US2003141625A1PendingUtilityA1

Process for forming a multilayer coextruded article and articles therefrom

41
Priority: Aug 20, 1998Filed: Feb 21, 2003Published: Jul 31, 2003
Est. expiryAug 20, 2018(expired)· nominal 20-yr term from priority
Inventors:Marcus David ShelbyLavonna BuehrigBenjamin Gamble
B29C 2948/92761B29C 2948/92666B29C 2948/92695B29C 48/023B29C 45/1642B29C 2948/9259B29C 2948/92152B29C 48/07B29C 2948/92266B29C 2948/92704B29C 2948/922B29C 2948/92485B29C 45/16B29C 48/12B29C 2948/92904B29C 2948/9279B29C 2948/92133B29C 48/92B29C 48/18B29C 2948/926B29C 45/1643B29C 48/09B29C 2948/92809
41
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Claims

Abstract

A process for coextrusion-molding a multilayer article comprising coextruding at a selected coextuding temperature (i) a first outer polymer resin layer having a) a viscosity, b) a melting temperature, and c) a degradation temperature at the selected coextuding temperature, and (ii) a second inner polymer resin layer having a) a viscosity, b) a melting temperature, and c) a degradation temperature at the selected coextuding temperature, wherein the ratio of the outer polymer resin viscosity to the inner polymer resin viscosity at the coextuding temperature is less than or equal to about 1 and the coextuding temperature is above the melting temperature of the highest melting resin and below the degradation temperature of the lowest degrading resin to form a multilayer article.

Claims

exact text as granted — not AI-modified
What is claimed is:  
     
         1 . A process for coextruding a multilayer article comprising coextruding at a selected coextruding temperature: 
 (i) a first outer polymer resin layer comprising at least one outer layer polymer resin having at the selected coextruding temperature: a) a viscosity; b) a melting temperature; and c) a degradation temperature; and    (ii) a second inner polymer resin layer comprising at least one inner layer polymer resin having at the selected coextruding temperature: a) a viscosity; b) a melting temperature; and c) a degradation temperature;    wherein the ratio of the outer layer polymer resin viscosity to the inner layer polymer resin viscosity at the coextruding temperature is less than or equal to about 1, and wherein the coextruding temperature is above the melting temperature of the highest melting resin and below the degradation temperature of the lowest degrading resin to form a multilayer article.    
     
     
         2 . The process of  claim 1 , wherein component (i) has an elasticity, component (ii) has an elasticity, and the ratio of the component (i) elasticity to the component (ii) elasticity at the coextruding temperature is approximately the reciprocal of the viscosity ratio.  
     
     
         3 . The process of  claim 1 , wherein component (i) comprises at least one performance polymer resin having an elasticity at the selected coextruding temperature.  
     
     
         4 . The process of  claim 1 , wherein component (ii) comprises at least one structural polymer resin having an elasticity at the selected coextruding temperature.  
     
     
         5 . The process of  claim 1 , wherein component (ii) comprises at least one performance polymer resin having an elasticity at the selected coextruding temperature.  
     
     
         6 . The process of  claim 1 , wherein component (i) comprises at least one structural polymer resin having an elasticity at the selected coextruding temperature.  
     
     
         7 . The process of  claim 1 , wherein component (i) or (ii) is a barrier resin.  
     
     
         8 . The process of  claim 1 , wherein component (i) or (ii) comprises a polyamide or a copolymer thereof, an ethylene-vinyl acetate copolymer (EVOH), a polyalcohol ether, a wholly aromatic polyester, a resorcinol diacetic acid-based copolyester, a polyalcohol amine, an isophthalate-containing polyester, poly(ethylene naphthalate) or a copolymer thereof, or a mixture thereof.  
     
     
         9 . The process of  claim 8 , wherein the polyamide comprises a partially aromatic polyamide, an aliphatic polyamide, a wholly aromatic polyamide, or a mixture thereof.  
     
     
         10 . The process of  claim 1 , wherein component (i) or (ii) comprises a saponified ethylene-vinyl acetate copolymer (EVOH).  
     
     
         11 . The process of  claim 1 , wherein component (i) or (ii) comprises a polyester.  
     
     
         12 . The process of  claim 1 , wherein component (ii) comprises a polyester.  
     
     
         13 . The process of  claim 12 , wherein the polyester is a homopolymer or a copolymer.  
     
     
         14 . The process of  claim 1 , wherein component (i) or (ii) comprises an aromatic polyester comprising a repeat unit of terephthalic acid, dimethyl terephthalate, isophthalic acid, dimethyl isophthalate, dimethyl-2,6 naphthalenedicarboxylate, 2,6-naphthalenedicarboxylic acid, 1,2-, 1,3- and 1,4-phenylene dioxydoacetic acid, ethylene glycol, diethylene glycol, 1,4-cyclohexanedimethanol (1,4-CHDM), 1,4-butanediol, neopentyl glycol or a mixture thereof.  
     
     
         15 . The process of  claim 1 , wherein component (i) or (ii) comprises poly(ethylene terephthalate) or a copolymer thereof.  
     
     
         16 . The process of  claim 2 , wherein the ratio of the outer polymer resin viscosity to the inner polymer resin viscosity at the coextruding temperature and the ratio of the outer polymer resin elasticity to the inner polymer resin elasticity at the coextruding temperature are approximately 1.  
     
     
         17 . The process of  claim 2 , wherein the ratio of the outer polymer resin viscosity to the inner polymer resin viscosity at the coextruding temperature is less than or equal to about 1 and greater than or equal to about 0.5 and the ratio of the outer polymer resin elasticity to the inner polymer resin elasticity is approximately the reciprocal of the viscosity ratio.  
     
