(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2009/0263645 A1
`Barger et al.
`(43) Pub. Date:
`Oct. 22, 2009
`
`US 20090263645A1
`
`(54) ANISOTROPIC FOAM-FILM COMPOSITE
`STRUCTURES
`
`(86) PCT No.:
`
`PCT/US07/73327
`
`(75)
`
`Inventors:
`
`Mark A. Barger, Midland, Ml
`(US); D3Vid Bland, M35011, OH
`(US); Michael H. Mazor, Midland,
`M} (US); Eric Baer, Cleveland, OH
`(US); Joseph Dooley, Midland, MI
`(US); Jerry A‘ Garcia’ Freeland’
`MI (US)
`
`Correspondence Address:
`WHYTE HIRSCHBOECK DUDEK S.C./DOW
`lntelleetual Property Department
`555 East Wells Street, Suite 1900
`Milwaukee, WI 53202 (US)
`
`<73) Assigneei
`
`d°W G1°ba1Te°hn°1°gies 1n°-
`
`(21) APP1~ N05
`
`12/3735363
`
`(22) PCT Filed:
`
`Jul. 12, 2007
`
`§ 371 (0)0).
`Jan‘ 14’ 2009
`0)’ (4) Date:
`Related U.S. Application Data
`l
`.
`l
`.
`(60) Provisional application No. 60/830,955, filed on Jul.
`14, 2005
`
`Publication Classification
`
`(51)
`
`Int. Cl.
`
`)
`’
`(
`(52) U.S. Cl. ................................... .. 428/316.6; 264/46.1
`(57)
`ABSTRACT
`
`Multilayer foam-film composite structures in which the cells
`Zihiiieiit 1222 3??effiificléiviriii§l~t“;S‘Z.¥‘l‘3§g1‘I£‘.i‘lfa§2Z.‘i
`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.
`
`Page 1 of 7
`
`BOREALIS EXHIBIT 1038
`
`Page 1 of 7
`
`BOREALIS EXHIBIT 1038
`
`

`
`US 2009/0263645 A1
`
`Oct. 22, 2009
`
`ANISOTROPIC FOAM-FILM COMPOSITE
`STRUCTURES
`
`FIELD OF THE INVENTION
`
`[0001] 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 com-
`prises 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 struc-
`tures.
`
`BACKGROUND OF THE INVENTION
`
`foam-film composite structures are
`[0002] Multilayer
`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 enve-
`lopes, shipping sacks, stand-up pouches,
`labels,
`thermo-
`formed packaging and tamper-evident packaging. However,
`various properties of these structures have room for improve-
`ment, particularly the properties of touglmess, tear resistance
`and puncture resistance.
`
`SUMMARY OF THE INVENTION
`
`In one embodiment of this invention, multilayer
`[0003]
`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 compos-
`ite 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
`cc
`99
`99
`ca
`“Anisotropic , anisotropic orientation , anisotro-
`[0004]
`pic 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 (width to
`thickness or x to y) are typically in the range from about 2:1
`to about 10:1, preferably from about 3:1 to about 5:1.
`[0005] The multilayer foam-film composite structure ofthe
`invention typically comprises an A/B structure of at least two
`layers, preferably of 5 to about 300 layers and more prefer-
`ably 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 (um) to about 100 um, preferably
`from about 0.5 pm to about 50 um and more preferably from
`about 1 pm to about 30 um. The foam layers comprise an
`
`expanded cellular thermoplastic resinous foam material typi-
`cally having a thickness from about 10 pm to about 1,000 um,
`preferably from about 50 pm to about 500 um and more
`preferably from about 75 pm to about 300 pm. The layers are
`interdigitated, i.e., interleaved, and in a generally parallel
`relationship with one another. The cross-sectional thickness
`ofthe multilayer foam-film composite structure ofthis inven-
`tion is dependent upon the number of layers and the thickness
`capacity of the extrusion equipment, but typically the thick-
`ness range is from about 10 pm to about 25 millimeters (mm),
`preferably from about 10 pm to about 5 mm and more pref-
`erably from about 100 pm to about 2 mm. The cells of the
`foam can be open or closed.
`[0006] The multilayer foam-film composite structures of
`this invention can be prepared by various methods, e.g., feed-
`block 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, Encyclope-
`dia 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 embodi-
`ment the structures are prepared by co-extrusion of at least
`two streams ofthe same or dissimilarthermoplastic materials.
