Multi-layer polyisophthalate and polyterephthalate articles and process therefor

Claim 2

A multi-layer packaging material, charcterized by: (a) at least a layer made from a polyterephthalate compound or copolymers thereof, said polyterephthalate compound made by the reaction of terephthalic acid or esters thereof with ethylene glycol and up to 30 mole percent of one or more glycols having from 3 to 12 carbon atoms, said polyterephthalate copolymer made by reacting terephthalate acid or esters thereof and up to 30 mole percent of a 4 to 40 carbon atom dicarboxylic compound with ethylene glycol and up to 30 mole percent of one or more of a 3 to 12 carbon atom glycol, said polyterephthalate copolymer made by the reaction of one or more different said dicarboxylic compounds or one or more different said glycols, said dicarboxylic compound being other than terephthalic acid or an ester thereof and selected from the group consisting of an alkyl dicarboxylic acid, an aryl dicarboxylic acid, an alkyl substituted aryl dicarboxylic acid, a dimer carboxylic acid, a diester of an alkyl dicarboxylic acid, a diester of an aryl or alkyl substituted aryl carboxylic acid, an alkali sulfo dialkyl isophthalate, and combinations thereof; (b) at least a layer made from a polyisophthalate compound or copolymers thereof, said polyisophthalate being the reaction product of an isophthalic compound and a glycol having from 2 to 12 carbon atoms, said isophthalic compound selected from the group consisting of isophthalic acid, and an alkyl ester of isophthalic acid having from 10 to 20 carbon atoms, said diol being ethylene glycol and containing from 0 to 60 mole percent of one or more compounds selected from the group consisting of a glycol having from 3 to 12 carbon atoms, a glycol ether having from 4 to 12 carbon atoms, and combinations thereof; said copolymers of said polyisophthalate being the reaction product of said isophthalic compound, said diol, and up to 60 mole percent of a carboxylic compound having from 4 to 40 carbon atoms based upon said isophthalic compound and said dicarboxylic acid or said ester thereof, said dicarboxylic acid or ester thereof being other than said isophthalic compound.

Claim 3

A multi-layer packaging material according to claim 1, further characterized in that the intrinsic viscosity of said polyisophthalate compound is 0.4 or greater and wherein said intrinsic viscosity of said polyterephthalate compound is 0.60 or greater.

Claim 4

A multi-layer packaging material according to claim 2, further characterized in that said polyisophthalate compound has an oxygen permeability of 8 cc'mil/100 in 2 'day'atm or less and a C0 2 permeability of 50 cc ·mil/100 in 2 'day'atm or less.

Claim 5

A multi-layer packagin material according to claim 3, further characterized in that said layers are contiguous to one another and wherein (a) said one or more dicarboxylic compounds forming said polyterephthalate layer is 20 mole percent or less and is selected from the group consisting of an alkyl dicarboxylic acid having from 4 to 12 carbon atoms, an aryl dicarboxylic acid having from 8 to 16 carbon atoms, an alkyl substituted aryl dicarboxylic acid having from 9 to 16 carbon atoms, a dimer dicarboxylic acid having from 34 to 40 carbon atoms, a diester of an alkyl dicarboxylic acid diester having from 6 to 20 carbon atoms, a diester of an aryl or an alkyl substituted aryl dicarboxylic acid having from 10 or 11 respectively to 20 carbon atoms, an alkali sulfo dimethyl isophthalate, and combinations thereof, wherein said one or more glycols is 20 mole percent or less and has from 3 to 10 carbon atoms or is a glycol ether having from 4 to 8 carbon atoms; (b) wherein said isophthalic compound of said polyisophthalate layer is selected from the group consisting of isophthalic acid, an alkyl ester of isophthalic acid having from 10 to 16 carbon atoms, and combinations thereof, wherein said dicarboxylic compound forming said isophthalate copolymers is selected from the group consisting of an alkyl dicarboxylic acid having from 4 to 12 carbon atoms, an aryl or alkyl substituted aryl dicarboxylic acid having from 8 or 9, respectively, to 16 carbon atoms, a dimer acid having from 34 to 40 carbon atoms, a diester of an alkyl dicarboxylic acid having from 6 to 20 carbon atoms, a diester of an aryl of an alkyl substituted aryl dicarboxylic acid having from 10 to 11 respectively to 20 carbon atoms, an alkali sulfo dimethyl isophthalate, and combinations thereof; wherein the amount of said dicarboxylic acid or ester thereof is from 0 to 30 mole percent when said acid is said alkyl acid or said dimer acid, and from 0 to 40 mole percent when said diacid compound is said remaining acids or esters; and wherein the amount of said diol other than said ethylene glycol and said glycol ether is 45 mole percent or less, wherein said diol has from 3 to 10 carbon atoms, and wherein said glycol ether has from 4 to 8 carbon atoms.

