阅读说明：本技术 共挤出聚合物制品及其制备方法 (Coextruded polymer articles and methods of making same ) 是由 罗纳德·W·奥森 托马斯·P·汉斯申 威廉·J·科佩基 瓦萨瓦·萨尼 拉马苏布拉马尼·库杜瓦 于 2019-01-14 设计创作，主要内容包括：本发明提供了一种共挤出聚合物制品(100,200),该共挤出聚合物制品包括相背的第一主表面(111)和第二主表面(211),其中多个突起部(114,117,214,214,217)仅从第一主表面(111,112,211,212)延伸,其中每个突起部(214)具有相背的至少第一侧和第二侧(218)以及从第一主表面(111,112,211,212)到远侧端部(116,216)的高度,其中按数量计突起部(114,117,214,214,217)中的至少大部分具有突出部(117,217),该突出部仅从第一侧(118,218)延伸,并且在一个方向上延伸至不超过第一主表面(111,112,211,212),并且在相反方向上延伸至小于相应突起部(214)的高度,其中突起部(114,117,214,214,217)延伸至第二主表面(111,112,211,212),其中存在从第一主表面(111)和第二主表面(211)延伸并且位于突起部(114,117,214,214,217)之间的区域(119,120,220),其中区域(119,120,220)包含第一材料,突起部(114,117,214,214,217)包含第二材料,并且突出部(117,217)包含第三材料,其中第二材料和第三材料是不同的,并且其中第二材料或第三材料中的至少一者包含粘合剂。本文所述的共挤出聚合物制品的用途包括粘合剂制品、家用清洁产品(例如拖把、除尘器、刷子、清洁布或棉绒滚筒)。(The present invention provides a coextruded polymeric article (100,200) comprising first and second opposing major surfaces (111, 211), wherein a plurality of projections (114,117,214,214,217) extend only from the first major surface (111,112,211,212), wherein each projection (214) has at least first and second opposing sides (218) and a height from the first major surface (111,112,211,212) to the distal end (116,216), wherein at least a majority by number of the projections (114,117,214,214,217) have projections (117,217) that extend only from the first side (118,218) and do not extend in one direction beyond the first major surface (111,112,211,212) and extend in an opposite direction to less than the height of the respective projection (214), wherein the projections (114,117,214,214,217) extend to the second major surface (111,112,211,212), wherein there is a region (119,120,220) that extends from the first and second major surfaces (111, 211) and is located between the projections (114,117,214,214,217), wherein the region (119,120,220) comprises a first material, the protrusion (114,117,214,214,217) comprises a second material, and the protrusion (117,217) comprises a third material, wherein the second material and the third material are different, and wherein at least one of the second material or the third material comprises an adhesive. Uses for the co-extruded polymeric articles described herein include adhesive articles, household cleaning products (e.g., mops, dusters, brushes, cleaning cloths, or lint rollers).)

1. A coextruded polymeric article comprising first and second opposed major surfaces, wherein a plurality of projections extend only from the first major surface, wherein each projection has at least first and second opposed sides and a height from the first major surface to a distal end, wherein at least a majority by number of the projections have projections extending only from the first side and in one direction to no more than the first major surface and in an opposite direction to less than the height of the respective projection, wherein the projections extend to the second major surface, wherein there is an area extending from the first and second major surfaces and between projections, wherein the area comprises a first material, the projections comprise a second material, and the protrusion comprises a third material, wherein the second material and the third material are different, and wherein at least one of the second material or the third material comprises an adhesive.

2. The co-extruded polymeric article of claim 1 having a length of at least 5 millimeters.

3. The co-extruded polymeric article of claim 2, wherein the protrusions and projections extend along the length of the co-extruded polymeric article.

4. The coextruded polymer article of any of the preceding claims, wherein there is a demarcation line between the joined projections and adjacent projections.

5. The coextruded polymer article of any of the preceding claims, wherein there is a demarcation line between a connected protrusion and an adjacent protrusion, connected region and protrusion.

6. The coextruded polymeric article of any preceding claim, wherein the protrusions are substantially parallel to each other and substantially perpendicular to the first major surface.

7. The coextruded polymer article of any preceding claim, wherein the protrusions have a height to thickness ratio of at least 2: 1.

8. The co-extruded polymeric article of any preceding claim, wherein the protrusions do not contact the first surface.

9. A method of making the coextruded polymeric article of any of the preceding claims, the method comprising:

providing an extrusion die comprising a plurality of shims positioned adjacent to one another, the shims together defining a first cavity, a second cavity, a third cavity, and a die slot, wherein the die slot has a distal opening, wherein the die slot is comprised of a first plurality of apertures, a second plurality of apertures, and a third plurality of apertures, wherein the plurality of shims comprises: a first plurality of repeating sequences of shims that together provide a fluid channel between the second cavity and the second orifice; a second plurality of repeating sequences of shims that together provide a fluid passage between the first cavity and the first aperture and that also together provide a fluid passage between the third cavity and the third aperture; and a third plurality of shims that together provide a fluid passage between the first cavity and the first orifice;

providing a first material to the first cavity of the extrusion die via extrusion, a second material to the second cavity of the extrusion die, and a third material to the third cavity of the extrusion die, wherein the second material and the third material are different, and wherein at least one of the second material and the third material comprises a binder;

extruding a layer from the distal opening of the die slot; and

quenching the extruded layer.

