coextrusion method, coextrusion matrix and extruded articles made from it

专利摘要:
COEXTRUSION METHOD, COEXTRUSION MATRIX AND EXTRUDED ARTICLES MADE IN THATA matrix comprising two matrix cavities, with each being capable of supplying polymeric material, and a distribution plate interposed between at least a portion of each of the two matrix cavities. The dispensing pIaca has a dispensing edge and a plurality of extrusion channels. The first and second extrusion channels extend from inlet openings in the first and second die cavities, respectively, to outlet openings at the dispensing edge. The outlet openings of the first and second extrusion channels are arranged in alternating positions along the dispensing edge. An extrusion method with such a die and an extruded article made of it are also presented. The method includes coextruding a first polymeric composition and a second polymeric composition. The extruded article comprises a plurality of first longitudinal bands of the first polymer composition alternating with a plurality of second longitudinal bands of the second polymer composition.
公开号:BR112012019731A2
申请号:R112012019731-2
申请日:2011-02-04
公开日:2020-08-18
发明作者:Michael R. Berrigan；John H.Horns；Anthony B. Ferguson；Thomas J. Rieger；Ronald W. Ausen；William C. Egbert
申请人:3M Innovative Propereties Company；
IPC主号:

专利说明:

“METHOD OF MANUFACTURING AN EXTRUDED ARTICLE, MATRIX FOR 'COEXTRUSION AND EXTRUDED FILM" Reference to Related Deposit Requests' This request claims the benefit of US Provisional Order No. 61 / 302,316, - 5 filed on February 8, 2010, the description of which is incorporated herein by reference in its entirety Background Background The coextrusion of multiple polymeric components into a single layered film is known in the art, for example, multiple polymeric flow streams have been combined in a matrix or feed block layered to provide an integrated multilayer film. Said coextrusion is also known to provide more complicated structures of coextruded film where the film is partitioned, not as coextensive layers in the direction of thickness, but as strips along the width dimension of the This has sometimes been called “side-by-side” coextrusion. Extruded products | 15 with side-oriented strips are described, for example, in U.S. Patent Numbers
4,435,141 (Weisner et al.), 6,159,544 (Liu et al.), 6,669,887 (Hilston et al.) And 7,678,316 (Ausen etal.). Although extrusion devices for the production of extruded products with extruded strips oriented side by side are known, there is still a need for alternatives and improvements to such devices. Summary In one aspect, the present description features a matrix useful for coextruding at least a first extrudable polymeric composition and a second extrudable polymeric composition. The matrix comprises a first matrix cavity in a first matrix portion, a second matrix cavity in a second matrix portion, a distribution plate interposed between at least a portion (for example, all or almost all) of the first cavity of the matrix. matrix and at least a portion (e.g., all or almost all) of the second matrix cavity. The distribution plate has a first side forming an outline of the first die cavity, a second side forming an outline of the second die cavity, a dispensing edge, a plurality of the first extrusion channels and a plurality of the second extrusion channels. The first extrusion channels extend from the inlet openings in the first die cavity to the outlet openings on the dispensing edge, and the second extrusion channels extend from the inlet openings in the second die cavity to the openings at the dispensing edge. The outlet openings of the first extrusion channels and the outlet openings of the second extrusion channels are arranged in alternating positions along the dispensing edge. Each of the first extrusion channels comprises two opposite side walls and a joining surface connecting the two 'opposite side walls, and the joining surface of at least part of the first extrusion channels is substantially parallel to the first side of the plate. distribution. In another aspect, the present description provides a method for producing an extruded article, the method comprising providing the matrix described above, providing a first polymeric composition to the first cavity of the matrix; supply a second polymer composition different from the first polymer composition to the second | matrix cavity; extruding the first polymeric composition through the plurality of first extrusion channels and the second polymeric composition through the plurality of the second extrusion channels so as to form a flow stream that has a width with alternating zones of the first and second polymeric compositions, and extruding the flow stream out of the die in a longitudinal direction to form the extruded article, the extruded article comprising a plurality of first longitudinal bands of the first polymeric composition alternating with a plurality of the second longitudinal bands of the second polymeric composition, at least part of the first longitudinal bands having, in a plane perpendicular to the longitudinal direction, a cross-sectional shape comprising substantially parallel opposite sides.
In the matrix and in the method according to the present description, the flow management of different polymeric compositions in side-by-side lanes can be advantageously performed with the use of a single pipe matrix with a distribution plate as opposed to approaches that require multiple matrices to achieve side-by-side coextrusion. In addition, in some embodiments, the matrix is readily modified to provide additional polymeric layers on the side-by-side lanes, where the layers can be the same or different from the polymers on the side-by-side lanes. The distribution plate can be used on the matrix flange with a short distance between the matrix flange and the dispensing edge, which allows a high level of control of the polymer streaks. The distribution plate can be relatively inexpensive to machine in order to meet the desired requirements for thickness, streak widths and streak length and to accommodate changes in pressure and polymer melting characteristics. The use of the distribution plate shown in the present invention can reduce or eliminate the need for costly machining of the primary die halves. In addition, the distribution plate that has the first and second sides has a geometry that allows it to readily seal against the first and second portions of the die. In this way, the distribution plate useful for practicing the present description can provide significant cost and performance advantages over, for example, matrix bars with more complex geometries. Typically, the distribution plate can be understood to have two main sides, each of which between the first main side and the second main side is connected to the dispensing edge and the opposite edge. In other words, the board. distribution can be understood to have only two sides, the first side and the second side, and only up to four edges.
The method and matrix according to the present description can be useful, for example, to prepare extruded articles with longitudinal bands that comprise different polymeric compositions. Thus, in another aspect, the present description features an extruded film that has the first and second lateral edges and a median line, the extruded film comprising an even number of first longitudinal bands of a first polymeric composition comprising a polymer inelastic alternating with a different number of second longitudinal bands of a second polymeric composition comprising an elastomeric polymer so that the second longitudinal bands are located at least on the first and second lateral edges and on the midline, each of the second longitudinal bands that are not located on the first and second side edges have a perforated line along its length. Typically, at least some of the first longitudinal bands have, in a plane perpendicular to the midline, a cross-sectional shape comprising substantially parallel opposite sides. In some embodiments, the extruded film comprises opposite main surfaces, and at least one of the main surfaces is provided with projections (for example, with heads that engage in a loop). Such films can be useful, for example, to provide hook strips that comprise inelastic polymers that have edges produced from softer elastomeric materials.
In preparing extruded film that has projections using the methods of the present invention presented here, it has now been found that it is possible to control the height of the film by controlling the composition of the second polymeric material. Consequently, in another aspect, the present description features an extruded film comprising a plurality of the first longitudinal bands of a first polymeric composition comprising an inelastic polymer alternating with a plurality of second longitudinal bands of a second polymeric composition comprising a mixture of an elastomeric polymer and an inelastic polymer, with both the plurality of the first longitudinal bands and the plurality of second longitudinal bands having projections, the projections of the plurality of the first longitudinal bands being substantially the same height as the projections of the plurality of the second bands longitudinal. Typically, at least some of the first longitudinal strips have, in a plane perpendicular to the longitudinal direction, a cross-sectional shape comprising substantially parallel opposite sides.
“Substantially the same height” can mean, for example, that the heights of the 'projections of the second bands can be in the range of 10, 8, 5, 4, 3, 2 or 1 percent a. the heights of the projections of the first bands. Such films can be useful, for example, to provide hook strips comprising inelastic polymers having edges - 5 made from softer elastomeric materials.
In this application, terms such as "one", "one" and "o / a" are not only intended for reference to a single entity, but include the general class of which a specific example can be used for illustration. The terms "one", "one", "a" and "o" are used interchangeably with the term "at least one". The phrases "at least one of" and "comprises at least one of" followed by a list refer to any of the items on the list and any combination of two or more items on the list. All numeric ranges are inclusive of your points end values and non-integer values between end points unless otherwise specified.
The term "alternating" for use in the present invention refers to a first extrusion channel or longitudinal strip that is disposed between any two second adjacent channels or strips (that is, second channels or strips that have only one first channel or strip between them) and a second channel or strip being arranged between any two first adjacent channels or tracks.
The terms "first" and "second" are used in this description. It will be understood that, unless otherwise specified, those terms are used only in their relative meaning. In particular, in some embodiments, certain components may be present in interchangeable and / or identical multiples (for example, pairs). For these components, the designation of "first" and "second" can be applied to the components | merely as a matter of convenience in describing one or more of the - modalities.
The term "matrix" will be understood to include a matrix through which materials (as described in the present invention) can be forced, pressed, pushed, shaped or otherwise directed through the matrix to provide the described product (for example , extruded article or extruded film).
The term "interconnecting in a loop", for use in the present invention, refers to the ability of a projection to be mechanically attached to a loop material. In general, stem projections with heads that engage in a loop have a head shape that is different from the shape of the stem. For example, the projection may be in the shape of a mushroom (for example, with a circular or oval head enlarged in relation to the stem), a hook, a palm tree, a nail, a T or a J. The interconnect capability in loop projections can be determined and defined by using woven, non-woven or knitted materials. A region of projections with heads that engage in a loop will generally provide, in combination with a loop material, at least one among a higher peel strength, dynamic shear strength or higher dynamic friction than a region at . of the headless projections that engage in a loop. Typically, projections that have heads that engage in a loop have a maximum thickness dimension of up to about 1 - 5 (in some embodiments, 0.9, 0.8, 0.7, 0.6, 0.5, or 0 , 45) millimeters.
