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Journal of Polymer & Composites Original Research

Performance Enhancement of COC-Modified LLDPE Films: Optimization of Stiffness, Tear Resistance, and Barrier through Plasma Surface Modification

  1. Hetal Shah Department of Plastic Technology, L.D College of Engineering, Ahmedabad
  2. Purvi Dave Facilitation Centre for Industrial Plasma Technologies (FCIPT), Institute for Plasma Research, Bhat, Gandhinagar
  3. Sudhir Kumar Nema Facilitation Centre for Industrial Plasma Technologies (FCIPT), Institute for Plasma Research, Bhat, Gandhinagar

Abstract

This study explores the development of high-performance packaging materials by blending commodity Linear Low-Density Polyethylene (LLDPE) with engineering cyclic olefin copolymer (COC) as a performance modifier. To leverage the processability of LLDPE alongside the structural rigidity of COC, blends were prepared at various weight ratios (95/05, 90/10, 85/15, and 80/20) using twin-screw melt extrusion, followed by the production of films and sheets via blown film extrusion and compression molding. The addition of COC significantly improved the mechanical properties of the LLDPE matrix; specifically, the tensile modulus increased three-fold with 10 wt% COC and five-fold with 20 wt% loading. While the inherent gas barrier properties of the films—measured through the Oxygen Transmission Rate (OTR) and Water Vapor Transmission Rate (WVTR)—improved with the addition of high-density COC domains, further optimization was achieved through surface modification. Thin organosilicon coatings were deposited onto 5 and 10 wt% COC blend films using plasma-enhanced chemical vapor deposition (PECVD) with hexamethyldisiloxane (HMDSO) and oxygen precursors. These PECVD coatings led to a substantial reduction in both the OTR and WVTR. As compared to uncoated L90C10 film, about 34% reduction in OTR and 43% reduction in WVTR is observed in SiOx coated L90C10 film. Scanning electron microscopy (SEM) confirmed the partial compatibility and interfacial adhesion between the COC phase and LLDPE matrix, providing a structural explanation for the enhanced mechanical and barrier properties. The findings indicate that LLDPE/COC blends, especially when enhanced by plasma surface treatments, represent a high-performance solution for the food, pharmaceutical, and industrial packaging applications.

Keywords

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