10. A method of making the coextruded polymeric article of any of claims 1 to 8, the method comprising:

providing an extrusion die comprising a plurality of shims positioned adjacent to one another, the shims together defining a first cavity, a second cavity, a third cavity, and a die slot, wherein the die slot has a distal opening, wherein the die slot is comprised of a first plurality of apertures, a second plurality of apertures, and a third plurality of apertures, wherein the plurality of shims comprises: a first plurality of repeating sequences of shims that together provide a fluid channel between the second cavity and a second orifice; a second plurality of repeating sequences of shims providing fluid passageways between the third cavity and third orifice; and a third plurality of shims that together provide a fluid passage between the first cavity and the first orifice;

providing a first material to the first cavity of the extrusion die via extrusion, a second material to the second cavity of the extrusion die, and a third material to the third cavity of the extrusion die, wherein the second material and the third material are different, and wherein at least one of the second material and the third material comprises a binder;

extruding a layer from the distal opening of the die slot; and

quenching the extruded layer.

11. A coextruded polymeric article comprising first and second opposed major surfaces, wherein a plurality of projections extend only from the first major surface, wherein each projection has at least first and second opposed sides and a height from the first major surface to a distal end, wherein at least a majority by number of the projections have projections extending only from the first side and in one direction to no more than the first major surface and in an opposite direction to less than the height of the respective projection, wherein the projections extend to the second major surface, wherein there is an area extending from the first and second major surfaces and between projections, wherein the area comprises a first material, the projections comprise a second material, and the protrusion comprises a third material, wherein at least two of the first material, the second material, or the third material are different, and wherein the first material, the second material, or the third material each comprise an adhesive.

12. The co-extruded polymeric article of claim 11 having a length of at least 5 millimeters.

13. The co-extruded polymeric article of claim 12, wherein the protrusions and projections extend along the length of the co-extruded polymeric article.

14. The coextruded polymer article of any of claims 11-13, wherein there is a demarcation line between the connected projections and adjacent projections.

15. The coextruded polymer article of any of claims 11-14, wherein there is a demarcation line between a connected protrusion and an adjacent protrusion, connected region and protrusion.

16. The coextruded polymeric article of any of claims 11-15, wherein the first material and the second material are the same.

17. The coextruded polymer article of any of claims 11-16, wherein the protrusions do not contact the first surface.

18. The coextruded polymeric article of any of claims 11-17, wherein the projections extend from no more than the first major surface to less than a height of the projections.

19. The coextruded polymer article of any of claims 11-18, wherein the protrusions have a surface that contacts the protrusions associated with a protrusion, wherein the surface is planar.

20. A method of making the coextruded polymeric article of any of claims 11 to 19, the method comprising:

providing an extrusion die comprising a plurality of shims positioned adjacent to one another, the shims together defining a first cavity, a second cavity, a third cavity, and a die slot, wherein the die slot has a distal opening, wherein the die slot is comprised of a first plurality of apertures, a second plurality of apertures, and a third plurality of apertures, wherein the plurality of shims comprises: a first plurality of repeating sequences of shims that together provide a fluid channel between the second cavity and the second orifice; a second plurality of repeating sequences of shims that together provide a fluid passage between the first cavity and the first aperture and that also together provide a fluid passage between the third cavity and the third aperture; and a third plurality of shims that together provide a fluid passage between the first cavity and the first orifice;

providing a first material to the first cavity of the extrusion die via extrusion, providing a second material to the second cavity of the extrusion die, and providing a third material to the third cavity of the extrusion die, wherein at least two of the first, second, and third materials are different, and wherein each of the first, second, and third materials comprises an adhesive;

extruding a layer from the distal opening of the die slot; and

quenching the extruded layer.

21. A method of making the coextruded polymeric article of any of claims 11 to 19, the method comprising:

providing an extrusion die comprising a plurality of shims positioned adjacent to one another, the shims together defining a first cavity, a second cavity, a third cavity, and a die slot, wherein the die slot has a distal opening, wherein the die slot is comprised of a first plurality of apertures, a second plurality of apertures, and a third plurality of apertures, wherein the plurality of shims comprises: a first plurality of repeating sequences of shims that together provide a fluid channel between the second cavity and a second orifice; a second plurality of repeating sequences of shims providing fluid passageways between the third cavity and third orifice; and a third plurality of shims that together provide a fluid passage between the first cavity and the first orifice;

providing a first material to the first cavity of the extrusion die via extrusion, providing a second material to the second cavity of the extrusion die, and providing a third material to the third cavity of the extrusion die, wherein at least two of the first, second, and third materials are different, and wherein each of the first, second, and third materials comprises an adhesive;

extruding a layer from the distal opening of the die slot; and

quenching the extruded layer.

Background

Coextruded polymer articles (including layers) having protrusions are known in the art. For example, it is known to provide a coextruded layer structure in which the layers are separated, not into coextensive layers in the thickness direction, but into ribbons or strands along the width dimension of the layers. This is sometimes referred to as "side-by-side" coextrusion.