The term "substantially parallel" for use in the present invention to refer to the two surfaces of the distribution board or to the two sides of a cross-sectional shape means that the two parallel surfaces or sides deviate from the parallel by up to 10 (In some embodiments , up to 7.5 or 5) degrees.
The term "substantially perpendicular", for use in the present invention, refers to the relationship between the side or rear walls of the extrusion channels and the first side of the distribution plate means that the wall and the first side deviate from the perpendicular by up to 10 (in some modalities, up to 7.5 or 5) degrees. However, the substantially perpendicular side or the back walls may have a curvature in the joint surface to eliminate a dead spot in one corner of the extrusion channel.
The summary above the present description is not intended to describe each modality presented or all the implementations of the present description. The following description more particularly illustrates the illustrative modalities. Therefore, it should be understood that the following drawings and description are for illustration purposes only and should not be read in such a way as to unduly limit the scope of this description.
Brief Description of the Drawings The description can be understood in a more complete way taking into account the detailed description below of the various modalities of the description together with the attached drawings.
Figure 1 is a perspective view of an extrusion die according to an embodiment of the present invention; Figure 2 is a cross-sectional side view of the extrusion die in figure —1 taken along section lines 2-2 in figure 1; Figure 2a is an enlargement of a region marked 2a in Figure 2; Figure 3 is a top view of an extrusion die distribution plate of Figures 1 and 2 shown in isolation; Figure 4 is a perspective view of an extrusion die distribution plate of Figures 1 and 2 shown in isolation;
Figure 4a is a cross-sectional side view of an embodiment of at least a portion of an extruded article preparable from a die and method according to the present description; 'Figure 5 is a cross-sectional side view of the extrusion die of figure - 5 1, taken along section lines 2-2 in figure 1, and having doors at the end of the die or at the rear of the die to form coextruded layers; Figure 5a is an enlargement of a region marked 5a in Figure 5; Figure 5b is a cross-sectional side view of an embodiment of at least a portion of an extruded article that has coextruded layers preparable with the extrusion die of Figure 5; Figure 6 is a perspective view of an embodiment of an extruded article according to the present description, the extruded article being in the form of a cylinder; Figure 7A is a cross-sectional perspective view of an extruded article where each of the longitudinal bands is provided with projections that have heads that engage in a loop; Figure 7B is a cross-sectional perspective view of an extruded article where one of the longitudinal bands is provided with projections that have heads that engage in a loop, and one of the longitudinal bands is provided with projections without heads that engage. in loop; Figure 8 is a schematic view of an apparatus and a method according to some modalities, where at least one of the strips of the extruded article is provided with projections; and Figure 9 is a cross-sectional side view of an extrusion die according to another embodiment, in which the die can be useful for forming coextruded layers.
Detailed Description In describing the preferred embodiments of the present invention, specific terminology will be used in order to obtain clarity. However, the description is not intended to be limited to the specific terms selected and each term so selected includes all technical equivalents that work in a similar way.
Now, with reference to figure 1, the illustrated embodiment of an extrusion die 20 according to the present description and useful for practicing the methods presented here includes a first die portion 22 and a second die portion 24. A dispensing plate 26, typically in the form of a profiled metal wedge, is disposed between the first and second portions of the die 22 and 24. The first die portion 22 has a first inlet 28 for receiving a supply of a first polymeric composition
SN NS MM "l 7/33 | extrudable, and the second matrix portion 24 has a second inlet 30 which serves to receive a supply of a second extrudable polymer composition. In typical operations, the first inlet 28 and the second inlet 30 are connected to the respective sources of 'extrudable polymeric compositions such as, for example, molten tubes or hoses - 5 of the conventional type connected to pumps or screw extruders. In some embodiments, materials can be supplied to the matrix using one or more extruders (for example, single or double screw). In other embodiments, the materials can be supplied to the die using, for example, a grid melter and a gear pump, or other sources of molten material (for example, fused polymeric material).
Now, with reference to figures 2 and 2a, the distribution plate 26 has a first side 32 and a second side 34 and a dispensing edge 36. The distribution plate 26 can be, for example, an integral or separate wedge, a membrane or other partition partition arranged for the purpose of separating the first and second matrix cavities 38, 40. The first side 32 of the distribution plate 26 and the first matrix portion 22 together define a first matrix cavity 38, and the second side 34 of the distribution plate 26 and the second matrix portion 24 together define a second matrix cavity 40. Heating elements 25 can be positioned on each portion of the matrix. In the example embodiment shown, the matrix portions 22 and 24 together define a recessed cavity 42 formed in front of the dispensing edge 36 and recessed within the matrix 20 from a matrix edge 44 through which the polymeric materials are extruded. The recessed cavity 42 includes a surface 43. During the use of the die 20, the cavities 38 and 40 on either side of the distribution plate 26 will be filled with pressurized extrudable polymeric material. Therefore, care must be taken that the pressure differential between these cavities 38 and 40 does not exceed the resistance to physical distortion of the distribution plate 26. In some embodiments, the distribution plate is at least 2.5, 3, 3,5, 4, 4,5, 5, 6, 7, 8, 9 or 10 millimeters (mm) thick.
In some embodiments, the die according to and / or useful for practicing the present description comprises an edge of the die 44 (for example, in the form of a slit or any desired shape) through which an extrudate comprising the first and second polymeric compositions can be extruded. As shown in figure 2a, the extrusion die distribution plate 26 according to and / or useful for practicing the present description can be designed and placed so that the dispensing edge 36 is lowered behind the die edge 44 and the cavity 42 can be formed. Lowering the dispensing edge 36 and forming the recessed cavity 42 are useful in many embodiments, but this is not considered a requirement of the present description. In some embodiments, the dispensing edge is in the range of about 2.5 centimeters (cm) from the matrix edge. In some embodiments, the 'dispensing edge is in the range of about 7.5, 6.25, 5, 3.75, 2.5, 1.9, 1.3, 0.635 a or 0.5 cm the edge of the matrix. For example, the dispensing edge can be in a range of about 0.5 to 7.5 cm, 0.5 to 2.5 or 0.635 to 2.5 cm from the rim of the die. At - 5 distance between the dispensing edge and the die rim should typically be long enough to establish the flow of the polymer extrudate, which typically requires that the distance over the height of the polymer be in a range of 1 to 10. If the the distance between the dispensing edge and the die edge is too long, for example, the longitudinal bands on the edges of the polymer extrudate may be distorted. The recessed cavity walls 42 can be straight (that is, the die opening can be dimensionally comparable! In height to the dispensing edge) or tapered towards the die edge 44 (i.e., the die opening can be smaller in height than the dispensing edge). It may also be desirable to taper the recessed cavity in width, for example, after combining the flow currents. Now, with reference to figure 3, several complete holes 46 can be formed through the distribution plate 26 to thereby receive a mechanism (for example, machine dowels) for holding the various components of the extrusion die 20 together as a set.
In the form of the distribution board according to and / or useful for practicing the present description shown in figure 4, the first and second extrusion channels 50, 52 are in the form of cut grooves in the distribution board 26. Each of the channels can also be, for example, in the form of a tunnel or other path cut or otherwise formed in the distribution plate. With reference to figure 4, a first plurality of grooves 50 in the form of grooves were cut on the first side 32 of the distribution plate 26, so that in the assembled matrix 20 the grooves 50 extend (that is, connect) from the first cavity 38 to the dispensing edge 36. In addition, a second plurality of grooves 52 in the form of grooves have been cut on the second side 34 of the distribution plate 26 so that in the assembled die 20 the grooves 52 extend from (i.e. ie, connect) from the second cavity 40 to the dispensing edge
36.Each of the channels 50 and 52, or grooves as shown, comprises opposite side walls 54 and 56, a rear wall 55 between the opposite side walls 54 and 56, a joining surface 58 that connects joining the side walls 54 and 56 (that is, a lower floor in the case of the first channels 50 and an upper roof in the case of the second channels 52), an inlet opening 60 on the corresponding side of the distribution plate 26 and an —opening opening 62, 62 'on the edge of dispensing 36 of the distribution plate 26 opposite the rear wall 55. As shown, channels 50 and 52 are arranged in alternating positions along the dispensing edge 36 such that a first channel 50 is disposed between any two adjacent second channels 52 Similarly, one: second channel 52 is disposed between any two adjacent first channels 50 ... The first extrusion channels 50 and second extrusion channels 52 can be formed n the distribution plate 26 by a number of different methods (for example, * 5 grinding, immersion electric discharge machining (EDM), acid grinding, electronic beam machining or diamond machining). This description is not intended to be limited to the type of training technique or equipment used to manufacture channels 50 and 52. BR The profiles of the first and second channels 50, 52 can be similar or different.
For example, the opposite side walls 54, 56 of each channel can be parallel to each other or can be arranged at an angle (for example, an acute, right or obtuse angle) to each other.
In some embodiments, the opposite side walls 54, 56 of each channel are substantially parallel to each other.
