Multilayer structures having annular profiles

• US 9,481,143 B2
• Filed: 10/18/2013
• Issued: 11/01/2016
• Est. Priority Date: 02/21/2009
• Status: Active Grant

• Current Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Original Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Inventors: Dooley, Joseph, Robacki, Jeffrey M., Barger, Mark A., Wrisley, Robert E., Crabtree, Sam L., Pavlicek, Calvin L.
• Primary Examiner(s): Sample, David
• Assistant Examiner(s): Flores, Jr., Donald M
• Application Number:
  US14/057,717
• Publication Number:
  US 20140044906A1
• Time in Patent Office: 1,110 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: B29C 48/0017 combined with blow-moulding or thermoforming
• CPC Class Codes: B29C 48/0018 combined with shaping by orienting, stretching or shrinking, e.g. film blowing B29C48/0017 takes precedence
• CPC Class Codes: B29C 48/09 Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
• CPC Class Codes: B29C 48/10 flexible, e.g. blown foils
• CPC Class Codes: B29C 48/12 Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
• CPC Class Codes: B29C 48/185 comprising six or more components, i.e. each component being counted once for each time it is present, e.g. in a layer
• CPC Class Codes: B29C 48/19 the layers being joined at their edges
• CPC Class Codes: B29C 48/21 the layers being joined at their surfaces
• CPC Class Codes: B29C 48/22 with means connecting the layers, e.g. tie layers or undercuts
• CPC Class Codes: B29C 48/255 Flow control means, e.g. valves flow dividers B29C48/695
• CPC Class Codes: B29C 48/335 Multiple annular extrusion nozzles in coaxial arrangement, e.g. for making multi-layered tubular articles
• CPC Class Codes: B29C 48/3363 using a layered die, e.g. stacked discs
• CPC Class Codes: B29C 48/34 Cross-head annular extrusion nozzles, i.e. for simultaneously receiving moulding material and the preform to be coated
• CPC Class Codes: B29C 48/495 Feed-blocks extrusion moulding of multi-component articles B29C48/16
• CPC Class Codes: B29C 48/71 for layer multiplication extrusion of multi-component articles B29C48/16
• CPC Class Codes: B29C 49/04 Extrusion blow-moulding
• CPC Class Codes: B29C 49/22 using multilayered preforms or parisons
• CPC Class Codes: B29C 55/28 of blown tubular films, e.g. by inflation extrusion moulding of tubular films B29C48/03
• CPC Class Codes: B29L 2023/001 Tubular films, sleeves
• CPC Class Codes: B32B 1/08 Tubular products
• CPC Class Codes: B32B 2266/0214 : Materials belonging to B32B27/00
• 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 2307/50 : having particular mechanical properties
• CPC Class Codes: B32B 2307/518 : bi-axially
• CPC Class Codes: B32B 2307/546 : Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/558 : Impact strength, toughness
• CPC Class Codes: B32B 2307/5825 : Tear resistant
• CPC Class Codes: B32B 2307/72 : Density
• CPC Class Codes: B32B 2307/7242 : Non-permeable
• CPC Class Codes: B32B 2307/7265 : Non-permeable
• CPC Class Codes: B32B 2439/70 : Food packaging
• CPC Class Codes: B32B 2439/80 : Medical packaging
• CPC Class Codes: B32B 2597/00 : Tubular articles, e.g. hoses, pipes
• CPC Class Codes: B32B 27/065 : of foam
• CPC Class Codes: B32B 27/08 : of synthetic resin
• CPC Class Codes: B32B 27/18 : characterised by the use of special additives
• CPC Class Codes: B32B 27/20 : using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 27/302 : comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 27/304 : comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/306 : comprising vinyl acetate or vinyl alcohol (co)polymers
• CPC Class Codes: B32B 27/308 : 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: B32B 27/325 : comprising polycycloolefins
• CPC Class Codes: B32B 27/34 : comprising polyamides
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 27/365 : comprising polycarbonates
• CPC Class Codes: B32B 27/40 : comprising polyurethanes
• CPC Class Codes: B32B 3/06 : for securing layers together; for attaching the product to another member, e.g. to a support , or to another product, e.g. groove/tongue, interlocking
• CPC Class Codes: B32B 3/263 : characterised by a layer having non-uniform thickness
• CPC Class Codes: B32B 3/28 : characterised by a layer comprising a deformed thin sheet , i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled B32B29/08 takes precedence
• CPC Class Codes: B32B 37/00 : Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
• CPC Class Codes: B32B 37/153 : at least one layer is extruded and immediately laminated while in semi-molten state
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/22 : characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04
• CPC Class Codes: B32B 5/32 : at least two layers being foamed and next to each other
• CPC Class Codes: Y10T 428/1352 : Polymer or resin containing [i.e., natural or synthetic]
• CPC Class Codes: Y10T 428/1393 : Multilayer [continuous layer]

