Method of making coextruded, cross-linked polyolefin foam with TPU cap layers
AssigneeToray Plastics (America), Inc.
InventorsDan Ben-Daat, Jesse Jude Baldwin, Kaitlyn Michelle Bock, Pawel Sieradzki
Life of this patent
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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 TPU cap layer. The multilayer foam structure can be obtained by coextruding a multilayer structure comprising at least one foam composition layer with at least one cap composition layer, irradiating the coextruded structure with ionizing radiation, and continuously foaming the irradiated structure.
Claims15
A multilayer foam structure comprising:
- a coextruded foam layer comprising a chemical foaming agent and polypropylene, polyethylene, or a combination of polypropylene and polyethylene;
- and
- a coextruded cap layer on a side of the foam layer, the cap layer comprising:
- at least 55 wt % thermoplastic polyurethane (TPU);
- and
- 20-25 wt. % polyether amine modified polypropylene, polyether amine modified polyethylene, or a combination of polyether amine modified polypropylene and polyether amine modified polyethylene.
A laminate comprising:
- a multilayer foam structure comprising:
- a coextruded foam layer comprising a chemical foaming agent and polypropylene, polyethylene, or a combination of polypropylene and polyethylene;
- and
- a coextruded cap layer on a side of the foam layer, the cap layer comprising:
- at least 55 wt % thermoplastic polyurethane (TPU);
- and
- 20-25 wt. % polyether amine modified polypropylene, polyether amine modified polyethylene, or a combination of polyether amine modified polypropylene and polyether amine modified polyethylene;
- and
- a laminate layer on a side of the cap layer opposite the foam layer.
A flooring system comprising:
- a top floor layer;
- a sub-floor layer;
- and
- at least one underlayment layer disposed between the sub-floor layer and the top floor layer, wherein the at least one underlayment layer comprises a multilayer foam structure comprising:
- a coextruded foam layer comprising a chemical foaming agent and polypropylene, polyethylene, or a combination of polypropylene and polyethylene;
- and
- a coextruded cap layer on a side of the foam layer, the cap layer comprising:
- at least 55 wt % thermoplastic polyurethane (TPU);
- and
- 20-25 wt. % polyether amine modified polypropylene, polyether amine modified polyethylene, or a combination of polyether amine modified polypropylene and polyether amine modified polyethylene.
Dependencies are inferred from the claim text.