In addition, the side walls 54, 56 of the first channels 50 can be formed perpendicularly or inclined at an angle (other than a right angle) to the first side of the distribution plate 26, or the side walls 54, 56 of the first channels 50 they can be formed to taper out of their joining surfaces 58 to the first side 32 and the dispensing edge 36 of the distribution plate 26 (that is, the distance between the side walls adjacent to the joining surface may be less than the distance between the side walls adjacent to the first side of the distribution plate, adjacent to the dispensing edge or both). Likewise, the side walls 54, 56 of the second channels 52 can be formed perpendicular or inclined at an angle (other than a right angle) with the second side 34 of the distribution plate 26, or the side walls 54, 56 of the second channels channels 52 can be formed so as to narrow out of their joining surfaces 58 to the second side and the dispensing edge of the distribution plate 26 (i.e., the distance between the side walls adjacent to the joining surface may be shorter than the distance between the side walls adjacent to the second side of the distribution plate, adjacent to the dispensing edge, or both). The side walls 54, 56 of both sets of channels 50, 52 can be perpendicular to, or angled or tapered out from their corresponding sides of the distribution plate 26 and the dispensing edge 36, or a set of channels ( for example, 50) can be perpendicular and the other set (for example, 52) tapered or tilted.
The use of angled die channels 50, 52 will create angled areas with respect to the plane of the extrudate (for example, a film). Shapes other than perpendicular, slanted and tapered shapes can be used when convenient in relation to this description.
The joining surface 58 of at least some (for example, all or almost all) of the first extrusion channels 50 is substantially parallel to the first side 32 of the distribution plate 26. In some embodiments, the joining surface 58 of at least
AEE EE EA DD EAE EEE A JE EEE IPI ISIGGIIEE SSI »Jj óÔO EPE AND IPI CECEEEEEEO3JDEC oo o» DD: DS 10/33 minus some (for example, all or almost all) of the second extrusion channels' 52 is substantially parallel to the second side 34 of the distribution board. In some NA embodiments, the joining surface 58 of at least some (for example, all or almost all) of both the first extrusion channels 50 and the second * 5 extrusion channels are substantially parallel to the first and second substantially parallel sides of the distribution board. A joint surface 58 that is substantially parallel to the first or second side of the distribution plate will typically form zones in the extrudate with substantially parallel side edges. A cross-sectional side view of at least a portion of the resulting extruded article is shown in figure 4a. In extruded article 64a, each of the longitudinal strips 66, 68 will have a cross-sectional shape in a plane perpendicular to the longitudinal direction with substantially lateral edges. parallel 65 and 67. Conversely, if the joining surface 58 of the extrusion channels 50 slopes at an angle (for example, an acute angle) towards the dispensing edge, the different flow path lengths resulting in the flow channel extrusion could typically lead to triangular shaped zones in the extrudate.
Depending on the desired configuration of the resulting extrudate, it may be desirable for the outlet openings 62 of the first channels 50 to extend from the first side 32 of the distribution plate 26 towards, but not all the way to the second side 34 of the distribution plate 26, to the outlet openings 62 'of the second channels 52 to extend from the second side 34 of the distribution plate 26 towards, but not all the way to the first side 32 of the distribution plate 26, or both. In this way, the degree to which the outlet openings 62, 62 'of the first and second channels 50, 52 overlap may vary (for example, the first and second outlet openings may not overlap, may have some overlap or can overlap completely) as described. Alternatively, the outlet openings 62 of the first channels 50 can extend from the first side 32 to the second side 34 of the distribution plate 26 (i.e., across the entire thickness of the distribution plate 26), the exit openings 62 ' the second channels 52 can extend from the second side 34 to the first side 32 of the distribution board 26 (i.e., across the entire thickness of the distribution board 26), or both. You can also use | a combination. ] In some modalities of the matrix according to and / or useful to practice the | In the present description, a pair of first and second extrusion channels 50, 52 may have uneven widths. In some embodiments, a pair of first and second extrusion channels 50, 52 may have uneven depths. In some embodiments, a pair of first and second extrusion channels 50, 52 can be both uneven and
| 11/33; i uneven depths.
In some modalities, the first exit opening of | : extrusion channel 62 has at least one of a width that is at least ten (in some embodiments, at least 20, 30, 40, 50, 60, 70, 80, 90, 100, 200, 300, 400 or; 500) percent greater than the width of at least one of the two second openings I - 5 of adjacent extrusion channel outlet 62 'or a depth that is at least | ten (in some modalities, at least 20, 30, 40, 50, 60, 70, 80, 90, 100 or 200) per | percent greater than the depth of at least one of the two second openings! outlet of adjacent extrusion channel 62 '. The width and depth of the first and the! second extrusion channels 50, 52 can be adjusted, for example, to accommodate the | properties of the extruded polymer (for example, viscosity, shear sensitivity and resistance to flow, which can increase according to the inverse of the | third power of the channel width) and to achieve the desired width of the bands | longitudinal lines in an extruded article.
The width of the outlet openings 62, 62 'of the first and second extrusion channels 50.52 can be adjusted as desired for a given application.
In some embodiments, the width of the second outlet openings 62 'of the extrusion channel 52 is greater than 1.5 mm (in some embodiments, at least 2, 3, 4, 5 or 6 mm), for example, in a strip from 1.5 mm to 15 mm, 1.5 mm to 12 mm or 2 mm to 10 mm.
Typically, the width of the first outlet openings 62 of the extrusion channel 52 is larger than the second outlet openings of the extrusion channel (for example, at least 10 percent larger than as described above) and can be at least 5, 6, 7, 8, 9 or 10 mm, for example, in a range of 10 mm to 25 mm, 15 mm to 25 mm or from 15 mm to 20 mm.
The maximum width of the outlet openings 62, 62 'of the first and second extrusion channels 50, 52 is | general determined by the width limitations of the manufacturing machining and can be, for example, at least 75, 80, 90 or 100 cm.
Widths can be adjusted to allow the manufacture of extruded polymer films for a wide variety of potential uses. | The depth of the outlet openings 62, 62 'of the first and second channels of | extrusion 50, 52 can be adjusted as desired for a given application and can | only be limited by the thickness of the distribution plate.
In some embodiments, the plaque | 30 distribution is at least 5, 6, 7, 8, 9 or 10mm thick.
In some | modalities, the distribution board has a thickness of up to 20, 25 or 30 mm.
In some embodiments, the depth of the outlet openings 62 'of the second extrusion channel 52 is at least 0.25 mm (in some embodiments, at least 0.5, 1, 2, 3, 4 or SmMm). The depth of the outlet openings 62 of the first extrusion channel 52 may be greater than that of the second outlet openings of the extrusion channel (for example, at least 10 percent greater as described above) and may be at least 1, 2, 3, 4, 5, 6.7, 8, 9 or 10 mm.
BR 12/33 In the distribution plate 26 mode illustrated in figure 4, both the first: extrusion channels 50 and the second extrusion channels 52 have side walls a. 54 and 56 and a rear wall 55 which are substantially perpendicular to the corresponding side of the distribution plate 26 from which they are cut. The extrusion channels - 5 can be considered as having a box shape. The first extrusion channels 50 and the second extrusion channels 52 have unequal widths (i.e., their corresponding side walls are not spaced the same distance). In addition, in the illustrated embodiments, the outlet openings 62 of the first extrusion channels 50 extend from the first side 32 of the distribution plate 26 to a middle portion of the distribution plate 26 between the first side 32 and the second side 34, and the outlet openings 62 'of the second extrusion channels 52 extend from the second side 34 of the distribution plate 26 to the middle portion so that the outlet openings 62 of the first extrusion channels 50 and the outlet openings 62' of the second extrusion channels 52 do not overlap.
The distribution plate 26 is typically compressed to form an airtight seal in a region adjacent to the dispensing edge 36 between both the first die portion 22 and the second die portion 24. These seals keep the polymeric material flowing in the cavities 38 and 40 totally separated until it is dispensed from the dispensing edge 36. The distance along the distribution plate 26 where the first and second matrix portions 22 and 24 are sealed against the distribution plate 26 needs to be long as enough to provide a robust seal and structural strength. The first polymeric material in the first cavity 38 can only reach the dispensing edge 36 by entering the openings 60 of the first grooves 50 in the direction of the first cavity 38 to the dispensing edge 36.60 The second polymeric material in the second cavity 40 can only reach the dispensing edge 36 by entering the (unidentified) openings in the first grooves 52 in the direction of the second cavity 40 to the dispensing edge 36. In some embodiments, the sealing of the first and second matrix portions and distribution is aided by use of adhesives and / or linings.