Claim 6

A multi-layer packaging material according to claim 4, further characterized in that said polyisophthalate layer thickness ranges from about 10 percent to about 90 percent of the total thickness of the packaging material.

Claim 7

A multi-layer packaging material according to claim 5, further characterized in that said intrinsic viscosity of said polyisophthalate compound is 0.5 dl/g or greater, wherein said glass transition temperature ranges from about 35°C to about 100°C, wherein said oxygen permeability is 7 or less, wherein said carbon dioxide permeability is 30 or less, and wherein the glass transition temperature of said polyterephthalate compound is from about 60°C to about 100°C.

Claim 8

A process for making a multi-layer packaging material, characterized by the steps of: (a) forming at least one layer made from a polyterephthalate compound, or copolymers thereof, said polyterephthalate made by the reaction of terephthalic acid or esters thereof with ethylene glycol and up to 30 mole percent of one or more glycols having from 3 to 12 carbon atoms, said polyterephthalate copolymer made by the reaction of terephthalic acid or esters thereof and up to 30 mole percent of one or more 4 to 40 carbon atom dicarboxylic compound, with ethylene glycol and up to 30 mole percent of one or more glycols having from 3 to 12 carbon atoms, said dicarboxylic compound being other than terephthalic acid or an ester thereof and selected from the group consisting of an alkyl dicarboxylic acid, an aryl dicarboxylic acid, an alkyl substituted aryl dicarboxylic acid, a dimer carboxylic acid, a diester of a dicarboxylic acid, a diester of an aryl or an alkyl substituted aryl diester, an alkali sulfo dialkyl isophthalate, and combinations thereof; (b) forming at least one layer made from a polyisophthalic compound or a copolymer thereof, said polyisophthalate being the reaction product of an isophthalic compound and a glycol having from 2 to 12 carbon atoms, said isophthalic compound selected from the group consisting of isophthalic acid, and an alkyl ester of isophthalic acid having from 10 to 20 carbon atoms, said glycol being ethylene glycol and containing from 0 to 60 mole percent of one or more compound - selected from the group consisting of a glycol having from 3 to 12 carbon atoms, a glycol ether having from 4 to 12 carbon atoms, and combinations thereof; said copolymers of said polyisophthalate being the reaction product of isophthalic compound, said diol, and up to 60 mole percent of a dicarboxylic compound having from 4 to 40 carbon atoms based upon said isophthalic compound and said dicarboxylic acid or ester thereof, said dicarboxylic acid or ester thereof being other than said isophthalic compound; and contacting said polyisophthalate layer with said polyterephthalate layer and forming the packing material.

Claim 9

A process for making a multi-layer packaging material, characterized by the steps of: (a) forming at least one layer made from a polyterephthalate compound, or copolymers thereof, said polyterephthalate made by the reaction of terephthalic acid or esters thereof with ethylene glycol and up to 30 mole percent of one or more glycols having from 3 to 12 carbon atoms, said polyterephthalate copolymer made by the reaction of terephthalic acid or esters thereof and up to 30 mole percent of one or more 4 to 40 carbon atom dicarboxylic compound, with ethylene glycol and up to 30 mole percent of one or more glycols having from 3 to 12 carbon atoms, said dicarboxylic compound being other than terephthalic acid or an ester thereof and selected from the group consisting of an alkyl dicarboxylic acid, an aryl dicarboxylic acid, an alkyl substituted aryl dicarboxylic acid, a dimer carboxylic acid, a diester of a dicarboxylic acid, a diester of an aryl or an alkyl substituted aryl diester, an alkali sulfo dialkyl isophthalate, and combinations thereof; (b) forming at least one layer made from a polyisophthalic compound or a copolymer thereof, said polyisophthalate being the reaction product of an isophthalic compound and a glycol having from 2 to 12 carbon atoms, said isophthalic compound selected from the group consisting of isophthalic acid, and an alkyl ester of isophthalic acid having from 10 to 20 carbon atoms, said glycol being ethylene glycol and containing from 0 to 60 mole percent of one or more compound - selected from the group consisting of a glycol having from 3 to 12 carbon atoms, a glycol ether having from 4 to 12 carbon atoms, and combinations thereof; said copolymers of said polyisophthalate being the reaction product of isophthalic compound, said diol, and up to 60 mole percent of a dicarboxylic compound having from 4 to 40 carbon atoms based upon said isophthalic compound and said dicarboxylic acid or ester thereof, said dicarboxylic acid or ester thereof being other than said isophthalic compound; and contacting said polyisophthalate layer with said polyterephthalate layer and forming the packing material.

