Film with improved tear strength

Abstract

Copolyester films comprising isophthalic acid residues are provided that exhibit improved tear strength that can be used in a number of applications, including in molded articles in the dental appliance market.

Description

Field of the Invention

[0001] The present invention generally pertains to the field of thermoplastic polymers. In particular, the present invention relates to polymer films that can be used to fabricate three-dimensional thermoformed articles, such as dental appliances. Background Art

[0002] Traditionally, metal braces have been used to reposition teeth to improve function or appearance. In recent years, metal braces have been replaced by plastic aligners in many cases. Aligners can be thermoformed to create a device that fits a patient's teeth and is designed to gradually move the teeth to a new, more desirable position. The aligner must be rigid enough to apply an initial force to the teeth and durable enough to resist cracking during use (including insertion onto and removal from the teeth). The ability of the aligner to resist tearing during processing and handling is also a critical criterion.

[0003] Aligners can be made from a single layer of plastic sheet, but multi-layer sheets (composed of two or more different plastic layers) can allow for more freedom to customize properties according to specific needs. However, the multi-layer sheet manufacturing process may be more difficult or costly than that of single-layer sheets.

[0004] It would be beneficial to provide a film or sheet that has an improved or broader range of customizable properties compared to current single-layer or multi-layer sheets. Summary of the Invention

[0005] It has been found that a single-layer film containing isophthalic acid (IPA) can be used to prepare more tear-resistant aligners. In an embodiment, a single-layer film can be provided that allows for more freedom to customize properties according to specific needs without increasing the complexity of multi-layer film extrusion.

[0006] It has also been found that blending a polymer containing isophthalic acid with a properly selected second component (in the same film / layer) in a structure having one component allows for the customization of the physical properties of the overall structure while maintaining the desired tear resistance and transparency.

[0007] The present invention is as described in the appended claims. Generally, the present invention relates to film structures that exhibit improved tear resistance while maintaining transparency and can be used in many applications, including thermoformed articles for the dental appliance market. The modulus can also be customized to meet the needs of the end user by varying the material selection and thickness of the film or layer. These structures can be prepared by extrusion, lamination, or other means known to those skilled in the art.

[0008] In one aspect, a film structure comprising a single copolyester or a multi-component composition is provided. In an embodiment, the multi-component composition comprises at least two different polymer components (A) and (B). In an embodiment, the polymer component (A) is present in an amount of 40 wt% to 99 wt%, or 50 wt% to 99 wt%, or greater than 50 wt% to 99 wt%, and the polymer component (B) is present in an amount of 1 wt% to 60 wt% or 1 wt% to 50 wt% or 1 wt% to less than 50 wt%. In an embodiment, the film is a single-layer structure. In other embodiments, the film is a multi-layer structure comprising one or more layers containing the multi-component composition. Detailed Description

[0009] As used herein, the term "film" includes both films and sheets and is intended to have its commonly accepted meaning in the art.

[0010] Unless the context clearly indicates otherwise, as used herein, the singular forms "a / an" and "the" include their plural referents. The terms "containing" or "including" are intended to be synonymous with the term "comprising," meaning that at least the specified compound, element, particle, or method step, etc. is present in the composition or article, but does not exclude the presence of other compounds, materials, method steps, etc., even if such other compounds, materials, particles, method steps, etc. have the same function as the specified one, unless expressly excluded in the claims.

[0011] In one aspect, a film comprising a copolyester is provided, the copolyester comprising:

[0012] (a) a dicarboxylic acid component, the dicarboxylic acid component comprising:

[0013] i) 1 mol% to 100 mol% of isophthalic acid residues; and

[0014] ii) 0 mol% to 99 mol% of terephthalic acid residues; and

[0015] iii) 0 mol% to 25 mol% of different aromatic and / or aliphatic dicarboxylic acid residues having up to 20 carbon atoms; and

[0016] (b) a diol component, the diol component comprising:

[0017] i) 50 mol% to 100 mol% of 1,4-cyclohexanedimethanol residues; and

[0018] ii) 0 mol% to 50 mol% of ethylene glycol residues; and

[0019] (iii) 0 to 25 mol% of different aromatic and / or aliphatic modified diol residues;

[0020] having an intrinsic viscosity of about 0.4 to about 1.1 dL / g measured at 25 °C at a concentration of 0.5 g / 100 ml in 60 / 40 (wt / wt) phenol / tetrachloroethane.

[0021] In an embodiment, there is provided a film comprising a copolyester, the copolyester comprising:

[0022] (a) a dicarboxylic acid component, the dicarboxylic acid component comprising:

[0023] i) 1 to 50 mol% of isophthalic acid residues; and

[0024] ii) 50 to 99 mol% of terephthalic acid residues;

[0025] (b) a diol component, the diol component comprising:

[0026] i) 1,4 - cyclohexanedimethanol residues;

[0027] having an intrinsic viscosity of about 0.4 to about 1.1 dL / g measured at 25 °C at a concentration of 0.5 g / 100 ml in 60 / 40 (wt / wt) phenol / tetrachloroethane. In another embodiment, the intrinsic viscosity is in the range of about 0.6 to about 1.0.

[0028] In an embodiment, there is provided a film comprising a multi - component composition, the multi - component composition comprising at least two different polymer components (A) and (B). In an embodiment, polymer component (A) is present in an amount of 40 wt% to 99 wt%, or greater than 40 wt% to 99 wt%, or 50 wt% to 99 wt% or greater than 50 wt% to 99 wt%, and polymer component (B) is present in an amount of 1 wt% to 60 wt%, or 1 wt% to less than 60 wt%, or 1 wt% to 50 wt%, or 1 wt% to less than 50 wt%. In an embodiment, polymer component (A) comprises a polyester, the polyester comprising:

[0029] (a) a dicarboxylic acid component, the dicarboxylic acid component comprising:

[0030] i) 1 to 100 mol% of isophthalic acid residues; and

[0031] ii) 0 to 99 mol% of terephthalic acid residues; and

[0032] iii) 0 to 25 mol% of different aromatic and / or aliphatic dicarboxylic acid residues having up to 20 carbon atoms; and

[0033] (b) A diol component, said diol component comprising:

[0034] i) 50 mol% to 100 mol% of 1,4-cyclohexanedimethanol residues; and

[0035] ii) 0 mol% to 50 mol% of ethylene glycol residues; and

[0036] iii) 0 mol% to 25 mol% of different aromatic and / or aliphatic modified diol residues;

[0037] having an intrinsic viscosity of about 0.4 to about 1.1 dL / g measured at 25 °C at a concentration of 0.5 g / 100 ml in 60 / 40 (wt / wt) phenol / tetrachloroethane; and

[0038] The polymer component (B) comprises a polyester different from the polyester in the polymer component (A).

[0039] In an embodiment, the polymer component (B) comprises a polyester, said polyester comprising:

[0040] (a) A dicarboxylic acid component, said dicarboxylic acid component comprising:

[0041] i) 50 mol% to 100 mol% of terephthalic acid residues;

[0042] ii) 0 mol% to 50 mol% of isophthalic acid residues; and

[0043] (b) A diol component, said diol component comprising:

[0044] i) 1 mol% to 100 mol% of 1,4-cyclohexanedimethanol residues; and

[0045] having an intrinsic viscosity of about 0.4 to about 1.0 dL / g measured at 25 °C at a concentration of 0.5 g / 100 ml in 60 / 40 (wt / wt) phenol / tetrachloroethane. In another embodiment, the intrinsic viscosity is in the range of about 0.6 to about 0.8.

[0046] In an embodiment, the polymer component (B) comprises a polyester, said polyester comprising:

[0047] (a) A dicarboxylic acid component, said dicarboxylic acid component comprising:

[0048] i) 50 mol% to 100 mol% of terephthalic acid residues;

[0049] ii) 0 mol% to 50 mol% of isophthalic acid residues; and

[0050] (b) A diol component, said diol component comprising:

[0051] (i) 1 to 100 mol% of 1,4 - cyclohexanedimethanol residues; and

[0052] (ii) 0 to 99 mol% of ethylene glycol residues; and

[0053] having an intrinsic viscosity of about 0.4 to about 1.0 dL / g measured at 25 °C at a concentration of 0.5 g / 100 ml in 60 / 40 (wt / wt) phenol / tetrachloroethane. In another embodiment, the intrinsic viscosity is in the range of about 0.6 to about 0.8.

[0054] In an embodiment, polymer component (B) comprises a polyester, the polyester comprising:

[0055] (a) a dicarboxylic acid component, the dicarboxylic acid component comprising:

[0056] (i) 50 to 100 mol% of terephthalic acid residues;

[0057] (ii) 0 to 50 mol% of isophthalic acid residues; and

[0058] (b) a diol component, the diol component comprising:

[0059] (i) 30 to 100 mol% of 1,4 - cyclohexanedimethanol residues; and

[0060] (ii) 0 to 70 mol% of 2,2,4,4 - tetramethyl - 1,3 - cyclobutanediol residues; and

[0061] having an intrinsic viscosity of about 0.4 to about 0.9 dL / g measured at 25 °C at a concentration of 0.5 g / 100 ml in 60 / 40 (wt / wt) phenol / tetrachloroethane. In another embodiment, the intrinsic viscosity is in the range of about 0.6 to about 0.8.

[0062] In an embodiment, polymer component (B) comprises a polyester, the polyester comprising:

[0063] (a) a dicarboxylic acid component, the dicarboxylic acid component comprising:

[0064] (i) 1 to 100 mol% of 1,4 - cyclohexanedicarboxylic acid residues; and

[0065] (b) a diol component, the diol component comprising:

[0066] (i) 1 to 100 mol% of 1,4 - cyclohexanedimethanol residues; and

[0067] An intrinsic viscosity of about 0.4 to about 0.9 dL / g as measured at 25 °C at a concentration of 0.5 g / 100 ml in 60 / 40 (wt / wt) phenol / tetrachloroethane. In another embodiment, the intrinsic viscosity is in the range of about 0.6 to about 0.8.

[0068] In an embodiment, polymer component (B) comprises a polyester which is a polyester ether. In an embodiment, the polyester ether comprises:

[0069] (a) A dicarboxylic acid component which comprises:

[0070] i) 1 mol% to 100 mol% of 1,4 - cyclohexanedicarboxylic acid residues; and

[0071] (b) A diol component which comprises:

[0072] i) 1 mol% to 99 mol% of 1,4 - cyclohexanedimethanol residues; and

[0073] ii) 1 mol% to about 50 mol%, or 1 mol% to 20 mol%, or 1 mol% to 15 mol%, or 2 mol% to 10 mol% of polytetramethylene ether glycol (PTMG) having a weight - average molecular weight of about 500 to about 2000, based on the number of moles of the diol component of the polyester ether; and

[0074] An intrinsic viscosity of about 0.7 to about 1.5 dL / g as measured at 25 °C at a concentration of 0.5 g / 100 ml in 60 / 40 (wt / wt) phenol / tetrachloroethane.

[0075] In another embodiment, the multicomponent composition comprises three polymer components (A), (B) and (C), wherein the polymer components are different. In an embodiment of the three - component composition, polymer component (A) is present in an amount of 40 wt% to 99 wt%, or greater than 40 wt% to 99 wt%, or 50 wt% to 99 wt% or greater than 50 wt% to 99 wt%, and polymer components (B) and (C) are each present in an amount of 1 wt% to 60 wt%, or 1 wt% to less than 60 wt%, or 1 wt% to 50 wt%, or 1 wt% to less than 50 wt%. In an embodiment of the three - component composition, polymer component (A) can be the polyester as described for component (A) in the embodiment of the (at least) two - component composition herein, and components (B) and (C) can independently be a polyester or copolyester as described for component (B) in the embodiment of the (at least) two - component composition herein, provided that components (B) and (C) are different.

[0076] In an embodiment of the three - component composition, polymer component (A) comprises a polyester which comprises:

[0077] (a) A dicarboxylic acid component, said dicarboxylic acid component comprising:

[0078] i) 1 mol% to 100 mol% of isophthalic acid residues; and

[0079] ii) 0 mol% to 99 mol% of terephthalic acid residues; and

[0080] iii) 0 mol% to 25 mol% of different aromatic and / or aliphatic dicarboxylic acid residues having up to 20 carbon atoms; and

[0081] (b) A diol component, said diol component comprising:

[0082] i) 50 mol% to 100 mol% of 1,4-cyclohexanedimethanol residues; and

[0083] ii) 0 mol% to 50 mol% of ethylene glycol residues; and

[0084] iii) 0 mol% to 25 mol% of different aromatic and / or aliphatic modified diol residues;

[0085] Having an intrinsic viscosity of about 0.4 to about 1.1 dL / g measured at 25 °C at a concentration of 0.5 g / 100 ml in 60 / 40 (wt / wt) phenol / tetrachloroethane; and polymer components (B) and (C) each comprise a polyester different from the polyester in polymer component (A), provided that components (B) and (C) are different from each other.

[0086] In other embodiments (for any of the embodiments described herein in this application), polymer component (A) is a polyester, said polyester comprising:

[0087] (a) A dicarboxylic acid component, said dicarboxylic acid component comprising:

[0088] i) 1 mol% to 100 mol% of isophthalic acid residues; and

[0089] ii) 0 mol% to 99 mol% of terephthalic acid residues; and

[0090] iii) 0 mol% to 25 mol% of different aromatic and / or aliphatic dicarboxylic acid residues having up to 20 carbon atoms; and

[0091] (b) A diol component, said diol component comprising:

[0092] i) 50 mol% to 100 mol% of 1,4-cyclohexanedimethanol residues; and

[0093] ii) 0 mol% to 50 mol% of ethylene glycol residues; and

[0094] iii) 0 to 25 mol% of different aromatic and / or aliphatic modified diol residues;

[0095] having an intrinsic viscosity of about 0.4 to about 1.1 dL / g measured at 25 °C at a concentration of 0.5 g / 100 ml in phenol / tetrachloroethane at 60 / 40 (wt / wt).

[0096] Examples of materials for the polyester component or polymer component (A) that can be used in multi-component blends can include Durastar MN611, MN621, and DS1910HF or Eastar CN015, A150, or CN005 copolyesters available from Eastman Chemical Company. Examples of materials for polymer component (B) or (C) can include PCT, or Eastar MN004, DN004, MN006, MB002, MN210, MN610, MN620, CN015 and 6763, or Ecdel TM Elastomer 9965, 9966 and / or 9967, or Medstar, or Neostar 19772, or Tritan MP100, MP150, MP200 or TX1800.