`Co-extrusion or simultaneous extrusion of two or more syn-
`thetic 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.
`
`[0007] 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 ofthe mate-
`rials comprises a thermoplastic resinous composition con-
`taining 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 ther-
`moplastic 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, respec-
`tively, combining the substreams to form a composite stream
`having the first substreams and the second substreams inter-
`digitated, 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.
`[0008] 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 blow-
`ing (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-
`
`Page 2 of 7
`
`Page 2 of 7
`
`

`
`US 2009/0263645 A1
`
`Oct. 22, 2009
`
`axial). Typical drawing ratios (based on a mono-axial draw-
`ing process) range from about 2:1 to about 10: 1, preferably
`from about 3:1 to about 5:1.
`
`For dimensioned articles, the multi-layer film-foam
`[0009]
`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.
`[0010] 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-forrning
`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 foarn-film composite
`structure.
`
`[0011] Many thermoplastic polyolefins are well-suited for
`use in the practice of this invention, and these include such
`polyolefins as polyethylene, polypropylene and polybuty-
`lene, 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., ATTANETM 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 (12) between about 0.5 and 10
`),
`linear
`low density
`polyethylene
`(LLDPE,
`e.g.,
`DOWLEXTM ethylene/1-octene polyethylene made by Dow
`with a typical density between about 0.92 and 0.94 and a
`typical
`12 between about 0.5 and 30), homogeneously
`branched, linear ethylene/ot-olefin copolymers (e.g., TAF-
`MER® polymers by Mitsui Chemicals America, Inc. and
`EXACTTM polymers by ExxonMobil Chemical (ExxonMo-
`bil)), homogeneously branched, substantially linear ethylene/
`ot-olefinpolymers (e.g.,AFFlNlTYTM and ENGAGETM poly-
`mers made by Dow and described inU.S. Pat. Nos. 5,272,236,
`5,278,272 and 5,380,810), catalytic linear statistical olefin
`copolymers (e.g., INFUSETM polyethylene/olefinblockpoly-
`mers, particularly polyethylene/ot-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® and ELVALOY® polymers, respectively, by
`E. 1. Du Pont du Nemours & Co. (Du Pont)) and ethylene/
`acrylic and ethylene/methacrylic acid (e.g., PRIMACORTM
`EAA polymers by Dow and NUCREL EMAA polymers by
`Du Pont), and various polypropylene resins (e.g., lNSPlRE®
`and VERSlFY® polypropylene resins made by Dow and
`VlSTAMAXX® polypropylene resins made by ExxonMo-
`bil).
`[0012] 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, chlo-
`
`rotrifluoromethane, dichlorodifluoromethane, trichlorofluo-
`romethane, perfluoroethane, 1-chloro-1, 1-difluoroethane,
`chloropentafluoroethane, dichlorotetrafluoroethane, trichlo-
`rotrifluoroethane, perfluoropropane, chloroheptafluoropro-
`pane, dichlorohexafluoropropane, perfluorobutane, chlo-
`rononafluorobutane,
`perfluorocyclobutane,
`azodicarbonarnide, azodiisobutyronitrile, benzenesulfonhy-
`drazide, 4,4-oxybenzene sulfonyl-semicarbazide, p-toluene
`sulfonyl
`semicarbazide,
`barium
`azodicarboxylate,
`N,N'dimethyl-N,N'-dinitrosoterephthalarnide,
`and
`trihy-
`drazino triazine. Currently, the partially halogenated hydro-
`carbons 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 poly-
`mer. 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-forrning 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 sufiicient to inhibit its activation, that is, to
`inhibit foaming ofthe melt stream during the incorporation of
`the expansion agent and subsequent processing of the com-
`position until the stream is expressed through the co-extru-
`sion die. Generally, this pressure should be at least 500 psig
`and is preferably at least 1000 psig.
`[0013] 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.
`[0014] 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 polyvi-
`nylidene chloride) or an oxygen scavenger formulation.
`[0015] Additives which are commonly incorporated into
`expandable polymer compositions, such as catalysts or accel-
`erators, surfactants, flame retardant additives, porosity con-
`trol 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.