In some embodiments, the cross-sectional shape of the distribution plate 26 when viewed from the dispensing edge 36 is generally rectangular, which is advantageous for forming a firm seal between the first matrix portion 22 and the second matrix portion 24, Accordingly, the matrix according to and / or useful for practicing the present description may have advantages over more complex matrices that have three matrix portions that need to be sealed against a matrix bar at angles to each other. In some embodiments, the distribution plate does not have a cross-sectional shape that is pentagonal. In some embodiments, the cross-sectional shape of the distribution board
| 13/33 in a plane perpendicular to the dispensing edge is also rectangular; In others | 'modalities, this cross section is generally wedge-shaped to provide the plate | .. with harder distribution in the region close to the dispensing edge. In the embodiment illustrated in figure 4, some of the inlet openings 60 of the * 5 first extrusion channels 50 (grooves as shown) comprise reinforcement members 59 extending from the distribution plate 26 along the inlet openings 60 towards to the dispensing edge 36. In some embodiments, at least some of the inlet openings 60 of the first extrusion channels 50 comprise reinforcement members 59. In some embodiments, all of the inlet openings 60 of the first extrusion channels 50 comprise reinforcement members 59. In some of these embodiments, the entry openings of the second extrusion channels 52 do not comprise reinforcement members 59. As shown in Figure 4, reinforcement member 59 extends over a joining surface 58 and tapers towards the edge dispensing
36. Reinforcement member 59 in the illustrated embodiment divides channel 50 so that the first inlet openings of extrusion channel 60 are separated into two sub-channels, but narrowing of reinforcement member 59 may allow the combination of a flow stream in the first outlet openings of the extrusion channel 62. The reinforcement member 59 can extend along the entire path through the joining surface 58 to the dispensing edge 36, as shown in figure 4, or the reinforcement member 59 can extend only part of the path through the joining surface 58. The reinforcement members formed. on the distribution board 26 can be useful, for example, for the structural reinforcement of the channels having widths of at least 15 mm to reduce the deflection of the distribution board 26 and prevent polymeric compositions on one side 34 of the distribution board 26 from crossing in lanes on the other side 32 of the distribution plate 26. Although the illustrated embodiment has reinforcement members 59 in the form of ribs extending through the entrance openings 60, other types of reinforcement members (for example, beams, beams and columns) are provided. The matrix and the method according to the present description are useful for extruding two different polymeric compositions. The phrase "different polymeric compositions" and the phrase "second polymeric composition different from the first polymeric composition" refer to having at least one difference. For example, different polymeric compositions could be made of different polymers or a different mixture of the same polymers or could have different additives (for example, dyes, plasticizers, compatibilizers or gas) in the same polymer or polymer blend. Any two polymeric compositions that can be made to flow through the first and second extrusion channels 50, 52 can be used. mass flow (or volume flow) of the two different polymeric compositions, since they are extruded through the first and second extrusion channels 50, 52 'respectively can be equal or uneven.
Depending on the intended end use, the two polymeric compositions .. can adhere to each other with a strong cohesive or adhesive bond, or can be readily separable from each other (ie the bond between the first and the second zones | * 5 can break with relative ease). A polymeric composition can be selected | as to its surface properties or its volume properties (eg tensile strength, elasticity, color, etc.). In addition, a polymeric composition can be selected to provide specific functional or aesthetic properties in the extruded article 1 such as elasticity, softness, hardness, firmness, flexibility, roughness, colors, textures | 10 or standards.
In some embodiments, the polymeric compositions that can be extruded in the matrix shown in the present invention are thermoplastic polymeric compositions (for example, polyolefins (for example, polypropylene and polyethylene), polyvinyl chloride, polystyrenes and block copolymers of polystyrene, nylon, polyesters (eg polyethylene terephthalate), polyurethanes and copolymers and mixtures thereof. However, the matrix according to the present description can also be useful for the coextrusion of polymeric materials that can be cross-linked (for example, by heat or radiation). When a heat-curable resin is used, matrix 20 may be heated to initiate curing in order to adjust the viscosity of the polymeric material and / or the pressure in the cavity of the corresponding matrix 38 and 40. Coextrusion of two different polymeric compositions can be useful, for example, to provide extruded articles having bands with different tactile properties.
A band can be softer to the touch than an adjacent band.
Such an extrudate can be useful, for example, to provide hook fastening strips that comprise soft edges.
A second longitudinal strip can become softer than a first adjacent longitudinal strip, for example, by using a second polymeric composition that is more elastomeric than the first polymeric composition or by using a second polymeric composition that is foamed.
In some embodiments, at least one of the two different polymeric compositions is foamed.
For example, in some embodiments, the second polymeric composition is foamed.
In these embodiments, the second polymeric composition can have the same composition as the first polymeric composition, except for the presence of gas in the composition, or the second polymeric composition can be made from a different polymer or different polymer blend from the first polymeric composition.
Foamed polymeric compositions can be prepared, for example, using one; chemical foaming agent (for example, a foaming agent available from Clariant Corp., Holden, Mass., under the trade name “HYDROCEROL") or by injecting a gas (for example, carbon dioxide or nitrogen) in the polymeric composition: In some embodiments of the method for making an extruded article and the extruded articles according to the present description, a first polymeric composition * 5 comprising an inelastic polymer and a second polymeric composition comprising a elastomeric polymer are extruded.The term "inelastic" refers to polymers from which films (0.002 to 0.5 mm thick) can be made that have little or no recovery from stretching or deformation. The first polymeric composition can be formed , for example, semicrystalline or amorphous polymers or mixtures. Inelastic polymers can be polyolefinic, predominantly formed from polymers such as polyethylene, polypropylene, polybuty polyethylene-polypropylene copolymers. In some embodiments, the first polymeric composition comprises polypropylene, polyethylene, polypropylene-polyethylene copolymer, or mixtures thereof.
The term "elastomeric" refers to the polymers from which films (0.002 to 0.5 mm thick) can be made that exhibit recovery from stretching or deformation. Exemplary elastomeric polymer compositions that can be used in the segmented multi-component polymeric films presented here include thermoplastic elastomers such as ABA block copolymers, polyurethane elastomers, polyolefin elastomers (e.g., metallocene polyolefin elastomers), polyester elastomers, ethylene elastomers - vinyl acetate and polyester elastomers. An ABA block copolymer elastomer is generally one where blocks A are polystyrene and blocks B are conjugated dienes (for example, lower alkylenedienes). Block A is generally formed predominantly of substituted (for example, alkylated) or unsubstituted (for example, polystyrene, poly (alfamethyl styrene) or poly (t-butylstyrene) portions), with an average molecular weight of about 4,000 at 50,000 grams per mol. Block B (s) is / are generally predominantly formed of conjugated dienes (for example, isoprene, 1,3-butadiene or ethylene-butylene monomers), which can be substituted or unsubstituted, and - which have a average molecular weight of about 5,000 to 500,000 grams per mol. Blocks A and B can be configured, for example, in linear, radial or star configurations. An ABA block copolymer can contain multiple A and / or B blocks, the blocks of which can be produced from the same or different monomers. A typical block copolymer is a linear ABA block copolymer, where A blocks can be the same or different, or a block copolymer having more than three blocks, predominantly ending with A. blocks. Multi-block copolymers can contain, for example, a certain proportion of AB diblock copolymers, which tend to form a more elastomeric film segment
16/33 | sticky. Other elastomers can be mixed with 'block copolymer elastomers, as long as the elastomeric properties are not adversely affected. .. Many types of thermoplastic elastomers are commercially available, including those from BASF under the trade name "STYROFLEX", available from Shell * 5 Chemicalss under the trade name "KRATON", available from Dow Chemical under the trade name "PELLETHANE" " or “ENGAGE”, obtained from DSM under the trade name “ARNITEL”, available from DuPont under the trade name “HYTREL”, and more. Thermoplastic elastomers, including styrene / ethylene-propylene / styrene / ethylene-propylene tetrablock, described in U.S. Patent No. 6,669,887 (Hilston et al.) May also be useful. | Elastomeric compositions can be selected, for example, as to their compatibility or adherence to inelastic compositions in an adjacent longitudinal strip in the extruded article presented here. The first and second polymeric compositions that have good mutual adhesion properties, for example, can be selected. End block reinforcing resins and compatibilizers can also be used in the second polymeric compositions.
In some embodiments, the second polymeric composition is a pressure sensitive adhesive. In some embodiments, the second polymeric composition is not a pressure sensitive adhesive. Pressure sensitive adhesives are well known to those skilled in the art as having properties including the following: (1) aggressive and permanent adhesion, (2) adhesion to no more than finger pressure, (3) sufficient ability to attach to one adherent and (4) sufficient cohesive strength for clean removal of the adherent In some applications (for example, for hook fastening strips having soft edges), it is desirable that the second polymeric composition does not have a sticky feel to the touch.
In some of the embodiments of the method for making an extruded article and the extruded articles according to the present description, the second polymeric composition comprising an elastomeric polymer further comprises an inelastic polymer. In some embodiments, by coextruding certain inelastic polymers (e.g., polypropylene) and certain thermoplastic elastomers in alternating side-by-side bands using the matrix and methods presented here, the band of thermoplastic elastomer is significantly thinner than the band of inelastic polymer. The present inventors have found that the inclusion of the inelastic polymer in the thermoplastic elastomer can be used to control the thickness of the second polymeric composition as it is extruded. The ratio between thermoplastic elastomer and inelastic polymer in the second polymeric composition can be in a range, for example, from 99.5: 0.5 to 0.5: 99.5, 99.5: 0.5 to 10:90, 99.5: 0.5 to 25:75, 99.5: 0.5 to 50:50, 99: 1 to 25:75, 95: 5 to 25:75, 90:10 to 25:75 or 90: 10 to 50:50, The control of the ratio between thermoplastic elastomer and
| 17/33 | inelastic polymer in the second polymeric composition can also be useful, for example, for | : control the height of the projections in the modalities of the extruded articles with projections! The. and for controlling the ability to split or perforate the longitudinal strip comprising the second polymeric composition, as further described below.