[0097] Unless otherwise specifically indicated, as used herein, the term "polyester" is intended to include "copolyester" and shall be understood to mean a synthetic polymer prepared by the reaction of one or more difunctional carboxylic acids and / or polyfunctional carboxylic acids with one or more difunctional hydroxy compounds and / or polyfunctional hydroxy compounds. Generally, the difunctional carboxylic acid may be a dicarboxylic acid, and the difunctional hydroxy compound may be a dihydric alcohol, such as a diol. The term "diol" as used herein includes, but is not limited to, diols, dihydric alcohols, and / or polyfunctional hydroxy compounds. As used herein, the term "residue" means any organic structure incorporated into the polymer by the polycondensation and / or esterification reaction of the corresponding monomer. As used herein, the term "repeat unit" means an organic structure having a dicarboxylic acid residue and a diol residue bonded through a carbonyl-oxy bond. Thus, for example, the dicarboxylic acid residue may be derived from a dicarboxylic acid monomer or its related acyl halide, ester, salt, anhydride, or a mixture thereof. Thus, as used herein, the term dicarboxylic acid is intended to include the dicarboxylic acid and any derivative of the dicarboxylic acid, including its related acyl halide, ester, half-ester, salt, half-salt, anhydride, mixed anhydride, or a mixture thereof, which may be used in the reaction with a diol to prepare the polyester. As used herein, the term "terephthalic acid" is intended to include terephthalic acid itself and its residue, as well as any derivative of terephthalic acid, including its related acyl halide, ester, half-ester, salt, half-salt, anhydride, mixed anhydride, or a mixture thereof or its residue, which may be used in the reaction with a diol to prepare the polyester.

[0098] In one embodiment, terephthalic acid may be used as a starting material. In another embodiment, dimethyl terephthalate may be used as a starting material. In another embodiment, a mixture of terephthalic acid and dimethyl terephthalate may be used as a starting material and / or an intermediate material.

[0099] The polyesters used in the present invention can generally be prepared from dicarboxylic acids and diols, which react in substantially equal proportions and are incorporated into the polyester polymer as their respective residues. Thus, the polyesters of the present invention can contain substantially equal molar proportions of acid residues (100 mol%) and diol (and / or polyfunctional hydroxy compound) residues (100 mol%). Accordingly, the mole percentages provided herein can be based on the total number of moles of acid residues, the total number of moles of diol residues, or the total number of moles of repeating units. For example, a polyester containing 30 mol% of isophthalic acid based on the total acid residues means that the polyester contains 30 mol% of isophthalic acid residues in a total of 100 mol% of acid residues. Thus, there are 30 moles of isophthalic acid residues per 100 moles of acid residues. In another example, a polyester containing 30 mol% of 2,2,4,4-tetramethyl-1,3-cyclobutanediol based on the total diol residues means that the polyester contains 30 mol% of 2,2,4,4-tetramethyl-1,3-cyclobutanediol residues in a total of 100 mol% of diol residues. Thus, there are 30 moles of 2,2,4,4-tetramethyl-1,3-cyclobutanediol residues per 100 moles of diol residues.

[0100] Unless otherwise specified, the molar percentages of the diacid monomers and the diol mol% relative to a single polyester component (contained in the blend) are based on a total of 100 mol% of diacid residues and 100 mol% of diol residues.

[0101] In embodiments having a polyester containing TMCD, the molar ratio of cis / trans 2,2,4,4-tetramethyl-1,3-cyclobutanediol can vary according to their respective pure forms or mixtures thereof. In certain embodiments, the molar percentage of cis and / or trans 2,2,4,4,-tetramethyl-1,3-cyclobutanediol is greater than 50 mol% cis and less than 50 mol% trans; or greater than 55 mol% cis and less than 45 mol% trans; or 30 mol% to 70 mol% cis and 70 mol% to 30 mol% trans; or 40 mol% to 60 mol% cis and 60 mol% to 40 mol% trans; or 50 mol% to 70 mol% trans and 50 mol% to 30 mol% cis or 50 mol% to 70 mol% cis and 50 mol% to 30 mol% trans; or 50 mol% to 60 mol% cis and 50 mol% to 40 mol% trans; or 50 mol% to 55 mol% cis and 45 mol% to 50 mol% trans; or 60 mol% to 70 mol% cis and 30 mol% to 40 mol% trans; or greater than 70 mol% cis and less than 30 mol% trans; wherein the sum of the molar percentages of cis and trans-2,2,4,4-tetramethyl-1,3-cyclobutanediol is equal to 100 mol%. The molar ratio of cis / trans 1,4-cyclohexanedimethanol can vary in the range of 50 / 50 to 0 / 100, such as between 40 / 60 and 20 / 80.

[0102] In the embodiment of polymer component (A) polyester, isophthalic acid or its ester (such as dimethyl isophthalate, for example) or mixture of terephthalic acid and its ester constitutes 20 mol% or more or at least 25 mol% of the dicarboxylic acid component used to form the polyester useful in the present invention. As used herein, unless otherwise expressly indicated, the terms "isophthalic acid" and "dimethyl isophthalate" are used interchangeably.

[0103] In certain embodiments of the polymer component (A) polyester, terephthalic acid or its ester (such as dimethyl terephthalate) or a mixture of terephthalic acid and its ester constitutes the majority of the dicarboxylic acid component for forming the polyester. In certain embodiments, the terephthalic acid residue may constitute a portion or all of the dicarboxylic acid component for forming the polyester, and the concentration of the terephthalic acid residue is at least 50 mol%, such as at least 55 mol%, at least 60 mol%, at least 65 mol%, at least 70 mol%, at least 75 mol%, at least 80 mol%, at least 85 mol%, at least 90 mol%, at least 95 mol% or at least 99 mol%. In certain embodiments, a higher amount of terephthalic acid can be used to prepare a polyester with higher impact strength. In one embodiment, dimethyl terephthalate is a portion or all of the dicarboxylic acid component for preparing the polyester that can be used in the present invention. As used herein, unless otherwise expressly indicated, the terms "terephthalic acid" and "dimethyl terephthalate" are used interchangeably.

[0104] In addition to isophthalic acid and terephthalic acid, the dicarboxylic acid component of the copolyester that can be used in polymer component (A) can also include up to 25 mol %, up to 20 mol %, up to 10 mol %, up to 5 mol % or up to 1 mol % of one or more modified aromatic dicarboxylic acids. Another embodiment contains 0 mol % of modified aromatic dicarboxylic acid. Therefore, if present, it is expected that the amount of one or more modified aromatic dicarboxylic acids can be within the scope of any one of these aforementioned endpoint values, including, for example, 0.01 mol % to 30 mol %, 0.01 mol % to 20 mol %, 0.01 mol % to 10 mol %, 0.01 mol % to 5 mol % and 0.01 mol % to 1 mol %. In one embodiment, the modified aromatic dicarboxylic acids that can be used in the present invention include but are not limited to those with up to 20 carbon atoms, and can be linear, para-oriented or symmetrical. Examples of the modified aromatic dicarboxylic acid useful in the present invention include, but are not limited to, 4,4'-biphenyl dicarboxylic acid, 1,4-naphthalene dicarboxylic acid, 1,5-naphthalene dicarboxylic acid, 2,6-naphthalene dicarboxylic acid, 2,7-naphthalene dicarboxylic acid, and trans-4,4'-stilbene dicarboxylic acid and esters thereof.

[0105] The carboxylic acid component that can be used for the polyester of polymer component (A) can further contain at most 20 carbon atoms aliphatic dicarboxylic acids, such as malonic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid and dodecanedioic acid dicarboxylic acid modification with one or more aliphatic dicarboxylic acids of at most 25 mol %, at most 20 mol %, at most 10 mol %, at most 5 mol % or at most 1 mol %, for example. Some embodiments can also include 0.01 mol % or more mol %, such as 0.1 mol % or more mol %, 1 mol % or more mol %, 5 mol % or more mol % or 10 mol % or more mol % of one or more modified aliphatic dicarboxylic acids. Another embodiment contains 0 mol % of modified aliphatic dicarboxylic acids. Therefore, if present, it is expected that the amount of one or more modified aliphatic dicarboxylic acids can be in the scope of any one of these aforementioned endpoint values, including, for example, 0.01 mol % to 10 mol % and 0.1 mol % to 10 mol %. The total mol % of dicarboxylic acid component is 100 mol %.

[0106] Can use ester of terephthalic acid and other modified dicarboxylic acids or their corresponding ester and / or salt to replace dicarboxylic acid.Suitable example of dicarboxylic acid ester includes but not limited to dimethyl ester, diethyl ester, dipropyl ester, diisopropyl ester, dibutyl ester and diphenyl ester.In one embodiment, ester is selected from at least one of following: methyl ester, ethyl ester, propyl ester, isopropyl ester and phenyl ester.

[0107] 1,4-cyclohexanedimethanol may be cis, trans, or a mixture thereof, for example, in a cis / trans ratio of 60:40 to 40:60. In another embodiment, trans-1,4-cyclohexanedimethanol may be present in an amount of 60 mol% to 80 mol%.

[0108] In embodiments, the diol component of the polyester of polymer component (A) above may contain up to 25 mole % of one or more modifying diols that are not 1,4-cyclohexanedimethanol, ethylene glycol, or 2,2,4,4-tetramethyl-1,3-cyclobutanediol.

[0109] The modified diols that can be used in the polyester can be diols other than adipic acid, 1,4-cyclohexanedimethanol, ethylene glycol or 2,2,4,4-tetramethyl-1,3-cyclobutanediol, and can contain 2 to 16 carbon atoms. Examples of suitable modified diols include, but are not limited to, 1,2-propylene glycol, 1,3-propylene glycol, neopentyl glycol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, p-xylene glycol, isosorbide or mixtures thereof. In another embodiment, the modified diol is 1,3-propylene glycol and / or 1,4-butanediol. In another embodiment, 1,3-propylene glycol and 1,4-butanediol are excluded as modified diols. In another embodiment, 2,2-dimethyl-1,3-propylene glycol is excluded as modified diols.

[0110] In embodiments, based on the total molar percentage of diol or diacid residues, the polyesters as described herein (for single-component copolyester films or for the polymer component (A) in multi-component films) may also contain from 0 mole% to 10 mole%, such as from 0.01 mole% to 5 mole%, from 0.01 mole% to 1 mole%, from 0.05 mole% to 5 mole%, from 0.05 mole% to 1 mole%, or from 0.1 mole% to 0.7 mole% of one or more residues of a branching monomer or branching agent (also referred to herein as a branching agent), the branching monomer or branching agent having 3 or more carboxyl substituents, hydroxyl substituents, or a combination thereof. In embodiments, based on the total molar percentage of diol or diacid residues, the polyesters as described herein (in embodiments of polymer component (B) and / or (C)) may also contain from 0 mole% to 10 mole%, such as from 0.01 mole% to 5 mole%, from 0.01 mole% to 1 mole%, from 0.05 mole% to 5 mole%, from 0.05 mole% to 1 mole%, or from 0.1 mole% to 0.7 mole% of a branching agent.

[0111] In certain embodiments, the branching monomer or branching agent may be added before and / or during and / or after the polymerization of the polyester. Thus, the polyesters useful in the present invention may be linear or branched.

[0112] Examples of branching monomers or branching agents may include, but are not limited to, polyfunctional acids or polyfunctional alcohols such as trimellitic acid, trimellitic anhydride, pyromellitic dianhydride, trimethylolpropane, glycerol, pentaerythritol, citric acid, tartaric acid, 3-hydroxyglutaric acid, etc. In one embodiment, the branching monomer residues may contain from 0.1 mole% to 0.7 mole% of one or more residues selected from at least one of the following: trimellitic anhydride, pyromellitic dianhydride, glycerol, sorbitol, 1,2,6-hexanetriol, pentaerythritol, trimethylolethane, and / or trimellitic acid. The branching monomer or branching agent may be added to the polyester reaction mixture or blended with the polyester in the form of a concentrate, as described, for example, in U.S. Patent Nos. 5,654,347 and 5,696,176, the disclosures of which patents regarding the branching monomers are incorporated herein by reference.

[0113] Maintaining the glass transition temperature above the conditions experienced by the film in dental appliances or other applications may be critical for the dimensional stability of the product. In certain embodiments, the Tg of the copolyester or multi-component film is at least 10°C, or at least 20°C, or at least 30°C, or at least 40°C, or at least 50°C higher than the expected use temperature (e.g., 35°C to 40°C, or about 37°C).

[0114] In certain embodiments, after exposure to a humidity above 90% RH for 24 hours or after immersion in water at the in-use temperature (e.g., 35 °C to 40 °C, or about 37 °C) for 24 hours, the Tg of the copolyester or multi-component film remains at least 10 °C, or at least 20 °C, or at least 30 °C, or at least 40 °C, or at least 50 °C higher than the expected in-use temperature.

[0115] In certain embodiments, the Tg of the isophthalic acid-containing polyester of the copolyester or polymer component (A) that can be used in the multi-component film can be about 50 °C to 130 °C, or 60 °C to 120 °C, or 70 °C to 110 °C. In certain embodiments, the Tg of the polyester that can be used in polymer components (B) and / or (C) can be about 30 °C to 130 °C, or 50 °C to 130 °C, or 70 °C to 130 °C, or 90 °C to 130 °C, or 100 °C to 130 °C, or 105 °C to 130 °C, or 110 °C to 130 °C, or 50 °C to 120 °C, or 70 °C to 120 °C, or 90 °C to 120 °C, or 100 °C to 120 °C, or 105 °C to 120 °C, or 110 °C to 120 °C, or 50 °C to 110 °C, or 70 °C to 110 °C, or 90 °C to 110 °C, or 100 °C to 110 °C, or 105 °C to 110 °C. The glass transition temperature (Tg) of the polyester can be determined using a TA DSC 2920 from Thermal Analyst Instrument at a scanning rate of 20 °C / min on a sample dried in a vacuum oven for 24 hours before testing.