`[0016] The multi-layer film-foam composite structures of
`this invention have a multiplicity of potential uses, and they
`provide certain advantages over structures more convention-
`ally used in these applications. The following is a non-limit-
`ing representation of these uses:
`
`Page 3 of 7
`
`Page 3 of 7
`
`

`
`US 2009/0263645 A1
`
`Oct. 22, 2009
`
`[0017] Medium-density, therrnoformable sheets, both flex-
`ible 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 appli-
`cations than many conventional alternatives.
`[0018] Acoustic panels and underlayments for use in auto-
`motive, building and construction, and appliance applica-
`tions. The structures of this invention often are more durable
`
`than cork and can carry a decorative surface.
`[0019]
`Puncture-resistant articles such as mailing enve-
`lopes, shipping sacks and bags (e.g., cement bags), pouches,
`low-density membranes (e.g., single-ply roofing), and meat-
`wrap film.
`[0020] Articles made by stretch and extrusion blow mold-
`ing. Articles made with the technology of this invention often
`display lower mass and have better insulation properties than
`similar articles otherwise made.
`
`Films such as down-gauged (mass) films; biode-
`[0021]
`gradable mulch film; tear-resistant, low-density shrink wrap
`film and tarp; abuse-resistant blister packaging; and opacity-
`enhanced films.
`
`[0022] Oxygen, water and/or chemical barrier foarn-film
`composites (e.g., for food, medical, electronic packaging).
`[0023]
`Insulation and/or ballistic-resistant house wrap.
`[0024] Low dielectric materials such as wire and cable
`sheathing, and semi-conductive sheets for electronics.
`[0025] Elastic tape—high strength for industrial, automo-
`tive (mounting tape), and wound care (bandages).
`[0026] Decorative labels, and labels or tags with high tear-
`strength and insulation properties.
`[0027] Artificial leather having tear-resistance and haptics
`(e.g., for clothing and footware).
`[0028] Breathable fabric for protective clothing.
`[0029]
`Synthetic cork for interior walls and offices.
`[0030]
`Pressure-sensitive adhesive tapes for attachment
`and assembly.
`[0031] Automotive interior applications (e.g., instrument
`panel skins, automotive carpet, headliner, door panel, cush-
`ioning under seat fabrics, dash mat, floor mats and sun
`shades).
`[0032]
`control.
`
`Filled-systems for coefficient of thermal expansion
`
`[0033] Dimensionally stable, moisture-absorbent systems.
`[0034]
`Protective composite structures
`for
`industrial,
`safety or commercial shipping applications.
`[0035]
`Foliated structures (e.g., perpendicular layers) for
`controlled permeation.
`[0036]
`Structures in which additives that interfere with
`foaming (e.g., fire retardants, inorganic fillers, active packag-
`ing additives, etc.) are positioned in the film component.
`[0037]
`Positioning functional additives in the cellular com-
`ponent for functionality; e.g., tamper resistant indicators, ion
`exchange additives, oxygen scavengers and permeation con-
`trol.
`
`Plastic paper or paperboard.
`[0038]
`[0039] Low-density plastic composites for building and
`construction applications
`(e.g., decks,
`siding,
`fencing,
`shingles, insulation sheathing).
`[0040] Elastic structures with non-woven properties.
`[0041] Light-weight, microwavable, plastic containers
`with insulation properties.
`[0042] Corrugated sheet.
`[0043]
`Insulative low-density tubing or pipe (pressurized or
`non-pressurized).
`
`Pipe wraps having insulation and/or sound deaden-
`[0044]
`ing properties.
`[0045] Extruded profiles and gaskets for window and door
`seals (automotive, building and construction and appliance
`applications).
`[0046] Gaskets and cap liners for automotive, industrial,
`and packaging (including beverage) applications.
`[0047] Tear-resistant tapes for industrial strapping.
`[0048] Heating, ventilation and air conditioning ducting
`having insulation and acoustic and vibration damping for
`automotive, building and construction applications.
`[0049] Cell-size control for improved processability in thin
`sheet and film (e.g., reduction in web breaks) applications.
`[0050] Alternatives to film-larninated skived foams.
`[0051] Artificial turf with improved tear strength (Recre-
`ation market).
`[0052] Constrained layer for quiet steel technology (metal-
`plastic laminate for noise and vibration damping).
`[0053] Marine interiors (e.g., light weight, water-resistant,
`soft touch, non-skid applications).
`[0054] The following examples are illustrative of certain
`specific embodiments ofthis invention. Unless indicated oth-
`erwise, all parts and percentages are by weight. Controls have
`a draw speed of l x; inventive examples have a draw speed of
`greater than l><.
