U.S. patent application number 13/178869 was filed with the patent office on 2011-11-24 for anisotropic foam-film composite structures.
Invention is credited to Eric Baer, Mark A. Barger, David Bland, Joseph Dooley, Jerry A. Garcia, Michael H. Mazor.
Application Number | 20110285048 13/178869 |
Document ID | / |
Family ID | 38669094 |
Filed Date | 2011-11-24 |
United States Patent
Application |
20110285048 |
Kind Code |
A1 |
Barger; Mark A. ; et
al. |
November 24, 2011 |
Anisotropic Foam-Film Composite Structures
Abstract
Multilayer foam-film composite structures in which the cells of
at least one foam layer have an anisotropic orientation exhibit at
least one enhanced property of toughness, tear resistance and
puncture resistance in comparison with a foam-film composite
structure alike in all aspects except for the anisotropic
orientation of the cells of at least one foam layer.
Inventors: |
Barger; Mark A.; (Midland,
MI) ; Bland; David; (Mason, OH) ; Mazor;
Michael H.; (Midland, MI) ; Baer; Eric;
(Cleveland, OH) ; Dooley; Joseph; (Midland,
MI) ; Garcia; Jerry A.; (Freeland, MI) |
Family ID: |
38669094 |
Appl. No.: |
13/178869 |
Filed: |
July 8, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12373863 |
Jan 14, 2009 |
7993739 |
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PCT/US07/73327 |
Jul 12, 2007 |
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13178869 |
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60830955 |
Jul 14, 2006 |
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Current U.S.
Class: |
264/101 ;
264/173.16 |
Current CPC
Class: |
B29C 48/08 20190201;
Y10T 428/249992 20150401; B29K 2105/045 20130101; B29K 2105/046
20130101; Y10T 428/249988 20150401; Y10T 428/249979 20150401; Y10T
428/249976 20150401; B32B 2038/0028 20130101; B29C 44/352 20130101;
B32B 5/18 20130101; Y10T 428/249977 20150401; B32B 2305/022
20130101; Y10T 428/249991 20150401; B29C 48/00 20190201; B29C 44/04
20130101; Y10T 428/249981 20150401; Y10T 428/249978 20150401; B32B
37/153 20130101; B29C 51/02 20130101 |
Class at
Publication: |
264/101 ;
264/173.16 |
International
Class: |
B29C 47/06 20060101
B29C047/06; B29C 47/76 20060101 B29C047/76 |
Claims
1. A method of a making a multilayer film-foam composite structure
comprising at least one film layer and at least one foam layer, the
foam layer comprising anisotropic cells, the method comprising
co-extruding film-foam laminates and subjecting the co-extruded
laminate to a deformation process in at least one direction.
2. The method of claim 1 in which the deformation process comprises
drawing the structure between a slot die and a film or sheet
casting roll at a predetermined drawing ratio.
3. The method of claim 1 in which the deformation process comprises
parison inflation.
4. The method of claim 1 in which the deformation process comprises
tenter-frame stretching.
5. The method of claim 1 in which the deformation process comprises
in-line vacuum forming.
6. The method of claim 2 in which the drawing ration is at least
about 2:1.
7. The method of claim 1 in which the co-extruded laminate is
deformed in at least two directions.
8. The method of claim 1 in which the co-extruded laminate is
deformed in three directions.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a division of U.S. Ser. No. 12/373,863,
filed Jan. 14, 2009, which is a 371 of PCT/US07/73327 filed Jul.
12, 2007 which claims the benefit of U.S. Ser. No. 60/830,955 filed
Jul. 14, 2006.
FIELD OF THE INVENTION
[0002] This invention relates to multilayer structures. In one
aspect, the invention relates to foam-film multilayer structures
while in another aspect, the invention relates to foam-film
multilayer structures in which the foam layer comprises anisotropic
cells. In yet another aspect, the invention relates to a process of
preparing such structures and in still another aspect, the
invention relates to the use of such structures.
BACKGROUND OF THE INVENTION
[0003] Multilayer foam-film composite structures are known, and the
structures of U.S. Pat. Nos. 3,557,265 and 5,215,691 are exemplary.
These structures can be made by various processes, including
lamination and co-extrusion, and uses in various applications,
including mailing envelopes, shipping sacks, stand-up pouches,
labels, thermoformed packaging and tamper-evident packaging.