[0116] In certain embodiments, the Tg of the polymer component after exposure to a high humidity or water immersion environment is relevant. This will be referred to as the "wet Tg". The wet Tg of the isophthalic acid-containing polyester of the copolyester or polymer component (A) that can be used in the multi-component film can be about 30 °C to 130 °C, or 50 °C to 130 °C, or 70 °C to 130 °C, or 90 °C to 130 °C, or 100 °C to 130 °C, or 105 °C to 130 °C, or 110 °C to 130 °C, or 50 °C to 120 °C, or 70 °C to 120 °C, or 90 °C to 120 °C, or 100 °C to 120 °C, or 105 °C to 120 °C, or 110 °C to 120 °C, or 50 °C to 110 °C, or 70 °C to 110 °C, or 90 °C to 110 °C, or 100 °C to 110 °C, or 105 °C to 110 °C. In certain embodiments, the wet Tg of the polyester that can be used in polymer components (B) and / or (C) can be about 30 to 130 °C, or 50 °C to 120 °C, or 70 °C to 110 °C. The wet Tg of the polyester can be determined using a TA DSC 2920 from Thermal Analyst Instrument at a scanning rate of 20 °C / min on a sample immersed in water at 40 °C for at least 24 hours before testing.

[0117] In an embodiment, when measured by DSC on a sample dried in a vacuum oven for 24 hours before testing at a scan rate of 20 °C / min using a TA DSC 2920 from Thermal Analyst Instrument, the glass transition temperature (Tg) of the polymer or multicomponent composition used to make the film can be at least 57 °C, or greater than 57 °C, or at least 67 °C, or greater than 67 °C, or at least 77 °C, or greater than 77 °C.

[0118] In addition, the multicomponent composition useful in the present invention may also contain 0.01 wt% to 20 wt%, or 0.01 wt% to 15 wt%, or 0.01 wt% to 10 wt%, or 0.01 wt% to 5 wt% of the total weight of the polyester composition of common additives such as colorants, dyes, slip aids or mold release agents, friction modifiers, rheological modifiers, processing aids, anti-caking agents, inorganic fillers, impact modifiers and / or stabilizers, including but not limited to heat stabilizers or hydrolysis stabilizers.

[0119] In certain embodiments, when the copolyester or polymer component (A) in the multicomponent film comprises a copolyester containing isophthalic acid residues and terephthalic acid residues, the acid component of the polyester may include but is not limited to at least one of the following range combinations: 1 mol% to 99 mol% isophthalic acid residues and 1 mol% to 99 mol% terephthalic acid residues; 1 mol% to 75 mol% isophthalic acid residues and 25 mol% to 99 mol% terephthalic acid residues; 1 mol% to 50 mol% isophthalic acid residues and 50 mol% to 99 mol% terephthalic acid residues; 5 mol% to less than 50 mol% isophthalic acid residues and greater than 50 mol% to 95 mol% terephthalic acid residues; 15 mol% to 50 mol% isophthalic acid residues and 50 mol% to 85 mol% terephthalic acid residues; 15 mol% to less than 40 mol% isophthalic acid residues and greater than 60 mol% to 85 mol% terephthalic acid residues; or 25 mol% to 50 mol% isophthalic acid residues and 50 mol% to 75 mol% terephthalic acid residues; or 25 mol% to 35 mol% isophthalic acid residues and 65 mol% to 75 mol% terephthalic acid residues; or 26 mol% to 48 mol% isophthalic acid residues and 65 mol% to 75 mol% terephthalic acid residues; or more than 20 mol% to less than 40 mol% isophthalic acid residues and greater than 60 mol% to 80 mol% terephthalic acid residues.

[0120] In other embodiments, when the copolyester or polymer component (A) in the multi-component film comprises a copolyester containing CHDM residues and EG residues, the diol component of the polyester can include, but is not limited to, at least one of the following range combinations: 1 mol% to 99 mol% 1,4-cyclohexanedimethanol and 1 mol% to 99 mol% ethylene glycol; 80 mol% to 99 mol% 1,4-cyclohexanedimethanol and 1 mol% to 80 mol% ethylene glycol; 60 mol% to 99 mol% 1,4-cyclohexanedimethanol and 1 mol% to 40 mol% ethylene glycol; 50 mol% to 99 mol% 1,4-cyclohexanedimethanol and 1 mol% to 50 mol% ethylene glycol; 40 mol% to 99 mol% 1,4-cyclohexanedimethanol and 1 mol% to 60 mol% ethylene glycol; 75 mol% to 99 mol% 1,4-cyclohexanedimethanol and 1 mol% to 25 mol% ethylene glycol; or 80 mol% to 99 mol% 1,4-cyclohexanedimethanol and 1 mol% to 20 mol% ethylene glycol.

[0121] In other embodiments, when the copolyester or polymer component (A) in the multi-component film comprises a copolyester containing TMCD in addition to other diol residues, the diol component of the polyester can include, but is not limited to, at least one of the following range combinations: 1 mol% to 99 mol% 2,2,4,4-tetramethyl-1,3-cyclobutanediol and 1 mol% to 99 mol% other diol; 1 mol% to 75 mol% 2,2,4,4-tetramethyl-1,3-cyclobutanediol and 25 mol% to 99 mol% other diol; 1 mol% to 50 mol% 2,2,4,4-tetramethyl-1,3-cyclobutanediol and 50 mol% to 99 mol% other diol; 1 mol% to 40 mol% 2,2,4,4-tetramethyl-1,3-cyclobutanediol and 60 mol% to 99 mol% other diol; 1 mol% to 35 mol% 2,2,4,4-tetramethyl-1,3-cyclobutanediol and 65 mol% to 99 mol% other diol; 1 mol% to 30 mol% 2,2,4,4-tetramethyl-1,3-cyclobutanediol and 70 mol% to 99 mol% other diol; 1 mol% to 25 mol% 2,2,4,4-tetramethyl-1,3-cyclobutanediol and 75 mol% to 99 mol% other diol; 1 mol% to 20 mol% 2,2,4,4-tetramethyl-1,3-cyclobutanediol and 80 mol% to 99 mol% other diol; or 1 mol% to 10 mol% 2,2,4,4-tetramethyl-1,3-cyclobutanediol and 90 mol% to 99 mol% other diol.

[0122] In other embodiments, when the copolyester or polymer component (A) in the multicomponent film comprises a copolyester containing isosorbide in addition to other diol residues, the diol component of the polyester can include, but is not limited to, at least one of the following range combinations: 1 mol% to 99 mol% isosorbide and 1 mol% to 99 mol% other diol; 1 mol% to 75 mol% isosorbide and 25 mol% to 99 mol% other diol; 1 mol% to 50 mol% isosorbide and 50 mol% to 99 mol% other diol; 1 mol% to 40 mol% isosorbide and 60 mol% to 99 mol% other diol; 1 mol% to 35 mol% isosorbide and 65 mol% to 99 mol% other diol; 1 mol% to 30 mol% isosorbide and 70 mol% to 99 mol% other diol; 1 mol% to 25 mol% isosorbide and 75 mol% to 99 mol% other diol; 1 mol% to 20 mol% isosorbide and 80 mol% to 99 mol% other diol; or 1 mol% to 10 mol% isosorbide and 90 mol% to 99 mol% other diol.

[0123] In other embodiments, when the copolyester or polymer component (A) in the multicomponent film comprises a copolyester containing neopentyl glycol in addition to other diol residues, the diol component of the polyester can include, but is not limited to, at least one of the following range combinations: 1 mol% to 99 mol% neopentyl glycol and 1 mol% to 99 mol% other diol; 1 mol% to 75 mol% neopentyl glycol and 25 mol% to 99 mol% other diol; 1 mol% to 50 mol% neopentyl glycol and 50 mol% to 99 mol% other diol; 1 mol% to 40 mol% neopentyl glycol and 60 mol% to 99 mol% other diol; 1 mol% to 35 mol% neopentyl glycol and 65 mol% to 99 mol% other diol; 1 mol% to 30 mol% neopentyl glycol and 70 mol% to 99 mol% other diol; 1 mol% to 25 mol% neopentyl glycol and 75 mol% to 99 mol% other diol; 1 mol% to 20 mol% neopentyl glycol and 80 mol% to 99 mol% other diol; or 1 mol% to 10 mol% neopentyl glycol and 90 mol% to 99 mol% other diol.

[0124] In other embodiments, when the copolyester or polymer component (A) in the multi-component film comprises a copolyester containing methyl propylene glycol (MP Diol), such as 2-methyl-1,3-propanediol, in addition to other diol residues, the diol component of the polyester may include, but is not limited to, at least one of the following range combinations: 1 mol% to 99 mol% methyl propylene glycol and 1 mol% to 99 mol% other diols; 1 mol% to 75 mol% methyl propylene glycol and 25 mol% to 99 mol% other diols; 1 mol% to 50 mol% methyl propylene glycol and 50 mol% to 99 mol% other diols; 1 mol% to 40 mol% methyl propylene glycol and 60 mol% to 99 mol% other diols; 1 mol% to 35 mol% methyl propylene glycol and 65 mol% to 99 mol% other diols; 1 mol% to 30 mol% methyl propylene glycol and 70 mol% to 99 mol% other diols; 1 mol% to 25 mol% methyl propylene glycol and 75 mol% to 99 mol% other diols; 1 mol% to 20 mol% methyl propylene glycol and 80 mol% to 99 mol% other diols; or 1 mol% to 10 mol% methyl propylene glycol and 90 mol% to 99 mol% other diols.

[0125] In an embodiment, the copolyester or multi-component film has at least one of the following properties selected from: a Tg of about 70°C to about 120°C measured at a scan rate of 20°C / min by a TA 2100 Thermal Analyst Instrument, a flexural modulus greater than about 1800 MPa (290,000 psi), or greater than 1900 MPa, or greater than 2000 MPa at 23°C as defined by ASTM D790, and an average tear propagation resistance greater than 30 N / mm, or 35 N / mm or 40 N / mm in the machine direction and transverse direction when measured according to ASTM D 1938. In one embodiment, the b* color value of the film is 2 or less, or less than 2, as determined by the L*a*b* color system measured in accordance with ASTM E 1348. In one embodiment, the haze value of the film is 30% or less, or 25% or less, or 20% or less, or less than 20%, or 15% or less, or 10% or less, or 5% or less as determined by the L*a*b* color system measured on a 0.75 mm film in accordance with ASTM D 1003.

[0126] In an embodiment, the polyester as described herein for embodiments of the copolyester or polymeric component (A) in the multicomponent film may exhibit at least one of the following intrinsic viscosities measured at 25 °C at a concentration of 0.5 g / 100 ml in 60 / 40 (wt / wt) phenol / tetrachloroethane: 0.40 to 1.2 dL / g; 0.40 to 1.1 dL / g; 0.40 to 1 dL / g; 0.40 to less than 1 dL / g; 0.40 to 0.98 dL / g; 0.40 to 0.95 dL / g; 0.40 to 0.90 dL / g; 0.40 to 0.85 dL / g; 0.40 to 0.80 dL / g; 0.40 to 0.75 dL / g; 0.40 to less than 0.75 dL / g; 0.40 to 0.72 dL / g; 0.40 to 0.70 dL / g; 0.10 to less than 0.70 dL / g; 0.10 to 0.68 dL / g; 0.10 to less than 0.68 dL / g; 0.40 to 0.65 dL / g; greater than 0.50 to 1.1 dL / g; greater than 0.50 to 1 dL / g; greater than 0.50 to less than 1 dL / g; greater than 0.50 to 0.98 dL / g; greater than 0.50 to 0.95 dL / g; greater than 0.50 to 0.90 dL / g; greater than 0.50 to 0.85 dL / g; greater than 0.60 to 0.80 dL / g; greater than 0.60 to 0.75 dL / g; greater than 0.60 to less than 1.1 dL / g; greater than 0.60 to 1.1 dL / g; greater than 0.60 to less than 0.9 dL / g; greater than 0.60 to 0.8 dL / g; greater than 0.60 to less than 0.8 dL / g; greater than 0.65 to 1.1 dL / g; greater than 0.65 to less than 0.9 dL / g; greater than 0.65 to 0.8 dL / g; 0.70 to 1.1 dL / g; 0.75 to 1.1 dL / g; 0.80 to 1.1 dL / g or 0.85 to 1.1 dL / g.

[0127] For some embodiments, the polyesters described herein in embodiments of polymer component (B) or (C) comprising 1,4 - cyclohexanedicarboxylate may exhibit at least one of the following inherent viscosities measured at 25 °C at a concentration of 0.5 g / 100 ml in 60 / 40 (wt / wt) phenol / tetrachloroethane: 0.40 to 1.2 dL / g; 0.40 to 1.1 dL / g; 0.40 to 1 dL / g; 0.40 to less than 1 dL / g; 0.40 to 0.98 dL / g; 0.40 to 0.95 dL / g; 0.40 to 0.90 dL / g; 0.40 to 0.85 dL / g; 0.40 to 0.80 dL / g; 0.40 to 0.75 dL / g; 0.40 to less than 0.75 dL / g; 0.40 to 0.72 dL / g; 0.40 to 0.70 dL / g; 0.10 to less than 0.70 dL / g; 0.10 to 0.68 dL / g; 0.10 to less than 0.68 dL / g; 0.40 to 0.65 dL / g; greater than 0.50 to 1.1 dL / g; greater than 0.50 to 1 dL / g; greater than 0.50 to less than 1 dL / g; greater than 0.50 to 0.98 dL / g; greater than 0.50 to 0.95 dL / g; greater than 0.50 to 0.90 dL / g; greater than 0.50 to 0.85 dL / g; greater than 0.60 to 0.80 dL / g; greater than 0.60 to 0.75 dL / g; greater than 0.60 to less than 1.1 dL / g; greater than 0.60 to 1.1 dL / g; greater than 0.60 to less than 0.9 dL / g; greater than 0.60 to 0.8 dL / g; greater than 0.60 to less than 0.8 dL / g; greater than 0.65 to 1.1 dL / g; greater than 0.65 to less than 0.9 dL / g; greater than 0.65 to 0.8 dL / g; 0.70 to 1.1 dL / g; 0.75 to 1.1 dL / g; 0.80 to 1.1 dL / g or 0.85 to 1.1 dL / g.

