Mono and multi-layer articles and extrusion methods of making the same

Abstract

An extruded blow molded bottle comprises a neck portion and a body portion. The body portion comprises a first inner layer and a second layer. The first inner layer comprises a first material selected from a group consisting of polyester, phenoxy type thermoplastics, phenoxy-polyolefin thermoplastic blends, and combinations thereof. The second layer comprises a second material selected from a group consisting of virgin PET, recycled PET, PETG, foam, polypropylene, polyester, polyolefins, phenoxy type thermoplastic, phenoxy-polyolefin thermoplastic blends, regrind scrap materials, and combinations thereof. The second material is different from the first material.

Description

RELATED APPLICATIONS [0001] This application claims the priority benefit under 35 U.S.C. § 119(e) of the provisional applications 60 / 563,021, filed Apr. 16, 2004, 60 / 575,231, filed May 28, 2004, 60 / 586,399, filed Jul. 7, 2004, 60 / 620,160, filed Oct. 18, 2004, and 60 / 643,008, filed Jan. 11, 2005, which are hereby incorporated by reference in their entireties.BACKGROUND OF THE INVENTION [0002] 1. Field of the Inventions [0003] This invention relates to articles having formable material, more specifically for mono and multi-layer articles having formable materials and methods of making such articles. [0004] 2. Description of the Related Art [0005] Articles have been commonly used for holding beverages and foodstuffs. The use of articles, such as plastic containers, as a replacement for entirely glass or metal containers in the packaging of beverages has become increasingly popular. The advantages of plastic packaging include lighter weight, decreased breakage as compared to glass, and ...

AI Technical Summary

Benefits of technology

[0015] In preferred embodiments, the expandable material has insulating properties to inhibit heat transfer through the walls of the container comprising the expandable material. The expandable material can therefore be used to maintain the temperature of food, fluids, or the like. In one embodiment, when liquid is in the container, the expandable material of the container reduces heat transfer between liquid within the container and the environment surrounding the container. In one arrangement, the container can hold a chilled liquid and the expandable material of the container is a thermal barrier that inhibits heat transfer from the environment to the chilled fluid. Alternatively, a heated liquid can be within the container and the expandable material of the container is a thermal barrier that reduces heat transfer from the liquid to the environment surrounding the container. Although use in connection with food and beverages is one preferred use, these containers may also be used with non-food items.

[0025] In one embodiment, an extruded profile for holding beverages comprises a first extruded layer comprising a material selected from the group consisting of phenoxy-type thermoplastic, phenoxy-polyolefin thermoplastic blend, and combinations thereof. A second extruded layer supports the first layer. At least one of the layers can have relatively high melt strength as compared to at least one of the other layers. The high melt strength layer can support and carry the lower melt strength layer in the profile. Thus, materials having dissimilar melt strengths can be used during the extrusion process. For example, a PET layer can be extruded with another material (e.g., phenoxy, olefins, PETG, foam, etc.) having a higher melt strength than PET. Additionally, recycled PET with a relatively low melt strength can be extruded with one or more other materials having a higher melt strength.

[0038] In one embodiment, a liquid dispensing system comprises a dispensing machine configured to communicate with a gas system. A fluid source comprises fluid. One or more extruded conduits are configured to be in fluid communication between the dispensing machine and the fluid source. The one or more extruded conduits comprise a first layer and a second layer. The first layer is suitable for contacting foodstuffs. The second layer provides support to the first layer. The second layer can have high melt strength and / or other properties that facilitate processing of the first layer.

[0044] In another embodiment, a method of producing a bottle comprises extruding a profile comprising a first layer and a second layer. The first layer comprises a first material selected from the group consisting of virgin PET, recycled PET, PETG, foam, polypropylene, polyester, polyolefins, phenoxy type thermoplastic, phenoxy-polyolefin thermoplastic blends, nanocomposites, regrind materials, and combinations thereof. The second layer comprises a second material selected from the group consisting of virgin PET, recycled PET, PETG, foam, polypropylene, polyester, polyolefins, phenoxy type thermoplastic, phenoxy-polyolefin thermoplastic blends, nanocomposites, regrind materials, and combinations thereof. The second material is different from the first material. One of the layers can have high melt strength and / or other properties that facilitate processing of the other layer.

[0045] In one embodiment, a liquid dispensing system comprises a dispensing machine configured to communicate with a gas system. A fluid source comprises fluid. One or more extruded conduits are in fluid communication between the dispensing machine and the fluid source. The one or more extruded conduits comprise a first layer and a second layer. The first layer is suitable for contacting foodstuffs and the second layer provides support to the first layer. The second layer can have high melt strength and / or other properties that facilitate processing of the first layer.

[0059] In some non-limiting embodiments, the articles may material comprise one or more layers or portions having one or more of the following advantageous characteristics: an insulating layer, a barrier layer, UV protection layers, protective layer (e.g., a vitamin protective layer, scuff resistance layer, etc.), a foodstuff contacting layer, a non-flavor scalping layer, non-color scalping layer. a high strength layer, a compliant layer, a tie layer, a gas scavenging layer (e.g., oxygen, carbon dioxide, etc), a layer or portion suitable for hot fill applications, a layer having a melt strength suitable for extrusion, strength, recyclable (post consumer and / or post-industrial), clarity, etc. In one embodiment, the monolayer or multi-layer material comprises one or more of the following materials: PET (including recycled and / or virgin PET), PETG, foam, polypropylene, phenoxy type thermoplastics, polyolefins, phenoxy-polyolefin thermoplastic blends, and / or combinations thereof.

Problems solved by technology

The PET bottle may not provide a suitable thermal barrier for limiting thermal communication through the walls of the PET bottles.

Similarly, most inexpensive containers for holding foodstuffs do not provide an effective thermal barrier to reduce heat transfer through the container.

Additionally, articles in the form of conduits, food packaging, and the like may have unsuitable structural, barrier, or other characteristics.

Many times fluids, foods, or beverages, such as carbonated soda, are stored in a container that may undesirably affect its contents.

Unfortunately, when the food contacts the surface of some materials of the known articles, the taste of the food may be adversely altered.

Images