Amoco Corporation

Robert D Pischke

Melvin L Luetkens, Jr

John C Schubert

Weilong L Chiang

David C Lindemann

Disclosed is a multi-layer sheet in a which a foamed thermpolastic core layer is extrusion coated with a multi-resin reclaim-containing layer, and an EVOH or acrylonitrile barrier layer is laminated to the multi-resin layer. The multi-resin layer is formulated to contain at least about 5 weight percent, and preferably about 8 to about 16 weight percent, based on the weight of the layer, of an adhesive resin to reduce the tendency of the barrier layer to delaminate from the multi-resin layer over time. The preferred adhesive is EMA.

Foamed core-reclaim multi layer sheet having improved resistance to

A method of producing a thermoplastic foam sheet comprising the step of (a) foaming, by extrusion, a mixture comprising polystyrene and a thermoplastic reclaim material obtained from a multi-layer sheet manufacturing process, wherein said thermoplastic reclaim material comprises polystyrene and a thermoplastic barrier resin selected from the group consisting of (i) copolymers of ethylene and vinyl alcohol, and (ii) polymers comprising a copolymer of acrylonitrile, to produce a foam sheet having an upper and lower surface.

Method of producing a thermoplastic foam sheet

The invention comprises a method for producing the multi-layer sheets of the invention comprising extrusion coating multi-resin layers onto each side of the foam core layer and then lamination of a barrier film layer onto one of the multi-resin layers.

Method for producing a foamed core-reclaim multi-layer sheet

The invention comprises a multi-layer thermoplastic foam sheet comprising a thermoplastic foam layer adjacent to at least one multi-resin layer, preferably comprising a reclaim material mixture recycled from the sheet manufacturing process, and which comprises a thermoplastic barrier resin. In a preferred embodiment, the multi-layer sheet of the invention comprises a four major layer sheet comprising a barrier film layer which comprises a thermoplastic oxygen barrier resin; an inner mutli-resin reclaim layer comprising the oxygen barrier resin used in the barrier film layer; a foam core layer adjacent to the inner multi-resin reclaim layer; and an outer multi-resin reclaim layer, also comprising the oxygen barrier resin, as the other outer layer of the multi-layer sheet. In a more preferred embodiment, impact polystyrene is added to the reclaim layers and polystyrene is used in the foam core to produce multi-layer sheets having an impact-resisting outer layer and a lightweight inner foam core layer, respectively.

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Duluth, GA, United States of America

Robert D Pischke