Recycled crosslinked vinyl-alcohol polymer coated films and methods to manufacture the same

• US 8,795,811 B2
• Filed: 06/29/2012
• Issued: 08/05/2014
• Est. Priority Date: 06/29/2012
• Status: Active Grant

• Current Assignee: Toray Plastics (America), Inc. (Toray Industries Incorporated)
• Original Assignee: Toray Plastics (America), Inc. (Toray Industries Incorporated)
• Inventors: Cloutier, Joshua R., Dou, Shichen, Paulino, Claudio, Jung, Chang Yeol
• Primary Examiner(s): Sample, David
• Assistant Examiner(s): Gugliotta, Nicole T
• Application Number:
  US13/538,092
• Publication Number:
  US 20140004301A1
• Time in Patent Office: 767 Days
• Field of Search: None
• US Class Current: 428/141
• CPC Class Codes: B32B 2255/10 on synthetic resin layer or on natural or synthetic rubber layer
• CPC Class Codes: B32B 2255/205 Metallic coating
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2270/00 Resin or rubber layer containing a blend of at least two different polymers
• CPC Class Codes: B32B 2272/00 Resin or rubber layer comprising scrap, waste or recycling material
• CPC Class Codes: B32B 2307/31 Heat sealable
• CPC Class Codes: B32B 2307/514 Oriented
• CPC Class Codes: B32B 2307/7244 Oxygen barrier
• CPC Class Codes: B32B 2307/7248 Odour barrier
• CPC Class Codes: B32B 2439/70 Food packaging
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/30 comprising vinyl (co)polymers; comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: C08K 5/07 Aldehydes; Ketones
• CPC Class Codes: C08L 2205/02 containing two or more polymers of the same C08L -group
• CPC Class Codes: C08L 29/04 Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
• CPC Class Codes: C09D 129/04 Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
• CPC Class Codes: Y10T 428/24355 Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]

Abstract

Embodiments herein relate to a polyolefin-containing film comprising a solidified form of a melt, the melt comprising at least 1 weight percent shredded recycled crosslinked vinyl-alcohol polymer coated polyolefin material and an amount of a compatibilizing agent and/or an un-crosslinking agent configured to un-crosslink the crosslinked vinyl-alcohol in the melt, the polyolefin-containing film having an average dimple count of less than about 50 dimples/4 in², and method of manufacturing the same.

Claims

1. A polyolefin-containing film comprising a solidified form of a melt, the melt comprising at least 1 weight percent shredded recycled crosslinked vinyl-alcohol polymer coated polyolefin material and an amount of an un-crosslinking agent configured to un-crosslink the crosslinked vinyl-alcohol in the melt, the polyolefin-containing film having an average dimple count of less than about 50 dimples/4 in².

2. The polyolefin-containing film of claim 1, wherein the polyolefin-containing film has an average dimple count of about 30 dimples/4 in².

3. The polyolefin-containing film of claim 1, wherein the melt contains at least 5 weight percent of the shredded recycled crosslinked vinyl-alcohol polymer coated polyolefin material.

4. The polyolefin-containing film of claim 1, wherein the compatibilizing agent comprises polyethylene grafted or copolymers that contain ester or acetate groups.

5. The polyolefin-containing film of claim 1, wherein the un-crosslinking agent comprises water.

6. The polyolefin-containing film of claim 1, wherein the shredded recycled crosslinked vinyl-alcohol polymer coated polyolefin material comprises both water and the compatibilizing agent.

7. The polyolefin-containing film of claim 1, wherein the melt comprises 1 to 10 parts by weight of the compatibilizing agent and/or 1 to 10 parts by weight of the un-crosslinking agent for 100 parts of the shredded recycled crosslinked vinyl-alcohol polymer coated polyolefin material.

8. The polyolefin-containing film of claim 1, wherein the vinyl-alcohol coated polymer comprises PVOH, EVOH, or blends thereof.

9. The polyolefin-containing film of claim 8, wherein the EVOH contains 10% ethylene or less.

10. A laminate film comprising the polyolefin-containing film of claim 1 and a metal-containing layer.

11. The polyolefin-containing film of claim 1, further comprising a compatibilizing agent.

12. A laminate film comprising the polyolefin-containing film of claim 11 and a metal-containing layer.

13. A polyolefin-containing film comprising a solidified form of a melt, the melt comprising at least 1 weight percent shredded recycled crosslinked vinyl-alcohol polymer coated polyolefin material and an amount of an un-crosslinking agent configured to un-crosslink the crosslinked vinyl-alcohol in the melt, wherein the polyolefin-containing film does not contain a compatibilizing agent, the polyolefin-containing film having an average dimple count of less than about 50 dimples/4 tn².

15. The polyolefin-containing film of claim 13, wherein the melt contains at least 5 weight percent of the shredded recycled crosslinked vinyl-alcohol polymer coated polyolefin material.

16. A laminate film comprising the polyolefin-containing film of claim 13 and a metal-containing layer.

14. A polyolefin-containing film comprising a solidified form of a melt, the melt comprising at least 1 weight percent shredded recycled crosslinked vinyl-alcohol polymer coated polyolefin material and an amount of an un-crosslinking agent configured to un-crosslink the crosslinked vinyl-alcohol in the melt, the polyolefin-containing film having an average dimple count of less than about 50 dimples/4 in².

17. The polyolefin-containing film of claim 14, wherein the melt contains at least 5 weight percent of the shredded recycled crosslinked vinyl-alcohol polymer coated polyolefin material.

18. A laminate film comprising the polyolefin-containing film of claim 14 and a metal-containing layer.