Poly(ethylene terephthalate)(CPET) multilayer oxygen-scavenging containers and methods of making

1. A multi-layer container comprising:

an outer layer comprising crystalline polyethylene terephthalate (CPET),

an inner layer, and

at least one middle layer interposed therebetween;

the middle layer including a blend of: at least one oxygen-scavenging component, at least one catalyst-containing concentrate, and a polymer consisting essentially of polyethylene terephthalate (PET);

wherein the middle layer contains at least one catalyst transition metal up to about 3%, by weight, of the multi-layer container; and

wherein substantially no adhesive material is interposed between the middle layer and the outer layer and/or the inner layer.

2. The multi-layer container of claim 1 , wherein the catalyst-containing concentrate depends on the ability to co-process eco extrusion or co injection) with the scavenging component.

3. The multi-layer container of claim 1 , wherein the catalyst-containing concentrate includes a transition metal selected from cobalt, copper, rhodium, ruthenium, palladium, tungsten, osmium, cadmium, silver, tantalum, hafnium, vanadium, titanium, chromium, nickel, zinc, and manganese.

4. The multi-layer container of claim 1 , wherein the catalyst-containing concentrate includes a transition metal in the form of a salt.

5. The multi-layer container of claim 1 , wherein the catalyst-containing concentrate includes a transition metal in the form of a salt, and wherein counter ions for the metal include one or more of carboxylates, including neodecanoates, octanoates, stearates, acetates, naphthalates, lactates, maleates, acetylacetonates, linoleates, oleates, palminates, 2-ethyl hexanoates, oxides, borides, carbonates, chlorides, dioxides, hydroxides, nitrates, phosphates, sulfates, and silicates.

6. The multi-layer container of claim 1 , wherein the catalyst-containing concentrate includes at least one of cobalt stearate or cobalt acetate that is present in a total concentration not exceeding about 3%, by weight, of the multi-layer container.

7. The multi-layer container of claim 1 , wherein the catalyst-containing concentrate comprises an oxidation catalyst blended with PET.

8. The multi-layer container of claim 1 , wherein a ratio of oxygen-scavenging component to catalyst-containing concentrate is about 5:95.

9. The multi-layer container of claim 1 , wherein a ratio of oxygen-scavenging component to catalyst-containing concentrate is about 10:90.

10. The multi-layer container of claim 1 , wherein a ratio of oxygen-scavenging component to catalyst-containing concentrate is about 20:80.

11. The multi-layer container of claim 1 , wherein a ratio of oxygen-scavenging component to catalyst-containing concentrate is about 30:70.

12. The multi-layer container of claim 1 , wherein a ratio of oxygen-scavenging component to catalyst-containing concentrate is about 40:60.

13. The multi-layer container of claim 1 , wherein a ratio of oxygen-scavenging component to catalyst-containing concentrate is about 50:50.

14. The multi-layer container of claim 1 , wherein a ratio of oxygen-scavenging component to catalyst-containing concentrate is about 60:40.

15. The multi-layer container of claim 1 , wherein a total concentration of oxygen-scavenging component in the middle layer is at least about 10%, by weight, of the multi-layer container.

16. The multi-layer container of claim 1 , wherein a total concentration of oxygen-scavenging component in the middle layer is at least about 5%, by weight, of the multi-layer container.

17. The multi-layer container of claim 1 , wherein a total concentration of oxygen-scavenging component in the middle layer is at least about 3%, by weight, of the multi-layer container.

18. The multi-layer container of claim 1 , wherein a total concentration of oxygen-scavenging component in the middle layer is at least about 2%, by weight, of the multi-layer container.

19. The multi-layer container of claim 1 , wherein a total concentration of oxygen-scavenging component in the middle layer is at least about 1%, by weight, of the multi-layer container.

20. The multi-layer container of claim 1 , wherein the outer layer of the multi-layer container has an oxygen permeation rate of no greater than about 3 cc O 2 /100 in 2 ·day·atm.

21. The multi-layer container of claim 1 , wherein the outer layer of the multi-layer container has an oxygen permeation rate of no greater than about 2 cc O 2 /100 in 2 ·day·atm.

22. The multi-layer container of claim 1 , wherein the outer layer of the multi-layer container has an oxygen permeation rate of no greater than about 1.5 cc O 2 /100 in 2 ·day·atm.

23. The multi-layer container of claim 1 , wherein the outer layer of the multi-layer container has an oxygen permeation rate of no greater than about 1 cc O 2 /100 in 2 ·day·atm.

24. The multi-layer container of claim 1 , wherein the outer layer of the multi-layer container has an oxygen permeation rate of no greater than about 0.5 cc O 2 /100 in 2 ·day·atm.

25. The multi-layer container of claim 1 , wherein the outer layer of the multi-layer container has an oxygen permeation rate of no greater than about 0 cc O 2 /100 in 2 ·day·atm.

