Coextruded, crosslinked polyolefin foam with KEE cap layers
AssigneeToray Plastics (America), Inc.
InventorsDan Ben-Daat, Jesse Jude Baldwin, Kaitlyn Michelle Bock, Pawel Sieradzki
Life of this patent
Estimating the term…
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 KEE cap layer. The multilayer foam structure can be obtained by coextruding a multilayer structure comprising at least one foam layer composition layer with at least one cap layer composition layer, irradiating the coextruded structure with ionizing radiation, and continuously foaming the irradiated structure.
Claims20
A multilayer foam structure comprising:
- a coextruded foam layer comprising polypropylene, polyethylene, or a combination of polypropylene and polyethylene;
- a coextruded cap layer on a side of the foam layer, the cap layer consisting of:
- 15-85 wt. % ketone-ethylene-ester (KEE) terpolymer, wherein the ester of the KEE comprises an acrylate;
- optionally, 1-8 wt. % additives;
- and
- polypropylene, polyethylene, or a combination of polypropylene and polyethylene;
- and
- a polyvinyl chloride (PVC) layer on a side of the coextruded cap layer opposite the coextruded foam layer;
- wherein the multilayer foam structure does not include a corona, plasma, or chemical surface treatment, or an adhesion primer or adhesive between the coextruded cap layer and the PVC layer.
A laminate comprising:
- a multilayer foam structure comprising:
- a coextruded foam layer comprising polypropylene, polyethylene, or a combination of polypropylene and polyethylene;
- a coextruded cap layer on a side of the foam layer, the cap layer consisting of:
- 15-85 wt. % ketone-ethylene-ester (KEE) terpolymer, wherein the ester of the KEE comprises an acrylate;
- optionally, 1-8 wt. % additives;
- and
- polypropylene, polyethylene, or a combination of polypropylene and polyethylene;
- and
- a laminate PVC layer on a side of the cap layer opposite the foam layer;
- wherein the laminate does not include a corona, plasma, or chemical surface treatment, or an adhesion primer or adhesive between the coextruded cap layer and the laminate PVC layer.
A flooring system, comprising:
- a PVC top floor layer;
- a sub-floor layer;
- and
- at least one underlayment layer disposed between the sub-floor layer and the PVC top floor layer, wherein the at least one underlayment layer comprises a multilayer foam structure comprising:
- a coextruded foam layer comprising polypropylene, polyethylene, or a combination of polypropylene and polyethylene;
- and
- a coextruded cap layer on a side of the foam layer, the cap layer consisting of:
- 15-85 wt. % ketone-ethylene-ester (KEE) terpolymer, wherein the ester of the KEE comprises an acrylate;
- optionally, 1-8 wt. % additives;
- and
- polypropylene, polyethylene, or a combination of polypropylene and polyethylene, wherein the PVC top floor layer is on a side of the coextruded cap layer opposite the coextruded foam layer;
- and
- wherein the flooring system does not include a corona, plasma, or chemical surface treatment, or an adhesion primer or adhesive between the coextruded cap layer and the PVC top floor layer.
Dependencies are inferred from the claim text.