Additional polymeric articles having protrusions that provide different configurations and/or properties (e.g., adhesive properties) than conventional articles are desirable. Some adhesive systems are known which switch from a relatively low adhesion state or a non-adhesion state to a much higher adhesion state (commonly referred to as "on-demand" systems) upon application of some trigger. Many of these systems use triggers such as solvents, ultraviolet light, heat or magnetic force to produce the layered adhesive properties once or repeatedly. These systems are limited in application for several reasons. For many of these triggers, the adhesive system must contain specific chemical groups, which limits the use of applications for which those chemical groups can be tolerated. These systems can only be used if a specific trigger is available and can be effectively applied to the adhesive system. In addition, some triggers can be difficult or inconvenient for the consumer to use. Certain triggers, as well as chemical groups in the adhesive that respond to such triggers, may be cost prohibitive.

There is a need for a "tack-on-demand" system in which the trigger is applicable to all adhesive chemistries, the trigger is more widely or even universally available, the trigger is not only easy to apply in an industrial manner but also easily applicable by the consumer, and the tack-on-demand system is not prohibitively expensive.

Disclosure of Invention

In one aspect, the present disclosure describes a first coextruded polymeric article comprising first and second opposing major surfaces, wherein a plurality of protrusions extend only from the first major surface (i.e., the second major surface is free of any protrusions), wherein each protrusion has opposing at least first and second sides and a height from the first major surface to the distal end, wherein at least a majority by number of the protrusions (i.e., at least 50% by number; in some embodiments, at least 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or even 100%) have protrusions that extend only from the first side and in one direction to no more than the first major surface and in an opposite direction to less than the height of the respective protrusion (i.e., less than the distal end of the respective protrusion), wherein the protrusions extend to the second major surface, wherein there is a region extending between the first major surface and the second major surface and located between the protrusions, wherein the region comprises a first material, the protrusions comprise a second material, and the protrusions comprise a third material, wherein the second material and the third material are different, and wherein at least one of the second material or the third material comprises an adhesive. As used herein, the term "different" means at least one of: (a) a difference of at least 2% of at least one infrared peak, (b) a difference of at least 2% of at least one nuclear magnetic resonance peak, (c) a difference of at least 2% of number average molecular weight, or (d) a difference of at least 5% of polydispersity. Examples of differences in polymeric materials that may provide differences between polymeric materials include composition, microstructure, color, and refractive index. The term "identical" with respect to the polymeric materials means not different.

In some embodiments, there is a line of demarcation between the connected projections and the adjacent projections. This configuration can be formed by the methods described herein, wherein the materials are coextruded in a manner that results in visible differently oriented lines at the polymer boundaries between the connected projections and protrusions. This demarcation or boundary region between the connected protrusions and projections can be detected using differential scanning calorimetry. Comparing the region containing mainly the dividing line (region 1) with the region containing substantially no material from the dividing line (region 2) by temperature modulated differential scanning calorimetry, a difference in heat flow/heat capacity is observed, which is believed to be consistent with a reduction in energy release or molecular orientation/internal stress. That is, while not wanting to be limited by theory, it is believed that the thermal signature of a region may be a combination of the material thermal transition and the material's response to the retained thermal/processing history. In some embodiments, there is a demarcation line between the connected region and the protrusion.

In another aspect, the present disclosure describes a first process for making a first co-extruded polymeric article described herein, the process comprising:

providing an extrusion die comprising a plurality of shims positioned adjacent to one another, the shims together defining a first cavity, a second cavity, a third cavity, and a die slot, wherein the die slot has a distal opening, wherein the die slot is comprised of a first plurality of apertures, a second plurality of apertures, and a third plurality of apertures, wherein the plurality of shims comprises: a first plurality of repeating sequences of shims that together provide a fluid channel between the second cavity and the second orifice; a second plurality of repeating sequences of shims that together provide a fluid passage between the first cavity and the first aperture and that also together provide a fluid passage between the third cavity and the third aperture; and a third plurality of shims that together provide a fluid passage between the first cavity and the first orifice;

providing a first material to the first cavity of the extrusion die via extrusion, a second material to the second cavity of the extrusion die, and a third material to the third cavity of the extrusion die, wherein the second material and the third material are different, and wherein at least one of the second material and the third material comprises a binder;

extruding a layer from the distal opening of the die slot; and

quenching the extruded layer.

In another aspect, the present disclosure describes a second process for making a first co-extruded polymeric article described herein, the process comprising:

providing an extrusion die comprising a plurality of shims positioned adjacent to one another, the shims together defining a first cavity, a second cavity, a third cavity, and a die slot, wherein the die slot has a distal opening, wherein the die slot is comprised of a first plurality of apertures, a second plurality of apertures, and a third plurality of apertures, wherein the plurality of shims comprises: a first plurality of repeating sequences of shims that together provide a fluid channel between the second cavity and a second orifice; a second plurality of repeating sequences of shims providing fluid passageways between the third cavity and third orifice; and a third plurality of shims that together provide a fluid passage between the first cavity and the first orifice;

providing a first material to the first cavity of the extrusion die via extrusion, a second material to the second cavity of the extrusion die, and a third material to the third cavity of the extrusion die, wherein the second material and the third material are different, and wherein at least one of the second material and the third material comprises a binder;

extruding a layer from the distal opening of the die slot; and

quenching the extruded layer.