However, various properties of these structures have room for
improvement, particularly the properties of toughness, tear
resistance and puncture resistance.
SUMMARY OF THE INVENTION
[0004] In one embodiment of this invention, multilayer foam-film
composite structures in which the cells of at least one foam layer
have an anisotropic orientation exhibit at least one enhanced
property of toughness, tear resistance and puncture resistance in
comparison with a foam-film composite structure alike in all
aspects except for the anisotropic orientation of the cells of at
least one foam layer. In another embodiment of the invention, the
anisotropic cell orientation is imparted to the at least one foam
layer in a mono-, bi- or multi-directional manner, e.g., by
drawing, tenter frame or bubble blowing, or thermoforming,
respectively. In still another embodiment of the invention, the
multilayer foam-film composite structure is used in a packaging
application.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0005] "Anisotropic", "anisotropic orientation", "anisotropic cell
orientation" and like terms mean that a typical cell in the foam
layer(s) of the multilayer film-foam composite structure has an
asymmetric shape, typically a shape that is larger in one dimension
than it is in the other dimensions. After cell orientation, the
cell anisotropy ratios (length to thickness or x to z) are
typically in the range from about 2:1 to about 10:1, preferably
from about 3:1 to about 5:1.
[0006] The multilayer foam-film composite structure of the
invention typically comprises an A/B structure of at least two
layers, preferably of 5 to about 300 layers and more preferably
between about 15 and about 75 layers. The exterior layers of the
structure comprise either foam or film, or one layer is film while
the other layer is foam. Each of the layers is in abutting
relationship with and fused to the immediate adjacent layers, and
preferably the layers alternate between film and foam. The film
layers comprise a solid, not-expanded thermoplastic resinous
material typically having a thickness from about 0.10 microns
(.mu.m) to about 100 .mu.m, preferably from about 0.5 .mu.m to
about 50 .mu.m and more preferably from about 1 .mu.m to about 30
.mu.m. The foam layers comprise an expanded cellular thermoplastic
resinous foam material typically having a thickness from about 10
.mu.m to about 1,000 .mu.m, preferably from about 50 .mu.m to about
500 .mu.m and more preferably from about 75 .mu.m to about 300
.mu.m. The layers are interdigitated, i.e., interleaved, and in a
generally parallel relationship with one another. The
cross-sectional thickness of the multilayer foam-film composite
structure of this invention is dependent upon the number of layers
and the thickness capacity of the extrusion equipment, but
typically the thickness range is from about 10 .mu.m to about 25
millimeters (mm), preferably from about 10 .mu.m to about 5 mm and
more preferably from about 100 .mu.m to about 2 mm. The cells of
the foam can be open or closed.
[0007] The multilayer foam-film composite structures of this
invention can be prepared by various methods, e.g., feedblock and
layer multiplication technology as taught in U.S. Pat. Nos.
3,557,265 and 5,202,074, sequential layering as taught in Dooley,
J. and Tung, H., Co-extrusion, Encyclopedia of Polymer Science and
Technology, John Wiley & Sons, Inc., New York (2002), or a
direct feedblock process as taught in U.S. Pat. No. 3,884,606. In
one preferred embodiment the structures are prepared by
co-extrusion of at least two streams of the same or dissimilar
thermoplastic materials. Co-extrusion or simultaneous extrusion of
two or more synthetic resinous materials is well-known in the art
and has been used for preparing sheet or film containing many
layers, for example, 50, 100 or several hundred layers. This method
is illustrated in U.S. Pat. Nos. 3,565,985, 3,557,265 and
3,884,606.
[0008] Co-extrusion can be broadly described as a method for
preparing a composite stream of interdigitated diverse synthetic
resinous materials in which at least one of the materials comprises
a thermoplastic resinous composition containing at least one
blowing or expansion agent, comprising providing at least a first
stream of heat-plastified synthetic resinous material and a second
stream of heat-plastified thermoplastic material neither of which
streams contain blowing or expansion agents, adding to at least of
the heat-plastified streams at least one blowing agent under a
pressure which is sufficient to substantially inhibit activity of
the blowing agent, dividing each of the streams into a plurality of
first substreams and a plurality of second substreams,
respectively, combining the substreams to form a composite stream
having the first substreams and the second substreams
interdigitated, and forming the stream into a desired configuration
having at least one major surface in which the layers of the
composite stream lie generally parallel to a major surface of the
desired configuration. The division of the individual streams of
heat-plastified thermoplastic into a plurality of substreams and
the combination of the substreams into a composite stream of
interdigitated layers is effected in a layer multiplying-combining
means such as the feedblock and die assembly shown in FIGS. 2-4, 6
and 7 of U.S. Pat. No. 3,557,265.
