Stretchable Clay Nanocomposite Barrier Film for Flexible Packaging

The goal of reconciling all packaging requirements, e.g., mechanical resistance, transparency, flexibility, and gas barrier properties, is immensely challenging for packaging materials. Particularly, the combination of flexibility and good gas barrier properties poses a serious problem, especially when barrier requirements can only be met by lamination with a metal foil, metalization, or vapor-deposited ceramic layers, as all of these tend to be nonstretchable. In this work, we produced a stretchable nanocomposite barrier composed of one-dimensional (1D) crystalline (Bragg stack) barrier films composed of alternating layers of poly(ethylene glycol) (PEG) and synthetic sodium fluorohectorite (Hec) nanosheets. By sandwiching the Bragg stack type film between two plasticized poly(vinyl alcohol) (PVOH) layers, a waterborne laminate was obtained that outperforms commercial polymer materials in terms of water vapor permeability (WVP = 2.8 g mm m^-2 day^-1 bar^-1 at 23 °C and 85% relative humidity), which is remarkable for an entirely water-soluble film. Moreover, no deterioration of barrier performance up to 10% elongation was observed, rendering the transparent self-standing laminate promising for thermoformed blister packaging, shrink wrap, or vacuum packaging. Besides the low WVP, the scalable and green processing method makes this technology auspicious for real-world applications.