In another aspect, the present disclosure describes a second coextruded polymeric article including first and second opposing major surfaces, wherein a plurality of protrusions extend only from the first major surface (i.e., the second major surface is free of any protrusions), wherein each protrusion has opposing at least first and second sides and a height from the first major surface to the distal end, wherein at least a majority by number (i.e., at least 50% by number; in some embodiments, at least 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or even 100%) of the protrusions have protrusions that extend only from the first side and in one direction to no more than the first major surface and in an opposite direction to less than the height of the respective protrusion (i.e., less than the distal end of the respective protrusion), wherein the protrusions extend to the second major surface, wherein there is a region extending between the first major surface and the second major surface and located between the protrusions, wherein the region comprises a first material, the protrusions comprise a second material, and the protrusions comprise a third material, wherein at least two of the first material, the second material, or the third material are different, and wherein the first material, the second material, or the third material each comprise an adhesive.

In another aspect, the present disclosure describes a first method of making a second coextruded polymer article described herein, the method comprising:

providing an extrusion die comprising a plurality of shims positioned adjacent to one another, the shims together defining a first cavity, a second cavity, a third cavity, and a die slot, wherein the die slot has a distal opening, wherein the die slot is comprised of a first plurality of apertures, a second plurality of apertures, and a third plurality of apertures, wherein the plurality of shims comprises: a first plurality of repeating sequences of shims that together provide a fluid channel between the second cavity and the second orifice; a second plurality of repeating sequences of shims that together provide a fluid passage between the first cavity and the first aperture and that also together provide a fluid passage between the third cavity and the third aperture; and a third plurality of shims that together provide a fluid passage between the first cavity and the first orifice;

providing a first material to the first cavity of the extrusion die via extrusion, providing a second material to the second cavity of the extrusion die, and providing a third material to the third cavity of the extrusion die, wherein at least two of the first, second, and third materials are different, and wherein each of the first, second, and third materials comprises an adhesive;

extruding a layer from the distal opening of the die slot; and

quenching the extruded layer.

In another aspect, the present disclosure describes a second method of making a second coextruded polymer article described herein, the method comprising:

providing an extrusion die comprising a plurality of shims positioned adjacent to one another, the shims together defining a first cavity, a second cavity, a third cavity, and a die slot, wherein the die slot has a distal opening, wherein the die slot is comprised of a first plurality of apertures, a second plurality of apertures, and a third plurality of apertures, wherein the plurality of shims comprises: a first plurality of repeating sequences of shims that together provide a fluid channel between the second cavity and a second orifice; a second plurality of repeating sequences of shims providing fluid passageways between the third cavity and third orifice; and a third plurality of shims that together provide a fluid passage between the first cavity and the first orifice;

providing a first material to the first cavity of the extrusion die via extrusion, providing a second material to the second cavity of the extrusion die, and providing a third material to the third cavity of the extrusion die, wherein at least two of the first, second, and third materials are different, and wherein each of the first, second, and third materials comprises an adhesive;

extruding a layer from the distal opening of the die slot; and

quenching the extruded layer.

Embodiments of the co-extruded polymeric articles described herein may include adhesive articles, household cleaning products (e.g., mops, dusters, brushes, cleaning cloths, or lint rollers), and wall attachments.

Embodiments of the coextruded polymer articles described herein may provide delamination properties such that, for some advantageous properties (e.g., adhesive levels), the coextruded polymer article exhibits one level or value of the property under base conditions or use conditions, and at least one different level or value of the property under at least one trigger condition or use condition.

Drawings

Fig. 1 is a schematic cross-sectional view of an exemplary coextruded polymeric article described herein.

Fig. 2 is a schematic cross-sectional view of another exemplary coextruded polymer article described herein.

Fig. 3 is a schematic cross-sectional view of an exemplary die cavity pattern just upstream of a dispensing slot of a die used to form the exemplary coextruded polymer articles described herein.

Fig. 4 is a schematic cross-sectional view of another exemplary die cavity pattern just upstream of a dispensing slot of a die used to form the exemplary coextruded polymer articles described herein.

Fig. 5A is a plan view of an exemplary embodiment of a shim suitable for forming a sequence of shims capable of forming an exemplary coextruded polymeric article such as shown in the schematic cross-sectional views of fig. 1 and 2.

Fig. 5B is an enlarged area near the dispensing surface of the gasket shown in fig. 5A.

Fig. 6A is a plan view of an exemplary embodiment of a gasket suitable for forming a gasket sequence capable of forming a coextruded polymeric article such as shown in the schematic cross-sectional views of fig. 1 and 2.

Fig. 6B is an enlarged area near the dispensing surface of the gasket shown in fig. 6A.

Fig. 7A is a plan view of an exemplary embodiment of a shim suitable for forming a sequence of shims capable of forming a coextruded polymeric article such as shown in the schematic cross-sectional views of fig. 1 and 2.

Fig. 7B is an enlarged area near the dispensing surface of the gasket shown in fig. 7A.

Fig. 8A is a plan view of an exemplary embodiment of a shim suitable for forming a sequence of shims capable of forming a coextruded polymeric article such as shown in the schematic cross-sectional views of fig. 1 and 2.

Fig. 8B is an enlarged area near the dispensing surface of the gasket shown in fig. 8A.

Fig. 9A is a plan view of an exemplary embodiment of a gasket suitable for forming a gasket sequence capable of forming a coextruded polymeric article such as shown in the schematic cross-sectional views of fig. 1 and 2.

Fig. 9B is an enlarged area near the dispensing surface of the gasket shown in fig. 9A.

