Ethylene vinyl alcohol (EVOH) films provide exceptional oxygen barrier properties in dry conditions—often achieving transmission rates below 1.5 cc/m²/day/atm—but experience significant performance degradation when exposed to moisture. This hygroscopic behavior stems from water molecules disrupting hydrogen bonding between EVOH chains, increasing free volume, and creating pathways for oxygen permeation that can reduce barrier efficiency by more than 60% at relative humidity levels above 75%.

The fundamental challenge lies in preserving EVOH's inherent oxygen barrier properties while simultaneously protecting it from moisture ingress in real-world packaging environments.

This page brings together solutions from recent research—including multilayer structures with hydrophobic skin layers, EVOH copolymers with specialized block characteristics, microfibrillated cellulose composites, and laminated thermosetting films. These and other approaches provide practical pathways to maintain barrier integrity under varying humidity conditions while preserving the mechanical properties needed for commercial packaging applications.

1. Laminated Film with Polymer-Based Sealant, Hydrophilic Blocking, and Hydrophobic Skin Layers

DONGWON SYSTEMS CORP, 2025

Laminated film for packaging materials with enhanced oxygen barrier properties and improved processing conditions. The film comprises a sealant layer, a blocking layer, and a skin layer. The sealant layer is a polymer-based barrier material, while the blocking layer contains hydrophilic polymers like PVA or EVOH. The skin layer is a hydrophobic polymer layer. The sealant layer and blocking layer are combined with a second adhesive layer, and the skin layer is applied on top. The film is manufactured through co-extrusion and heat sealing, achieving optimal barrier properties while maintaining processing conditions.

2. Laminated Film Structure with Heat-Curable and Thermoforming Layers for Enhanced Oxygen Barrier and Molding Integrity

CHOI JOON YEONG, Choi Jun-young, 2024

Molded film for food packaging that provides excellent oxygen barrier properties, molding efficiency, and food preservation by laminating heat-curable films and thermoforming films. The molded film has a first heat-curable film, a thermoforming film, and a second heat-curable film. The heat-curable films are CPR films made of TER polymer. The thermoforming film is an EVOH co-extrusion film. The films are laminated and extruded melted polymer is pressed between them. This configuration prevents tearing, sticking, and deformation during container molding. It also achieves low oxygen permeability (0.5-1.5 cc/m2/day/atm) and allows uniform EVOH molding in deep containers.

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3. Vacuum Packaging Film with Multi-Layered Structure Including EVOH and Carbon Nanowire Layers for Salmon Preservation

Jeon Byeong-chan, JEONBYEONGCHAN, 2024

Vacuum packaging method and film for preserving salmon products to prevent spoilage during distribution and storage. The method involves rapidly freezing the salmon using the vacuum film, then thawing in two steps. The film has layers like ethylene vinyl alcohol (EVOH) for gas barrier, antibacterial and antioxidant layers, and a carbon nanowire layer for rigidity. The film prevents spoilage during long-term distribution, thawing, and storage. Rapid freezing and thawing steps preserve quality.

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4. Method for Extrusion Laminating Thermosetting Films onto EVOH-Containing Thermoforming Films for Molded Packaging

Choi Jun-young, CHOI JOON YEONG, 2024

Method for manufacturing molded food packaging films with improved oxygen barrier and molding efficiency. The method involves laminating a thermosetting film onto the top and bottom of an EVOH-containing thermoforming film. This is done by extrusion lamination. The laminated structure is then compressed to form the molded packaging. The laminated construction provides improved oxygen barrier properties and prevents tearing or sticking during molding. The thickness of the EVOH layer is balanced in the molded container.

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5. Method for Packaging Food Utilizing Multilayer Film with EVOH Core and Thermosetting Laminates

Choi Jun-young, CHOI JOON YEONG, 2024

Method for packaging food using containers with improved oxygen barrier and shrinkage properties. The method involves using a specific multilayer film structure for thermoforming the containers. The film has an EVOH layer sandwiched between thermoplastic layers for oxygen barrier. A thermosetting layer is laminated on the top and bottom for strength. The film thickness is optimized for container depth to prevent distortion. Additives like floating bodies, suspended particles, and heat-reflective materials are included in the film layers for further benefits like preventing sticking, improving molding, and extending shelf life.

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6. Polyethylene Film with Additive-Enhanced Oxygen and Water Barrier Properties and Method of Controlled Additive Incorporation

BENEPAK PACKAGING CO LTD, 2023

Oxygen barrier polyethylene film and preparation method thereof for enhancing barrier properties beyond conventional polyethylene films. The film combines enhanced oxygen and water barrier performance with improved mechanical properties, particularly tensile strength and elongation at break, through the incorporation of specific additives. The preparation method enables controlled incorporation of these additives into the polyethylene matrix, ensuring consistent performance across different environmental conditions.