[0009] The multilayer film-foam composite structure is subjected to
drawing (mono-, bi- or multi-axial) while in the molten state to
achieve macroscopic cellular orientation. Examples of drawing
include, but are not limited to, (i) mono-axial drawing between a
slot die and a film or sheet casting roll, (ii) Parison inflation,
either for free surface bubble blowing (bi-axial), or inflation
into a mold (blow molding, multi-axial), (iii) tenter-frame
stretching, either simultaneous or sequential bi-axial, and (iv)
in-line vacuum forming (multi-axial). Typical drawing ratios (based
on a mono-axial drawing process) range from about 2:1 to about
10:1, preferably from about 3:1 to about 5:1.
[0010] For dimensioned articles, the multi-layer film-foam
composite structure can be re-heated to effect the stretching
operation. Once drawn or stretched, the multi-layer film-foam
composite structure is stabilized by cooling, either assisted
(e.g., chiller rolls, quenching, etc.) or unassisted, i.e.,
equilibrating to ambient temperature.
[0011] Most any thermoplastic polymeric material which can be
formed into a film or which can be blown, i.e., foamed, can be
employed in the practice of the invention including, without
limitation, thermoplastic polyolefins, aliphatic and aromatic
polyesters, polyurethanes and various blends of these materials.
These and other polymers can be used either as an expandable
polymeric composition, or a film-forming composition, or the same
polymeric material can be employed for each purpose, e.g.,
polystyrene can be employed as both an expandable polymer and as a
film-forming polymer in the same multilayer foam-film composite
structure.
[0012] Many thermoplastic polyolefins are well-suited for use in
the practice of this invention, and these include such polyolefins
as polyethylene, polypropylene and polybutylene, polyvinylchloride
(both rigid and flexible), polystyrene, ethylcellulose,
poly(vinylchloride)vinylidene chloride, polymethylmethacrylate and
the like. Specific examples of olefinic polymers useful in this
invention include ultra-low density polyethylene (ULDPE, e.g.,
ATTANE.TM. ethylene/1-octene polyethylene made by The Dow Chemical
Company ("Dow") with a typical density between about 0.900 and
0.925 and a typical melt index (I.sub.2) between about 0.5 and 10),
linear low density polyethylene (LLDPE, e.g., DOWLEX.TM.
ethylene/1-octene polyethylene made by Dow with a typical density
between about 0.92 and 0.94 and a typical I.sub.2 between about 0.5
and 30), homogeneously branched, linear ethylene/.alpha.-olefin
copolymers (e.g., TAFMER.RTM. polymers by Mitsui Chemicals America,
Inc. and EXACT.TM. polymers by ExxonMobil Chemical (ExxonMobil)),
homogeneously branched, substantially linear
ethylene/.alpha.-olefin polymers (e.g., AFFINITY.TM. and ENGAGE.TM.
polymers made by Dow and described in U.S. Pat. Nos. 5,272,236,
5,278,272 and 5,380,810), catalytic linear statistical olefin
copolymers (e.g., INFUSE.TM. polyethylene/olefin block polymers,
particularly polyethylene/.alpha.-olefin block polymers and
especially polyethylene/1-octene block polymers, made by Dow and
described in WO 2005/090425, 2005/090426 and 2005/090427), and high
pressure, free radical polymerized ethylene copolymers such as
ethylene/vinyl acetate (EVA) and ethylene/acrylate and
ethylene/methacrylate polymers (e.g., ELVAX.RTM. and ELVALOY.RTM.
polymers, respectively, by E. I. Du Pont du Nemours & Co. (Du
Pont)) and ethylene/acrylic and ethylene/methacrylic acid (e.g.,
PRIMACOR.TM. EAA polymers by Dow and NUCREL EMAA polymers by Du
Pont), and various polypropylene resins (e.g., INSPIRE.RTM. and
VERSIFY.RTM. polypropylene resins made by Dow and VISTAMAXX.RTM.
polypropylene resins made by ExxonMobil).