[0128] In various embodiments, the relative amounts of components (A), (B), and (C) can be selected from: 25 wt% to 99 wt% of component (A) and 1 wt% to 75 wt% of component (B) and / or (C), or greater than 25 wt% to 99 wt% of component (A) and 1 wt% to less than 75 wt% of component (B) and / or (C), or 30 wt% to 99 wt% of component (A) and 1 wt% to 70 wt% of component (B) and / or (C), or 35 wt% to 99 wt% of component (A) and 1 wt% to 65 wt% of component (B) and / or (C), 40 wt% to 99 wt% of component (A) and 1 wt% to 60 wt% of component (B) and / or (C), or greater than 40 wt% to 99 wt% of component (A) and 1 wt% to less than 60 wt% of component (B) and / or (C), or 45 wt% to 99 wt% of component (A) and 1 wt% to 55 wt% of component (B) and / or (C), or 50 wt% to 99 wt% of component (A) and 1 wt% to 50 wt% of component (B) and / or (C), or greater than 50 wt% to 99 wt% of component (A) and 1 wt% to less than 50 wt% of component (B) and / or (C), or 55 wt% to 99 wt% of component (A) and 1 wt% to 45 wt% of component (B) and / or (C), or 60 wt% to 99 wt% of component (A) and 1 wt% to 40 wt% of component (B) and / or (C), or 65 wt% to 99 wt% of component (A) and 1 wt% to 35 wt% of component (B) and / or (C), or 70 wt% to 99 wt% of component (A) and 1 wt% to 30 wt% of component (B) and / or (C), or 75 wt% to 99 wt% of component (A) and 1 wt% to 25 wt% of component (B) and / or (C), or 80 wt% to 99 wt% of component (A) and 1 wt% to 20 wt% of component (B) and / or (C), or 25 wt% to 95 wt% of component (A) and 5 wt% to 75 wt% of component (B) and / or (C), or 30 wt% to 95 wt% of component (A) and 5 wt% to 70 wt% of component (B) and / or (C), or 35 wt% to 95 wt% of component (A) and 5 wt% to 65 wt% of component (B) and / or (C), or 40 wt% to 95 wt% of component (A) and 5 wt% to 60 wt% of component (B) and / or (C), or 45 wt% to 95 wt% of component (A) and 5 wt% to 55 wt% of component (B) and / or (C), or 50 wt% to 95 wt% of component (A) and 5 wt% to 50 wt% of component (B) and / or (C), or 55 wt% to 95 wt% of component (A) and 5 wt% to 45 wt% of component (B) and / or (C), or 60 wt% to 95 wt% of component (A) and 5 wt% to 40 wt% of component (B) and / or (C), or 65 wt% to 95 wt% of component (A) and 5 wt% to 35 wt% of component (B) and / or (C),or 70 wt% to 95 wt% of component (A) and 5 wt% to 30 wt% of component (B) and / or (C), or 75 wt% to 95 wt% of component (A) and 5 wt% to 25 wt% of component (B) and / or (C), or 80 wt% to 95 wt% of component (A) and 5 wt% to 20 wt% of component (B) and / or (C), or 25 wt% to 90 wt% of component (A) and 10 wt% to 75 wt% of component (B) and / or (C), or 30 wt% to 90 wt% of component (A) and 10 wt% to 70 wt% of component (B) and / or (C), or 35 wt% to 90 wt% of component (A) and 10 wt% to 65 wt% of component (B) and / or (C), or 40 wt% to 90 wt% of component (A) and 10 wt% to 60 wt% of component (B) and / or (C), or 45 wt% to 90 wt% of component (A) and 10 wt% to 55 wt% of component (B) and / or (C), or 50 wt% to 90 wt% of component (A) and 10 wt% to 50 wt% of component (B) and / or (C), or 55 wt% to 90 wt% of component (A) and 10 wt% to 45 wt% of component (B) and / or (C), or 60 wt% to 90 wt% of component (A) and 10 wt% to 40 wt% of component (B) and / or (C), or 65 wt% to 90 wt% of component (A) and 10 wt% to 35 wt% of component (B) and / or (C), or 70 wt% to 90 wt% of component (A) and 10 wt% to 30 wt% of component (B) and / or (C), or 75 wt% to 90 wt% of component (A) and 10 wt% to 25 wt% of component (B) and / or (C), or 80 wt% to 90 wt% of component (A) and 10 wt% to 20 wt% of component (B) and / or (C).

[0129] The relative amounts of the components containing polyester in various embodiments (in a multi-component composition) are described below. For the purposes of this application: "CHDM and TMCD polyester" refers to any embodiment described herein for a polyester containing both CHDM residues and TMCD residues in the diol component of the polyester; "CHDM and EG polyester" refers to any embodiment described herein for a polyester containing both CHDM residues and EG residues in the diol component of the polyester; "isosorbide polyester" refers to any embodiment described herein for a polyester containing isosorbide residues in the diol component of the polyester; "polyester ether" refers to any embodiment described herein for a polyester containing a polyester ether in the diol component of the polyester; "isophthalic acid copolyester" refers to any embodiment described herein for a polyester containing isophthalic acid residues in the diacid component of the polyester; and "terephthalic acid copolyester" refers to any embodiment described herein for a polyester containing terephthalic acid residues in the diacid component of the polyester; and "cyclohexanedicarboxylic acid (CHDA) polyester" refers to any embodiment described herein for a polyester containing CHDA residues in the diacid component of the polyester.

[0130] In an embodiment, the multi-component composition comprises a polymer component (A) containing isophthalic acid polyester and a component (B) containing CHDM and EG polyester or CHDM and TMCD copolyester in one of the following amounts: 40 wt% to 99 wt% of component (A) and 1 wt% to 60 wt% of component (B), or greater than 40 wt% to 99 wt% of component (A) and 1 wt% to less than 60 wt% of component (B), or 45 wt% to 99 wt% of component (A) and 1 wt% to 55 wt% of component (B), or 50 wt% to 99 wt% of component (A) and 1 wt% to 50 wt% of component (B), or greater than 50 wt% to 99 wt% of component (A) and 1 wt% to less than 50 wt% of component (B), or 55 wt% to 99 wt% of component (A) and 1 wt% to 45 wt% of component (B), or 60 wt% to 99 wt% of component (A) and 1 wt% to 40 wt% of component (B), or 65 wt% to 99 wt% of component (A) and 1 wt% to 35 wt% of component (B), or 70 wt% to 99 wt% of component (A) and 1 wt% to 30 wt% of component (B), or 75 wt% to 99 wt% of component (A) and 1 wt% to 25 wt% of component (B), or 80 wt% to 99 wt% of component (A) and 1 wt% to 20 wt% of component (B), or 55 wt% to 95 wt% of component (A) and 5 wt% to 45 wt% of component (B), or 60 wt% to 95 wt% of component (A) and 5 wt% to 40 wt% of component (B), or 65 wt% to 95 wt% of component (A) and 5 wt% to 35 wt% of component (B), or 70 wt% to 95 wt% of component (A) and 5 wt% to 30 wt% of component (B), or 75 wt% to 95 wt% of component (A) and 5 wt% to 25 wt% of component (B), or 80 wt% to 95 wt% of component (A) and 5 wt% to 20 wt% of component (B), or 55 wt% to 90 wt% of component (A) and 10 wt% to 45 wt% of component (B), or 60 wt% to 90 wt% of component (A) and 10 wt% to 40 wt% of component (B), or 65 wt% to 90 wt% of component (A) and 10 wt% to 35 wt% of component (B), or 70 wt% to 90 wt% of component (A) and 10 wt% to 30 wt% of component (B), or 75 wt% to 90 wt% of component (A) and 10 wt% to 25 wt% of component (B), or 80 wt% to 90 wt% of component (A) and 10 wt% to 20 wt% of component (B).

[0131] In an embodiment, the multicomponent composition comprises a polymer component (A) containing isophthalic acid polyester and a component (B) containing isosorbide copolyester in one of the following amounts: 40 wt% to 99 wt% component (A) and 1 wt% to 60 wt% component (B), or greater than 40 wt% to 99 wt% component (A) and 1 wt% to less than 60 wt% component (B), or 45 wt% to 99 wt% component (A) and 1 wt% to 55 wt% component (B), or 50 wt% to 99 wt% component (A) and 1 wt% to 50 wt% component (B), or greater than 50 wt% to 99 wt% component (A) and 1 wt% to less than 50 wt% component (B), or 55 wt% to 99 wt% component (A) and 1 wt% to 45 wt% component (B), or 60 wt% to 99 wt% component (A) and 1 wt% to 40 wt% component (B), or 65 wt% to 99 wt% component (A) and 1 wt% to 35 wt% component (B), or 70 wt% to 99 wt% component (A) and 1 wt% to 30 wt% component (B), or 75 wt% to 99 wt% component (A) and 1 wt% to 25 wt% component (B), or 80 wt% to 99 wt% component (A) and 1 wt% to 20 wt% component (B), or 55 wt% to 95 wt% component (A) and 5 wt% to 45 wt% component (B), or 60 wt% to 95 wt% component (A) and 5 wt% to 40 wt% component (B), or 65 wt% to 95 wt% component (A) and 5 wt% to 35 wt% component (B), or 70 wt% to 95 wt% component (A) and 5 wt% to 30 wt% component (B), or 75 wt% to 95 wt% component (A) and 5 wt% to 25 wt% component (B), or 80 wt% to 95 wt% component (A) and 5 wt% to 20 wt% component (B), or 55 wt% to 90 wt% component (A) and 10 wt% to 45 wt% component (B), or 60 wt% to 90 wt% component (A) and 10 wt% to 40 wt% component (B), or 65 wt% to 90 wt% component (A) and 10 wt% to 35 wt% component (B), or 70 wt% to 90 wt% component (A) and 10 wt% to 30 wt% component (B), or 75 wt% to 90 wt% component (A) and 10 wt% to 25 wt% component (B), or 80 wt% to 90 wt% component (A) and 10 wt% to 20 wt% component (B).

[0132] In an embodiment, the multi-component composition comprises a polymer component (A) containing isophthalic acid polyester and a component (B) containing CHDA polyester in one of the following amounts: 40 wt% to 99 wt% of component (A) and 1 wt% to 60 wt% of component (B), or greater than 40 wt% to 99 wt% of component (A) and 1 wt% to less than 60 wt% of component (B), or 45 wt% to 99 wt% of component (A) and 1 wt% to 55 wt% of component (B), or 50 wt% to 99 wt% of component (A) and 1 wt% to 50 wt% of component (B), or greater than 50 wt% to 99 wt% of component (A) and 1 wt% to less than 50 wt% of component (B), or 55 wt% to 99 wt% of component (A) and 1 wt% to 45 wt% of component (B), or 60 wt% to 99 wt% of component (A) and 1 wt% to 40 wt% of component (B), or 65 wt% to 99 wt% of component (A) and 1 wt% to 35 wt% of component (B), or 70 wt% to 99 wt% of component (A) and 1 wt% to 30 wt% of component (B), or 75 wt% to 99 wt% of component (A) and 1 wt% to 25 wt% of component (B), or 80 wt% to 99 wt% of component (A) and 1 wt% to 20 wt% of component (B), or 55 wt% to 95 wt% of component (A) and 5 wt% to 45 wt% of component (B), or 60 wt% to 95 wt% of component (A) and 5 wt% to 40 wt% of component (B), or 65 wt% to 95 wt% of component (A) and 5 wt% to 35 wt% of component (B), or 70 wt% to 95 wt% of component (A) and 5 wt% to 30 wt% of component (B), or 75 wt% to 95 wt% of component (A) and 5 wt% to 25 wt% of component (B), or 80 wt% to 95 wt% of component (A) and 5 wt% to 20 wt% of component (B), or 55 wt% to 90 wt% of component (A) and 10 wt% to 45 wt% of component (B), or 60 wt% to 90 wt% of component (A) and 10 wt% to 40 wt% of component (B), or 65 wt% to 90 wt% of component (A) and 10 wt% to 35 wt% of component (B), or 70 wt% to 90 wt% of component (A) and 10 wt% to 30 wt% of component (B), or 75 wt% to 90 wt% of component (A) and 10 wt% to 25 wt% of component (B), or 80 wt% to 90 wt% of component (A) and 10 wt% to 20 wt% of component (B).

[0133] In an embodiment, the multi-component composition comprises a polymer component (A) containing an isophthalic acid polyester and a polymer component (B) containing a copolyester, the copolyester comprising: a dicarboxylic acid component comprising at least 50 mol%, based on the mol% of the dicarboxylic acid component being 100 mol%, of diacid residues selected from terephthalic acid, cyclohexanedicarboxylic acid (CHDA) or furandicarboxylic acid (FDCA); and a diol component comprising at least 40 mol%, or at least 50 mol%, or at least 60 mol% of diol residues of CHDM.In an embodiment, the polymer components (A) and (B) are present in one of the following amounts: 40 wt% to 99 wt% of component (A) and 1 wt% to 60 wt% of component (B), or greater than 40 wt% to 99 wt% of component (A) and 1 wt% to less than 60 wt% of component (B), or 45 wt% to 99 wt% of component (A) and 1 wt% to 55 wt% of component (B), or 50 wt% to 99 wt% of component (A) and 1 wt% to 50 wt% of component (B), or greater than 50 wt% to 99 wt% of component (A) and 1 wt% to less than 50 wt% of component (B), or 55 wt% to 99 wt% of component (A) and 1 wt% to 45 wt% of component (B), or 60 wt% to 99 wt% of component (A) and 1 wt% to 40 wt% of component (B), or 65 wt% to 99 wt% of component (A) and 1 wt% to 35 wt% of component (B), or 70 wt% to 99 wt% of component (A) and 1 wt% to 30 wt% of component (B), or 75 wt% to 99 wt% of component (A) and 1 wt% to 25 wt% of component (B), or 80 wt% to 99 wt% of component (A) and 1 wt% to 20 wt% of component (B), or 55 wt% to 95 wt% of component (A) and 5 wt% to 45 wt% of component (B), or 60 wt% to 95 wt% of component (A) and 5 wt% to 40 wt% of component (B), or 65 wt% to 95 wt% of component (A) and 5 wt% to 35 wt% of component (B), or 70 wt% to 95 wt% of component (A) and 5 wt% to 30 wt% of component (B), or 75 wt% to 95 wt% of component (A) and 5 wt% to 25 wt% of component (B), or 80 wt% to 95 wt% of component (A) and 5 wt% to 20 wt% of component (B), or 55 wt% to 90 wt% of component (A) and 10 wt% to 45 wt% of component (B), or 60 wt% to 90 wt% of component (A) and 10 wt% to 40 wt% of component (B), or 65 wt% to 90 wt% of component (A) and 10 wt% to 35 wt% of component (B), or 70 wt% to 90 wt% of component (A) and 10 wt% to 30 wt% of component (B), or 75 wt% to 90 wt% of component (A) and 10 wt% to 25 wt% of component (B), or 80 wt% to 90 wt% of component (A) and 10 wt% to 20 wt% of component (B).

