Containers comprising a closed cell foam layer

Abstract

In preferred embodiments there are provided containers such as bottles comprising at least one layer made from a foamable material comprising a polymeric carrier material and microspheres which expand during heat treatment to form the foam. The articles may be mono and multilayer. The articles can be formed by various methods.

1 . A bottle comprising
 a neck portion adapted to engage a closure; and   a body portion comprising a first layer and a second layer, the second layer comprising an expandable material comprising a polymer material and microspheres that enlarge during heat treatment, the first layer positioned interior to the second layer,   wherein the microspheres are partially and/or fully expanded.   
   
   
       2 . The bottle of  claim 1 , wherein the first layer comprises a material suitable for contacting foodstuffs. 
   
   
       3 . The bottle of  claim 1 , wherein the first layer comprises a material including at least one material selected from a group consisting of polyester, polypropylene, phenoxy-type thermoplastic, and combinations thereof. 
   
   
       4 . The bottle of  claim 1 , wherein the polymer material of the expandable material comprises polyethylene, post-consumer PET and/or recycled PET. 
   
   
       5 . The bottle of  claim 1 , wherein the expandable material is configured to expand to form foam when heated above an expansion temperature. 
   
   
       6 . The bottle of  claim 1 , wherein the expandable material comprises about 5% to about 60% by weight of the preform. 
   
   
       7 . The bottle of  claim 1 , wherein the neck portion consists of the same material as the first layer. 
   
   
       8 . The bottle of  claim 1 , further comprising a barrier layer comprising barrier material having a permeability to oxygen and carbon dioxide which is less than that of polyethylene terephthalate. 
   
   
       9 . The bottle of  claim 8 , wherein the barrier layer forms at least a portion of the body portion of the bottle. 
   
   
       10 . A bottle comprising:
 a neck portion; and   a body portion comprising:
 an inner layer comprising polyester; and 
 an outer layer comprising foam material, the foam material comprising a polymer material and microspheres that enlarge during heat treatment, wherein the microspheres are partially and/or fully expanded. 
   
   
   
       11 . The bottle of  claim 10 , wherein the inner layer comprises polyethylene terephthalate. 
   
   
       12 . The bottle of  claim 10 , wherein the polymer material of the outer layer comprises recycled or post-consumer polyethylene terephthalate. 
   
   
       13 . The bottle of  claim 10 , wherein the neck portion is configured to receive a closure. 
   
   
       14 . The bottle of  claim 10 , wherein the bottle is made by blow molding a preform having a neck finish and preform body portion.