The extruded article produced according to the present method can comprise a plurality of first strips of the first polymeric material alternating with a plurality of second longitudinal strips of the second polymeric material. A first lane is disposed between any two adjacent second lanes, and a second lane is disposed between any two adjacent adjacent lanes. In some embodiments, at least one of the first longitudinal bands and at least one of the second longitudinal bands are integrally joined. The joining of at least one of the first longitudinal bands and at least one of the second longitudinal bands can be carried out in the region 43 in the cavity 42 between the dispensing edge 36 and the edge of the matrix 44 as shown in figure 2a. Typically, the first longitudinal bands are generally parallel to each other, the second longitudinal bands are generally parallel to each other, and the first and second longitudinal bands are generally parallel to each other. Each of the tracks can have a number of different shapes in cross section.
The coextruded strips prepared according to the method presented here allow the alternation of polymeric compositions arranged in the width direction (transverse or x direction), whose strips extend along the length of the article or film (the y direction or machine direction) . In some embodiments, the polymeric composition of each strip is generally consistent in the direction of the thickness (z direction) of the article (for example, film). That is, although there may be certain inhomogeneities in the first or second polymeric composition, in some modalities, the tracks are not segmented in direction 2 of the film.
In some embodiments, the method for making an extruded article according to the present description comprises coextruding a layer on at least one of the opposite main surfaces of the extruded article. “Coextrusion” refers to the application of the layer within the matrix shown here instead of in a post-extrusion stage. The layer can be of any desired thickness. In some embodiments, the layer can be considered a layer of skin, which can have a thickness, for example, that is up to 10, 8, 6, 5, 4, 3 or 2 percent of the thickness of the extruded article (for example , the film). Therefore, in the modalities of an article (for example, film) where —layer layers on both opposite surfaces of the extruded article, the thickness of the strip of the first or second polymeric composition can be at least 80, 85, 90, 95 or 96 percent of the thickness of the extruded article.
AND A | i 18/33 | Although the coextruded layer could be formed from one of the first | | ] polymeric composition or the second polymeric composition, in some embodiments, the layer comprises a third polymeric composition that is different from both the first | polymeric composition and the second polymeric composition.
As above, the term | * 5 “different” used here refers to having at least one difference.
For example, the third polymeric composition could be made of a different polymer than the first and the second polymeric composition of a different mixture of the same polymers.
In addition, the third polymeric composition could have an additive (for example, dyes, plasticizers or compatibilizers) not found in the first or second polymeric composition or it could not have an additive (for example, dyes, plasticizers or compatibilizers) that are present in a among the first or second polymeric compositions.
A cross-sectional view of a portion of an exemplary extruded article 64b is shown in Figure 5b, where the longitudinal bands 68, 66 composed of the first and the second polymeric compositions, respectively, have coextruded layers 70. Figure 5 illustrates a side view in cross section of the matrix according to and / or useful to practice the present description, with the matrix having doors at the end of the matrix or at the rear of the matrix to form coextruded layers.
Although figure 85 shows ports 74 at the edge of the die and ports 72 at the rear of the die, it should be understood that the die does not need to have both characteristics to form coextruded layers.
Now, with reference to figure 5a, each die portion 22 and 24 has a port 74 near the rim of the die into which a third polymeric composition could be fed.
In the illustrated embodiment, the doors 74 are between the rim of the matrix 44 and the dispensing edge 36 of the distribution plate 26. The third polymeric composition could be fed to at least one of the doors 74 and exit through the corresponding slot 76 to form a layer coextruded on at least one of the opposite brush surfaces of the extruded article.
Doors 74 could be introduced into matrix portions 22, 24 by perforation or other suitable methods.
Doors 74 can be useful for forming coextruded layers in a relatively narrow matrix (for example, up to about 25 cm wide). In this embodiment, the layers 70 on the opposite faces of the article - extruded64 can be the same or different.
Also shown in figure 5 are ports 72 at the rear of the matrix.
Ports 72 are in the form of ring rings around entries 28 and 30. Ring rings can be substantially round or oval.
In this embodiment, the third polymeric composition can surround the first and the second polymeric compositions as they are extruded in their respective matrix cavities 38,40 and through their respective extrusion channels 50, 52 in the distribution plate.
Coextruded layers can also be formed in a method according to the present description using a multiple pipe matrix 110 as shown in figure a 9. In the illustrated embodiment, pipe 175 is positioned close to matrix portion 124, and pipe 173 is positioned close to the matrix portion 122. The first side 132 of the * 5 distribution plate 126 and the first matrix portion 122 together define a first matrix cavity 138, and the second side 134 of the distribution plate 126 and the second portion matrix 124 define together a second matrix cavity 140. Although not shown in figure 9, the inputs can be used to introduce the first and second polymeric compositions into the first and second matrix cavities 138 and 140, respectively, using the entries as shown in figures 2 and 5. Entries 178 can be used to introduce a third polymer composition or third and fourth polymer compositions into pipes 175 and 173. The third polymer composition or the third and fourth compositions | polymeric materials are extruded through channels 176 to provide layers on surfaces | top and bottom of the extrudate coming out of the dispensing edge 136 of the distribution plate
126.Pipes 173 and 175 can be at an angle (for example, about 20 to 50 or at a 30 degree angle) with the distribution plate 126. Heating elements 125 can be positioned in each matrix portion 122 and 124 and pipes 173 and 175.
Again with reference to figure 9, an extruded article with the coextruded upper and lower layers is formed after the extrudate reaches region 143 and is extruded out of the edge of matrix 144. The third and fourth polymeric compositions may differ from each other and each one can be different from the first and second polymeric compositions. Therefore, the matrix and the method according to the present description can be useful to form the extruded article 64b, where the first and second longitudinal strips 66 and 68 and the two coextruded layers 70 shown in figure 5b are individually made of different polymeric compositions.
Although figure 9 illustrates a three-pipe matrix 110 with a central pipe divided by the distribution plate 126 to define cavities 138 and 140, other configurations may be useful to provide coextruded layers downstream of the distribution plate 126. Some useful configurations include additional pipes to provide multiple coextruded layers (for example, more than one layer on each opposite surface) in the extruded article.
In some embodiments, the method and / or matrix according to the present description can be useful for forming extruded articles that are segmented in the direction of the thickness. For example, two or more dies according to the present description - can be used in combination to provide a multilayer article. Each layer can have a different arrangement of at least two different polymeric compositions in segments that alternate along the cross direction of the film and that extend longitudinally. -a In some modalities of the method according to the present description, the matrix can dispense the flow current in the free space, or in some modalities, the * 5 flow current can be absorbed in a cylinder, blanket or substrate.
Once the extruded article has been formed, several secondary operations can then be performed on the article.
Examples of such secondary operations may include embossing, laminating, splitting, protrusions | and stretching in length and / or width.
For example, the extruded article may comprise | opposite main surfaces, and the method may further comprise providing —projections on at least one of the main surfaces (for example, by micro-replication or otherwise | replication of a pattern on one or both of the main surfaces of the extruded article). Providing such projections may comprise bringing one or both of the main surfaces of the extruded article into contact with a shaped cylinder, shaped mat, shaped film or a combination thereof.
The method may also comprise cooling or abruptly heating the extruded article, respectively, on a surface! cooled or heated, for example, a cylinder, blanket, flat or curved plate, or substrate.
Figure 6 illustrates an embodiment of an extruded article according to and / or; produced in accordance with the present description, the extruded article being a film in the form of a cylinder.
In the illustrated embodiment, the extruded article 80 comprises an even number (4 as shown) of the first longitudinal bands 88 and an odd number (5 as shown) of the second longitudinal bands 86. Different numbers of bands may also be useful; for example, 2 or 6 first longitudinal bands 88 can alternate with 3 or 7, respectively, second longitudinal bands 86. Second longitudinal bands 86 are typically located on the first and second side edges 87, 89 and along the midline at 80 m of the movie.
In the illustrated embodiment, each of the second longitudinal strips not located on the first or second lateral edge has a perforated line 85 along its length.
The perforated line may be in the form of, for example, a series of perforations or slits.
The perforated line can also be a reduction in thickness along a portion of the second longitudinal strip.
For example, the thickness can be reduced by forming a groove in the second longitudinal strip.
When a series of perforations is used to provide a perforated line, the length and spacing of the perforations can be selected to provide a stable cylinder that can be unscrewed safely when desired.
In some modalities, the length of the perforations can be less than 15 (in some modalities, up to 14, 13, 12, 11 or 10) mm.
In addition, the composition of the second polymeric composition can be adjusted so that the second longitudinal bands can be safely perforated.
For example, the present inventors have found that the second longitudinal bands formed from a material that is 'very soft' are difficult to safely pierce and that it is advantageous to include a polymer | to inelastic with the elastomeric polymer in the second polymeric composition (see | above).
In some embodiments of Article 80, the film comprises opposing main surfaces, and at least one of the opposing main surfaces has projections. The extruded article 80 may be useful, for example, in the manufacture of fastening flaps (for example, for disposable absorbent articles such as pants-type diapers, open-type diapers and underwear for incontinence). The cylinder can be unscrewed while the longitudinal bands 88, 86 are separated along the lines of weakness 85 in the second longitudinal bands 86 to provide a first individual longitudinal band 89 having a second longitudinal band 86 along each of its side edges. . The strip thus formed can be cut in the transverse direction to provide an individual fastening tab having a central region comprising the first inelastic polymeric composition and edges comprising the second polymeric composition comprising an elastomeric polymer. A fixation tab with edges comprising an elastomeric polymer can be softer to the touch and less irritating to the skin when applying or using a disposable absorbent article.