[0013] Most any of the known blowing agents can be employed,
including gaseous materials, volatile liquids and chemical agents
which decompose into a gas and other byproducts. Representative
blowing agents include, without limitation, nitrogen, carbon
dioxide, air, methyl chloride, ethyl chloride, pentane, isopentane,
perfluoromethane, chlorotrifluoromethane, dichlorodifluoromethane,
trichlorofluoromethane, perfluoroethane,
1-chloro-1,1-difluoroethane, chloropentafluoroethane,
dichlorotetrafluoroethane, trichlorotrifluoroethane,
perfluoropropane, chloroheptafluoropropane,
dichlorohexafluoropropane, perfluorobutane, chlorononafluorobutane,
perfluorocyclobutane, azodicarbonamide, azodiisobutyronitrile,
benzenesulfonhydrazide, 4,4-oxybenzene sulfonyl-semicarbazide,
p-toluene sulfonyl semicarbazide, barium azodicarboxylate,
N,N'dimethyl-N,N'-dinitrosoterephthalamide, and trihydrazino
triazine. Currently, the partially halogenated hydrocarbons are
preferred blowing agents. Generally, the blowing agent will be
incorporated into the resin composition which is to be foamed in
amounts ranging from 1 to 100 parts by weight of blowing or
expansion agent per 100 parts of polymer. The addition of a small
amount of expansion agent, e.g., 0.1 to 1 part of expansion agent
per 100 parts of polymer, to the film-forming composition has been
found to improve compatibility and adhesion between the foam and
film layers. Film quality is also improved by practicing this
variant. The blowing agent must be incorporated into its melt
stream under a pressure which is sufficient to inhibit its
activation, that is, to inhibit foaming of the melt stream during
the incorporation of the expansion agent and subsequent processing
of the composition until the stream is expressed through the
co-extrusion die. Generally, this pressure should be at least 500
psig and is preferably at least 1000 psig.
[0014] The density of each foam layer is typically in the range of
about 0.03 to about 0.8, preferably in the range of about 0.10 to
about 0.5, grams per cubic centimeter (g/cc) as measured by ASTM D
3575-93 W-B. The density of the multi-layer film-foam composite
structure is typically in the range from about 0.05 to about 0.9,
preferably in the range of about 0.15 to about 0.6 g/cc.
[0015] The multi-layer film-foam composite structure can comprise
one or more skin or cap layers to improve flow stability of the
structure through the die. If present, each skin layer can comprise
greater than zero up to about 40 percent by weight based on the
total weight of the structure, preferably between about 5 and about
30 percent by weight. The skin layer can be non-adhering such that
it can be removed from the rest of the structure after manufacture.
Moreover, the multi-layer film-foam composite structure can
incorporate one or more functionalities such as a gas barrier layer
(e.g., a film layer of ethylene vinyl alcohol copolymer or
polyvinylidene chloride) or an oxygen scavenger formulation.
[0016] Additives which are commonly incorporated into expandable
polymer compositions, such as catalysts or accelerators,
surfactants, flame retardant additives, porosity control agents,
antioxidants, colorants, pigments, fillers and the like can be
incorporated into the composite of the invention. Such additives
will generally be used in conventional amounts. In a particularly
preferred embodiment, it has been found that incorporating from 0.1
to 25, preferably 1 to 20 and most preferably 5 to 15, percent by
weight of carbon black into the extrudable polymer compositions,
especially those polymer compositions which contain no expansion
agent or only a small property-improving amount of expansion agent,
provides products having an enhanced insulation value.
[0017] The multi-layer film-foam composite structures of this
invention have a multiplicity of potential uses, and they provide
certain advantages over structures more conventionally used in
these applications. The following is a non-limiting representation
of these uses:
[0018] Medium-density, thermoformable sheets, both flexible and
rigid, for use in automotive, durables, appliance and packaging
applications. The structures of this invention often display lower
mass and better retention of physical, tensile and/or flexibility
properties that are important to these applications than many
conventional alternatives.