Abstract

Disclosed are multilayer film structures having annular profiles, and methods and apparatus of making the structures disclosed. The annular multilayer articles have a uniform thickness, at least four layers and comprise overlapped and non-overlapped circumferential areas; wherein the layer structure of the non-overlapped area is doubled in the overlapped layer. A method of making the structure includes providing a multilayer flow stream with at least four layers of thermoplastic resinous materials; feeding the multilayer flow stream to a distribution manifold of an annular die to form an annular multilayer flow stream; and removing the annular multilayer flow stream from the annular die to form the annular multilayer structure. Also disclosed is an apparatus, comprising: a feedblock, with optional layer multiplier, that provides a multilayer flow stream of at least four layers to the manifold of an annular die; and an annular die having at least one distribution manifold that extrudes a multilayer flow stream.

Claims

1. An annular multilayer article having a uniform thickness and comprising overlapped and non-overlapped circumferential areas;

the non-overlapped area having a microlayer portion with at least one additional layer on a first and second side of the microlayer portion;

the microlayer portion having at least 30 layers;

the microlayer portion having a microlayer structure; and

the layer structure in the overlapped area is doubled the non-overlapped area;

wherein the microlayer structure is maintained in the overlapped area.

2. An annular multilayer article according to claim 1 wherein the annular multilayer article is a multilayer blown film and wherein the at least one additional layer on the first and second side of the microlayer portion encapsulates the microlayer portion.

3. An annular multilayer article according to claim 1 wherein the annular multilayer article comprises at least one thermoplastic resinous material.

4. An annular multilayer article according to claim 3 wherein the thickness between the overlapped area and the non-overlapped area vary by less than 5%.

5. An annular multilayer article according to claim 3 wherein the thickness between the overlapped area and the non-overlapped area vary by less than 2%.

6. An annular multilayer article according to claim 3 wherein the annular multilayer article has a thickness between 7 micrometers and 380 micrometers.

7. An annular multilayer article according to claim 3 wherein the annular multilayer article has a thickness between 1 millimeter and 13 millimeters.

8. An annular multilayer article according to claim 3 wherein the thermoplastic resinous material is at least one of polyethylene, polypropylene, polybutylene, or polyvinylchloride.

9. An annular multilayer article according to claim 3 wherein at least one layer of the annular multilayer article comprises a linear low density polyethylene.

10. An annular multilayer article according to claim 3 wherein the thermoplastic resinous material is a monovinylidene aromatic polymer.

11. An annular multilayer article according to claim 3 wherein the thermoplastic resinous material is a polyester.

12. An annular multilayer article according to claim 3 wherein the annular multilayer article comprises a flame retardant.

13. An annular multilayer article according to claim 3 wherein the annular multilayer article comprises a colorant or pigment.

14. An annular multilayer article, the annular multilayer article comprising at least one thermoplastic resinous material, an overlapped area, and a non-overlapped area;

wherein,

the annular multilayer article is a multilayer blown film having a uniform thickness with a variance between the overlapped area and the non-overlapped area of less than 5%;

the non-overlapped area has a microlayer portion with at least one additional layer on a first and second side of the microlayer portion which encapsulates the microlayer portion;

the microlayer portion has at least 30 layers;

the microlayer portion has a microlayer structure;

the layer structure of the non-overlapped area is doubled in the overlapped area; and

the microlayer structure is maintained in the overlapped area.

15. An annular multilayer article according to claim 14 wherein the annular multilayer article has a thickness between 7 micrometers and 380 micrometers.

16. An annular multilayer article according to claim 14 wherein the annular multilayer article has a thickness between 1 millimeter and 13 millimeters.

17. An annular multilayer article according to claim 14 wherein the thermoplastic resinous material is at least one of polyethylene, polypropylene, polybutylene, or polyvinylchloride.

18. An annular multilayer article according to claim 14 wherein at least one layer of the annular multilayer article comprises a linear low density polyethylene.

19. An annular multilayer article according to claim 14 wherein the thermoplastic resinous material is a monovinylidene aromatic polymer.

20. An annular multilayer article according to claim 14 wherein the thermoplastic resinous material is a polyester.