In embodiments of this description in which the projections are provided in the extruded article, the projections can be produced in at least one or more of the first longitudinal bands, in at least one or more of the second longitudinal bands, or both. In some modalities, projections are provided both in the first longitudinal bands and in the second longitudinal bands. The projections provided in at least some of the longitudinal bands can be formed using the methods known in the art. For example, an extruded article, when leaving the matrix shown here, can be fed into a mold surface that moves continuously with cavities with the inverse shape of the projections. The cavities may be in the shape of the protrusion with a looping head or it may be in the form of a precursor to a hook element (for example, a partially formed hook element) In some embodiments, the projections (for example, hooks, rods or ribs) are formed as shown schematically in figure 8. The extruded article 90 after leaving matrix 1 passes between a choke formed by two cylinders 101, 103. Alternatively, the extruded article could be strangled, for example, between a matrix face and the surface of the cylinder. At least one of the cylinders 103 has cavities (not shown) in the inverse form of the projections. The pressure provided by the choke forces the resin into the cavities. In some embodiments, a vacuum can be used to evacuate the cavities for ease of filling the cavities. The choke is sufficiently wide, so that a coherent film holder '90 is also formed over the cavities. A mold surface and cavities a can be cooled by air or water (for example, by air or water) before removing the integrally formed support and formed rods erect from the mold surface * 5 as by a peeling cylinder. This provides an extruded film 90 having integrally formed upright rods or hooks 84. In some embodiments, the extruded article which is projected has at least one coextruded layer. For example, a layer of skin coextruded from an inelastic material can be useful to facilitate the removal of the rods formed from the surface of the mold.
If the projections formed when leaving the cavities described above in relation to figure 8 do not have heads that engage in a loop, the projections formed could subsequently be formed on hooks by a capping method as described in US patent No. 5,077,870 (Melbye et al.), the description of which is incorporated herein by reference in its entirety. Typically, the method of capping includes deforming the tip portions of the projections 84 using heat and / or pressure. Heat and pressure, if both are used, could be applied in sequence or simultaneously.
Another useful method for providing projections in at least some of the longitudinal bands of the extruded article presented here is described, for example, in US patent no.
4,894,060 (Nestegard), which presents a method of preparing the hook profile | 20 extruded and is incorporated here, as a reference in its entirety. Typically, these projections are formed by passing a current of polymeric flow through a patterned matrix bead (for example, cut by electrical discharge machining) to form a blanket with wave ridges downward, cutting the ridges and stretching the blanket to form separate projections. The ribs can form hook precursors and display the cross-sectional shape of the functional hooks to be formed. The ribs of the thermoplastic blanket layer are then transversely cut or slit at spaced locations along the length of the rib to form distinct portions of the rib having lengths in the direction of the rib essentially corresponding to the length of the projections to be formed.
Extruded articles (e.g., films) according to and / or produced according to the present description may comprise projections on at least one of the first longitudinal bands or the second longitudinal bands and on at least one of the main opposite surfaces of the film. In some of these embodiments, the extruded article can be useful in a Velcro fastening system, for example, as a hook strap. In some - modalities, the projections (for example, hooks, rods or ribs) are provided in a first longitudinal strip. In some modalities, both the first and the second longitudinal bands have projections. In some modalities, the second tracks
| 23/33 longitudinals are exempt from projections.
Figure 7A illustrates an exemplary extruded article '81A (for example, an extruded film) where the first and second longitudinal strips 88, 86a are independently provided with projections with heads that engage in loop 82. Figure 7B illustrates an extruded article example 81B (for example, an extruded film) - * 5 projections in the first longitudinal bands 88 comprise heads that engage loop 82, and where projections in the second longitudinal bands 88 comprise rods without heads that engage loop 84. In In the illustrated embodiment, the projections 82 and 84 have substantially the same height, which can be useful, for example, for the uniform handling of an extruded article presented in the present invention in the form of a blanket or cylinder.
Having projections with substantially the same height in the first and second longitudinal bands may also be desirable, for example, for reasons of appearance or tactile sensation.
The height of the projections can be controlled by controlling the height of the film by adjusting, for example, the composition of the second polymeric composition as described above.
If a capping process is used to form heads that engage in a loop in the projections in the first and second longitudinal bands, the composition of the second polymeric composition can be adjusted, for example, to make the heights of the projections in the first and second longitudinal bands substantially the same. before the capping process.
If a capping process is used to form heads that engage in a loop in the projections in only one of the first and second longitudinal bands (for example, the first longitudinal bands), the composition of the second polymeric composition can be adjusted, for example, to make the heights of the projections in the second longitudinal bands shorter than the projections in the first longitudinal bands so that after the capping process, the heights of the projections in the first and second longitudinal bands are substantially the same.
The method and matrix described herein can be used to make a variety of films or film-like articles as well as other coextruded articles (for example, privacy film, light film or coextruded tubes). Selected modalities of the description In a first embodiment, the present description presents a matrix for coextrusion of at least a first extrudable polymer composition and a second extrudable polymer composition, the matrix comprising: a first matrix cavity in a first matrix portion; a second matrix cavity in a second matrix portion; and a distribution plate interposed between at least a portion of the first matrix cavity and at least a portion of the second matrix cavity, the distribution plate having a first side that forms an outline of the first matrix cavity, a second opposite side which it forms an outline of the second die cavity, a dispensing edge, a plurality of the first extrusion channels and a plurality of the second extrusion channels, with the plurality of the first 'extrusion channels extending from the inlet openings in the first .. the die cavity to come out of the openings in the dispensing edge, the plurality of the second extrusion channels extending from the inlet openings in the i * 5 second die cavity to the outlet openings in the dispensing edge, with the ! outlet openings of the plurality of the first extrusion channels and the openings of! exit from the plurality of second extrusion channels being arranged in alternating positions along the dispensing edge, each of the first extrusion channels comprising two opposite side walls and a joining surface that connects two opposite side walls, and the The joining surface of at least part of the first extrusion channels is substantially parallel to the first side of the distribution plate.
In a second embodiment, the present description provides the matrix according to the first embodiment, with each of the first extrusion channels additionally comprising a rear wall opposite the outlet opening and connecting the two opposite side walls, the rear wall being substantially perpendicular to the first side of the distribution board.
In a third embodiment, the present description presents the die according to the first or second embodiment, with each outlet opening of the first and second extrusion channels having a minimum width greater than 1.5 mm.
In a fourth embodiment, the present description presents the matrix according to any one of the first to the third embodiments, with at least some of the first extrusion channels comprising a reinforcement member.
In a fifth embodiment, the present description presents the matrix according to any one of the first to the fourth embodiments, the two opposite side walls of the first extrusion channels being substantially perpendicular to the first side of the distribution plate.
In a sixth modality, the present description presents the matrix according to any one of the first to the fifth modalities, with the outlet openings of the first extrusion channels extending from the first side of the distribution plate towards, but not all the path to the second side of the distribution plate, and with the outlet openings of the second extrusion channels extending from the second side of the distribution plate in the direction, but not along the entire path to the first side of the distribution plate, so that an overlapping zone is formed between the outlet openings of the first extrusion channels and the outlet openings of the second extrusion channels.
In a seventh modality, the present description presents the matrix according to 'any one of the first to the fifth modalities, with the exit openings | that of the first extrusion channels extends from the first side of the distribution plate to a middle portion between the first side and the second side of the distribution plate, and * 5 with the outlet openings of the second extrusion channels extending from the second side of the distribution plate to the middle portion so that the outlet openings of the first extrusion channels and the outlet openings of the second extrusion channels do not overlap.
In an eighth embodiment, the present description presents the matrix according to any one of the first to the seventh modalities, the distribution plate being at least 5 mm thick.
In a ninth embodiment, the present description presents the matrix according to any one of the first to the eighth modalities, the matrix further comprising an edge of the matrix within 2.5 cm from the dispensing edge.
In a tenth modality, the present description presents the matrix according to any one of the first to the ninth modalities, with the first extrusion channels and the second extrusion channels having uneven widths.
In an eleventh modality, the present description presents the matrix according to any one of the first to the eleventh modalities, with the first extrusion channels and the second extrusion channels having uneven depths.
In a twelfth embodiment, the present description presents a method for manufacturing an extruded article, the method comprising: providing the matrix according to any one of the first to the eleventh modalities; providing a first polymer composition in the first matrix cavity; providing a second polymeric composition, different from the first polymeric composition, in the second matrix cavity; extruding the first polymeric composition through the plurality of first extrusion channels and the second polymeric composition through the plurality of second extrusion channels so as to form a flow stream having a width with alternative zones of the first and second polymeric compositions; and extruding the flow stream out of the die in a longitudinal direction to form the extruded article comprising a plurality of first longitudinal bands of the first polymeric composition alternating with a plurality of - second longitudinal bands of the second polymeric composition, at least at least part of the first longitudinal bands has, in a plane perpendicular to the longitudinal direction, a cross-sectional shape that comprises opposite sides: substantially parallel.
.. In a thirteenth modality, this description presents the method of | according to the twelfth modality, with at least one of the first | * 5 longitudinal bands are integrally joined to at least one of the second longitudinal bands.
In a fourteenth modality, the present description presents the method according to any one of the twelfth to the thirteenth modalities, being | that the first polymeric composition comprises an inelastic polymer.
In a fifteenth embodiment, the present description presents the method according to any one of the twelfth through the fourteenth modalities, the second polymeric composition comprising an elastomeric polymer.