`SPECIFIC EMBODIMENTS
`
`Foam-film samples with different degrees ofmacro-
`[0055]
`cellular orientation are prepared using a co-extrusion line that
`consists oftwo 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 oftwo 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><0.2 centimeters
`(cm)
`(width><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 struc-
`ture. Overall extrusion rate is held constant at approximately
`2.3 kilograms per hour (kg/l1r),
`[0056] Extrudates are subsequently prepared and charac-
`terized for cell size using a stereo-optical microscope. Aver-
`age 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><4.8 mm><sheet thickness at a
`strain rate of 100%/minute in an Instron Universal Testing
`machine. All testing is conducted at ambient conditions
`(about 23 C and atmospheric pressure).
`[0057] 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 l><). Those examples in which the film
`consists of three layers has a higher density than the remain-
`ing 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 direc-
`tion elongation with insignificant change in transverse direc-
`tion toughness at lower density compared to their three layer
`analogs.
`
`Page 4 of 7
`
`Page 4 of 7
`
`

`
`US 2009/0263645 A1
`
`Oct. 22, 2009
`
`Materials
`
`Foam Component
`
`Film Component
`
`Foaming Agent
`
`EX. # Resin Gra e
`
`3P? PF-814
`1
`2 P3PF-814
`3 T30 3 en
`
`4 T30 3 en
`
`5 T30 3 en
`
`6 T30 3 en
`
`7 T30 3 en
`
`8 T30 3 en
`
`9 T30 3 en
`
`0
`
`Vol.
`%1
`
`{esin Grade
`
`Vol.
`%1 Com3ound
`
`3P? 3F-814
`50
`3P 33-8 4
`50
`70 A33NI'3Y PL-
`880
`70 A33NI'3Y PL-
`880
`70 A33NI'3Y PL-
`880
`70 A33NI'3Y PL-
`880
`70 A33NI'3Y PL-
`880
`70 A33NI'3Y PL-
`880
`70 A33NI'3Y PL-
`880
`50 3)33 503A
`
`50 Azo icaraonami e
`50 Azo icaraonami e
`30 Azo icaraonami e
`
`30 Azo icaraonami e
`
`30 Azo icaraonami e
`
`30 Azo icaraonami e
`
`30 Azo icaraonami e
`
`30 Azo icaraonami e
`
`30 Azo icaraonami e
`
`50 SA30AM 333-50
`
`50 3)33 503A
`
`50 SA30AM 333-50
`
`4
`
`Wt
`%2
`
`1.75
`1.75
`2
`
`2
`
`1
`
`1
`
`1
`
`1
`
`1
`
`2.5
`
`2.5
`
`2.5
`
`Number
`of Layers
`
`32
`3
`16
`
`16
`
`32
`
`32
`
`3
`
`3
`
`3
`
`32
`
`32
`
`3
`
`4AFF NITY
`3G8200
`1 A33N TY
`3G8200
`2 A33N TY
`3G8200
`3 A33N TY
`3G8200
`4 A33N TY
`3G8200
`SLDPE 503A
`3 end**
`3)33503A
`3 end**
`3)33503A
`3 end**
`3)33503A
`3 end**
`
`5
`
`6
`
`7
`
`8
`
`50 3)33 503A
`
`50 SA30AM 333-50
`
`50 3)33 503A
`
`50 SA30AM 333-50
`
`50 3)33 503A
`
`50 SA30AM 333-50
`
`86
`
`86
`
`86
`
`86
`
`3VOH-44#
`
`14 SA30AM 333-50
`
`3VOH-44#
`
`14 SA30AM 333-50
`
`3VOH-27#
`
`14 SA30AM 333-50
`
`3VOH-27#
`
`14 SA30AM 333-50
`
`2.5
`
`2.5
`
`2.5
`
`2.5
`
`2.5
`
`2.5
`
`3
`
`3
`
`17
`
`17
`
`17
`
`17
`
`EXttuder
`Temperature (C.)
`
`Additional
`Temperatures (C.)