26. The multi-layer container of claim 1 , wherein the outer layer of the multi-layer container has an oxygen permeation rate of less than about 0 cc O 2 /100 in 2 ·day·atm.

27. The multi-layer container of claim 1 , wherein the multi-layer container has an oxygen headspace absorption effect of about 0 cc O 2 ingress after about 5 days.

28. The multi-layer container of claim 1 , wherein the multi-layer container has an oxygen headspace absorption effect of less than about 0 cc O 2 ingress after about 5 days.

29. The multi-layer container of claim 1 , wherein the multi-layer container has an oxygen headspace absorption effect of more than about 0.3% headspace oxygen reduction after about 20 days.

30. The multi-layer container of claim 1 , wherein the multi-layer container has an oxygen absorption effect that increases over time after about 5 days after manufacturing of the multi-layer container.

31. The multi-layer container of claim 1 , wherein the middle layer has an oxygen-scavenging component to catalyst-containing concentrate ratio of greater than about 0.05.

32. The multi-layer container of claim 1 , wherein the catalyst-containing concentrate includes one or more oxidation catalysts.

33. The multi-layer container of claim 32 , wherein the catalyst-containing concentrate depends on the scavenging component.

34. A multi-layer container comprising:

an outer layer comprising crystalline polyethylene terephthalate (CPET),

an inner layer, and

at least one middle layer interposed therebetween;

the middle layer including a blend of: at least one oxygen-scavenging component, at least one catalyst-containing concentrate, and a polymer consisting essentially of polyethylene terephthalate (PET); wherein the middle layer contains at least one catalyst transition metal up to about 3%, by weight, of the multi-layer container;

the multi-layer container having:

i) a ratio of oxygen-scavenging component to catalyst-containing concentrate of about 5:95;

ii) a total concentration of oxygen-scavenging component in the middle layer of at least about 0.5%, by weight, of the multi-layer container;

iii) an oxygen permeation rate of the outer layer no greater than about 3 cc O 2 /100 in 2 ·day·atm;

iv) an oxygen headspace absorption effect of about 0 cc O 2 ingress after about 5 days; and

v) an oxygen absorption effect of that increases over time after about 5 days after manufacturing of the multi-layer container;

wherein substantially no adhesive material is interposed between the middle layer and the outer layer and/or the inner layer.

35. The multi-layer container of claim 34 , wherein the inner layer comprises a crystalline poly(ethylene terephthalate) polymer (CPET).

36. The multi-layer container of claim 34 , wherein the percentage of crystallinity of the CPET is varied, depending on barrier properties and heat resistance properties desired.

37. The multi-layer container of claim 34 , wherein at least one of the outer layer and the inner layer is at least about 1 to about 1.5 mils in thickness.

38. The multi-layer container of claim 34 , wherein the middle layer is present in an amount of at least about 1%, by weight, of the multi-layer container.

39. The multi-layer container of claim 34 , wherein the outer layer has a thickness of about 1 mil or more.

40. The multi-layer container of claim 34 , wherein the middle layer has an oxygen-scavenging component to catalyst-containing concentrate ratio of greater than about 0.05.

41. The multi-layer container of claim 34 , wherein a ratio of the oxygen-scavenging component to catalyst-containing concentrate in the middle layer is about a 50:50 ratio.

42. The multi-layer container of claim 34 , wherein the container has an oxygen absorption of about 50 cc O 2 , per gram of oxygen-scavenging component present in the multi-layer container.

43. The multi-layer container of claim 34 , wherein the oxygen-scavenging component present is at least about 0.5% or greater, by weight, of the multi-layer container.

44. The multi-layer container of claim 34 , wherein the oxygen-scavenging component present is at least about 2% or greater, by weight, of the multi-layer container.

45. The multi-layer container of claim 34 , wherein the oxygen-scavenging component is present at about 2% or less, by weight, of the multi-layer container.

46. The multi-layer container of claim 34 , wherein at least one inner layer comprises an amorphous poly(ethylene terephthalate) polymer (APET).

47. The multi-layer container of claim 34 , wherein at least one inner layer comprises an amorphous poly(ethylene terephthalate) polymer (APET) having a thickness of about 1 mil or more.

48. The multi-layer container of claim 34 , wherein the blend of the oxygen-scavenging component and the catalyst-containing concentrate is present in the middle layer at about a 5:95 ratio.

49. The multi-layer container of claim 48 , wherein the middle layer has a thickness of about 0.5 mil.

50. The multi-layer container of claim 49 , wherein the container has an oxygen absorption of about 50 cc O 2 , per gram of oxygen-scavenging component.

51. A method of making the multi-layer container, comprising:

providing a middle layer including a blend of:

a polymer consisting essentially of polyethylene terephthalate (PET);

at least one oxygen-scavenging component; and,

at least one catalyst-containing concentrate that contains at least one catalyst transition metal up to about 3%, by weight, of the multi-layer container; and,

interposing the middle layer between at least one outer layer and at least one inner layer without the use of an adhesive material.