7. Multilayer Film with Alternating Aliphatic Polyester and Ethylene Vinyl Alcohol Layers

SK MICROWORKS CO LTD, 2023

Multilayer barrier film with improved oxygen barrier and transparency compared to single-layer films. The film has alternating layers of an aliphatic polyester resin and ethylene vinyl alcohol (EVOH) resin. This multilayer structure reduces oxygen permeability to 30 cc/m2.day or less, while maintaining transparency. The film can be made by alternately extruding and stacking the two resins, followed by biaxial stretching and heat-setting. The aliphatic polyester layer provides mechanical strength and stability, while the EVOH layer provides oxygen barrier properties.

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8. Multilayer Structure with Ethylene-Vinyl Alcohol Copolymer Featuring Specific Block Characteristics for Uniform Oxygen Barrier Performance

Kuraray Co., Ltd., KURARAY CO LTD, 2022

Multilayer structure with enhanced oxygen barrier properties through a novel ethylene-vinyl alcohol copolymer. The copolymer, with a specific block characteristic of ethylene units, enables superior oxygen barrier performance in multilayer structures while maintaining excellent moisture barrier properties. The copolymer's unique block structure ensures uniform oxygen barrier performance across the multilayer structure, even after long-term storage. The copolymer's improved oxygen barrier properties enable effective packaging applications where oxygen barrier properties are critical, such as food packaging and medical packaging.

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9. Method for Forming Antibacterial Film via Primer Coating with Horseradish Extract Oil and Polyurethane Acrylate Oligomers

Choi Jun-young, CHOI JOON YEONG, 2022

A method for manufacturing food packaging materials that can effectively maintain the freshness of contents like food and inhibit bacterial spoilage without direct contact with the food. The method involves coating a substrate with a primer containing ingredients like horseradish extract oil, polyurethane acrylate oligomers, and shell powder. This primer is cured to form an antibacterial coating that can be laminated onto another primer-coated substrate to create a bonded antibacterial film. This antibacterial film can be combined with thermoformed packaging films to provide food packaging materials that extend shelf life by blocking oxygen and suppressing contaminants.

10. Oxygen Barrier Film with Dual Microfibrillated Cellulose Suspensions and Specific Particle Size Distribution

STORA ENSO OYJ, 2022

Oxygen barrier film comprising microfibrillated cellulose (MFC) with enhanced mechanical properties and barrier performance. The film is made by suspending MFC with a specific size distribution profile, where the first suspension has a median particle size between 25-35 μm, and the second suspension has a median particle size between 10-12 μm. This dual suspension formulation enables the creation of a film with superior mechanical strength and barrier properties compared to conventional MFC films. The film achieves lower oxygen transmission rates (OTR) below 10 ml/m2/24h at 50% RH and higher strain at break values of at least 3.5%, making it suitable for packaging applications where oxygen barrier properties are critical.

11. Barrier Composition for Multilayer Films with Starch, Plasticizer, and Microfibrillated Cellulose

FUNDACAO UNIV FEDERAL DE SAO CARLOS UFSCAR, 2022

Barrier composition for multilayer films and packaging with improved oxygen barrier properties. The composition contains modified or unmodified starch, plasticizer, and microfibrillated cellulose (MFC). The starch and MFC fill any pores formed in the film to further improve barrier properties. The composition can also contain clay. The starch, plasticizer, and MFC are mixed into a dispersion and heated, then cooled. This allows the clay to disperse and prevents agglomeration. The dispersion is then used to coat the substrate to form the barrier layer. The multilayer structure can have additional layers like a carrier layer.

12. Gas Barrier Film with Metallized Microfibrillated Cellulose Layer and Dispersion Coating

STORA ENSO OYJ, 2022

Gas barrier film for paper and paperboard packaging materials with improved oxygen transmission rate (OTR) at high relative humidity (RH). The film comprises a microfibrillated cellulose layer with a metallized surface, where the metallization layer enhances barrier properties even at elevated temperatures and humidity. The film is combined with a dispersion coating layer to achieve optimal barrier performance, enabling recyclable packaging materials for liquid packaging applications.

13. Gas Barrier Film with Grafted Microfibrillated Cellulose and Polymer Layer

STRA ENSO OIJAY, 2022

Gas barrier film for packaging materials based on paper and paperboard that provides improved oxygen barrier properties at high humidity and temperature compared to conventional barrier films. The film structure involves a microfibrillated cellulose (MFC) layer, at least one surface of which is grafted with a fatty acid halide. A polymer layer is then applied onto the grafted MFC surface. This combination provides both good liquid and oxygen barrier properties, particularly at high humidity and temperature.

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14. Microfibrillated Cellulose Film with Fatty Acid Halide and Polymer Grafting Combined with Polymer Layer

STORA ENSO OYJ, 2021

Microfibrillated cellulose (MFC) film for packaging materials that maintains superior oxygen barrier properties under high humidity conditions. The film combines an MFC layer with a polymer layer, where the MFC layer is grafted with a fatty acid halide and a polymer. The MFC layer, which is naturally stable under moderate conditions, exhibits enhanced barrier performance at high humidity and temperature compared to conventional MFC films. The polymer layer enhances the barrier properties while maintaining stability.

