Melt processable composition from recycled multi-layer articles containing a fluoropolymer layer

Abstract

The invention relates to a composition that has been obtained by the melt-process recycling of one or more multi-layer articles, where the multi-layer articles are composed of at least one melt-processible fluoropolymer layer. The composition of the invention is a compatible blend of the different layers from the multi-layer articles. The other layers of the multi-layer articles are also melt-processible, and include one or more layers chosen from: a) a melt-processible fluoropolymer of a different composition, b) a non-fluoropolymer, and c) a barrier layer. The composition is useful for forming an article in a melt-process operation. The composition may be used by itself, may be blended with other virgin or recycled materials, or may be used at low levels with melt-processible polymers as a process aid.

1 . A melt processible polymer composition comprising a compatible melt blend formed from one or more recycled multi-layer articles, wherein said multi-layer article comprises at least one melt-processible fluoropolymer layer. 
     
     
         2 . The polymer composition of  claim 1 , wherein said multi-layer article further comprises at least one other layer comprising a melt-processible fluoropolymer having a different chemical composition form the first fluoropolymer layer. 
     
     
         3 . The polymer composition of  claim 1 , wherein said at least one melt-processible fluoropolymer layer comprises a polyvinylidene fluoride (PVDF) homopolymer or copolymer. 
     
     
         4 . The polymer composition of  claim 2 , wherein all fluoropolymer layers consist of a PVDF homopolymer or copolymer. 
     
     
         5 . The polymer composition of  claim 1 , wherein said multi-layer article further comprises at least one non-fluoropolymer layer. 
     
     
         6 . The polymer composition of  claim 5 , wherein at least one non-fluoropolymer layer is selected from the group consisting of TPE (thermoplastic elastomer); thermoplastic vulcanates (TPV); thermoplastic olefins (TPO); thermoplastic vulcanates (TPV) containing grafted or reacted functional groups; thermoplastic vulcanates that are polyamide based (PA based); thermoplastic vulcanates that are thermoplastic polyester elastomer based; acrylate rubbers; thermoplastic polyurethanes (TPU) based on either polyesters or polyethers; polyesters and copolyesters; polyamides and copolyamides; silicones; neoprene; nitrile rubber; butyl rubber; polyamides, polyolefins; and chlorinated vinyls. 
     
     
         7 . The polymer composition of  claim 1 , wherein said multi-layer article further comprises at least one barrier layer. 
     
     
         8 . The polymer composition of  claim 7 , wherein said barrier layer is ethylene vinyl alcohol (EVOH) or poly(vinyl alcohol). 
     
     
         9 . The polymer composition of  claim 1  comprising 1 to 100 weight percent fluoropolymer, 0 to 40 weight percent of a barrier polymer, and 0 to 99 weight percent of a non-fluoropolymer, the total adding to 100 percent. 
     
     
         10 . The polymer composition of  claim 9  comprising 20 to 90 weight percent fluoropolymer, 5 to 25 weight percent of a barrier polymer, and 25 to 75 weight percent of a non-fluoropolymer, the total adding to 100 percent. 
     
     
         11 . The polymer composition of  claim 10  comprising 25 to 70 weight percent fluoropolymer, 5 to 25 weight percent of a barrier polymer, and 25 to 75 weight percent of a non-fluoropolymer, the total adding to 100 percent. 
     
     
         12 . The polymer composition of  claim 1 , wherein said recycled multi-layer article(s) comprise at least one disposable manufacturing system used in biomedical or pharmaceutical production. 
     
     
         13 . The polymer composition of  claim 1 , wherein said polymer composition further comprises, in addition to said recycled multi-layered articles from 5 to 50 weight percent of one or more other melt-processible polymers compatible with said recycled multi-layered articles. 
     
     
         14 . The polymer composition of  claim 1  comprising polyvinylidene fluoride (PVDF) homopolymer or copolymer, and thermoplastic polyurethane (TPU). 
     
     
         15 . The polymer composition of  claim 14 , further comprising ethylene vinyl alcohol (EVOH) barrier polymer. 
     
     
         16 . A polymer article formed by a heat processing operation comprising the polymer composition of  claim 1 . 
     
     
         17 . The polymer article of  claim 16 , wherein said polymer composition comprises the recycled melt blend as a process aid in a matrix polymer, wherein the fluoropolymer weight percent in the article is from 0.05 to 20 weight percent. 
     
     
         18 . The polymeric article of  claim 17 , wherein said matrix polymer is selected from the group consisting of a polyvinyl chloride (PVC), polycarbonate (PC), polyamide or copolyamide, polycarbonate/polyester blends, thermoplastic urethanes (TPU) and polyolefins. 
     
     
         19 . A process for forming a polymeric article from a recycled multi-layer structure comprising the steps of
 a. forming a multi-layer article, having each layer adhered to the adjoining layer(s), wherein said multi-layer structure comprises an inner fluoropolymer layer, and at least one other layer chemically different from the fluoropolymer inner layer,   b. washing and/or sterilizing the multi-layer structure   c. grinding the washed and/or sterilized multi-layer structure into small pieces or flakes;   d. cleaning the pieces or flakes to remove non-polymeric materials and other contaminants;   e. Optionally screening or sizing the flakes or pieces, and regrinding if needed to obtain the desired average particle size;   f. mixing or blending the flakes or small particles;   g. melting the flakes or small particles   h. extruding the melted flakes or small particles into pellets directly into final articles; and   i. thermoforming the pellets into final articles.   
     
     
         20 . The process of  claim 19 , wherein the multi-layer of step a) further comprises a barrier layer of ethylene vinyl alcohol (EVOH) or poly(vinyl alcohol) (PVOH), and at least one elastomeric non-fluoropolymer layer.