Multi-layer laminate structure

• US 20040209021A1
• Filed: 04/18/2003
• Published: 10/21/2004
• Est. Priority Date: 04/18/2003
• Status: Abandoned Application

• Current Assignee: International Paper Company
• Original Assignee: International Paper Company
• Inventors: Shih, Keith S.
• Application Number:
  US10/418,524
• Publication Number:
  US 20040209021A1
• Time in Patent Office: Days
• US Class Current: 428/34.2
• CPC Class Codes: B32B 2270/00 Resin or rubber layer containing a blend of at least two different polymers
• CPC Class Codes: B32B 2307/7242 Non-permeable
• CPC Class Codes: B32B 2439/70 Food packaging
• CPC Class Codes: B32B 27/10 of paper or cardboard
• CPC Class Codes: B32B 27/18 characterised by the use of special additives
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/34 comprising polyamides
• CPC Class Codes: C08L 23/04 Homopolymers or copolymers of ethene
• CPC Class Codes: C08L 23/0846 Copolymers of ethene with unsaturated hydrocarbons containing other atoms than carbon or hydrogen atoms
• CPC Class Codes: C08L 23/0876 Neutralised polymers, i.e. ionomers
• CPC Class Codes: C08L 23/0884 Epoxide containing esters
• CPC Class Codes: C08L 51/06 grafted on to homopolymers or copolymers of aliphatic hydrocarbons containing only one carbon-to-carbon double bond
• CPC Class Codes: Y10T 428/1303 Paper containing [e.g., paperboard, cardboard, fiberboard, etc.]

Abstract

A multi-layer structure for fabricating a beverage container having two or more layers comprising paperboard and at least one barrier layer formed of a blend of polyethylene, nylon and a compatibilizer selected from maleic anhydride modified polyethylene, zinc neutralized ethylene methacrylic acid, sodium neutralized ethylene methacrylic acid, ethylene acrylic acid copolymers, ethylene methacrylic acid copolymers and epoxy functionalized polyethylene. The containers or cartons made from the laminates containing the blend offer substantial heat resistance and exhibit superior abuse resistance. The method and process of making the blend and multi-layer structure are also disclosed.

Claims

1. Process for producing a compatibilized blend of polyethylene and nylon which comprises forming a mixture of polyethylene, nylon, and a compatibilizer which is a member selected from the group consisting of maleic anhydride modified polyethylene, zinc neutralized ethylene methacrylic acid, sodium neutralized ethylene methacrylic acid, ethylene methacrylic acid copolymers, ethylene acrylic acid copolymers and epoxy functionalized polyethylene and heating said mixture in an extruder to a temperature which is sufficient to form a homogeneous melt blend of said polyethylene, nylon and compatibilizer.

2. A process according to claim 1 which comprises forming said blend by separately introducing each of said polyethylene, nylon and compatibilizer into said extruder for forming said mixture in situ.

3. A process according to claim 1 which comprises forming said blend by dry mixing said polyethylene, nylon and compatibilizer prior to introduction into the extruder.

4. A compatibilized blend of polyethylene, nylon and a compatibilizer which is a member selected from the group consisting of maleic anhydride modified polyethylene, zinc neutralized ethylene methacrylic acid, sodium neutralized ethylene methacrylic acid, ethylene methacrylic acid copolymers, ethylene acrylic acid copolymers and epoxy functionalized polyethylene.

5. A compatibilized blend according to claim 4 wherein said polyethylene is a member selected from the group consisting of low density polyethylene, linear low density polyethylene, metallocene polyethylene and mixtures thereof.

6. A compatibilized blend according to claim 4 wherein said nylon is a member selected from the group consisting of nylon 6, nylon 7, nylon 8, nylon 11, nylon 12, nylon 6-6, nylon 6-9, nylon 6-10, copolymer of nylon 6 and nylon 6-6, amorphous nylon, MXD6 nylon, nylon nanoclay composite and mixtures thereof.

7. A compatibilized blend according to claim 4 wherein said nylon is nylon 6.

8. A compatibilized blend according to claim 4 wherein said polyethylene is low density polyethylene and said nylon is nylon 6.

9. A compatibilized blend according to claim 4 wherein said compatibilizer is present in said blend in an amount of about 0.1 wt. % to about 15 wt. %.

10. A compatibilized blend according to claim 4 wherein said blend contains less than about 40 wt. % of said polyethylene.

11. A compatibilized blend according to claim 4 wherein said blend contains more than about 60 wt. % of said nylon.

12. A compatibilized blend according to claim 4 wherein said compatibilizer is present in an amount of about 0.1 wt. % to about 15 wt. % said polyethylene is present in an amount of less than about 40 wt. % and said nylon is present in an amount of more than about 60 wt. %.

13. A multi-layer laminate material having two or more layers comprising at least one layer comprising a compatibilized blend according to claim 4.

14. A laminated material comprising a paperboard substrate and a layer formed of a compatibilized blend according to claim 4 deposited on one surface of the paperboard.

15. A beverage container comprising a multi-layered structure comprising a paperboard substrate and at least one barrier layer formed of a compatibilized blend according to claim 4.

16. A beverage container according to claim 15 wherein said barrier layer is deposited on one surface of said paperboard.