Claim 10

A process for making a multi-layer packaging material, according to claim 7, further characterized in that the intrinsic viscosity of said polyisophthalate compound is 0.4 or greater, wherein said polyisophthalate compound has an oxygen permeability of 8 cc'mil/100 in 2 'day'atm or less, and a C02 permeability of 50 cc. mil/100 in 2 'day'atm or less, and wherein the intrinsic viscosity of said polyterephthalate compound is 0.60 or greater.

Claim 11

A process for making a multi-layer packaging material, according to claim 8, further characterized in that (a) said one or more dicarboxylic compounds forming said polyterephthalate layer is 20 mole percent or less and is selected from the group consisting of an alkyl dicarboxylic acid havign from 4 to 12 carbon atoms, an aryl dicarboxylic acid having from 8 to 16 carbon atoms, an alkyl substituted aryl dicarboxylic acid having from 9 to 16 carbon atoms, a dimer dicarboxylic acid having from 34 to 40 carbon atoms, a diester of an alkyl dicarboxylic acid having from 6 to 20 carbon atoms, a diester of an aryl or an alkyl substituted aryl dicarboxylic acid having from 10 or 11 respectively to 20 carbon atoms, an alkali sulfo dimethyl isophthalate, and combinations thereof, wherein said one or more glycol diols has from 3 to 10 carbon atoms, or is a glycol ether having from 4 to 8 carbon atoms; (b) wherein said isophthalic compound is said polyisophthalate layer is selected from the group consisting of isophthalic acid, an alkyl ester of isophthalic acid having from 10 to 16 carbon atoms, and combinations thereof, wherein said dicarboxylic compound forming said isophthalate copolymers is selected from the group consisting of an alkyl dicarboxylic acid having from 4 to 12 carbon atoms, an aryl or alkyl substituted aryl dicarboxylic acid having from 8 or 9, respectively, to 16 carbon atoms, a dimer acid having from 34 to 40 carbon atoms, a diester of an alkyl dicarboxylic acid having from 6 to 20 carbon atoms, a diester of an aryl or an alkyl substituted aryl dicarboxylic acid having from 10 or 11 respectively to 20 carbon atoms, an alkali sulfo dimethyl isophthalate, and combinations thereof; wherein the amount of said dicarboxylic acid or ester thereof is from 0 to 30 mole percent when said acid is said alkyl acid or said dimer acid, and from 0 to 40 mole percent when said diacid compound is said remaining acids or esters; and wherein the amount of said diol other than said ethylene glycol and said glycol ether is 45 mole percent or less, wherein said diol has from 3 to 10 carbon atoms, and wherein said glycol ether has from 4 to 8 carbon atoms.

Claim 12

A process for making a multi-layer packaging material, according to claim 9, further characterized in that said polyisophthalate layer thickness ranges from about 10 percent to about 90 percent of the total thickness of the packaging material, wherein said intrinsic viscosity of said polyisophthalate compound is 0.5 dl/g or greater, wherein the glass transition temperature of said polyisophthalate compound ranges from about 35°C to about 100°C, wherein said oxygen permeability is 7 or less, and wherein said carbon dioxide permeability is 30 or less, and wherein the glass transition temperature of said polyterephthalate compound is from about 60°C to about 100°C.