Fig. 10 is a perspective assembly view of several different exemplary gasket sequences employing the gaskets shown in fig. 5A-9A for making the exemplary coextruded polymer articles described herein, including regions, protrusions, and projections in a repeating arrangement as shown in fig. 1 and 2.

FIG. 11 is a perspective view of some of the gasket sequences of FIG. 10, further exploded to show some individual gaskets.

Fig. 12A is a plan view of an embodiment of a shim suitable for forming an exemplary shim sequence capable of forming a coextruded polymeric article such as shown in the schematic cross-sectional views of fig. 1 and 2 and using a die hole pattern as shown in fig. 4.

Fig. 12B is an enlarged area near the dispensing surface of the gasket shown in fig. 12A.

Fig. 13 is an exploded perspective view of an example of a mount suitable for an extrusion die constructed from multiple repetitions of the shim sequence of fig. 10 and 11.

Fig. 14 is a perspective view of the mount of fig. 13 in an assembled state.

Fig. 15 is an optical image of the article of example 1.

Detailed Description

Referring to fig. 1, an exemplary first co-extruded polymeric article 100 has opposing first 111 and second 112 major surfaces. The plurality of protrusions 114 extend only from the first major surface 111 (i.e., not from the second major surface 112) and have a height h from the first major surface 111 to the distal end 116₁. At least a majority (i.e., at least 50% by number; in some embodiments, at least 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or even 100%) of the protrusions 114 have a protrusion 117 that extends only from the first side 118 and in one direction does not extend beyond the first major surface 111 and in an opposite direction extends to less than the height of the respective protrusion (i.e., less than the distal end of the respective protrusion). The protrusion 114 extends to the second major surface 112. Region 119 at the first major surface111 and second major surface 112 and between protrusions 114. Region 120 comprises a first material. The protrusion 117 comprises a second material. The protrusion comprises a third material. The second material and the third material are different. At least one of the second material or the third material comprises an adhesive. As shown, there is a dividing line 121 between the connected protrusion 114 and projection 117. Although not shown, in some embodiments, there is a boundary between the connected region (119) and the protrusion (114). The distance d measured from the respective midpoints of the two protrusions₁To indicate the number of protrusions in a given distance. Distance d measured from the nearest side of the two protrusions₂For indicating the distance between the protrusions.

In some embodiments, at least one of the first material, the second material, or the third material of the first co-extruded polymeric articles described herein independently comprises at least one of a thermoplastic resin (e.g., at least one of a polyolefin (e.g., polypropylene and polyethylene), polyvinyl chloride, polystyrene, nylon, polyester (e.g., polyethylene terephthalate), or an elastomer (e.g., an ABA block copolymer, polyurethane, polyolefin elastomer, polyurethane elastomer, metallocene polyolefin elastomer, polyamide elastomer, ethylene vinyl acetate elastomer, and polyester elastomer), including copolymers and blends thereof). In some embodiments, at least one of the first material, the second material, or the third material of the first co-extruded polymeric articles described herein independently comprises an adhesive. In some embodiments, at least one of the first adhesive, the second adhesive, or the third adhesive of the first co-extruded polymeric articles described herein is independently at least one of an acrylate copolymer pressure sensitive adhesive, a rubber-based adhesive (e.g., those based on at least one of natural rubber, polyisobutylene, polybutadiene, butyl rubber, or styrene block copolymer rubber), a silicone polyurea-based adhesive, a silicone polyoxamide-based adhesive, a polyurethane-based adhesive, or a poly (alkenyl ether) adhesive, including copolymers and blends thereof.

In some embodiments, the first material and the second material of the first co-extruded polymeric articles described herein are the same. In some embodiments, the first material and the second material of the first co-extruded polymeric articles described herein are different. In some embodiments, the first material and the third material of the first co-extruded polymeric articles described herein are the same.

Referring to fig. 2, an exemplary second coextruded polymeric article 200 has opposing first and second major surfaces 211 and 212. The plurality of protrusions 214 extend only from the first major surface 212 (i.e., the second major surface 212 is free of any protrusions). Each protrusion 214 has at least first and second opposing sides 218, 219 and a height h from first major surface 211 to distal end 216₂. At least a majority (i.e., at least 50% by number; in some embodiments, at least 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or even 100%) of the protrusions 214 have a protrusion 217 that extends only from the first side 218 and in one direction to no more than the first major surface 211 and in an opposite direction to less than the height of the respective protrusion (i.e., less than the distal end of the respective protrusion). The protrusion 214 extends to the second major surface 212. Region 220 extends from first major surface 211 and second major surface 212 and is located between protrusions 214. Region 220 comprises a first material. The protrusion 217 comprises a second material. The protrusion 217 comprises a third material. At least two of the first material, the second material, or the third material are different. The first material, the second material, and the third material each comprise an adhesive. As shown, there is a boundary 221 between the connected protrusion 214 and the protrusion 217. Although not shown, in some embodiments, there is a demarcation line between the connected region (219) and the protrusion (214). The distance d measured from the respective midpoints of the two protrusions₃To indicate the number of protrusions in a given distance. Distance d measured from the nearest side of the two protrusions₄For indicating the distance between the protrusions.