     
         18 . The process of  claim 1 , wherein component (i) comprises an ethylene-vinyl acetate copolymer (EVOH), component (ii) comprises poly(ethylene terephthalate) or a copolymer thereof, and the ratio of the outer polymer resin viscosity to the inner polymer resin viscosity and the ratio of the outer polymer resin elasticity to the inner polymer resin elasticity at the coextruding temperature is approximately 1.  
     
     
         19 . A multilayer article produced by the process of  claim 1 .  
     
     
         20 . The article of  claim 19  in the form of a film, sheet, tube, pipe, profile, preform, or container.  
     
     
         21 . A process for coextruding a 5-layer article comprising coextruding at a selected coextruding temperature: 
 (i) two outer polymer resin layers each comprising an outer layer polymer resin having at the selected coextruding temperature: a) a viscosity; b) a melting temperature; and c) a degradation temperature;    (ii) two intermediate polymer resin layers disposed between a core layer and the two outer layers, the two intermediate resin layers each comprising an intermediate layer polymer resin having at the selected coextruding temperature: a) a viscosity; b) a melting temperature; and c) a degradation temperature; and    (iii) a core layer comprising a core layer polymer resin having at the selected coextruding temperature: a) a viscosity; b) a melting temperature; and c) a degradation temperature;    wherein at each polymer resin interface the ratio of the outermost polymer resin viscosity to the next innermost polymer resin viscosity at the coextruding temperature is less than or equal to about 1 and the coextruding temperature is above the melting temperature of the highest melting resin and below the degradation temperature of the lowest degrading resin to form a 5-layer article.    
     
     
         22 . The process of  claim 21 , wherein at each interface of the five layers the ratio of the outermost polymer resin viscosity to the next innermost polymer resin viscosity at the coextruding temperature is less than or equal to about 1 and greater than or equal to about 0.5.  
     
     
         23 . The process of  claim 21 , wherein components (i), (ii) and (iii) have an elasticity at the coextruding temperature, and the ratio of the outermost polymer resin elasticity to the next innermost polymer resin elasticity at the coextruding temperature is approximately the reciprocal of the viscosity ratio.  
     
     
         24 . The process of  claim 21 , wherein component (i) comprises a structural polymer resin.  
     
     
         25 . The process of  claim 21 , wherein component (ii) comprises a structural polymer resin.  
     
     
         26 . The process of  claim 21 , wherein component (ii) comprises a performance polymer resin.  
     
     
         27 . The process of  claim 21 , wherein component (iii) comprises a structural polymer resin.  
     
     
         28 . The process of  claim 21 , wherein component (iii) comprises a performance polymer resin.  
     
     
         29 . The process of  claim 21 , wherein component (i) comprises a structural polymer resin having a structural resin elasticity, component (ii) comprises a structural polymer resin having a structural resin elasticity, and component (iii) comprises at least one performance polymer resin having a performance resin elasticity, and at each interface of the five layers the ratio of the outermost polymer resin elasticity to the next innermost polymer resin elasticity at the coextruding temperature is approximately the reciprocal of the viscosity ratio.  
     
     
         30 . The process of  claim 21 , wherein components (i) and (ii) comprise a polyester.  
     
     
         31 . The process of  claim 21 , wherein components (i) and (ii) comprise an aromatic polyester comprising repeat units of terephthalic acid, dimethyl terephthalate, isophthalic acid, dimethyl isophthalate, dimethyl-2,6 naphthalenedicarboxylate, 2,6-naphthalenedicarboxylic acid, 1,2-, 1,3- or 1,4-phenylene dioxydoacetic acid, ethylene glycol, diethylene glycol, 1,4-cyclohexanedimethanol (1,4-CHDM), 1,4-butanediol, neopentyl glycol or mixtures thereof.  
     
     
         32 . The process of  claim 21  wherein component (i) comprises poly(ethylene terephthalate) or a copolymer thereof.  
     
     
         33 . The process of  claim 21 , wherein component (ii) comprises poly(ethylene terephthalate) regrind.  
     
     
         34 . The process of  claim 21 , wherein component (iii) is a barrier resin.  
     
     
         35 . The process of  claim 21 , wherein component (iii) comprises a polyamide or a copolymer thereof, an ethylene-vinyl acetate copolymer (EVOH), a polyalcohol ether, a wholly aromatic polyester, a resorcinol diacetic acid-based copolyester, a polyalcohol amine, an isophthalate-containing polyester, poly(ethylene naphthalate) or a copolymer thereof, or a mixture thereof.  
     
     
         36 . The process of  claim 35 , wherein the polyamide comprises a partially aromatic polyamide, an aliphatic polyamide, a wholly aromatic polyamide, or a mixture thereof.  
     
     
         37 . The process of  claim 21 , wherein component (iii) comprises a saponified ethylene-vinyl acetate copolymer (EVOH) or poly(m-xylylene adipamide).  
     
     
         38 . The process of  claim 21 , wherein component (i) comprises poly(ethylene terephthalate) or a copolymer thereof, component (ii) comprises poly(ethylene terephthalate) regrind and component (iii) comprises poly(m-xylylene adipamide), and at each polymer resin interface the ratio of the outermost polymer resin viscosity to the next innermost polymer resin viscosity at the coextruding temperature is less than or equal to about 1.  
     
     
         39 . A 5-layer article produced by the process of  claim 21 .  
     
     
         40 . The article of  claim 39  in the form of a film, sheet, tube, pipe, profile, preform, or container.

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