Method of making coextruded, crosslinked multilayer polyolefin foam structures from recycled crosslinked polyolefin foam material
AssigneeToray Plastics (America), Inc.
InventorsJesse Jude Baldwin, Dan Ben-Daat, Winston Kenneth Bishop, III, Kaitlyn Michelle Bock, Pawel Sieradzki
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Abstract
The present disclosure is directed to a physically crosslinked, closed cell continuous multilayer foam structure comprising at least one foam polypropylene/polyethylene layer with a recycled polyolefin material layer. The multilayer foam structure can be obtained by coextruding a multilayer structure comprising at least one nonrecycled foam composition layer with at least one recycled foam composition layer, irradiating the coextruded structure with ionizing radiation, and continuously foaming the irradiated structure.
Claims28
A method of forming a multilayer structure comprising:
- shredding a polyolefin foam, agglomerating the shredded foam, and granulating the agglomerated foam to form a recycled, crosslinked polyolefin foam material;
- and
- coextruding:
- a first layer comprising:
- polypropylene, polyethylene, or a combination of polypropylene and polyethylene;
- and
- a first chemical foaming agent;
- and
- a second layer on a side of the first layer, the second layer comprising:
- 2.5-25 wt. % the recycled, crosslinked polyolefin foam material;
- 75-97.5 wt. % polypropylene, polyethylene, or a combination of polypropylene and polyethylene;
- and
- a second chemical foaming agent.
A method of forming a multilayer foam structure comprising:
- shredding a polyolefin foam, agglomerating the shredded foam, and granulating the agglomerated foam to form a recycled, crosslinked polyolefin foam material;
- coextruding:
- a first layer comprising:
- polypropylene or polyethylene;
- and
- a first chemical foaming agent;
- and
- a second layer on a side of the first layer, the second layer comprising:
- 2.5-25 wt. % the recycled, crosslinked polyolefin foam material;
- 75-97.5 wt. % polypropylene, polyethylene, or a combination of polypropylene and polyethylene;
- and
- a second chemical foaming agent;
- irradiating the coextruded layers with ionizing radiation;
- and
- foaming the irradiated, coextruded layers.
Dependencies are inferred from the claim text.