc. - Applicants: Michelman, Inc. - Inventors: Francis Jacques; Robin Cooper; Kevin Gillie; Rymma Sushko - Web page: https://patentgrep.com/patent/US10766228B2 ## CPC - B32B 15/016: {all layers being formed of aluminium or aluminium alloys} - B32B 33/00: Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class - C08J 7/0423: {with at least one layer of inorganic material and at least one layer of a composition containing a polymer binder} - C08J 7/043: Improving the adhesiveness of the coatings per se, e.g. forming primers (adhesives in the form of films or foils characterised by the primer layers between the polymer carriers and the adhesives C09J7/50) - C08J 7/046: Forming abrasion-resistant coatings; Forming surface-hardening coatings - C08J 7/048: Forming gas barrier coatings - B32B 2255/26: Polymeric coating - C08J 2367/02: Polyesters derived from dicarboxylic acids and dihydroxy compounds; (C08J2367/06 takes precedence) - C08J 2429/04: Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29) ## Abstract Embodiments of the present disclosure provide a coated film structure including a substrate layer, an overcoat layer, and at least one intermediate layer disposed between the substrate layer and the overcoat layer. The substrate layer includes a polymer film substrate, the overcoat layer includes polyvinyl alcohol, and the at least one intermediate layer includes aluminum oxide. The substrate layer has a thickness from 1 μm to 120 μm and the overcoat layer has a dry coat weight of from about 0.05 g/m2 to about 1.5 g/m2. The coated film structure has an oxygen transmission rate of less than about 0.70 cm3/m2/day at 90% relative humidity and 23° C. as measured in accordance with ASTM D3985. Further, the coated film structure has a water vapor transmission rate of less than 1.00 g/m2/day at 90% relative humidity and 37.8° C. as measured in accordance with ASTM E-398. ## Claims ### Claim 1 A coated film structure comprising: a substrate layer comprising a polymer film substrate, the substrate layer having a thickness of from 1 μm to 120 μm; an overcoat layer comprising amorphous polyvinyl alcohol, the overcoat layer having a dry coat weight of from about 0.05 g/m2 to about 1.5 g/m2; and at least one intermediate layer disposed between the substrate layer and the overcoat layer, the intermediate layer comprising aluminum oxide and having a thickness from about 5 nm to about 30 nm; wherein the coated film structure comprises a rigid amorphous fraction (RAF) at an interface of the overcoat layer and the at least one intermediate layer, the overcoat layer comprising at least 30 weight percent RAF (% RAF) based on the total weight of the overcoat layer; wherein the coated film structure has an oxygen transmission rate of less than about 0.70 cm3/m2/day at 90% relative humidity and 23° C. as measured in accordance with ASTM D3985; and a water vapor transmission rate of less than 1.00 g/m2/day at 90% relative humidity and 37.8° C. as measured in accordance with ASTM E-398. ### Claim 2 (depends on 1) The coated film structure of claim 1, wherein the polymer film substrate comprises a polymer selected from the group consisting of polylactic acid (PLA), polyethylene terephthalate (PET), biaxially oriented polyethylene terephthalate (BOPET), oriented polypropylene (OPP), biaxially oriented polypropylene (BOPP), cast Polypropylene (CPP), Polyethylene (PE) and biaxially oriented polyamide. ### Claim 3 (depends on 1) The coated film structure of claim 1, further comprising at least one coating layer located between the substrate layer and the at least one intermediate layer. ### Claim 4 (depends on 3) The coated film structure of claim 3, wherein the at least one coating layer comprises polyvinyl alcohol. ### Claim 5 (depends on 1) The coated film structure of claim 1, wherein the coated film structure has an oxygen transmission rate of from about 0.1 cm3/m2/day to about 0.2 cm3/m2/day at 0% relative humidity at 23° C. ### Claim 6 (depends on 1) The coated film structure of claim 1, wherein the overcoat layer has a glass transition temperature (Tg) of less than 75° C. ### Claim 7 (depends on 1) The coated film structure of claim 1, wherein the at least one intermediate layer, the overcoat layer, or both comprise one or more additives selected from a wax, a biocide, an adhesive, or combinations thereof. ### Claim 8 (depends on 1) The coated film structure of claim 1, wherein the polymer film substrate comprises BOPET. ### Claim 9 (depends on 1) The coated film structure of claim 1, wherein the overcoat layer further comprises an adhesion promoter. ### Claim 10 (depends on 1) The coated film structure of claim 1, wherein the overcoat layer further comprises a polyethylene wax. ### Claim 11 (depends on 10) The coated film structure of claim 10, wherein the overcoat layer further comprises a catalyst. ### Claim 12 (depends on 1) The coated film structure of claim 1, wherein the overcoat layer further comprises a crosslinker. ### Claim 13 (depends on 1) The coated film structure of claim 1, wherein the overcoat layer further comprises a crosslinker for the amorphous polyvinyl alcohol; an adhesion enhancer comprising polyethylene imine; a crosslinker for the polyethylene imine; and a catalyst. ### Claim 14 (depends on 1) The coated film structure of claim 1, wherein the overcoat layer has the dry coat weight of from about 0.10 g/m2 to about 0.75 g/m2; and wherein the intermediate layer has a thickness from about 5 nm to about 15 nm. ### Claim 15 (depends on 1) The coated film structure of claim 1, wherein the overcoat layer has the dry coat weight of from about 0.15 g/m2 to about 0.6 g/m2; and wherein the intermediate layer has a thickness from about 5 nm to about 10 nm. ### Claim 16 A coated film structure comprising: a biaxially oriented polyethylene terephthalate (BOPET) substrate layer having a thickness of from 1 μm to 120 μm; an overcoat layer comprising amorphous polyvinyl alcohol, the overcoat layer having a dry coat weight of from about 0.05 g/m2 to about 1.5 g/m2; and an intermediate layer disposed between the BOPET substrate layer and the overcoat layer, the intermediate layer comprising aluminum oxide and having a thickness from about 5 nm to about 30 nm; wherein the coated film structure comprises a rigid amorphous fraction (RAF) at an interface of the overcoat layer and the intermediate layer, the overcoat layer comprising at least 30 weight percent RAF (% RAF) based on the total weight of the overcoat layer; wherein the coated film structure has an oxygen transmission rate of less than about 0.70 cm3/m2/day at 90% relative humidity and 23° C. as measured in accordance with ASTM D3985; and a water vapor transmission rate of less than 1.00 g/m2/day at 90% relative humidity and 37.8° C. as measured in accordance with ASTM E-398. ### Claim 17 (depends on 16) The coated film structure of claim 16, wherein the overcoat layer has the dry coat weight of from about 0.10 g/m2 to about 0.75 g/m2; and wherein the intermediate layer has a thickness from about 5 nm to about 15 nm. ### Claim 18 (depends on 16) The coated film structure of claim 16, wherein the overcoat layer has the dry coat weight of from about 0.15 g/m2 to about 0.6 g/m2; and wherein the intermediate layer has a thickness from about 5 nm to about 10 nm.