Method of improving the environmental stretch crack resistance of RPET without solid stating

Abstract

Blends of non-solid stated RPET and an amount of PEN and/or NDC less than about 10 percent by weight are used as at least one layer of an article, such as a container or a preform for blow molding a container, having an inner layer of a thermoplastic material. The addition of the small amount of PEN and/or NDC allows the direct use of RPET without solid stating, and provides articles having environmental stretch crack resistance, color, and organoleptic properties comparable to that of virgin PET.

1 . A multi-layered article comprising: 
 an inner layer comprising a thermoplastic material; and    a second layer comprising non-solid stated RPET and PEN and/or NDC, wherein the PEN and/or NDC is present in an amount of less than about  10  percent by weight of the second layer.    
     
     
         2 . The article according to  claim 1 , wherein the article is a container or a preform for blow molding a container.  
     
     
         3 . The article according to  claim 1 , wherein the thermoplastic material in the inner layer is virgin PET.  
     
     
         4 . The article according to  claim 1 , wherein the RPET is present in at least one additional layer in an amount greater than 90 percent by weight.  
     
     
         5 . The article according to  claim 1 , further comprising at least one barrier layer positioned between the inner thermoplastic layer and the second layer or positioned outside the second layer.  
     
     
         6 . The article according to  claim 5 , wherein the barrier layer adheres to an outer surface of the inner layer.  
     
     
         7 . The article according to  claim 5 , wherein the barrier layer comprises at least one of a thermoplastic epoxy-type, a phenoxy-type, and a poly(hydroxyamino ether) material.  
     
     
         8 . The article according to  claim 5 , wherein the thermoplastic epoxy-type is a poly(hydroxyamino ether).  
     
     
         9 . The article according to  claim 1 , wherein the PEN and/or NDC is present in the second layer in an amount of from about 0.001 to less than about 10 percent by weight of the second layer.  
     
     
         10 . The article according to  claim 1 , wherein the PEN and/or NDC is present in an amount of from about 1 to about 4.5 percent by weight of the second layer.  
     
     
         11 . The article according to  claim 1 , wherein the PEN and/or NDC is present in an amount of from about 3 to about 4 percent by weight of the second layer.  
     
     
         12 . A method of forming a multilayer article, the method comprising: 
 obtaining an inner layer of the article;    obtaining a blend comprising non-solid stated RPET and PEN and/or NDC, wherein the PEN and/or NDC is present in an amount of less than about 10 percent by weight of the blend;    forming at least one layer comprising the blend; and    positioning the blend around at least a portion of the inner layer to form at least a portion of the article.    
     
     
         13 . The method according to  claim 12 , wherein the PEN and/or NDC is present in an amount of from about 0.5 to about 10 percent by weight of the blend.  
     
     
         14 . The method according to  claim 12 , wherein the PEN and/or NDC is present in an amount of from about 1 to about 5 percent by weight of the blend.  
     
     
         15 . The method according to  claim 12 , wherein the article is a container or a preform for forming a container.  
     
     
         16 . The method according to  claim 12 , wherein the inner layer comprises virgin PET.  
     
     
         17 . The method according to  claim 12 , wherein the inner layer is obtained by molding a thermoplastic material.  
     
     
         18 . The method according to  claim 12 , wherein the inner layer is obtained by injection molding a thermoplastic material.  
     
     
         19 . The method according to  claim 12 , wherein forming the layer comprising the blend comprises injection molding the blend around the inner layer.  
     
     
         20 . The method according to  claim 12 , further comprising forming at least one layer comprising a gas barrier material between the inner thermoplastic layer and the second layer or outside the second layer.  
     
     
         21 . The method according to  claim 20 , wherein the gas barrier material comprises at least one of a thermoplastic epoxy-type, a phenoxy-type, and a poly(hydroxyamino ether) material.  
     
     
         22 . The method according to  claim 21 , wherein the gas barrier material is a poly(hydroxyamino ether) material.  
     
     
         23 . A container or preform for blow molding a container, comprising: 
 a molded inner layer comprising virgin PET; and    a second molded layer positioned around at least a portion of the inner layer, wherein the second layer comprises non-solid stated RPET and an amount of PEN and/or NDC of less than about 10 percent by weight of the second layer.    
     
     
         24 . A method of making a container or a preform, comprising: 
 molding a first layer comprising virgin PET;    forming a blend comprising non-solid stated RPET and PEN and/or NDC, wherein the PEN and/or NDC is present in an amount of less than about 10 percent by weight; and    molding at least one layer comprising the blend around at least a portion of the inner layer to form at least a portion of the container or preform.