`
`Foam
`EX. # Component
`
`Fi m
`Component
`
`Feed-
`block
`
`Multialiers
`
`)ie
`
`Draw
`Speed
`
`1
`2
`3
`4
`5
`6
`7
`8
`9
`10
`11
`12
`13
`14
`15
`16
`
`2 0
`2 0
`2 0
`2 0
`2 0
`2 0
`2 0
`2 0
`2 0
`2 5
`2 5
`2 5
`2 5
`2 5
`2 5
`2 5
`
`2 0
`2 0
`2 0
`2 0
`2 0
`2 0
`2 0
`2 0
`2 0
`2 5
`2 5
`2 5
`2 5
`2 5
`2 5
`2 5
`
`2 0
`2 0
`2 0
`2 0
`2 0
`2 0
`2 0
`2 0
`2 0
`2 5
`2 5
`2 5
`2 5
`2 5
`2 5
`2 5
`
`2 0
`2 0
`2 0
`2 0
`2 0
`2 0
`2 0
`2 0
`2 0
`2 5
`2 5
`2 5
`2 5
`2 5
`2 5
`2 5
`
`60
`60
`60
`60
`60
`60
`60
`60
`60
`55
`55
`55
`55
`55
`55
`55
`
`X
`2X
`X
`3X
`X
`4X
`X
`2X
`3X
`X
`4X
`X
`2X
`3X
`X
`2X
`
`Page 5 of 7
`
`Page 5 of 7
`
`

`
`US 2009/0263645 A1
`
`Oct. 22, 2009
`
`17
`18
`
`215
`215
`
`-continued
`215
`215
`
`215
`215
`
`215
`215
`
`155
`155
`
`1x
`2x
`
`lvol % 3ased on volumetric flow rates of unexpanded (solid) polymer
`2wt %, oading based on Foa.mable Component
`3Pro- ax PF814 polypropylene homopolyrner ofhigh melt strength by Basell (MFR of3.0 and
`density of0.902 gcc)
`4AFF NITY PL1880 ethylene/1-octene copolymer by Dow (MFR of1.0 and density of0.902
`g/cc)ADFL EX Q200F low modulus thermoplastic olefin resin by Basell (MFR of0.8 and density of
`0.882 gcc
`6LDP 3 503A by Dow (MFR of1.9 and density of0.923 gcc)
`7FUSA 3OND N MN493D MAH-grafted ethylene/1-octene copolymer by Dupont (MFR of 1.2
`and density of0.87 g/cc)
`8EVA 3 L171 ethylene/vinyl alcohol copolymer by EVALCA (MFR of4.0 and density of 1.20
`g/cc)EVA 3 E171 ethylene/vinyl alcohol copolymer by EVALCA (MFR of3.3 and density of 1.14)
`#EVO} -Ethylene vinyl alcohol copolymer number indicates mole % ethylene in copolymer TPO
`Blend is 75/25 w/w mixture oftwo polypropytlene resins, PF-814 and 5Adflex OF-200, both sup-
`plied 3y Basell Inc.
`**A-90/10 w/w blend of LDPE/7Fusabond MN-493D Barner Foam-Film Samples (15-18) used
`Skin layers of 503A (Incorporated into film component as % Film in the Table
`All MF { measured according to ASTM D 1238 and 2.16 kg. Pro-fax and Adflex measured at 230
`C.; A:FINITY, LDPE 503A measured at 190 C.; and EVAL L171 and E171 easured at 210 C.
`
`Overall
`
`Foam
`
`Final
`
`Cell Size
`
`Tensile Properties
`Machine Direction
`
`Tensile Properties
`Traverse Direction
`
`Density Density Thickness
`
`microns
`
`Anisotrophy Break Stress
`
`Break @
`
`Break Stress
`
`Break @
`
`Ex. #
`1
`2
`3
`4
`5
`6
`7
`8
`9
`10
`11
`12
`13
`14
`15
`16
`17
`18
`
`(g/cc)
`0.3
`
`(gcc)
`0.18
`
`0.28
`0.28
`0.21
`0.21
`0.35
`
`0.32
`
`0.51
`
`0.26
`0.36
`0.39
`0.29
`
`0.35
`0.35
`0.57
`
`0.62
`0.48
`
`0.66
`0.69
`0.71
`0.38
`0.49
`0.52
`0.42
`
`(mils)
`
`75
`
`70
`25
`89
`
`61
`55
`
`71
`63
`35
`
`Z
`100
`575
`70
`30
`90
`50
`215
`
`560
`70
`
`400
`290
`93
`200
`180
`350
`150
`
`Y
`
`X
`
`Ratio (X/Z)
`
`650
`
`1100
`
`35
`
`65
`
`150
`
`185
`
`7580
`
`1500
`
`390
`210
`
`750
`422
`160
`220
`240
`120
`
`.9
`
`5
`
`3.7
`
`2.7
`
`2.6
`4.5
`0.8
`.2
`0.7
`0.8
`
`(Pa)
`7.5
`10
`6.5
`10.5
`6
`13.4
`10.6
`14.6
`8.9
`13.8
`25
`8
`
`9.3
`8
`7.9
`7.5
`6.7
`
`Elongation (%)
`12
`4.4
`270
`490
`180
`550
`276
`404
`230
`250
`280
`438
`
`363
`155
`150
`37
`41
`
`(Pa)
`6.5
`5.4
`6.5
`5.5
`6.5
`5.8
`1
`7.8
`5
`12.7
`14.2
`7
`
`5.2
`4.5
`4.2
`5
`5
`
`Elongation (%)
`12
`60
`270
`280
`260
`230
`260
`260
`102
`230
`250
`417
`
`314
`40
`29
`16
`20
`
`‘wt %, loading based on Foamable Component
`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 polypro-
`pytlene resins, PF-814 and Adflex OF-200, both supplied by Bassell Inc.
