Composite film assemblies having sealing and barrier properties for use as in-mold labels, articles with in-mold labels, and methods of making same

A composite film assembly for use as in-mold labels in molded articles, the composite film comprising:

• a first film defining a top layer;
• and
• a second film defining a bottom layer, wherein at least one of the first and second films comprises a heat sealable material such that the first and second films are sealable to themselves and each other in an optional overlap region to form a curl resistant or peel resistant bond;
• wherein the composite film assembly is bondable via the bottom layer to a material forming the molded article.

A method of forming a molded article with an in-mold label, the method comprising:

• providing at least one in-mold label comprising a composite film assembly, the composite film including
• a first film defining a top layer, and
• a second film defining a bottom layer, wherein at least one of the first and second films comprises a heat sealable material;
• placing the at least one in-mold label in a mold cavity to form at least one region of label overlap;
• introducing a molten plastic shot material to the mold cavity, wherein the plastic shot material contacts the bottom layer of the at least one in-mold label to bond thereto, and wherein heat from the shot material causes the first and second films to molecularly bond in the at least one region of label overlap to form a curl resistant or peel resistant bond at the at least one region of label overlap;
• and
• cooling the plastic shot material to form the molded article, wherein the in-mold label is bonded to and structurally integral with the molded article.

A composite film assembly for use as in-mold labels in molded articles, the composite film comprising:

• a first film defining a top layer;
• a second film defining a bottom layer;
• and
• a first barrier layer operably coupled to at least one of the first and second films and sandwiched therebetween,
• wherein the composite film assembly is bondable to a material forming the molded article, and
• wherein the composite film assembly is substantially free of EVOH.