Multilayer polymer articles and process for making the same

Abstract

A multilayer polymer composite structure that includes a first layer including a polymer and at least one mineral filler and a second layer including a polymer. A third layer is positioned between the first layer and the second layer, wherein the third layer includes a mixture of material from at least the first and second layers. Preferably, the third layer is formed by recycling and mixing excess material from the multilayer polymer structure. The second layer can further include a colorant. The multilayer polymer structure can also include a fourth and/or fifth layer comprising a high clarity polymer and/or a high gloss polymer that provides a glossy surface or a sealant polymer that provides surface capable of being sealed. In a preferred embodiment, the multilayer polymer structure is thermoformed into a multilayer polymer article such as a container. Preferably, the container is a drinking cup. The process for preparing a multilayer polymer article includes an in-line or continuous single line extrusion-thermoform-trim system, including direct sheet extrusion of the polymer layer having the mineral filler.

Dependencies are inferred from the claim text.