[0134] In certain embodiments, for the above-described multi-component compositions, the polymer component (A) has an acid component containing 20 to 60 mol% isophthalic acid residues and a diol component containing at least 50 mol%, or at least 60 mol%, or at least 70 mol% CHDM residues, and the component (B) has the following composition: (1) an acid component having at least 50 mol% TPA residues and a diol component having at least 45 mol%, or at least 50 mol%, or at least 60 mol% CHDM residues; or (2) an acid component having at least 50 mol% TPA residues and a diol component having at least 45 mol%, or at least 50 mol%, or at least 60 mol% CHDM residues and 5 to 40 mol%, or 5 to 30 mol% TMCD residues; or (3) an acid component having at least 50 mol% TPA residues and a diol component having at least 45 mol%, or at least 50 mol%, or at least 60 mol% CHDM residues and 5 to 30 mol%, or 5 to 20 mol% isosorbide residues; or (4) an acid component having at least 50 mol% TPA residues and a diol component having at least 45 mol%, or at least 50 mol%, or at least 60 mol% CHDM residues and 5 to 45 mol%, or 5 to 40 mol%, or 5 to 30 mol% EG residues; or (5) an acid component having at least 50 mol% TPA residues and a diol component having at least 45 mol%, or at least 50 mol%, or at least 60 mol% EG residues and 5 to 45 mol%, or 5 to 40 mol%, or 5 to 30 mol% CHDM residues; or (6) an acid component having at least 50 mol% TPA residues and a diol component having at least 20 mol%, or at least 40 mol%, or at least 50 mol% NPG residues; or (7) an acid component having at least 50 mol% TPA residues and a diol component having at least 20 mol%, or at least 40 mol%, or at least 50 mol% methylpropanediol residues; or (8) an acid component having at least 50 mol% CHDA residues and a diol component having at least 45 mol%, or at least 50 mol% CHDM residues; or (9) an acid component having at least 50 mol% CHDA residues and a diol component having at least 45 mol%, or at least 50 mol% CHDM residues and 5 to 40 mol%, or 5 to 30 mol% TMCD residues; or (10) an acid component having at least 50 mol% CHDA residues and a diol component having at least 45 mol%, or at least 50 mol%, or at least 60 mol% CHDM residues and 5 to 30 mol%, or 5 to 20 mol% isosorbide residues;or (11) an acid component having at least 50 mol%, or at least 60 mol%, or at least 70 mol% of CHDA residues and a diol component having at least 45 mol%, or at least 50 mol%, or at least 60 mol% of CHDM residues and 5 mol% to 30 mol%, or 5 mol% to 20 mol% of polyalkylene ether diol (e.g., polytetramethylene ether diol) residues; or (12) an acid component having at least 50 mol% of CHDA residues and a diol component having at least 45 mol%, or at least 50 mol%, or at least 60 mol% of CHDM residues and 5 mol% to 40 mol%, or 5 mol% to 30 mol% of EG residues; or (13) an acid component having at least 50 mol% of CHDA residues and a diol component having at least 20 mol%, or at least 40 mol%, or at least 50 mol% of NPG residues; or (14) an acid component having at least 50 mol% of CHDA residues and a diol component having at least 20 mol%, or at least 40 mol%, or at least 50 mol% of methylpropanediol residues; or (15) an acid component having at least 50 mol% of FDCA residues and a diol component having at least 45 mol%, or at least 50 mol% of CHDM residues; or (16) an acid component having at least 50 mol% of FDCA residues and a diol component having at least 45 mol%, or at least 50 mol% of CHDM residues and 5 mol% to 40 mol%, or 5 mol% to 30 mol% of TMCD residues; or (17) an acid component having at least 50 mol% of FDCA residues and a diol component having at least 45 mol%, or at least 50 mol%, or at least 60 mol% of CHDM residues and 5 mol% to 30 mol%, or 5 mol% to 20 mol% of isosorbide residues; or (18) an acid component having at least 50 mol% of FDCA residues and a diol component having at least 45 mol%, or at least 50 mol%, or at least 60 mol% of CHDM residues and 5 mol% to 40 mol%, or 5 mol% to 30 mol% of EG residues; or (19) an acid component having at least 50 mol% of FDCA residues and a diol component having at least 20 mol%, or at least 40 mol%, or at least 50 mol% of NPG residues; or (20) an acid component having at least 50 mol% of FDCA residues and a diol component having at least 20 mol%, or at least 40 mol%, or at least 50 mol% of methylpropanediol residues.;

[0135] In certain embodiments, for the above-described multi-component compositions, the polymeric component (A) has an acid component containing from 20 to 60 mole % isophthalic acid residues and a diol component containing at least 50 mole %, or at least 60 mole %, or at least 70 mole % CHDM residues, and component (B) has the following composition: (1) an acid component having at least 50 mole % TPA residues and a diol component having at least 45 mole %, or at least 50 mole %, or at least 60 mole % CHDM residues and from 5 to 30 mole %, or from 5 to 20 mole %, or from 5 to 40 mole %, or from 5 to 30 mole %, or from 5 to 20 mole % isosorbide residues and from 5 to 40 mole %, or from 5 to 30 mole %, or from 5 to 20 mole % EG residues; or (2) an acid component having at least 50 mole % CHDA residues and a diol component having at least 45 mole %, or at least 50 mole %, or at least 60 mole % CHDM residues and from 5 to 30 mole %, or from 5 to 20 mole %, or from 5 to 40 mole %, or from 5 to 30 mole %, or from 5 to 20 mole % isosorbide residues and from 5 to 40 mole %, or from 5 to 30 mole %, or from 5 to 20 mole % EG residues; or (3) an acid component having at least 50 mole % FDCA residues and a diol component having at least 45 mole %, or at least 50 mole %, or at least 60 mole % CHDM residues and from 5 to 30 mole %, or from 5 to 20 mole %, or from 5 to 40 mole %, or from 5 to 30 mole %, or from 5 to 20 mole % isosorbide residues and from 5 to 40 mole %, or from 5 to 30 mole %, or from 5 to 20 mole % EG residues.

[0136] In certain embodiments, the polymeric component (A) as described herein is the minor component in the multi-component composition. In such embodiments, the major component can be the polymeric component (B) as described in any of the embodiments herein.

[0137] In any embodiment of the multi-component composition, the multi-component composition containing a blend of the polymeric component (A) with the polymeric component (B) and / or (C) contains diacid residues that comprise from about 5 to about 35, or 5 to 30, or 5 to 25, or 10 to 35, or 10 to 30, or 10 to 25, or 15 to 35, or 15 to 30, or 15 to 25, or 20 to 35, or 20 to 30, or 20 to 25, or 25 to 35, or 25 to 30, or 30 to 35 net mole percent IPA residues, wherein the blend contains a total of 100 mole % of diacid residues and a total of 100 mole % of diol residues.

[0138] The “net mole percent” of a monomer residue in a polyester blend means the total mole % of the monomer of the corresponding diacid residue or diol residue contained in the total blend. For example, the net mole percent of a diacid monomer residue relative to a polyester blend means the total amount (in mole percent) of the diacid monomer counted for all diacid residues (of all individual polymer components) contained in the blend. Thus, if polyester A contains 70 mole % TPA residues and 30 mole % IPA residues (based on 100 mole % diacid residues of polyester A); polyester B contains 95 mole % TPA residues and 5 mole % IPA residues (based on 100 mole % diacid residues of polyester B); and the blend contains 75 wt % polyester A and 25 wt % polyester B; then based on the total diacid residues of the blend, the blend has a net mole % of IPA residues of about 23.8 mole %.

[0139] In certain embodiments, a single-component or multi-component composition forms one or more layers in a multilayer film structure or is included in one or more layers in a multilayer film structure. In an embodiment, the multilayer film structure is a three-layer structure having a core layer and two outer layers, one outer layer on each side of the core layer. In an embodiment, the core layer contains the multi-component composition and the outer layers are made of other polymer compositions. In an embodiment, at least one of the outer layers contains the multi-component composition and the core layer is made of another polymer composition.

[0140] In an embodiment, a multilayer sheet (or film) is provided that includes at least two layers, the at least two layers including a first layer and a second layer, where the first layer includes or consists of an IPA-containing polyester and / or a multi-component composition as described herein, and the second layer includes a polyester different from the polyester / composition of the first layer. In an embodiment, the second layer includes any polyester that can be used as component A, B, or C in the multi-component composition described herein. In one embodiment, the first layer includes any multi-component composition described herein and the second layer includes a TMCD-containing polyester.

[0141] Depending on the application, examples of suitable second layer polyester materials may include Eastman Tritan TM MP100, TX1000, TX1500, TX2000, TX1800, MX710, MX711, MX810, MX900, and MX730 copolyesters available from Eastman Chemical Company.

[0142] In one embodiment, the first layer comprises any of the multicomponent compositions described herein, and the second layer comprises a CHDA polyester and / or a polyester elastomer (e.g., a polyether ester elastomer). Depending on the application, examples of suitable polyester materials for such a second layer may include Neostar TM Polyester 19972, available from Eastman Chemical Company. In certain embodiments, depending on the application, examples of suitable polyester elastomers (e.g., polyether ester elastomers) for such a second layer may include Ecdel TM Elastomer 9966 (and / or 9967) and / or Eastar TM Copolyester 6763.

[0143] In other embodiments, the first layer comprises any of the multicomponent compositions described herein, and the second layer comprises an elastomeric material. In embodiments, the elastomeric material may be selected from styrene block copolymers (SBCs), silicone rubbers, elastomeric alloys, thermoplastic elastomers (TPEs), thermoplastic vulcanizates (TPVs) elastomers, polyurethane elastomers, block copolymer elastomers, polyolefin blend elastomers, thermoplastic polyester elastomers (e.g., copolyester elastomers or polyether ester elastomers), thermoplastic polyamide elastomers, or combinations thereof (e.g., blends of at least two of the listed elastomeric materials). In certain embodiments, the second layer may be a polyester elastomer (e.g., a polyether ester elastomer) and / or a polyurethane elastomer.

[0144] In embodiments, the second layer may comprise a polyether ester or a copolyether ester (COPE), such as the (PCCE) commercially available from, for example, Eastman Chemical Company. The term "polyester" as used herein with respect to the second layer is intended to include copolyether esters. The copolyether ester may be derived from a dicarboxylic acid component comprising 1,4-cyclohexanedicarboxylic acid or an ester-forming derivative thereof (such as dimethyl-1,4-cyclohexanedicarboxylate) and / or consisting essentially of the same. Such acids and esters are sometimes referred to herein as DMCD. The diol component may consist essentially of 1,4-cyclohexanedimethanol (CHDM) and polytetramethylene ether glycol (PTMG). The copolyether ester may also contain a branching agent, e.g., a polyfunctional branching agent having at least 3 carboxyl or hydroxyl groups in an amount of about 0.1 mol% to about 1.5 mol% based on the acid or diol component.

[0145] In an embodiment, the diacid component of the copolyester ether comprises residues of 1,4-cyclohexanedicarboxylic acid or dimethyl-1,4-cyclohexanedicarboxylate having a trans isomer content of at least 65%, or at least 70%, or at least 80% or at least 85%. In one embodiment, the diacid component of the copolyester ether may consist essentially of DMCD and may have a trans isomer content of at least 70%, or at least 80%, or at least 85%.

[0146] In an embodiment, based on the total number of acid residues at 100 wt% and the total number of diol residues at 100 wt%, the polyester ether included in the second layer may comprise 70 wt% - 100 wt%, or 80 wt% to 100 wt%, or 90 wt% to 100 wt%, or 95 wt% to 100 wt%, or 98 wt% to 100 wt% of residues of 1,4-cyclohexanedicarboxylic acid or its ester. The polyester ether may comprise residues of 1,4-cyclohexanedimethanol and polytetramethylene ether glycol.

[0147] In certain embodiments, the polyester ether may comprise residues of polytetramethylene ether glycol residues in an amount of from 1 mol% to 50 mol%, or from 5 mol% to 50 mol%, or from 10 mol% to 50 mol%, or from 15 mol% to 50 mol%, or from 20 mol% to 50 mol% or from 25 mol% to 50 mol%, or from 30 mol% to 50 mol%, or from 35 mol% to 50 mol%, or from 40 mol% to 50 mol%, or from 45 mol% to 50 mol%, or from 1 mol% to 45 mol%, or from 5 mol% to 45 mol%, or from 10 mol% to 45 mol%, or from 15 mol% to 45 mol%, or from 20 mol% to 45 mol% or from 25 mol% to 45 mol%, or from 30 mol% to 45 mol%, or from 35 mol% to 45 mol%, or from 40 mol% to 45 mol%, or from 1 mol% to 40 mol%, or from 5 mol% to 40 mol%, or from 10 mol% to 40 mol%, or from 15 mol% to 40 mol%, or from 20 mol% to 40 mol% or from 25 mol% to 40 mol%, or from 30 mol% to 40 mol%, or from 35 mol% to 40 mol%, or from 1 mol% to 35 mol%, or from 5 mol% to 35 mol%, or from 10 mol% to 35 mol%, or from 15 mol% to 35 mol%, or from 20 mol% to 35 mol% or from 25 mol% to 35 mol%, or from 30 mol% to 35 mol%, or from 1 mol% to 30 mol%, or from 5 mol% to 30 mol%, or from 10 mol% to 30 mol%, or from 15 mol% to 30 mol%, or from 20 mol% to 30 mol% or from 25 mol% to 30 mol%, or from 1 mol% to 25 mol%, or from 5 mol% to 25 mol%, or from 10 mol% to 25 mol%, or from 15 mol% to 25 mol%, or from 20 mol% to 25 mol%, or from 1 mol% to 20 mol%, or from 5 mol% to 20 mol%, or from 10 mol% to 20 mol%, or from 15 mol% to 20 mol%, or from 1 mol% to 15 mol%, or from 5 mol% to 15 mol%, or from 10 mol% to 15 mol%, or from 1 mol% to 10 mol%, or from 5 mol% to 10 mol%, or from 1 mol% to 5 mol%.

