Mono and multi-layer articles and extrusion methods of making the same
An extruded blow molded bottle comprises a neck portion and a body portion. The body portion comprises a first inner layer and a second layer. The first inner layer comprises a first material selected from a group consisting of polyester, phenoxy type thermoplastics, phenoxy-polyolefin thermoplastic blends, and combinations thereof. The second layer comprises a second material selected from a group consisting of virgin PET, recycled PET, PETG, foam, polypropylene, polyester, polyolefins, phenoxy type thermoplastic, phenoxy-polyolefin thermoplastic blends, regrind scrap materials, and combinations thereof. The second material is different from the first material.
1 . A bottle comprising:
a neck portion; and
a body portion comprising a first inner layer and a second layer, the first inner layer comprising a first material selected from a group consisting of phenoxy type thermoplastics, phenoxy-polyolefin thermoplastic blends, and combinations thereof, and the second layer comprising a foam material, the foam material comprising an expandable material and a carrier material, the first inner layer and the second layer being coextruded to form a profile;
wherein the bottle is made by blow molding the coextruded profile.
2 . The bottle of claim 1 , wherein the second layer is an outer layer.
3 . The bottle of claim 1 , wherein the second layer is an intermediate layer between the first inner layer and an outer layer.
4 . The bottle of claim 1 , wherein the first inner layer has a wall thickness less than about one half of a wall thickness of the second layer.
5 . The bottle of claim 1 , wherein the first inner layer has a wall thickness less than about one quarter of a wall thickness of the second layer.
6 . The bottle of claim 1 , wherein the first inner layer has a wall thickness less than about one tenth of a wall thickness of the second layer.
7 . The bottle of claim 1 , wherein the expandable material comprises microspheres.
8 . The bottle of claim 1 , wherein the carrier material comprises polypropylene.
9 . The bottle of claim 1 , wherein one or more of the first inner layer and the second layer comprises a barrier material having a permeability to oxygen and carbon dioxide which is less than that of polyethylene terephthalate.
10 . The bottle of claim 1 , wherein a tie layer is positioned between the first inner layer and the second layer.
11 . The bottle of claim 1 , wherein the neck portion is configured to receive a closure.
12 . A method of forming a bottle, comprising:
coextruding a profile having a first inner layer and a second layer, the first inner layer comprising a first material selected from a group consisting of phenoxy type thermoplastics, phenoxy-polyolefin thermoplastic blends, and combinations thereof, and the second layer comprising a foam material, the foam material comprising an expandable material and a carrier material; and
blow molding the profile to form a bottle.
13 . The method of claim 12 , further comprising cooling the bottle to control the expansion of the expandable material.
14 . The method of claim 12 , further comprising heating the bottle to control the expansion of the expandable material.
15 - 46 . (canceled)
47 . An extruded profile for carrying beverages, comprising:
a first extruded inner layer comprising a material selected from the group consisting of phenoxy-type thermoplastic, phenoxy-polyolefin thermoplastic blend, and combinations thereof; and
a second extruded layer comprising a material selected from the group consisting of foam, polypropylene, regrind scrap materials from a profile forming process, and combinations thereof, the second extruded layer supporting the first extruded inner layer.
48 . The extruded profile of claim 47 , wherein the first layer is suitable for contact with foodstuffs.
49 . The extruded profile of claim 47 , wherein the second layer comprises an expandable material.
50 . The extruded profile of claim 49 , wherein the expandable material is adapted to expand by heat treatment.
51 . The extruded profile of claim 50 , wherein the expandable material comprises microspheres that enlarge during heat treatment.
52 . The extruded profile of claim 50 , wherein the heat treatment comprises a preheating cycle for elevating the temperature of the profile for blow molding.
53 . The extruded profile of claim 49 , wherein the expandable material comprises a polymer carrier material and a foaming agent.
54 . The extruded profile of claim 49 , wherein the expandable material comprises mostly fully collapsed microspheres, partially expanded microspheres, or fully expanded microspheres.
55 . The extruded profile of claim 49 , wherein the expandable material is configured to expand to form foam when heated above an expansion temperature.
56 . The extruded profile of claim 49 , wherein the expandable material comprises about 5% to about 60% of the profile.
57 . The extruded profile of claim 49 , wherein the expandable material comprise mostly PP by weight.
58 . The extruded profile of claim 49 , wherein the expandable material comprises less than about 40% by weight of the profile.
59 . The extruded profile of claim 49 , wherein the expandable material comprises less than about 20% by weight of the profile.
60 . The extruded profile of claim 49 , wherein the expandable material comprises microspheres and a carrier material selected from the group consisting of polypropylene, PET, and combinations thereof.
61 . The extruded profile of claim 47 , wherein at least one of the first layer and the second layer comprises a barrier material.
62 . The extruded profile of claim 61 , further comprising another layer comprising barrier material.