[0019] Acoustic panels and underlayments for use in automotive,
building and construction, and appliance applications. The
structures of this invention often are more durable than cork and
can carry a decorative surface.
[0020] Puncture-resistant articles such as mailing envelopes,
shipping sacks and bags (e.g., cement bags), pouches, low-density
membranes (e.g., single-ply roofing), and meat-wrap film.
[0021] Articles made by stretch and extrusion blow molding.
Articles made with the technology of this invention often display
lower mass and have better insulation properties than similar
articles otherwise made.
[0022] Films such as down-gauged (mass) films; biodegradable mulch
film; tear-resistant, low-density shrink wrap film and tarp;
abuse-resistant blister packaging; and opacity-enhanced films.
[0023] Oxygen, water and/or chemical barrier foam-film composites
(e.g., for food, medical, electronic packaging).
[0024] Insulation and/or ballistic-resistant house wrap.
[0025] Low dielectric materials such as wire and cable sheathing,
and semi-conductive sheets for electronics.
[0026] Elastic tape--high strength for industrial, automotive
(mounting tape), and wound care (bandages).
[0027] Decorative labels, and labels or tags with high
tear-strength and insulation properties.
[0028] Artificial leather having tear-resistance and haptics (e.g.,
for clothing and footware).
[0029] Breathable fabric for protective clothing.
[0030] Synthetic cork for interior walls and offices.
[0031] Pressure-sensitive adhesive tapes for attachment and
assembly.
[0032] Automotive interior applications (e.g., instrument panel
skins, automotive carpet, headliner, door panel, cushioning under
seat fabrics, dash mat, floor mats and sun shades).
[0033] Filled-systems for coefficient of thermal expansion
control.
[0034] Dimensionally stable, moisture-absorbent systems.
[0035] Protective composite structures for industrial, safety or
commercial shipping applications.
[0036] Foliated structures (e.g., perpendicular layers) for
controlled permeation.
[0037] Structures in which additives that interfere with foaming
(e.g., fire retardants, inorganic fillers, active packaging
additives, etc.) are positioned in the film component.
[0038] Positioning functional additives in the cellular component
for functionality; e.g., tamper resistant indicators, ion exchange
additives, oxygen scavengers and permeation control.
[0039] Plastic paper or paperboard.
[0040] Low-density plastic composites for building and construction
applications (e.g., decks, siding, fencing, shingles, insulation
sheathing).
[0041] Elastic structures with non-woven properties.
[0042] Light-weight, microwavable, plastic containers with
insulation properties.
[0043] Corrugated sheet.
[0044] Insulative low-density tubing or pipe (pressurized or
non-pressurized).
[0045] Pipe wraps having insulation and/or sound deadening
properties.
[0046] Extruded profiles and gaskets for window and door seals
(automotive, building and construction and appliance
applications).
[0047] Gaskets and cap liners for automotive, industrial, and
packaging (including beverage) applications.
[0048] Tear-resistant tapes for industrial strapping.
[0049] Heating, ventilation and air conditioning ducting having
insulation and acoustic and vibration damping for automotive,
building and construction applications.
[0050] Cell-size control for improved processability in thin sheet
and film (e.g., reduction in web breaks) applications.
[0051] Alternatives to film-laminated skived foams.
[0052] Artificial turf with improved tear strength (Recreation
market).
[0053] Constrained layer for quiet steel technology (metal-plastic
laminate for noise and vibration damping).
[0054] Marine interiors (e.g., light weight, water-resistant, soft
touch, non-skid applications).
[0055] The following examples are illustrative of certain specific
embodiments of this invention. Unless indicated otherwise, all
parts and percentages are by weight. Controls have a draw speed of
1x; inventive examples have a draw speed of greater than 1x.
SPECIFIC EMBODIMENTS
[0056] Foam-film samples with different degrees of macro-cellular
orientation are prepared using a co-extrusion line that consists of
two 0.75 inch diameter single screw extruders that feed two
components. One component contains a chemical foaming agent through
gear pumps into a two layer A/B feedblock and a series of two
channel layer multipliers similar in design to those described in
U.S. Pat. No. 5,202,074. The multiplied layered feed-stream is then
forwarded into a die having cross-sectional dimensions of
7.6.times.0.2 centimeters (cm) (width.times.thickness). The
expanded foam material is extruded onto a chilled casting roll
equipped with an air knife. The speed of the casting roll is varied
in order to draw the sample in the machine direction and orient the
cellular structure. Overall extrusion rate is held constant at
approximately 2.3 kilograms per hour (kg/hr).