[0148] In certain embodiments, the polyester ether may comprise residues of polytetramethylene ether glycol residues in an amount of from 1 mol% to 20 mol%, or from 1 mol% to 15 mol%, or from 1 mol% to 12 mol%, or from 1 mol% to 10 mol%, or from 3 mol% to 12 mol%, or from 5 mol% to 10 wt%, or from 7 mol% to 10 mol%.

[0149] In one embodiment, the polyester portion of the polyether ester comprises residues of at least one diol as described for the polyesters useful in the present invention. In certain embodiments, the polyester portion of the polyether ester comprises residues of at least one diol selected from ethylene glycol, diethylene glycol, triethylene glycol, isosorbide, propane-1,3-diol, butane-1,4-diol, 2,2-dimethylpropane-1,3-diol (neopentyl glycol), 2,2,4,4,-tetramethyl-1,3-cyclobutanediol, pentane-1,5-diol, hexane-1,6-diol, 1,4-cyclohexanedimethanol, 3-methyl-pentane-(2,4)-diol, 2-methylpentane-(1,4)-diol, 2,2,4-trimethylpentane-(1,3)-diol, 2-ethylhexane-(1,3)-diol, 2,2-diethylpropane-(1,3)-diol, hexane-(1,3)-diol, 1,4-bis-(hydroxyethoxy)-benzene, 2,2-bis-(4-hydroxycyclohexyl)-propane, 2,4-dihydroxy-1,1,3,3-tetramethyl-cyclobutane, 2,2-bis-(3-hydroxyethoxyphenyl)-propane, 2,2-bis-(4-hydroxypropoxyphenyl)-propane, and mixtures thereof. In an embodiment, aside from residues of polytetramethylene ether glycol (PTMG), the balance of the diol component of the polyether ester is substantially 1,4-cyclohexanedimethanol (CHDM) residues. In an embodiment, the diol component of the polyether ester comprises less than 10 mol%, or less than 5 mol%, or less than 2 mol%, or less than 1 mol% of diol residues other than residues of CHDM and PTMG.

[0150] In an embodiment, the polyether ester may comprise 50 wt% to 95 wt%, or 55 wt% to 95 wt%, or 60 wt% to 95 wt%, or 70 wt% to 95 wt%, or 75 wt% to 95 wt%, or 80 wt% to 95 wt% of residues of 1,4-cyclohexanedimethanol residues. In an embodiment, the polyether ester is free of residues of ethylene glycol.

[0151] In an embodiment, the second layer may comprise a polyester ether having an intrinsic viscosity (IV) in the range of 0.70 to 1.5 dL / g, or 0.8 to 1.4 dL / g, or 0.9 to 1.3 dL / g, 1.0 to 1.2 dL / g, or 1.1 to 1.2 dL / g, or 1.14 to 1.18 dL / g, measured at 25 °C at a concentration of 0.5 g / 100 ml in 60 / 40 (wt / wt) phenol / tetrachloroethane. In an embodiment, the polyester ether has a glass transition temperature (Tg) measured by DSC of less than 0 °C, or less than -10 °C, or less than -20 °C, or less than -30 °C, or in the range of -60 °C to 0 °C, or -50 °C to -10 °C, -60 °C to -20 °C, or -50 °C to -30 °C. In an embodiment, the polyester ether has an elongation at break of at least 200%, or at least 300%, or at least 350%, or in the range of 200% to 600%, or 300% to 500%, measured according to ASTM D 638; and / or a flexural modulus in the range of 50 to 250 Mpa, or 100 to 200 MPa, measured according to ASTM D 790; and / or a tear strength of at least 200 N, or at least 250 N, or at least 300 N or in the range of 200 N to 500 N, or 250 N to 450 N, or 300 N to 400 N, measured according to ASTM D 1004.

[0152] In one embodiment, the copolyester ether contained in the second layer may have an intrinsic viscosity of about 0.70 to about 1.5 dL / g, measured at 25 °C at a concentration of 0.5 g / 100 ml in 60 / 40 (wt / wt) phenol / tetrachloroethane, and may comprise:

[0153] A. A dicarboxylic acid component comprising and / or consisting essentially of 1,4-cyclohexanedicarboxylic acid, and

[0154] B. A diol component consisting essentially of:

[0155] (1) 1,4-cyclohexanedimethanol, and

[0156] (2) Based on the number of moles of the diol component of the polyester ether, about 1 mol% to about 50 mol%, or 1 mol% to 20 mol%, or 1 mol% to 15 mol%, or 2 mol% to 10 mol% of polytetramethylene ether glycol (PTMG) having a weight average molecular weight of about 500 to about 2000.

[0157] In one embodiment, the copolyester ether may further comprise (3) a branching agent having at least three COOH or OH functional groups and 3 to 60 carbon atoms in an amount of about 0.1 mol% to about 1.5 mol%, or 0.1 mol% to 1.0 mol%, based on the total mole% of the acid or diol components. In embodiments, the branching agent may include one or more branching agents and examples thereof, as described herein with respect to other polyesters.

[0158] In an embodiment, the multilayer sheet (or film) is a three-layer structure having a core layer and two outer layers, one outer layer on each side of the core layer. In an embodiment, the core layer contains the second composition and the outer layers are made of the first composition. In other embodiments, the core layer contains the first composition and the outer layers are made of the second composition.

[0159] As described above, the total thickness of the film may range from about 100 μm to about 3000 μm, or from about 300 μm to about 3000 μm. In other embodiments, the thickness of the sheet ranges from about 380 μm to about 1600 μm, or from about 500 μm to 1000 μm.

[0160] Single-component or multi-component composition films can be prepared by lamination and extrusion and other methods.

[0161] In embodiments of a film structure having at least three layers, the thickness of the core layer may range from about 1 μm to about 1000 μm. In certain embodiments, the thickness of the core layer ranges from about 1 μm to about 725 μm, or 1 μm to 600 μm. In certain embodiments, the thickness of each outer layer individually ranges from about 1 μm to about 2000 μm. In another embodiment, the outer layer thickness ranges from about 25 μm to about 2000 μm.

[0162] In an embodiment, the multilayer sheet has a total thickness in the range of 100 to 1050 microns, or 500 to 1050 microns, or 500 to 1000 microns, or 600 to 900 microns, or 600 to 800 microns, or 635 microns (25 mils) to 889 microns (35 mils), or 635 microns (25 mils) to 762 microns (30 mils). In an embodiment, the thickness of the second layer is 10% to 75%, or 10% to 70%, or 10% to 65%, or 10% to 60%, or 10% to 55%, or 10% to 50%, or 15% to 45%, or 20% to 40%, or 20% to 35%, or 25% to 35% of the total thickness of the multilayer sheet. In an embodiment, the thickness of the second layer is 20% to 75%, or 20% to 70%, or 20% to 65%, or 20% to 60%, or 20% to 55%, or 20% to 50%, or 25% to 75%, or 25% to 70%, or 25% to 65%, or 25% to 60%, or 25% to 55%, or 25% to 50%, or 30% to 75%, or 30% to 70%, or 30% to 65%, or 30% to 60%, or 30% to 55%, or 30% to 50%, or 35% to 75%, or 35% to 70%, or 35% to 65%, or 35% to 60%, or 35% to 55%, or 35% to 50% of the total thickness of the multilayer sheet.

[0163] Multilayer films can be prepared by coextrusion, extrusion lamination, thermal lamination, adhesive lamination, etc. In coextrusion, a multilayer polymer is prepared by melting the polymer composition of each layer in different extruders, which are fed into a coextrusion module or die. The multilayer sheet or film is formed in the module or die. Extrusion lamination is a process in which at least two sheets or films (single layer or coextruded) are bonded together by extruding a polymer melt between them to prepare a multilayer structure. Adhesive lamination requires at least two sheets or films (single layer or coextruded) and uses a liquid adhesive to bond them together to prepare a multilayer sheet or film. Thermal lamination is a batch process in which cut sheets or films of various compositions or structures are laminated in a hot press. Multiple combinations and multiple layers can be fabricated using these methods.

[0164] If a multi-layer film having a core layer and an outer layer as described herein tends to separate or delaminate from each other during processing or use, at least one intermediate "adhesive layer" can be used between such layers. In one embodiment, the multi-layer film has at least five film layers, including a core layer A and two outer layers B, with one layer B on each side of the core layer A, and an adhesive layer between layer A and each layer B, i.e., "B-adhesive-A-adhesive-B". In certain embodiments, such an adhesive layer can comprise one or more copolymers selected from the following: polyethylene copolymers, polypropylene copolymers, acid anhydride-modified polyolefins, acid / acrylic ester-modified ethylene vinyl acetate copolymers, acid-modified ethylene acrylate, acid anhydride-modified ethylene acrylate, modified ethylene acrylate, modified ethylene vinyl acetate, acid anhydride-modified ethylene vinyl acetate copolymers, acid anhydride-modified high-density polyethylene, acid anhydride-modified linear low-density polyethylene, acid anhydride-modified low-density polyethylene, acid anhydride-modified polypropylene, ethylene ethyl acrylate maleic anhydride copolymer and ethylene butyl acrylate maleic anhydride terpolymer, ethylene-α-olefin copolymers, olefin unsaturated carboxylic acid or carboxylic acid derivative copolymers, ethylene-methacrylic acid copolymers, ethylene-vinyl acetate copolymers, ethylene-methacrylic acid copolymers, unsaturated dicarboxylic anhydride graft copolymers, maleic anhydride grafted ethylene-vinyl acetate copolymers, maleic anhydride grafted polyethylene, styrene-butadiene copolymers, C3 or higher α-olefin copolymers having a high α-olefin comonomer content, propylene-1-butene copolymers, and mixtures thereof.

[0165] In an embodiment, the film (e.g., a single-layer or multi-layer film, depending on the embodiment) has an average tear propagation resistance of at least 30 N / mm, or at least 31 N / mm, or at least 32 N / mm, or at least 33 N / mm, or at least 34 N / mm, or at least 35 N / mm, or at least 36 N / mm, or at least 37 N / mm, or at least 38 N / mm, or at least 39 N / mm, or at least 40 N / mm, or at least 45 N / mm, or at least 50 N / mm, or at least 60 N / mm, or at least 70 N / mm, or in the range of 30 N / mm to 100 N / mm, or 30 N / mm to 80 N / mm, or 30 N / mm to 60 N / mm, or 30 N / mm to 55 N / mm, or 30 N / mm to 50 N / mm, 35 N / mm to 100 N / mm, or 35 N / mm to 80 N / mm, or 35 N / mm to 60 N / mm, or 35 N / mm to 55 N / mm, or 35 N / mm to 50 N / mm, 40 N / mm to 100 N / mm or 40 N / mm to 80 N / mm or 40 N / mm to 60 N / mm or 40 N / mm to 55 N / mm or 40 N / mm to 50 N / mm, or 50 N / mm to 100 N / mm, or 50 N / mm to 80 N / mm, or 50 N / mm to 70 N / mm, or 50 N / mm to 60 N / mm, or 60 N / mm to 100 N / mm, or 60 N / mm to 80 N / mm, or 60 N / mm to 70 N / mm, measured according to ASTM D1938.In an embodiment, the film (e.g., a single-layer or multi-layer film, depending on the embodiment) has an average tear propagation resistance in the transverse direction of at least 30 N / mm, or at least 31 N / mm, or at least 32 N / mm, or at least 33 N / mm, or at least 34 N / mm, or at least 35 N / mm, or at least 36 N / mm, or at least 37 N / mm, or at least 38 N / mm, or at least 39 N / mm, or at least 40 N / mm, or at least 45 N / mm, or at least 50 N / mm, or at least 60 N / mm, or at least 70 N / mm, or at least 80 N / mm, or in the range of 30 N / mm to 100 N / mm, or 30 N / mm to 80 N / mm, or 30 N / mm to 60 N / mm, or 30 N / mm to 55 N / mm, or 30 N / mm to 50 N / mm, 35 N / mm to 100 N / mm, or 35 N / mm to 80 N / mm, or 35 N / mm to 60 N / mm, or 35 N / mm to 55 N / mm, or 35 N / mm to 50 N / mm, 40 N / mm to 100 N / mm or 40 N / mm to 80 N / mm or 40 N / mm to 60 N / mm or 40 N / mm to 55 N / mm or 40 N / mm to 50 N / mm, or 50 N / mm to 100 N / mm, or 50 N / mm to 80 N / mm, or 50 N / mm to 70 N / mm, or 50 N / mm to 60 N / mm, or 60 N / mm to 100 N / mm, or 60 N / mm to 80 N / mm, or 60 N / mm to 70 N / mm, or 70 N / mm to 100 N / mm, or 70 N / mm to 80 N / mm, as measured according to ASTM D 1938.In an embodiment, the film (e.g., a single-layer or multi-layer film, depending on the embodiment) has an average tear propagation resistance measured according to ASTM D 1938 of at least 30 N / mm, or at least 31 N / mm, or at least 32 N / mm, or at least 33 N / mm, or at least 34 N / mm, or at least 35 N / mm, or at least 36 N / mm, or at least 37 N / mm, or at least 38 N / mm, or at least 39 N / mm, or at least 40 N / mm, or at least 45 N / mm, or at least 50 N / mm, or at least 60 N / mm, or at least 70 N / mm, or in the range of 30 N / mm to 100 N / mm, or 30 N / mm to 80 N / mm, or 30 N / mm to 60 N / mm, or 30 N / mm to 55 N / mm, or 30 N / mm to 50 N / mm, 35 N / mm to 100 N / mm, or 35 N / mm to 80 N / mm, or 35 N / mm to 60 N / mm, or 35 N / mm to 55 N / mm, or 35 N / mm to 50 N / mm, 40 N / mm to 100 N / mm or 40 N / mm to 80 N / mm or 40 N / mm to 60 N / mm or 40 N / mm to 55 N / mm or 40 N / mm to 50 N / mm, or 50 N / mm to 100 N / mm, or 50 N / mm to 80 N / mm, or 50 N / mm to 70 N / mm, or 50 N / mm to 60 N / mm, or 60 N / mm to 100 N / mm, or 60 N / mm to 80 N / mm, or 60 N / mm to 70 N / mm in the machine direction and the transverse direction.