In some embodiments, the first and second co-extruded polymeric articles described herein have a (machine direction) length of at least 5mm (in some embodiments, at least 10mm, 25mm, 50mm, 1cm, 5cm, 10cm, 50cm, 75cm, 1m, 5m, 10m, 25m, 50m, 100m, 500m, or even at least 1000 m). In some embodiments, the protrusions and projections extend along the length of the coextruded polymeric article (i.e., have a respective length of at least 5mm (in some embodiments, at least 10mm, 25mm, 50mm, 1cm, 5cm, 10cm, 50cm, 75cm, 1m, 5m, 10m, 25m, 50m, 100m, 500m, or even at least 1000 m)).

In another aspect, the present disclosure describes a first process for making a first co-extruded polymeric article described herein, the process comprising:

providing an extrusion die comprising a plurality of shims positioned adjacent to one another, the shims together defining a first cavity, a second cavity, a third cavity, and a die slot, wherein the die slot has a distal opening, wherein the die slot is comprised of a first plurality of apertures, a second plurality of apertures, and a third plurality of apertures, wherein the plurality of shims comprises: a first plurality of repeating sequences of shims that together provide a fluid channel between the second cavity and the second orifice; a second plurality of repeating sequences of shims that together provide a fluid passage between the first cavity and the first aperture and that also together provide a fluid passage between the third cavity and the third aperture; and a third plurality of shims that together provide a fluid passage between the first cavity and the first orifice;

providing a first material to the first cavity of the extrusion die via extrusion, a second material to the second cavity of the extrusion die, and a third material to the third cavity of the extrusion die, wherein the second material and the third material are different, and wherein at least one of the second material and the third material comprises a binder;

extruding a layer from the distal opening of the die slot; and

quenching the extruded layer.

In another aspect, the present disclosure describes a second process for making a first co-extruded polymeric article described herein, the process comprising:

providing an extrusion die comprising a plurality of shims positioned adjacent to one another, the shims together defining a first cavity, a second cavity, a third cavity, and a die slot, wherein the die slot has a distal opening, wherein the die slot is comprised of a first plurality of apertures, a second plurality of apertures, and a third plurality of apertures, wherein the plurality of shims comprises: a first plurality of repeating sequences of shims that together provide a fluid channel between the second cavity and a second orifice; a second plurality of repeating sequences of shims providing fluid passageways between the third cavity and third orifice; and a third plurality of shims that together provide a fluid passage between the first cavity and the first orifice;

providing a first material to the first cavity of the extrusion die via extrusion, a second material to the second cavity of the extrusion die, and a third material to the third cavity of the extrusion die, wherein the second material and the third material are different, and wherein at least one of the second material and the third material comprises a binder;

extruding a layer from the distal opening of the die slot; and

quenching the extruded layer.

In another aspect, the present disclosure describes a first method of making a second coextruded polymer article described herein, the method comprising:

providing an extrusion die comprising a plurality of shims positioned adjacent to one another, the shims together defining a first cavity, a second cavity, a third cavity, and a die slot, wherein the die slot has a distal opening, wherein the die slot is comprised of a first plurality of apertures, a second plurality of apertures, and a third plurality of apertures, wherein the plurality of shims comprises: a first plurality of repeating sequences of shims that together provide a fluid channel between the second cavity and the second orifice; a second plurality of repeating sequences of shims that together provide a fluid passage between the first cavity and the first aperture and that also together provide a fluid passage between the third cavity and the third aperture; and a third plurality of shims that together provide a fluid passage between the first cavity and the first orifice;

providing a first material to the first cavity of the extrusion die via extrusion, providing a second material to the second cavity of the extrusion die, and providing a third material to the third cavity of the extrusion die, wherein at least two of the first, second, and third materials are different, and wherein each of the first, second, and third materials comprises an adhesive;

extruding a layer from the distal opening of the die slot; and

quenching the extruded layer.

In another aspect, the present disclosure describes a second method of making a second coextruded polymer article described herein, the method comprising:

providing an extrusion die comprising a plurality of shims positioned adjacent to one another, the shims together defining a first cavity, a second cavity, a third cavity, and a die slot, wherein the die slot has a distal opening, wherein the die slot is comprised of a first plurality of apertures, a second plurality of apertures, and a third plurality of apertures, wherein the plurality of shims comprises: a first plurality of repeating sequences of shims that together provide a fluid channel between the second cavity and a second orifice; a second plurality of repeating sequences of shims providing fluid passageways between the third cavity and third orifice; and a third plurality of shims that together provide a fluid passage between the first cavity and the first orifice;

providing a first material to the first cavity of the extrusion die via extrusion, providing a second material to the second cavity of the extrusion die, and providing a third material to the third cavity of the extrusion die, wherein at least two of the first, second, and third materials are different, and wherein each of the first, second, and third materials comprises an adhesive;

extruding a layer from the distal opening of the die slot; and

quenching the extruded layer.

Each of the regions, protrusions, and projections described herein for coextruded polymer articles (including those shown in fig. 1 and 2) can be considered to be unitary (i.e., have a substantially uniform composition) and not fibrous. In addition, the protrusions and projections are not nonwoven materials, nor are they applied or added as a second step. However, in some embodiments described below, portions of the article may be apertured. Typically, the protrusions and projections are coextruded and melt bonded together to form a coextruded continuous polymeric article having the protrusions and projections.