`** A-90/10 w/w blend ofLDPE/Fusabond N MN493D Barner Foam-Film Samples (15-18) used Skin layers of503A (Incorporated into film
`component as % Film in the Table
`
`[0058] Although the invention has been described in con-
`siderable 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 appli-
`cations cited in the specification are incorporated herein by
`reference.
`
`1. A multilayer film-foam composite structure comprising
`at least one film layer in abutting relationship with at least two
`
`foam layers, each foam layer comprising anisotropic cells
`that have a cell anisotropy width to thickness ratio from 3: 1 to
`5:1.
`2. The structure of claim 1 in which the anisotropic cells of
`the foam layer have an anisotropic length O() to thickness (Z)
`ratio of greater than 1.
`3. The structure of claim 1 in which the anisotropic cells of
`the foam layer have an anisotropic X to Z ratio of greater than
`about 2.
`4. The structure of claim 1 comprising at least five layers of
`which two are foam layers and three are foam layers and
`which the film and foam layers alternate.
`
`Page 6 of 7
`
`Page 6 of 7
`
`

`
`US 2009/0263645 A1
`
`Oct. 22, 2009
`
`5-7. (canceled)
`8. The structure of claim 1 comprising at least fifteen layers
`ofwhich at least seven layers are film and at least seven layers
`are foam and the film and foam layers alternate.
`9. The structure of claim 8 wherein the external layers are
`film layers.
`10. The structure of claim 8 wherein the external layers are
`foam layers.
`11. The structure of claim 1 in which at least one ofthe film
`
`and foam layers comprises a polyolefin.
`12. The structure of claim 1 in which at least one film layer
`and at least one foam layer comprises a polyolefin.
`13. The structure of claim 12 in which the polyolefin is a
`polyethylene or polypropylene.
`14. The structure of claim 1 comprising at least one of an
`oxygen, water and chemical barrier layer.
`15. A method of a making a multilayer film-foam laminate
`comprising at least one film layer in abutting relationship with
`at least two foam layers, the foam layers comprising aniso-
`tropic cells, the method comprising co-extruding a film-foam
`laminate and subjecting the co-extruded laminate to a defor-
`mation process in at least one direction such that the aniso-
`tropic cells have a width to thickness ratio from 3:1 to 5: 1.
`
`16. The method of claim 15 in which the deformation
`
`process comprises drawing the structure between a slot die
`and a film or sheet casting roll at a drawing ratio from 2:1 to
`10: 1 .
`17. The method of claim 15 in which the deformation
`
`process comprises parison inflation.
`18. The method of claim 15 in which the deformation
`
`process comprises tenter-frame stretching.
`19. The method of claim 15 in which the deformation
`
`process comprises in-line Vacuum forming.
`20. (canceled)
`21. The method of claim 15 in which the co-extruded
`laminate is deformed in at least two directions.
`22. The method of claim 15 in which the co-extruded
`laminate is deformed in three directions.
`23. The structure of claim 1 in which the cells of the foam
`
`layers are open.
`24. The structure of claim 1 in which the cells of the foam
`
`layers are closed.
`25. (canceled)
`
`Page 7 of 7
`
`Page 7 of 7