[0166] In an embodiment, the film (e.g., a single-layer or multi-layer film, depending on the embodiment) has an average tear propagation resistance of at least 30 N / mm, or at least 31 N / mm, or at least 32 N / mm, or at least 33 N / mm, or at least 34 N / mm, or at least 35 N / mm, or at least 36 N / mm, or at least 37 N / mm, or at least 38 N / mm, or at least 39 N / mm, or at least 40 N / mm, or at least 45 N / mm, or at least 50 N / mm, or at least 60 N / mm, or at least 70 N / mm, or in the range of 30 N / mm to 100 N / mm, or 30 N / mm to 80 N / mm, or 30 N / mm to 60 N / mm, or 30 N / mm to 55 N / mm, or 30 N / mm to 50 N / mm, 35 N / mm to 100 N / mm, or 35 N / mm to 80 N / mm, or 35 N / mm to 60 N / mm, or 35 N / mm to 55 N / mm, or 35 N / mm to 50 N / mm, 40 N / mm to 100 N / mm or 40 N / mm to 80 N / mm or 40 N / mm to 60 N / mm or 40 N / mm to 55 N / mm or 40 N / mm to 50 N / mm, or 50 N / mm to 100 N / mm, or 50 N / mm to 80 N / mm, or 50 N / mm to 70 N / mm, or 50 N / mm to 60 N / mm, or 60 N / mm to 100 N / mm, or 60 N / mm to 80 N / mm, or 60 N / mm to 70 N / mm, as measured according to ASTM D1938; and / or a force retention rate of 70% or less, or 50% or less, or 30% or less, or 5% to 70%, or 5% to 50%, or 10% to 50%, or 20% to 40%, as measured as described in the examples herein;and / or a flexural modulus in the range of greater than 1000 Mpa, or at least 1200 Mpa, or at least 1500 Mpa, or greater than 1000 to 2400 Mpa, or greater than 1000 to 2200 Mpa, or greater than 1200 to 2400 Mpa, or greater than 1200 to 2200 Mpa, or greater than 1500 to 2400 Mpa, or greater than 1500 to 2200 Mpa, or 1600 to 2400 Mpa, or 1600 to 2200 Mpa, or 1600 to 2000 Mpa, or 1700 to 2400 Mpa, or 1700 to 2200 Mpa, or 1700 to 2000 Mpa, or 1800 to 2400 Mpa, or 1800 to 2300 Mpa, or 1800 to 2200 Mpa, or 1800 to 2000 Mpa, or 1900 to 2400 Mpa, or 1900 to 2300 Mpa, or 1900 to 2200 Mpa, or 1900 to 2000 Mpa, or 2000 to 2400 Mpa, or 2000 to 2300 Mpa, or 2000 to 2200 Mpa, or 2100 to 2400 Mpa, or 2100 to 2300 Mpa, or 2200 to 2400 Mpa, as measured according to ASTM D 790. In an embodiment, the multilayer sheet has the above-mentioned tear force and force retention properties. In an embodiment, the film has each of the above-mentioned tear force, force retention and flexural modulus properties. The force retention property of the examples was analyzed on a film sample with a thickness of 0.7 - 0.8 mm and a width of 3.1 - 3.3 mm in tensile mode using dynamic mechanical analysis (DMA). The sample was held at 0.5% strain for 24 hours, during which the stress was monitored. This test was carried out at 37 °C and a relative humidity of 90% - 100% (which may include testing while immersed in water).;

[0167] In an embodiment, the film has a total thickness in the range of 100 to 1050 microns, or 500 to 1050 microns, or 500 to 1000 microns, or 600 to 900 microns, or 600 to 800 microns, or 635 microns (25 mils) to 889 microns (35 mils), or 635 microns (25 mils) to 762 microns (30 mils). In an embodiment of a multilayer film, the thickness of the inner layer (or core layer) can be 10% to 50%, or 15% to 45%, or 20% to 40%, or 20% to 35%, or 25% to 35% of the total thickness of the multilayer film.

[0168] Due to its structure with customizable modulus and excellent tear resistance, the film can be used to prepare removable dental appliances, such as removable orthodontic tooth positioning appliances, provided that the film has a sufficiently high modulus and excellent tear resistance. See, for example, U.S. Patent Nos. 9,655,691; 9,655,693; and 10,052,176; which are incorporated herein by reference.

[0169] Thus, in one embodiment, the present invention provides a removable dental appliance having one or more tooth receiving cavities shaped to receive at least some of the patient's teeth, the appliance comprising a polymeric structure formed from any of the films described herein.

[0170] In another embodiment, the present invention provides a removable orthodontic tooth positioning appliance having tooth receiving cavities shaped to directly receive at least some of the patient's teeth, the appliance comprising a polymeric structure formed from a film comprising a single-component or multi-component composition comprising at least one polymer component (A) and optionally a polymer component (B), wherein the polymer component (A) is present in an amount of 40 wt% to 100 wt%, or 50 wt% to 100 wt%, and the polymer component (B) is present in an amount of 0 wt% to 60 wt%, or 0 wt% to 50 wt%; and wherein

[0171] the polymer component (A) comprises a polyester, the polyester comprising:

[0172] (a) a dicarboxylic acid component, the dicarboxylic acid component comprising:

[0173] i) 1 mol% to 100 mol% of isophthalic acid residues; and

[0174] ii) 0 mol% to 99 mol% of terephthalic acid residues; and

[0175] iii) 0 mol% to 25 mol% of different aromatic and / or aliphatic dicarboxylic acid residues having up to 20 carbon atoms; and

[0176] (b) a diol component, the diol component comprising:

[0177] i) 1 mol% to 100 mol% of 1,4-cyclohexanedimethanol residues; and

[0178] ii) 0 mol% to 99 mol% of ethylene glycol residues; and

[0179] iii) 0 mol% to 25 mol% of different aromatic and / or aliphatic modified diol residues;

[0180] an intrinsic viscosity of from about 0.4 to about 1.1 dL / g, measured at 25 °C at a concentration of 0.5 g / 100 ml in 60 / 40 (wt / wt) phenol / tetrachloroethane; and the polymer component (B) comprises a polyester different from the polyester in the polymer component (A), and wherein when measured according to ASTM D 1938, the film has an average tear propagation resistance greater than 30 N / mm, or greater than 35 N / mm, or greater than 40 N / mm in the machine direction and the transverse direction; and

[0181] wherein when measured according to ASTM D 1003 on a 0.75 mm film, the multicomponent film has a haze value of less than 30% or less than 20%, and wherein the total thickness of the film is between 100 microns and 3000 microns or between 300 microns and 3000 microns.

[0182] In another embodiment, the polymer component (A) comprises a polyester, the polyester comprising:

[0183] (a) a dicarboxylic acid component, the dicarboxylic acid component comprising:

[0184] i) from 1 mol% to 100 mol% of isophthalic acid residues; and

[0185] ii) from 0 mol% to 99 mol% of terephthalic acid residues;

[0186] (b) a diol component, the diol component comprising:

[0187] i) from 1 mol% to 100 mol% of 1,4-cyclohexanedimethanol residues; and

[0188] ii) from 0 mol% to 99 mol% of ethylene glycol residues;

[0189] an intrinsic viscosity of from about 0.4 to about 1.1 dL / g, measured at 25 °C at a concentration of 0.5 g / 100 ml in 60 / 40 (wt / wt) phenol / tetrachloroethane.

[0190] In another embodiment, the polymer component (A) comprises a polyester, the polyester comprising:

[0191] (a) a dicarboxylic acid component, the dicarboxylic acid component comprising:

[0192] i) from 1 mol% to 50 mol% of isophthalic acid residues; and

[0193] ii) from 50 mol% to 99 mol% of terephthalic acid residues;

[0194] (b) a diol component, the diol component comprising:

[0195] i) residues of 1,4 - cyclohexanedimethanol;

[0196] Having an intrinsic viscosity of about 0.4 to about 1.1 dL / g as measured at 25 °C at a concentration of 0.5 g / 100 ml in 60 / 40 (wt / wt) phenol / tetrachloroethane. In another embodiment, the intrinsic viscosity of polymer component (A) is between about 0.6 and 0.8 dL / g.

[0197] In an embodiment, a film comprising a multi - component composition for forming an appliance may include any of the film embodiments described herein and any combination of polymer components (A) and (B) for a two (or more) - component composition or any combination of polymer components (A), (B), and (C) for a three (or more) - component composition.

[0198] In another embodiment, the present invention provides a removable orthodontic tooth - positioning appliance having a tooth - receiving cavity shaped to directly receive at least some of the patient's teeth, the appliance comprising a multi - layer polymer structure formed from a film, the film including two outer layers and at least one core layer, wherein at least one layer comprises the multi - component composition described herein.

[0199] In an embodiment, the dental appliance can be made from any of the single - layer or multi - layer films described herein.

[0200] The present invention can be further illustrated by the following examples of certain of its embodiments, but it is to be understood that these examples are included for illustrative purposes only and are not intended to limit the scope of the invention unless specifically stated otherwise.

[0201] Example

[0202] The following examples are provided to illustrate certain embodiments of the present invention.

[0203] Preparation of thin film sample

[0204] All blends were compounded on a 26 mm twin - screw extruder and strand - pelletized prior to film extrusion. The compounding barrel and die temperatures were in the range of 260 °C - 270 °C. Film samples were extruded on a 1.5” single - screw extruder with a target film thickness of 0.7 - 0.8 mm. The film extrusion barrel temperature was 260 °C - 270 °C. All materials were dried prior to compounding and extrusion. The properties provided were tested using the methods outlined in the “Test Methods” described herein.

[0205] Test Methods

[0206] The tensile properties of the examples were determined using the test method derived from ASTM D882. The film thickness was 0.7 to 0.8 mm. Small V-shaped tensile bars were cut from the film. Unless otherwise specified, the samples were conditioned for at least 40 hours and tested at 23 °C / 50% relative humidity. A crosshead speed of 1.27 mm / min was used.

[0207] The flexural properties of the examples were determined using the test method derived from ASTM D790 Procedure A. The film thickness was 0.7 to 0.8 mm. Unless otherwise specified, the film was conditioned for 40 hours and tested at 23 °C / 50% relative humidity. A crosshead speed of 1.27 mm / min was used.

[0208] The tear propagation resistance of the examples was determined using the test method derived from ASTM D1938. The film thickness was 0.7 to 0.8 mm. Unless otherwise specified, the film was conditioned for 40 hours and tested at 23 °C / 50% relative humidity. A load was applied at 250 mm per minute.

[0209] The hardness of the examples was determined using the test method derived from ASTM D2240. The film thickness was 0.7 to 0.8 mm, and the samples were stacked if necessary to achieve the required test thickness. Unless otherwise specified, the samples were conditioned for at least 40 hours and tested at 23 °C / 50% relative humidity.

[0210] Unless otherwise specified, L*, a*, and b* were determined on 0.75 mm films in accordance with ASTM E 1348 and ASTM E308.

[0211] Unless otherwise specified, haze % and transmission % were determined on 0.75 mm films in accordance with ASTM D 1003.

[0212] Unless otherwise specified, the glass transition temperature (Tg) was determined using a TA DSC 2920 from a Thermal Analyst Instrument at a scan rate of 20 °C / min on samples dried in a vacuum oven for 24 hours before testing.

[0213] Unless otherwise specified, the force retention properties were analyzed using dynamic mechanical analysis (DMA) in tensile mode on film samples with a thickness of 0.7 - 0.8 mm and a width of 3.1 - 3.3 mm. The samples were held at 0.5% strain for 24 hours, during which the stress was monitored. The test was conducted at 37 °C and 90% - 100% relative humidity (which may include testing while immersed in water).

[0214] Example

[0215] The materials used in the examples include:

[0216] R1 - Durastar MN621 (Eastman Chemical Company)

[0217] R2 - Durastar MN611 (Eastman Chemical Company)

[0218] R3 - Eastar CN015 (Eastman Chemical Company)

[0219] R4 - Neostar 19972 (Eastman Chemical Company)

[0220] R5 - Tritan MP100 (Eastman Chemical Company)

[0221] R6 - Tritan MP200 (Eastman Chemical Company)

[0222] R7 - Tritan TX1800 (Eastman Chemical Company)

[0223] R8 - Eastar MN210 (Eastman Chemical Company)

[0224] R9 - Medstar (Eastman Chemical Company)

[0225] Example 1

[0226] Table 1 provides examples comparing films prepared from copolyesters R1, R2, and R3 and blends of R2 with copolyester R4. Copolyesters R1, R2, and R3 have diacid components that contain approximately 26 mol% IPA residues, 35 mol% IPA residues, and 48 mol% IPA residues, respectively, based on the total mol% of diacid residues of each copolyester. R4 is a polyester with a diacid component that contains CHDA residues and no IPA residues.

[0227] Comparative Example 2

[0228] Table 2 provides comparative examples of films prepared from copolyesters R5 and R6 and blends of R5 with copolyester R4. Both copolyesters R5 and R6 do not contain IPA residues, but the glycol residues contained in these copolyesters include TMCD residues.

[0229] Table 1 - Characteristics of the Examples

[0230]

[0231] Analysis of Table 1 reveals that the films (single - component and multi - component) according to Example 1 can provide the ability to adjust certain properties such as modulus while maintaining high tear resistance.

[0232] Table 2 - Characteristics of Example 2

[0233]

[0234]

[0235] Analysis of Table 2 reveals that the comparative examples according to Example 2 exhibit lower tear propagation resistance compared to the examples in Table 1 according to Example 1.

[0236] Example 3

[0237] Table 3 provides examples comparing films prepared from blends of R1 with polyester R5; blends of R2 with polyesters R5, R8, and R9 respectively; and blends of R3 with polyester R5. Polyester R8 has a diacid component without any IPA residues and a diol component containing diol residues, most of which are ethylene glycol (EG) residues and a few are CHDM residues. Polyester R9 has a diacid component without any IPA residues and a diol component containing diol residues, most of which are CHDM residues and a few are EG residues.