Referring again to fig. 1, the co-extruded polymeric article 100 can be prepared, for example, by extrusion from a die having a plurality of channels from cavities within the die to a dispensing slot, including the exemplary dies described herein (see, e.g., fig. 3 and 4). The die may conveniently be formed from a plurality of shims. In some embodiments, the plurality of shims comprises a plurality of sequences of shims comprising shims that provide a passageway between the first and second cavities and the dispensing slot. In some of these embodiments, there will be additional shims that provide a channel between the first and/or second and/or third (or more) cavities and the dispensing slot.

In some embodiments, the shims will be assembled according to a scheme that provides for a variety of different types of shim sequences. Since different applications may have different requirements, the sequence may have a variety of different numbers of shims. The sequence may be a repetitive sequence that is not limited to a specific number of repetitions in a specific region. Or the sequence may be irregularly repeated, but a different gasket sequence may be used. The shape of the channels within, for example, a gasket sequence may be the same or different. Examples of channel cross-sectional shapes include circular, square, and rectangular shapes. In some embodiments, a shim that provides a passageway between one cavity and a dispensing slot may have a flow restriction compared to a shim that provides a passageway between another cavity and a dispensing slot. The width of the distal opening may be the same or different, for example, in different sequences of shims. For example, the portion of the distal opening provided by the shim providing the passage between one cavity and the dispensing slot may be narrower than the portion of the distal opening provided by the shim providing the passage between the other cavity and the dispensing slot.

The single cavity and channel provide a conduit for the polymer to the aperture to form the protrusion, and membrane base region. These individual fluid streams merge together at the die slot portion of the die to form a continuous solid coextruded polymer article. The spacer shim provides a connecting slot to form a line of demarcation connecting the tab, the protrusion and the area.

In some embodiments, an extrusion die described herein comprises a pair of end blocks for supporting a plurality of shims. In these embodiments it is convenient for one or even all of the shims to each have at least one through hole for passing a connector between a pair of end blocks. Bolts disposed within such through holes are a convenient method for assembling shims to end blocks, but other alternatives for assembling an extrusion die may be recognized by one of ordinary skill. In some embodiments, at least one end block has an inlet for introducing fluid material into one or both of the cavities.

In some embodiments, the shims will be assembled according to a scheme that provides a repeating sequence of shims of various different types. Each repetition of the repeating sequence may have a different number of pads. For the first example, the following describes a repeating sequence that utilizes 5 shims to form the orifice pattern shown in fig. 3 to form the coextruded polymer article shown in fig. 1. When suitably provided with a molten polymer, the five-shim repeating sequence extrudes a continuous film through the die slot to form a coextruded polymer article having protuberances and protrusions.

In some embodiments, the assembled gasket (conveniently bolted between the end blocks) further comprises a manifold body for supporting the gasket. The manifold body has at least one (e.g., in some embodiments, at least two, three, four, or more) manifold therein having an outlet. An expansion seal (e.g., made of copper or an alloy thereof) is provided to seal the manifold body and the gasket such that the expansion seal defines a portion of at least one of the cavities (in some embodiments, a portion of both the first and second cavities), and such that the expansion seal allows a conduit to be formed between the manifold and the cavities.

Typically, the length of the channel between the cavity and the dispensing orifice is at most 5 mm. Sometimes, the fluid channel to one array has a greater fluid restriction than the fluid channel to one or more of the other arrays.

Shims for the dies described herein typically have a thickness in the range of 50 microns to 125 microns, although thicknesses outside this range are also useful. Typically, the fluid channels have a thickness in the range of 50 to 750 microns and a length of less than 5mm (smaller lengths are generally preferred for tapering channel thicknesses), although thicknesses and lengths outside these ranges are also useful. For large diameter fluid channels, several shims of smaller thickness may be stacked together, or a single shim having the desired channel width may be used.

The spacers are tightly compressed to prevent gaps between the spacers and polymer leakage. For example, bolts of 12mm (0.5 inch) in diameter are typically used and tightened to their recommended torque rating at extrusion temperatures. In addition, the shims are aligned to provide uniform extrusion through the extrusion orifice, as misalignment can result in strands being extruded from the die at an angle that hinders the bonding required for netting. To facilitate alignment, an alignment key (alignment key) may be cut into the shim. In addition, a vibration table may be used to provide smooth surface alignment of the extrusion tip.

In the practical method described herein, the polymeric material can be simply hardened by cooling. This may be conveniently achieved passively by ambient air, or actively by, for example, quenching the extruded first and second polymeric materials on a chilled surface (e.g., a chill roll). In some embodiments, the first polymeric material and/or the second polymeric material and/or the third polymeric material is a low molecular weight polymer that requires curing by cross-linking, which may be performed, for example, by electromagnetic or particle radiation. In some embodiments, it is desirable to maximize the time of quenching to increase bond strength.

Fig. 3 is a schematic cross-sectional view of an exemplary die orifice pattern just upstream of a dispensing slot of a die used to form the exemplary coextruded polymer articles described herein. The orifice plane 300 shows a first orifice 317, a second orifice 323, and a third orifice 319. As will be described in detail later, the orifices are spaced apart to provide channel sidewalls between the channels through the use of spacer shims. The individual fluid streams are combined together with a dividing line to form a continuous coextruded polymer article in the final slot orifice (not shown) of the die.