In a sixteenth embodiment, the present description presents the method according to the fifteenth embodiment, the second polymeric composition further comprising an inelastic polymer.
In a seventeenth modality, the present description presents the method according to any one of the twelfth to the sixteenth modalities, with at least one of the first longitudinal strips having an uneven width with the width of a second adjacent longitudinal stripe.
In an eighteenth embodiment, the present description presents the method according to any one of the twelfth through the seventeenth modalities, with at least one of the first or second polymeric compositions being foamed.
In a nineteenth modality, the present description presents the method according to any one of the twelfth to the eighteenth modalities, with the extruded article having opposite main surfaces, the method additionally comprising the coextrusion of a third polymeric composition to form a layer on at least one of the opposite main surfaces of the extruded article.
In a twentieth modality, the present description presents the method according to the nineteenth modality, the third polymeric composition being different from both the first polymeric composition and the second polymeric composition.
In a twenty-first embodiment, the present description presents the method according to any one of the twelfth to the eighteenth modalities, with the extruded article having opposite main surfaces, the method further comprising the coextrusion of a third polymeric composition to form a layer on one of the opposite main surfaces of the extruded article and a fourth polymer composition on the other of the opposite main surfaces of the extruded article, wherein the first, second, third and fourth polymeric composition are individually 'different from each other. .. In a twelfth embodiment, the present description presents the method according to any one of the twelfth to the twenty-first modalities, * 5 being that the extruded article has opposite main surfaces, the method additionally comprising providing projections on at least one of the surfaces main opposites.
In a twenty-third modality, the present description presents the method according to the twenty-second modality, and providing projections comprises putting at least one of the main surfaces of the extruded article in contact with at least one of a shaped cylinder, shaped mat or film conformed.
In a twenty-fourth modality, the present description presents the method according to any one of the twenty-second to the twenty-third modalities, and the projections are provided in at least some of the first longitudinal bands, and the projections comprise heads that engage in loop.
In a twenty-fifth modality, the present description presents the method according to any one of the twenty-second to the twenty-fourth modalities, and the projections are provided in at least some of the second longitudinal bands and comprise rods without heads that engage in loop .
In a twenty-sixth modality, the present description presents the method according to any one of the twenty-second to the twenty-fifth modalities, being that both the plurality of first longitudinal bands and the plurality of second longitudinal bands are provided with projections, the projections of plurality of first longitudinal bands being substantially the same height as the projections of the plurality of second longitudinal bands.
In a twenty-seventh modality, the present description presents the method according to any one from the twelfth to the twenty-sixth modality, with the extruded article being formed in a cylinder.
In a twenty-eighth modality, the present description presents the method of - according to any one of the twelfth to the twenty-seventh modalities, with at least some of the second longitudinal bands having perforated lines along their lengths.
In a twenty-ninth modality, the present description features an extruded film that has the first and second lateral edges and a median line, the extruded film that comprises an even number of first longitudinal bands of a first polymeric composition comprising an inelastic polymer alternating with an odd number of second longitudinal bands of a second polymeric composition comprising a
28/33 | i elastomeric polymer so that the second longitudinal bands are located at least on the first and second lateral edges and on the midline, and at least .. some of the second longitudinal bands have perforated lines along their lengths. In some of these modalities, each of the second longitudinal strips * 5 not located on the first or second side edges has a perforated line along its length.
In a thirtieth embodiment, the present description presents an extruded film according to the twenty-ninth embodiment, the second polymeric composition additionally comprising an inelastic polymer.
In a thirty-first modality, the present description presents an extruded film according to the twenty-ninth or thirty-first modality, the extruded film comprising opposite main surfaces, and at least one of the opposite main surfaces is provided with projections.
In a thirty-second embodiment, the present description presents an extruded film according to any of the twenty-ninth to the thirty-first embodiments, with at least one of the first longitudinal strips having an uneven width with the width of a second adjacent longitudinal stripe.
In a thirty-third modality, the present description presents an extruded film according to any one of the twenty-ninth to the thirty-second modalities, the extruded film being in the form of a cylinder.
In a thirty-fourth modality, the present description presents an extruded film according to any of the twenty-ninth to the thirty-third modalities, with both the first longitudinal bands and the second longitudinal bands having projections on at least one of the main surfaces opposite, the projections of the first longitudinal bands being substantially the same height as the projections of the second longitudinal bands.
In a thirty-fifth embodiment, the present description presents an extruded film having opposite main surfaces and comprising a plurality of first longitudinal bands of a first polymeric composition comprising an inelastic polymer alternating with a plurality of second longitudinal bands of a second polymeric composition comprises a mixture of an elastomeric polymer and an inelastic polymer, with both the plurality of first longitudinal bands and the plurality of second longitudinal bands having projections on at least one of the opposite main surfaces, the projections of the plurality of first longitudinal bands being substantially the same height as the projections of the plurality of second longitudinal bands.
In a thirty-sixth modality, the present description presents a film 'extruded according to the thirty-fourth or thirty-fifth modality, with the -. projections provided in the first longitudinal bands comprise heads that engage in a loop.
NNE) In a thirty-seventh modality, the present description presents an extruded film according to any one of the thirty-fourth to the thirty-sixth modalities, and the projections provided in the second longitudinal bands comprise rods without heads that engage in loop.
In a thirty-eighth modality, the present description presents a film | 10 extruded according to any of the thirty-fourth to the thirty-seventh | modalities, and the projections comprise heads that engage in loop. | In a thirty-ninth modality, the present description presents an extruded film according to any of the twenty-ninth through the thirty-eighth | modalities, and the extruded film is in the form of a cylinder.
Examples Several non-limiting examples have been prepared to demonstrate the apparatus and method for producing the extruded article. For each of these examples, a coextrusion matrix was generically assembled as shown in figure 1. The first portion of matrix 22 and a second portion of matrix 24 were manufactured from stainless steel 17-4 generically as shown in figure 2. For In example 1, a distribution plate 26 was prepared from a 1 mm thick (40 mils) precision base stainless steel sheet, generally as shown in figures 3 and 4. For examples 2 to 8, the Distribution plate 26 was prepared from a 2 mm (80 mils) thick, precision stainless steel sheet. The distribution plate 26 was machined to provide a first and a second plurality of extrusion channels 50 and 52, generally as shown in figure 4. This machining was done using a high speed computer numerically controlled grinding machine. The extrusion channels 50 and 52 were cut at the dispensing edge 36 of the distribution plate 26. The dimensions of the channels are shown in the tables | and 3, below, with the depth referring to the thickness of the dispensing edge. The extrusion channels 50 and 52 were 28 mm long (from the dispensing edge 36 to the rear wall 55). The inlet openings of the extrusion channels 50 were formed with reinforcement ribs 59 that extended 24 mm from the rear wall 55 towards the dispensing edge 36. The extrusion channels were prepared with a repetition through the dispensing edge in a pattern alternating, in a spacing of the width of the channels of polymer A plus the
NEN O o 30/33 width of the polymer B channels, as shown in tables 1 and 3, below. The total width of the edge of the matrix 44 was 20 cm (8 inches). .. Examples 1 to 4 In each of the examples 1-4 below, the first input for material (which introduces * 5 Ada Polymer Table 1 below into the extrusion die) was loaded with a concentrated melt sequence around an extruder. 40 mm double thread. The second material inlet (which introduces polymer B from table 1 below into the extrusion die) was loaded with a melted sequence concentrated around a 50 mm single screw extruder. The temperatures of the used extrusion cylinder ranged from 100 to 230ºC, with the lowest temperatures corresponding to the inlet section. The measuring section of the extruder was maintained at 230ºC. The matrix temperature was 230ºC for both sides of the pipe. The total mass output of the process was in the range of 15 to 20 Kg / h. Example 1 was performed at a mass production of 5 kg / h and at a lower linear speed. During the coextrusion passages, the matrix was positioned adjacent to a cooled cylinder such that the coextruded film was abruptly cooled while being removed from the cooled cylinder. Along the blanket, the coextruded film was rolled into a cylinder. The mass ratio between polymer A of the main channel and polymer B of the secondary channel varied to achieve the targeted parallel lane dimensions. The main channel polymer A was a film grade polypropylene (PP) copolymer, a polypropylene impact copolymer obtained from Dow Chemical Co. Midland, MI, under the trade name “DOW C700-35N POLYPROPYLENE” which was pigmented The secondary channel polymer B was a polyolefin thermoplastic elastomer or a mixture of polyolefin and polyolefin thermoplastic elastomer. In Table 1, TPE is an ethylene-octene copolymer obtained from Dow Chemical Co. under the trade name “ENGAGE 8200 POLYOLEFIN ELASTOMER”, and LDPE is a low density polyethylene obtained from ExxonMobil Chemical Co., Houston, TX, under the trade name “EXXON MOBIL LD 123.LN”. Extrusion materials and temperatures and conditions for Examples 1 to 4 were as shown in Table 1. Below: Table 1 [OT eemeT TBemoz TBemos | Bxemos |
PP PP PP Copolymer PP | LDPE Copolymer of PP (ratio | of PP (ratio (ratio = = 40/60) = 50/50) 50/50) polymer extruder cylinder À
| Temperatures of 100-230ºC 100-230ºC 100-230ºC 100-230ºC 1 polymer extruder cylinder B "Temperature of 230ºC 230ºC 230ºC 230ºC matrix 'Matrix Ratio and 2/1 8/1 8/1 8/1 of the Channel Dimensions of 20 , 0 mm x 20.0 mm x 20.0 mm x 16.0 mm x Channel A of 0.5 mm 0.5 mm 0.5 mm 0.5 mm Polymer (width x depth) Dimensions of 10.0 mm x 2.5mmx 2.5mmx 20mmx Channel 0.5 mm 0.5 mm 0.5 mm 0.5 mm Polymer B (width x depth) Speed 3 m / min 20 m / min 20 m / min 20 m / min Removal Examples 1 to 4 resulted in coextruded films with alternating bands of pigmented polymer A and bands of clear polymer B in the transverse direction of the film.The dimensions of the streak width and the base weights of the film are given in Table 2, below. Table 2 Example Base Weight of | Streak Width of | Film Streak Width (g / m ) Polymer A (mm) Polymer B (mm) Examples 5 to 8 Examples 5 to 8 were prepared as described above for the examples 1 to 4 with the following modifications. The streak support thicknesses were modified by varying the ratio of TPE and PP and keeping the other process conditions constant. The extrusion materials and temperatures and conditions for Examples 5 to 8 were as shown in Table 3, below. Table 3 [Example 5 Example 6 Example 7 Example 8 Polymer à Copolymer of | Copolymer of | Copolymer of | Copolymer of
PP PP PP PP Polymer B TPE & Blend | TPE & Mixture | TPE & Mixture | TPE & Copolymer Blend | Copolymer Copolymer PP Copolymer (ratio | of PP (ratio | of PP (ratio | of PP (ratio
32/33! | [] = 10000) = 85/15) = 75/25) = 50/50) 'Temperatures from 100-230ºC 100-230ºC 100-230ºC 100-230ºC Í extruder cylinder of | Polymer à | Temperatures from 100-230ºC 100-230ºC 100-230ºC 100-230ºC i 'extruder cylinder; polymer B 1 Temperature of 230ºC 230ºC 230ºC 230ºC matrix Matrix Ratio and 8/1 8/1 8/1 8/1 of the Channel Dimensions of 20.0 mm x 20.0 mm x 20.0 mm x 16.0 mm x 0.5 mm channel 0.5 mm 0.5 mm 0.5 mm Polymer A (width x height) Dimensions of 25 mm x 25 mm x 2.5 mm x 2.0 mm x 0.5 mm channel 0.5 mm 0.5 mm 0.5 mm Polymer B (width x height) Speed of 20 m / min 20 m / min 20 m / min 20 m / min Removal Examples 5 to 8 resulted in coextruded films with alternating bands of pigmented polymer A and bands of clear polymer B in the transversal direction of the film.