[0057] Extrudates are subsequently prepared and characterized for
cell size using a stereo-optical microscope. Average cell size with
respect to the machine (length), width and thickness directions (x,
y and z, respectively) is determined via manual cell count, and an
anisotropy ratio is expressed as the ratio of cell sizes in the x
and z directions, respectively. Average cell size of the undrawn
examples is obtained by averaging the dimensions in the three
orthogonal directions. Density is calculated in accordance with
ASTM D3575-93 W-B, and tensile properties are determined by testing
die cut samples (dimensions 22 mm.times.4.8 mm.times.sheet
thickness at a strain rate of 100%/minute in an Instron Universal
Testing machine. All testing is conducted at ambient conditions
(about 23C and atmospheric pressure).
[0058] The conditions and results are report in Tables 1 and 2.
Examples 1, 3, 5, 7, 10, 12, 15 and 17 are controls (the draw speed
of each was 1x). Those examples in which the film consists of three
layers has a higher density than the remaining examples. Regarding
cell size, Z is a measure of the vertical, Y of the transverse or
width, and X of machine direction or length. As is evident from
these results, the drawn samples exhibit significant enhancements
in machine direction elongation with insignificant change in
transverse direction toughness at lower density compared to their
three layer analogs.
TABLE-US-00001 Materials Extruder Additional Foam Component Film
Component Foaming Agent Number Temperature (C.) Temperatures (C.)
Ex. vol. vol. Wt of Foam Film Feed- Multi- Draw # Resin Grade
%.sup.1 Resin Grade %.sup.1 Compound %.sup.2 Layers Component
Component block pliers Die Speed 1 .sup.3PP PF-814 50 .sup.3PP
PF-814 50 Azodicarbonamide 1.75 32 210 210 210 210 160 1x 2 PP
PF-814 50 PP PF-814 50 Azodicarbonamide 1.75 3 210 210 210 210 160
2x 3 TPO Blend 70 AFFINITY PL- 30 Azodicarbonamide 2 16 210 210 210
210 160 1x 1880 4 TPO Blend 70 AFFINITY PL- 30 Azodicarbonamide 2
16 210 210 210 210 160 3x 1880 5 TPO Blend 70 AFFINITY PL- 30
Azodicarbonamide 1 32 210 210 210 210 160 1x 1880 6 TPO Blend 70
AFFINITY PL- 30 Azodicarbonamide 1 32 210 210 210 210 160 4x 1880 7
TPO Blend 70 AFFINITY PL- 30 Azodicarbonamide 1 3 210 210 210 210
160 1x 1880 8 TPO Blend 70 AFFINITY PL- 30 Azodicarbonamide 1 3 210
210 210 210 160 2x 1880 9 TPO Blend 70 AFFINITY PL- 30
Azodicarbonamide 1 3 210 210 210 210 160 3x 1880 10 .sup.4AFFINITY
50 LDPE 503A 50 SAFOAM FPE-50 2.5 32 215 215 215 215 155 1x EG8200
11 AFFINITY 50 LDPE 503A 50 SAFOAM FPE-50 2.5 32 215 215 215 215
155 4x EG8200 12 AFFINITY 50 LDPE 503A 50 SAFOAM FPE-50 2.5 3 215
215 215 215 155 1x EG8200 13 AFFINITY 50 LDPE 503A 50 SAFOAM FPE-50
2.5 3 215 215 215 215 155 2x EG8200 14 AFFINITY 50 LDPE 503A 50
SAFOAM FPE-50 2.5 3 215 215 215 215 155 3x EG8200 15 .sup.6LDPE
503A 86 EVOH-44# 14 SAFOAM FPE-50 2.5 17 215 215 215 215 155 1x
Blend** 16 LDPE 503A 86 EVOH-44# 14 SAFOAM FPE-50 2.5 17 215 215
215 215 155 2x Blend** 17 LDPE 503A 86 EVOH-27# 14 SAFOAM FPE-50
2.5 17 215 215 215 215 155 1x Blend** 18 LDPE 503A 86 EVOH-27# 14
SAFOAM FPE-50 2.5 17 215 215 215 215 155 2x Blend** .sup.1vol %
