Mono and Multi-Layer Articles and Injection Molding Methods of Making the Same

Abstract

In preferred embodiments methods and apparatuses can produce articles that have expandable thermoplastic material. The articles may be mono- and multilayer. The articles can be formed by various methods.

What is claimed is: 
     
         1 . A method for making an overmolded container comprising:
 providing a preform for a container, the preform comprising a thermoplastic polymer;   overmolding an expandable thermoplastic overmold material over at least a portion of the preform to form an overmolded preform; and   blow molding the overmolded preform to form an overmolded container.   
     
     
         2 . The method of  claim 1 , wherein the expandable thermoplastic overmold material inhibits heat transfer through the walls of the container. 
     
     
         3 . The method of  claim 1 , wherein the expandable thermoplastic overmold material comprises plastic. 
     
     
         4 . The method of  claim 1 , wherein the expandable thermoplastic overmold material is crosslinked. 
     
     
         5 . The method of  claim 1 , wherein the overmolded container is a beverage container. 
     
     
         6 . The method of  claim 1 , wherein the thermoplastic polymer comprises a polyester. 
     
     
         7 . The method of  claim 6 , wherein the thermoplastic polymer comprises a polyethylene terephthalate copolymer. 
     
     
         8 . The method of  claim 1 , wherein the overmold material is selected from ethylene acrylic acid, ethylene vinyl acetate, linear low density polyethylene, polyethylene, and polypropylene. 
     
     
         9 . The method of  claim 1 , wherein the overmold material is selected from the group consisting of a polyolefin, a modified polyolefin, and combinations thereof. 
     
     
         10 . The method of  claim 1 , wherein the overmold material is selected from the group consisting of acrylic-olefin copolymer, polyester, and combinations thereof. 
     
     
         11 . The method of  claim 1 , wherein the overmold material has a density less than 1.00 g/cc. 
     
     
         12 . The method of  claim 1 , wherein the overmold material further comprises one or more additives. 
     
     
         13 . The method of  claim 12 , wherein the one or more additives are selected from the group consisting of a colorant, a UV protection additive, a lubricant, a thermal stabilizer, an antioxidant, and combinations thereof. 
     
     
         14 . The method of  claim 1 , wherein the blow molding process comprises preheating the overmolded preform and then stretch blow molding the preheated preform. 
     
     
         15 . The method of  claim 1 , wherein the overmolded material covers a majority of the outer surface of the overmolded container. 
     
     
         16 . A blow molded container produced by the method of  claim 1 . 
     
     
         17 . A packaged beverage comprising the blow molded bottle of  claim 16  and a beverage disposed inside the bottle. 
     
     
         18 . A method for recycling an overmolded container comprising:
 providing the container of  claim 16 ; and   separating the overmolded layer from the container body.   
     
     
         19 . The method of  claim 18 , wherein the separating process comprises recycling of the container. 
     
     
         20 . An overmolded preform comprising:
 a thermoplastic polymer preform suitable for blow molding into a bottle; and   an overmold material, which comprises a crosslinked thermoplastic material, overmolded over at least a portion of the preform.