Mucell Extrusion, LLC

Mark E Lindenfelzer

Mehdi Saniei

Jere R Anderson

Samuel Edward Dix

Eric Victor Fredrickson

James K Sakorafos

Nicholas R Torraco

Simon Dominey

John F Ryan

David Stirling

A multilayer foam film suitable for direct and non-direct food contact and aseptic packaging application is disclosed.

Multi-layer polymer foam film for packaging applications and the method of making the same

A multilayer foam film with an enhanced perceived surface whiteness comprising for light-blocking, signage, and general packaging application is disclosed. In an embodiment, the film has a bulk density of less than 0.962 gr/cmwherein more than 50% of the cells in the foam layer are closed cells. In an embodiment, the multilayer foam film has a thickness greater than 1 mil and one of the solid skin layers contains white pigment. In another embodiment the white skin layer has a skin whiteness value of greater than 80 according to ASTM E313-73, and a skin layer tint value of less than 1 according to ASTM E313-73, and The lightness value (L*) of the white skin layer of greater than 90 in CIE L*a*b* dimension according to ASTM E308. In an embodiment, the film has a very smooth surface with a smoothness value of less than 25 in Sheffield smoothness unit configuration according to TAPPI T 538.

Lightweight multilayer foam film with enhanced perceived surface whiteness

A multilayer foam film comprising high density polyethylene for direct and non-direct food contact and aseptic packaging application is disclosed. In an embodiment, the film has a bulk density of less than 0.962 gr/cmwherein more than 50% of the cells in the foam layer are closed cells. In an embodiment, the foam films are thick (generally more than 8 mils thick) and have a bending stiffness value of more than 18, in Taber stiffness unit configuration according to TAPPI/ANSI T 489 om-15, and the ratio of the mass per unit area (the mass of a unit area of the film in gram per meter-squared (gr/m)) over the stiffness value in Taber unit configuration is equal to or less than 13. In an embodiment, the film has a very smooth surface with a smoothness value of less than 25 in Sheffiled smoothness unit configuration according to TAPPI T 538. The described foam film can have a water vapor transmission rate value of less than 1 gr/m/24 hr, according to ASTM E398-13. The described foam film can have an oxygen transmission rate value of less than 10 cc/m/24 hr, according to ASTM D3985.

Lightweight polyethylene film for aseptic packaging applications and the product resulting therefrom and the process of making the same

Thermoformed polymeric foam articles and methods of forming the same are described. In some embodiments, thermoformed articles are produced from multi-layer foamed sheet where the formed article has a density equal to or less than the precursor multi-layer sheet. One of the layers of the thermoformed article may be a polymer foam layer having a density reduction between 5% and 50% as compared to the solid polymer. Such polymer foam layers can be referred to as 'medium density' or “high density” foams. Advantageously, the methods described herein are practical for commercial use and, for example, can be used to produce a variety of thermoformed articles suitable for use in many different applications.

Multi-layer thermoformed polymeric foam articles and methods

A recyclable multilayer synthetic foam container that does not wick, for direct and non-direct food contact and aseptic packaging application is disclosed. In one aspect, a container comprises a pre-creased and/or folded multilayer synthetic foam sheet comprising at least one foam layer, that can be hermetically sealed along the edges, wherein the synthetic board sheet is a recyclable material that does not wick. In another aspect, the product has a bending stiffness value greater than 17 in Taber stiffness unit configuration according to TAPPI/ANSI T 489 om-15. In some embodiments, the product can have an oxygen transmission rate of less than 20 cc/m/24 hr, according to ASTM D3985. In some embodiments, the product can have a water vapor transmission rate of less than 10 gr/m/24 hr, according to ASTM E398-13.

Synthetic foamed container that does not wick and a method of making the same

A method of making multilayer foam sheet from recycled polyester sources, which may be used for packaging applications. The method comprises a co-extrusion system comprising at least two single screw extruders. A low I.V. polyester feedstock comprising up to 100% of the polyester flakes from recycled sources with an intrinsic viscosity (I.V.) of lower than 0.8 dL/g as measured by ASTM D4603-18 is directly being fed into the extruders. Supercritical physical blowing agent is introduced into the melted polyester feedstock in at least one of the extruders wherein the processing temperature is in the range of 15% lower than the melting temperature and 15% higher than the melting temperature. Then, coextruding the feedstock from the extruders of the co-extrusion system through a flat sheet die to make a multilayer foam sheet, wherein at least one layer is a foam layer comprising low I.V. polyester.

Method of making flat foam sheet comprising recycled pet and the product resulting therefrom

Thermoformed polymeric foam articles are described herein In some embodiments, the articles are made by a manufacturing method (e.g., a continuous process) which involves the extrusion and subsequent thermoforming of a blowing agent containing thermoplastic sheet. The thermoformed polymeric foam articles may have a lower density than the precursor sheet from which they are formed. In some but not all embodiments, the precursor sheet is a multi-layer sheet which includes at least one foam layer. In such embodiments, the thermoformed articles also include multiple layers and at least one foam layer.

Thermoformed polymeric foam articles and methods

This invention relates to an anisotropic multilayer film and the process of making a multilayer film, wherein a supercritical blowing agent is introduced to at least one layer, wherein at least one layer comprises 10 to 100 percent by weight LLDPE with a melt index of 0.2 to 2 g/10 min. The film in this invention can have a surface with an average Sheffield smoothness, according to TAPPI T 538, of less than 100. The film in this invention can have a puncture propagation tear resistance, in accordance with ASTM D2582, greater than 500 g/mil.

Anisotropic thin polyethylene sheet and applications thereof and the process of making the same

Methods of forming polymeric foams are provided. The methods may involve co-extruding a foam layer along with one or more skin layers. In some embodiments, the skin layer(s) may be removed (e.g., in a peeling operation); while, in other embodiments, the skin layer(s) may form part of the final article. The methods are particularly well suited for producing polymeric foams from polymeric materials that are considered to be difficult to foam by those of skill in the art.

Method of forming polymeric foam and related foam articles

A method of forming a blown polymeric foam film is described herein. As described further below, equipment design (e.g., die design) and processing conditions may be controlled to form blown films having desired characteristics.

Method of forming blown polymeric foam film

Compression molded polymeric foam articles and methods are described herein. Equipment design and processing techniques may be controlled to form compression molded articles having desired characteristics.

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Milton, MA, United States of America

Mark E Lindenfelzer