based on volumetric flow rates of unexpanded (solid) polymer
.sup.2wt %, loading based on Foamable Component .sup.3Pro-fax PF814
polypropylene homopolymer of high melt strength by Basell (MFR of
3.0 and density of 0.902 g/cc) .sup.4AFFINITY PL1880
ethylene/1-octene copolymer by Dow (MFR of 1.0 and density of 0.902
g/cc) .sup.5ADFLEX Q200F low modulus thermoplastic olefin resin by
Basell (MFR of 0.8 and density of 0.882 g/cc) .sup.6LDPE 503A by
Dow (MFR of 1.9 and density of 0.923 g/cc) .sup.7FUSABOND N MN493D
MAH-grafted ethylene/1-octene copolymer by Dupont (MFR of 1.2 and
density of 0.87 g/cc) .sup.8EVAL L171 ethylene/vinyl alcohol
copolymer by EVALCA (MFR of 4.0 and density of 1.20 g/cc)
.sup.9EVAL E171 ethylene/vinyl alcohol copolymer by EVALCA (MFR of
3.3 and density of 1.14) #EVOH-Ethylene vinyl alcohol copolymer
number indicates mole % ethylene in copolymer TPO Blend is 75/25
w/w mixture of two polypropytlene resins, PF-814 and .sup.5Adflex
OF-200, both supplied by Basell Inc. **A-90/10 w/w blend of
LDPE/.sup.7Fusabond MN-493D Barner Foam-Film Samples (15-18) used
Skin layers of 503A (Incorporated into film component as % Film in
the Table All MFR measured according to ASTM D 1238 and 2.16 kg.
Pro-fax and Adflex measured at 230 C.; AFFINITY, LDPE 503A measured
at 190 C.; and EVAL L171 and E171 measured at 210 C.
TABLE-US-00002 Tensile Properties Tensile Properties Overall Foam
Final Cell Size (Machine Direction) (Traverse Direction) Density
Density Thickness (microns) Anisotrophy Break Stress Break @ Break
Stress Break @ Ex. # (g/cc) (g/cc) (mils) Z Y X Ratio (X/Z) (Pa)
Elongation (%) (Pa) Elongation (%) 1 0.3 0.18 100 1 7.5 12 6.5 12 2
75 575 650 1100 1.9 10 4.4 5.4 60 3 0.28 70 1 6.5 270 6.5 270 4
0.28 30 35 150 5 10.5 490 5.5 280 5 0.35 0.21 70 90 1 6 180 6.5 260
6 0.35 0.21 25 50 65 185 3.7 13.4 550 5.8 230 7 0.57 0.35 89 215 1
10.6 276 1 260 8 14.6 404 7.8 260 9 0.62 61 560 7580 1500 2.7 8.9
230 5 102 10 0.48 0.32 55 70 1 13.8 250 12.7 230 11 25 280 14.2 250
12 0.66 0.51 71 400 1 8 438 7 417 13 0.69 63 290 390 750 2.6 14
0.71 35 93 210 422 4.5 9.3 363 5.2 314 15 0.38 0.26 200 160 0.8 8
155 4.5 40 16 0.49 0.36 180 220 1.2 7.9 150 4.2 29 17 0.52 0.39 350
240 0.7 7.5 37 5 16 18 0.42 0.29 150 120 0.8 6.7 41 5 20 .sup.1wt
%, loading based on Foamable Component {circumflex over ( )}vol %
based on volumetric flow rates of unexpanded (solid) polymer
#EVOH-Ethylene vinyl alcohol copolymer number indicates mole %
ethylene in copolymer TPO Blend is 75/25 w/w mixture of two
polypropytlene resins, PF-814 and Adflex OF-200, both supplied by
Bassell Inc. **A-90/10 w/w blend of LDPE/Fusabond N MN493D Barner
Foam-Film Samples (15-18) used Skin layers of 503A (Incorporated
into film component as % Film in the Table
[0059] Although the invention has been described in considerable
detail by the preceding examples, this detail is for the purpose of
illustration and is not to be construed as a limitation upon the
invention as described in the following claims. All United States
patents and published patent applications cited in the
specification are incorporated herein by reference.
* * * * *