15. Oxygen Barrier Film Fabrication via Controlled Fibrillation of Cellulose Microfibrils with Dual-Suspension Particle Size Distribution

STORA ENSO OYJ, 2021

Manufacturing oxygen barrier films through controlled fibrillation of cellulose microfibrils (MFCs) with optimized size distribution. The process involves creating a suspension of MFCs with a specific particle size distribution, where the first suspension comprises fibers with a median diameter between 25-35 μm, while the second suspension comprises fibers with a median diameter below 25 μm. This dual-suspension approach enables the formation of an MFC suspension with a balanced particle size distribution, which is then used to produce the oxygen barrier film. The film exhibits superior barrier properties, including low oxygen transmission rates and high strain at break, while maintaining its barrier integrity over time.

16. Gas Barrier Film with Fatty Acid Halide Grafted Microfibrillated Cellulose and Thermoplastic Polymer Coating

STORA ENSO OYJ, 2021

Gas barrier film for paper and paperboard packaging materials that provides improved oxygen barrier properties at high relative humidity compared to traditional barriers. The film has a microfibrillated cellulose (MFC) layer with one surface grafted with fatty acid halide. This is coated with a polymer layer containing a thermoplastic polymer like PE. The fatty acid halide graft improves the MFC barrier at high RH, and the polymer layer provides additional barrier. The polymer can have a tie layer between the MFC and polymer for adhesion. This film can replace aluminum in packaging like liquid cartons to provide stable oxygen barriers at high RH and humidity.

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17. Multilayer Packaging Material with Ethylene-Vinyl Alcohol-Copolymer Layer Exhibiting Controlled Block Character for Enhanced Oxygen Barrier Performance

KURARAY CO LTD, 2021

Multilayer packaging material exhibiting superior oxygen barrier performance through a novel copolymer-based solution. The material comprises a multilayer structure with a layer containing an ethylene-vinyl alcohol-copolymer with a block character of ethylene units in a particular range, and a production method that enables excellent viscosity stability even after long-term storage. The solution is prepared by controlling the polymerization conditions to achieve a block character of ethylene units less than 0.90, resulting in enhanced oxygen barrier performance.

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18. Thermoforming Film Container with Non-Stretched Polypropylene and Polyethylene Layers

Choi Jun-young, CHOI JOON YEONG, 2021

In-line thermoforming film container for food packaging that exhibits excellent oxygen and moisture barrier properties, has excellent physical rigidity and antibacterial properties, can maintain the freshness of food for a long time, and can inhibit bacterial spoilage. The container includes a non-stretched polypropylene (CPP) layer, a PE (polyethylene) layer positioned on the top of the non-stretched polypropylene (CPP; casting polypropylene) layer, and the PE (polyethylene) layer.

19. Barrier Film with Enzymatically Decomposed Microfibrillated Cellulose for Controlled Oxygen Transmission

STORA ENSO OYJ, 2020

A barrier film exhibiting superior oxygen transmission properties even at high relative humidity conditions through the controlled decomposition of microfibrillated cellulose during film formation. The film demonstrates improved barrier performance compared to conventional methods, maintaining its oxygen transmission rate even at relative humidity levels of 50% at 23°C and 85% at 38°C. This is achieved through the enzymatic decomposition of microfibrillated cellulose during film formation, which selectively targets and degrades the finer fibrillar structures while preserving the coarser elements.

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20. Multi-Layer Polypropylene Film with Gas Barrier and Adhesive Layers Featuring Polypropylene Terpolymer and Stretch-Induced Property Enhancement

LOTTE CHEMICAL CORP, 2020

Polypropylene-based food packaging film with excellent adhesion to containers, oxygen blocking, shrinkage, and clarity. The film has an inner layer with a polypropylene terpolymer, a gas barrier layer of EVOH, PVDC, or nylon, and a top layer with the same polypropylene terpolymer. An adhesive layer between the barrier and inner layers can contain a modified polypropylene. The film is stretched after coextrusion to enhance properties.

21. Multi-layer Film with Polyamide and Polyethylene Terephthalate Outer Layer, LLDPE and TiO2 Intermediate Layer, and Polyolefin Inner Layer

22. Multi-Layer Plastic Film with Polyolefin, Soft Polyether Copolymer, and EVOH Oxygen Barrier Layers

23. Fibrous-Based Film with Microfibrillated Cellulose and Oxygen Barrier Polymer Layers Coextruded on Cellulose Substrate

24. Flexible Oxygen Barrier Film with Prefabricated MFC Layer and Laminated Polyethylene and Oxygen Barrier Polymer Layers

25. Multilayer Barrier Film Comprising Microfibrillated and Dialdehyde Cellulose Suspensions

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