The dimensions of the streak thickness are given as shown in table 4. The width of the streak of polymer A was 13 mm, and the width of the streak of polymer B was 4 mm for each of the 5a8ê & examples. Table 4 Example Film thickness of the streak Film thickness of the polymer A (a) polymer streak B (yum) i Examples 9 and 10 Examples 9 and 10 were prepared as described above for examples 2 and 4, except that the projections were provided on a surface of the film article - extruded.
The projections were formed as shown and described for figure 8. The extruded film article, at the exit of the matrix, was passed between a choke formed by two cylinders, with one of the cylinders with cavities in the shape of the projections.
This provided a segmented, multi-component polymeric film having upright rods integrally formed on a surface.
The rods were subsequently formed into hooks by a capping method, as described in U.S. Patent No. '5,077,870 (Melbye et al.), Column 5, lines 50-60. Each of examples 9 to 10 were .. formed with an arrangement of 246 hooks per square centimeter (1,600 hooks per square inch) with a total height of 360 µm, a supporting film thickness * 5 of 100um, and with a hook head of 300 - 330 μm in diameter.
This invention can employ several modifications and alterations without leaving the spirit and scope of it. Consequently, this description is not limited to the modalities described above, but is intended to be controlled by the limitations set out in the claims presented below, as well as by any equivalents thereof. This description can be adequately practiced in the absence of any element not specifically described in the present invention. All patents and patent applications mentioned above, including those in the | Background, are incorporated here in their entirety as a reference. |

权利要求:
Claims (12)
[1]
CLAIMS '1. Matrix for the coextrusion of at least one first polymeric composition .. extrudable and a second extrudable polymeric composition, the matrix being CHARACTERIZED by the fact that it comprises: a first matrix cavity in a first matrix portion; a second matrix cavity in a second matrix portion; and a distribution plate interposed between at least a portion of the first matrix cavity and at least a portion of the second matrix cavity, the distribution plate having a first side that forms an outline of the first matrix cavity, a second opposite side which forms a contour of the second die cavity, a dispensing edge, a plurality of first extrusion channels and a plurality of second extrusion channels, with the plurality of first extrusion channels extending from the inlet openings in the first cavity of die to exit the openings on the dispensing edge, the plurality of second extrusion channels extending from the inlet openings in the second cavity of the die to the outlet openings on the dispensing edge, with the outlet openings of the plurality of first extrusion channels and the outlet openings of the plurality of second extrusion channels being arranged in high positions along the dispensing edge, each of the first extrusion channels comprising two opposite side walls and a joining surface that connects two opposite side walls, and the joining surface of at least part of the first extrusion channels it is substantially parallel to the first side of the distribution board.
[2]
2. Die according to claim 1, CHARACTERIZED by the fact that each of the first extrusion channels additionally comprises a rear wall opposite the outlet opening and connecting the two opposite side walls, the rear wall being substantially perpendicular to the first side the distribution board.
[3]
3. Die, according to claim 1 or 2, CHARACTERIZED by the fact that each of at least some of the first extrusion channels comprises a reinforcement member.
[4]
Matrix according to any one of claims 1 to 3, CHARACTERIZED by the fact that the two opposite side walls of the first extrusion channels are substantially perpendicular to the first side of the distribution plate.
[5]
5. Method of manufacturing an extruded article, the method being 'CHARACTERIZED by understanding: e. providing the matrix according to any one of claims 1 to 4; providing a first polymer composition in the first matrix cavity; 25 providing a second polymer composition, different from the first polymer composition, in the second matrix cavity; extruding the first polymeric composition through the plurality of first extrusion channels and the second polymeric composition through the plurality of second extrusion channels so as to form a flow stream having a width with alternative zones of the first and second polymeric compositions; and extruding the flow stream out of the die in a longitudinal direction to form the extruded article comprising a plurality of first longitudinal bands of the first polymeric composition alternating with a plurality of second longitudinal bands of the second polymeric composition, at least part of the first longitudinal bands has, in a plane perpendicular to the longitudinal direction, a cross-sectional shape that comprises substantially parallel opposite sides.
[6]
6. Method according to claim 5, CHARACTERIZED by the fact that the first polymeric composition comprises an inelastic polymer, and the second polymeric composition comprises an elastomeric polymer.
[7]
Method according to claim 6, CHARACTERIZED by the fact that the second polymeric composition additionally comprises an inelastic polymer.
[8]
8. Method according to any one of claims 5 to 7, CHARACTERIZED by the fact that at least one of the first or second polymeric compositions is foamed.
[9]
A method according to any one of claims 5 to 8, wherein the extruded article has opposite main surfaces, the method being CHARACTERIZED in that it additionally comprises coextruding a third polymeric composition to form a layer in at least one opposite main surfaces of the extruded article, in which the third polymeric composition is different from both the first polymeric composition and the second polymeric composition.
[10]
10. Method according to any of claims 5 to 9, wherein the extruded article has opposite main surfaces, the method being CHARACTERIZED in that it additionally comprises providing projections on at least one of the opposite main surfaces.
3/3 |
[11]
11. Extruded film that has first and second side edges and a line! : median, and the extruded film is CHARACTERIZED because it comprises an .. even number of first longitudinal bands of a first polymeric composition that | comprises an inelastic polymer alternating with an odd number of second longitudinal bands * 5 of a second polymeric composition comprising an elastomeric polymer so that the second longitudinal bands are located at least on the first and second side edges and on the midline, and where at least some of the second longitudinal bands have perforated lines along their lengths.
[12]
12. Extruded film CHARACTERIZED by having opposite main surfaces and comprising a plurality of first longitudinal bands of a first polymeric composition comprising an inelastic polymer alternating with a plurality of second longitudinal bands of a second polymeric composition that | comprises a mixture of an elastomeric polymer and an inelastic polymer, being | Although the plurality of first longitudinal bands and the plurality of second longitudinal bands are provided with projections on at least one of the opposing main surfaces, the projections of the plurality of first longitudinal bands being substantially the same height as the projections of the plurality of second bands; longitudinal.

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公开号 | 公开日

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法律状态:
2020-09-01| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2020-10-06| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2020-10-27| B08F| Application dismissed because of non-payment of annual fees [chapter 8.6 patent gazette]|Free format text: REFERENTE A 9A ANUIDADE. |

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2021-01-19| B11B| Dismissal acc. art. 36, par 1 of ipl - no reply within 90 days to fullfil the necessary requirements|

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2021-11-03| B350| Update of information on the portal [chapter 15.35 patent gazette]|

优先权:

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申请号 | 申请日 | 专利标题

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US30231610P| true| 2010-02-08|2010-02-08|

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US61/302,316|2010-02-08|

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PCT/US2011/023684|WO2011097436A1|2010-02-08|2011-02-04|Method of co-extruding, co-extrusion die, and extruded articles made therefrom|

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