[0238] Table 3 - Characteristics of Example 3

[0239]

[0240]

[0241] Analysis of Table 3 reveals that the examples according to Example 3 exhibit higher tear propagation resistance of the blends with R5 compared to pure R5 (CE 2 - 1). In addition, the R2 blends according to Examples 3 - 4 and 3 - 5 exhibit higher tear propagation resistance compared to the R2 blend of Example 3 - 1.

[0242] Example 4

[0243] Table 4 provides examples comparing films prepared from blends of R2 with polyester R7 and blends of R4 with R7. R7 does not contain IPA residues, but the diol residues contained in the copolyester include TMCD residues and residues of a polyfunctional alcohol.

[0244] Table 4 - Characteristics of Example 4

[0245]

[0246] Analysis of Table 4 reveals that Examples 4-1 and 4-2 have relatively close tear propagation resistance, but Example 4-1 has a higher modulus.

[0247] Example 5

[0248] Table 5 provides examples comparing films prepared from blends of R3 with different amounts of polyester R5.

[0249] Table 5 - Characteristics of Example 5

[0250]

[0251] Analysis of Table 5 reveals that blends having at least 40 wt% R3 exhibit higher tear propagation resistance and comparable or higher modulus compared to pure R5 (CE 2-1), and the higher the amount of R3, the higher the tear propagation resistance.

[0252] Example 6

[0253] Table 6 provides examples comparing films prepared from blends of R2 with different amounts of polyester R5 and blends with different amounts of R7. The single-layer films described in Table 6 were prepared using a pellet / pellet blend of the resin at the ratios described in Table 6. The pellets were blended to the appropriate ratio and then dried overnight using a dry-form dryer. Then, single-layer films of each blended resin sample were extruded on a 1.5” single-screw extruder with a target film thickness of 0.7 - 0.8 mm. The film extrusion barrel temperature was 260°C - 270°C. The provided characteristics were tested using the methods outlined in the “Test Methods” described herein.

[0254] Table 6 - Characteristics of Example 6

[0255]

[0256] Analysis of Table 6 reveals that blends with R5 and R7 have relatively similar results, but the R5 blends generally exhibit higher tear propagation resistance, while the R7 blends generally exhibit higher force retention.

[0257] The present invention has been described in detail with specific reference to certain embodiments thereof, but it is to be understood that variations and modifications can be made within the spirit and scope of the invention.

Claims

1. A film comprising a copolyester, said copolyester comprising: (a) A dicarboxylic acid component, said dicarboxylic acid component comprising: i) 1 mol% to 100 mol% of isophthalic acid residues; and ii) 0 mol% to 99 mol% of terephthalic acid residues; and iii) 0 mol% to 25 mol% of different aromatic and / or aliphatic dicarboxylic acid residues having up to 20 carbon atoms; and (b) A diol component, said diol component comprising: i) 1 mol% to 100 mol% of 1,4 - cyclohexanedimethanol residues; and ii) 0 mol% to 99 mol% of different aromatic and / or aliphatic modified diol residues having up to 20 carbon atoms; and Having an intrinsic viscosity of about 0.4 to about 1.1 dL / g measured at 25 °C at a concentration of 0.5 g / 100 ml in 60 / 40 (wt / wt) phenol / tetrachloroethane; and Having an average tear propagation resistance greater than 30 N / mm or 40 N / mm or greater in the machine direction and the transverse direction when measured according to ASTM D 1938; and Having a haze value of less than 30% or less than 20% when measured on a 0.75 mm film according to ASTM D 1003; and Wherein the total thickness of the film is between 100 microns and 3000 microns.

2. The film according to claim 1, wherein said copolyester comprises: (a) A dicarboxylic acid component, said dicarboxylic acid component comprising: i) 1 mol% to 100 mol% of isophthalic acid residues; and ii) 0 mol% to 99 mol% of terephthalic acid residues; (b) A diol component, said diol component comprising: i) 1 mol% to 100 mol% of 1,4 - cyclohexanedimethanol residues; and ii) 0 mol% to 99 mol% of ethylene glycol residues; Having an intrinsic viscosity of about 0.4 to about 1.1 dL / g measured at 25 °C at a concentration of 0.5 g / 100 ml in 60 / 40 (wt / wt) phenol / tetrachloroethane; and Having an average tear propagation resistance greater than 30 N / mm or 40 N / mm or greater in the machine direction and the transverse direction when measured according to ASTM D 1938; and Having a haze value of less than 30% or less than 20% when measured on a 0.75 mm film according to ASTM D 1003; and Wherein the total thickness of the film is between 100 microns and 3000 microns.

3. The film according to claim 1, wherein said copolyester comprises: (a) A dicarboxylic acid component, said dicarboxylic acid component comprising: i) 1 mol% to 50 mol% of isophthalic acid residues; and ii) 50 mol% to 99 mol% of terephthalic acid residues; (b) A diol component, said diol component comprising: i) 1,4 - cyclohexanedimethanol residues; Having an intrinsic viscosity of about 0.4 to about 1.1 dL / g measured at 25 °C at a concentration of 0.5 g / 100 ml in 60 / 40 (wt / wt) phenol / tetrachloroethane; and has an average tear propagation resistance greater than 30 N / mm or 40 N / mm or greater in the machine direction and the transverse direction when measured according to ASTM D 1938; and has a haze value of less than 30% or less than 20% when measured according to ASTM D 1003 on a 0.75 mm film; and wherein the total thickness of the film is between 100 microns and 3000 microns.

4. A film comprising a multi-component composition, the multi-component composition comprising at least two polymer components (A) and (B), wherein polymer component (A) is present in an amount of 40 wt% to 99 wt% or 50 wt% to 99 wt%, and polymer component (B) is present in an amount of 1 wt% to 60 wt% or 1 wt% to 50 wt%; and wherein polymer component (A) comprises a polyester, the polyester comprising: (a) a dicarboxylic acid component, the dicarboxylic acid component comprising: i) 1 mol% to 100 mol% of isophthalic acid residues; and ii) 0 mol% to 99 mol% of terephthalic acid residues; and iii) 0 mol% to 25 mol% of different aromatic and / or aliphatic dicarboxylic acid residues having up to 20 carbon atoms; and (b) a diol component, the diol component comprising: i) 50 mol% to 100 mol% of 1,4-cyclohexanedimethanol residues; and ii) 0 mol% to 50 mol% of ethylene glycol residues; and iii) 0 mol% to 25 mol% of different aromatic and / or aliphatic modified diol residues; having an intrinsic viscosity of about 0.4 to about 1.1 dL / g as measured at 25 °C in 60 / 40 (wt / wt) phenol / tetrachloroethane at a concentration of 0.5 g / 100 ml; and polymer component (B) comprises a polyester different from the polyester in polymer component (A); and wherein when measured according to ASTM D 1938, the multi-component film has an average tear propagation resistance greater than 30 N / mm or 40 N / mm or greater in the machine direction and the transverse direction; and wherein when measured according to ASTM D 1003 on a 0.75 mm film, the multi-component film has a haze value of less than 30% or less than 20%; and wherein the total thickness of the film is between 100 microns and 3000 microns.

5. The film according to claim 4, wherein polymer component (A) comprises: (a) a dicarboxylic acid component, the dicarboxylic acid component comprising: i) 1 mol% to 100 mol% of isophthalic acid residues; and ii) 0 mol% to 99 mol% of terephthalic acid residues; and (b) a diol component, the diol component comprising: i) 50 mol% to 100 mol% of 1,4-cyclohexanedimethanol residues; and ii) 0 mol% to 50 mol% of ethylene glycol residues; and having an intrinsic viscosity of about 0.4 to about 1.1 dL / g as measured at 25 °C in 60 / 40 (wt / wt) phenol / tetrachloroethane at a concentration of 0.5 g / 100 ml.

6. The film according to claim 4, wherein polymer component (A) comprises: (a) A dicarboxylic acid component, said dicarboxylic acid component comprising: (a) A dicarboxylic acid component, said dicarboxylic acid component comprising: i) 1 mol% to 50 mol% of isophthalic acid residues; and ii) 50 mol% to 99 mol% of terephthalic acid residues; (b) A diol component, said diol component comprising: i) 1,4-cyclohexanedimethanol residues; and having an intrinsic viscosity of about 0.4 to about 1.0 dL / g measured at 25 °C at a concentration of 0.5 g / 100 ml in 60 / 40 (wt / wt) phenol / tetrachloroethane.

7. The film according to claim 4, wherein the polymer component (B) comprises: (a) A dicarboxylic acid component, said dicarboxylic acid component comprising: i) 50 mol% to 100 mol% of terephthalic acid residues; ii) 0 mol% to 50 mol% of isophthalic acid residues; and (b) A diol component, said diol component comprising: i) 1 mol% to 100 mol% of 1,4-cyclohexanedimethanol residues; and ii) 0 mol% to 99 mol% of ethylene glycol residues; and having an intrinsic viscosity of about 0.4 to about 1.0 dL / g measured at 25 °C at a concentration of 0.5 g / 100 ml in 60 / 40 (wt / wt) phenol / tetrachloroethane.

8. The film according to claim 4, wherein the polymer component (B) comprises: (a) A dicarboxylic acid component, said dicarboxylic acid component comprising: i) 50 mol% to 100 mol% of terephthalic acid residues; ii) 0 mol% to 50 mol% of isophthalic acid residues; and (b) A diol component, said diol component comprising: i) 30 mol% to 100 mol% of 1,4-cyclohexanedimethanol residues; and ii) 0 mol% to 70 mol% of ethylene glycol residues; and having an intrinsic viscosity of about 0.4 to about 0.9 dL / g measured at 25 °C at a concentration of 0.5 g / 100 ml in 60 / 40 (wt / wt) phenol / tetrachloroethane.

9. The film according to claim 4, wherein the polymer component (B) comprises: (a) A dicarboxylic acid component, said dicarboxylic acid component comprising: i) 50 mol% to 100 mol% of terephthalic acid residues; ii) 0 mol% to 50 mol% of isophthalic acid residues; and (b) A diol component, said diol component comprising: i) 30 mol% to 100 mol% of 1,4-cyclohexanedimethanol residues; and ii) 0 mol% to 70 mol% of 2,2,4,4-tetramethyl-1,3-cyclobutanediol residues; and having an intrinsic viscosity of about 0.4 to about 0.9 dL / g measured at 25 °C at a concentration of 0.5 g / 100 ml in 60 / 40 (wt / wt) phenol / tetrachloroethane.

10. The film according to claim 4, wherein the polymer component (B) comprises: (a) A dicarboxylic acid component, said dicarboxylic acid component comprising: i) 50 mol% to 100 mol% of terephthalic acid residues; ii) 0 mol% to 50 mol% of isophthalic acid residues; and (b) A diol component, the diol component comprising: i) 60 mol% to 100 mol% of 1,4-cyclohexanedimethanol residues; and ii) 0 mol% to 40 mol% of 2,2,4,4-tetramethyl-1,3-cyclobutanediol residues; and having an intrinsic viscosity of about 0.4 to about 0.9 dL / g measured at 25 °C at a concentration of 0.5 g / 100 ml in 60 / 40 (wt / wt) phenol / tetrachloroethane.

11. The film according to claim 4, wherein the polymer component (B) comprises: (a) A dicarboxylic acid component, the dicarboxylic acid component comprising: i) 1 mol% to 100 mol% of 1,4-cyclohexanedicarboxylic acid residues; ii) 0 mol% to 99 mol% of terephthalic acid residues; and (b) A diol component, the diol component comprising: i) 50 mol% to 100 mol% of 1,4-cyclohexanedimethanol residues; and ii) 0 mol% to 50 mol% of one or more different aromatic and / or aliphatic modified diol residues; and having an intrinsic viscosity of about 0.4 to about 1.2 dL / g measured at 25 °C at a concentration of 0.5 g / 100 ml in 60 / 40 (wt / wt) phenol / tetrachloroethane.

12. The film according to claim 4, wherein the polymer component (B) comprises: (a) A dicarboxylic acid component, the dicarboxylic acid component comprising: i) 1,4-cyclohexanedicarboxylic acid residues; and (b) A diol component, the diol component comprising: i) 1,4-cyclohexanedimethanol residues; and having an intrinsic viscosity of about 0.4 to about 1.2 dL / g measured at 25 °C at a concentration of 0.5 g / 100 ml in 60 / 40 (wt / wt) phenol / tetrachloroethane.

13. The film according to any one of claims 1 to 12, wherein the film has a total thickness of about 100 μm to about 3000 μm, or about 300 μm to about 3000 μm, or about 380 μm to about 1600 μm, or about 500 μm to about 1000 μm.

14. The film according to any one of claims 1 to 13, wherein when measured according to ASTM D 1938, the film has an average tear propagation resistance of greater than 35 N / mm, or at least 40 N / mm, or at least 50 N / mm, or at least about 60 N / mm, or at least about 70 N / mm in the machine direction and the transverse direction.

15. The film according to any one of claims 1 to 14, wherein the film has a flexural modulus of about 1200 to 2400 MPa measured according to ASTM D 790.

16. The film according to claim 15, wherein the film has a flexural modulus of about 1600 to 2300 MPa, or 1800 to 2300 MPa, or 2000 to 2300 MPa measured according to ASTM D 790.

17. The film according to any one of claims 1 to 16, wherein the film comprises from 0.1% to 20% by weight of a modified filler or additive, such as an inorganic filler, a colorant, a dye, a slip agent or a release agent, an anti-caking aid, a friction improver, a rheology modifier, an impact modifier and / or a stabilizer, such as a heat stabilizer or a UV stabilizer.

18. The film according to any one of claims 1 to 17, wherein the polyester or multicomponent composition of the film has a glass transition (Tg) of at least 57 °C or at least 60 °C or at least 70 °C or at least 80 °C.

19. A removable dental appliance having at least one tooth receiving cavity shaped to receive at least some of the patient's teeth, the appliance comprising the film according to any one of claims 1 to 18.

20. A removable orthodontic tooth positioning appliance having a tooth receiving cavity shaped to directly receive at least some of the patient's teeth, the appliance comprising the film according to any one of claims 1 to 18.

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