Fig. 4 is a schematic cross-sectional view of another exemplary die orifice pattern just upstream of a dispensing slot of a die used to form the exemplary coextruded polymer articles described herein. The orifice plane 400 shows a first orifice 417, a second orifice 423, and a third orifice 419. As will be described in detail later, the apertures are spaced apart to provide channel sidewalls between the channels. The individual fluid streams are combined together with a dividing line to form a continuous coextruded polymer article in the final slot orifice (not shown) of the die. The dividing line is formed at the orifices spaced at a minimum amount by the spacer. These shims typically have a thickness in the range of 50 microns to 200 microns. The depth of the final slot is long enough and the distance between the orifices is so close that a continuous article is formed in the final slot of the die, i.e., the sum of the formation of all orifices.

Referring now to fig. 5A and 5B, a plan view of a shim 500 is shown. The gasket 500 has a first hole 560a, a second hole 560b, a third hole 560c, and a fourth hole 560 d. When shim 500 is assembled with other shims as shown in fig. 10 and 11, bore 560a helps define first cavity 562a, bore 560b helps define second cavity 562b, bore 560c helps define third cavity 562c, and bore 560d helps define third cavity 562 d. When the shims are assembled as shown in fig. 10 and 11, the channels 568a, 568b, 568c and 568d cooperate with similar channels on adjacent shims to allow access from the cavities 562a, 562b, 562c and 562d to the dispensing surfaces of the appropriate shims.

The shim 500 has several apertures 547 to allow, for example, bolts for retaining the shim 500 and other components described below to enter the assembly. Shim 500 also has a dispensing surface 567, and in this embodiment, dispensing surface 567 has an indexing groove 580 that can receive a key of an appropriate shape to easily assemble the discrete shims into a die. The shim may also have an identification notch 582 to help verify that the die has been assembled in the desired manner. This embodiment has shoulders 590 and 592 that may facilitate mounting of an assembled die using a mount of the type shown in FIG. 13. Shim 500 has dispensing opening 556, but it should be noted that this shim has no connection between dispensing opening 556 and any of cavities 562a, 562b, 562c, or 562 d. Shim 500 serves as a spacer shim and provides sidewalls for the channels of adjacent shims. Opening 556 provides a continuous dispensing slot for extrusion. The continuous slot enables the polymer streams to merge together to form a dividing line in the coextruded polymer article between the die orifices.

Referring to fig. 6A and 6B, a plan view of a shim 600 is shown. The gasket 600 has a first hole 660a, a second hole 660b, a third hole 660c, and a fourth hole 660 d. When the gasket 600 is assembled with other gaskets as shown in fig. 10 and 11, the aperture 660a helps define a first cavity 662a, the aperture 660b helps define a second cavity 662b, the aperture 660c helps define a third cavity 662c, and the aperture 660d helps define a third cavity 662 d. When the pads are assembled as shown in fig. 10 and 11, the channels 668a, 668b, 668c, and 668d cooperate with similar channels on adjacent pads to allow access from the cavities 662a, 662b, 662c, and 662d to the dispensing surface of the appropriate pad.

The shim 600 has several holes 647 to allow, for example, bolts for holding the shim 600 and other components described below to enter the assembly. Shim 600 also has a dispensing surface 667 and, in this embodiment, dispensing surface 667 has indexing grooves 680 that can receive appropriately shaped keys to ease assembly of the discrete shims into a die. The shim may also have an identification notch 682 to help verify that the die has been assembled in the desired manner. This embodiment has shoulders 690 and 692 that can facilitate mounting of an assembled die using a mount of the type shown in fig. 13. The gasket 600 has a dispensing opening 656 in a dispensing surface 667. Dispensing opening 656 can be seen more clearly in the enlarged view shown in fig. 6B. It may appear that there is no path from the cavity 662a to the dispensing opening 656 via, for example, the channel 668a, but when the sequence of fig. 6 is fully assembled, the flow has a path in the dimension perpendicular to the plane of the drawing.

Referring to fig. 7A and 7B, a plan view of shim 700 is shown. Spacer 700 has first hole 760a, second hole 760b, third hole 760c, and fourth hole 760 d. When the gasket 700 is assembled with other gaskets as shown in fig. 10 and 11, the aperture 760a helps define a first cavity 762a, the aperture 760b helps define a second cavity 762b, the aperture 760c helps define a third cavity 762c, and the aperture 760d helps define a third cavity 762 d. When the shims are assembled as shown in fig. 10 and 11, the channels 768a, 768b, 768c, and 768d cooperate with similar channels on adjacent shims to allow access from the cavities 762a, 762b, 762c, and 762d to the dispensing surfaces of the appropriate shims.

Shim 700 has several holes 747 to allow, for example, bolts for holding shim 700 and other components described below to enter the assembly. Shim 700 also has a dispensing surface 767, and in this embodiment, dispensing surface 767 has an indexing groove 780 that can receive a suitably shaped key to easily assemble the discrete shims into a die. The shim may also have an identification notch 782 to help verify that the die has been assembled in the desired manner. This embodiment has shoulders 790 and 792 that may facilitate mounting of the assembled die using a mount of the type shown in fig. 13. Shim 700 has dispensing opening 756, but it should be noted that this shim has no connection between dispensing opening 756 and any of cavities 762a, 762b, 762c, or 762 d. Shim 700 is a spacer shim and provides a sidewall for the channel of an adjacent shim. Opening 756 provides a continuous dispensing slot for extrusion. The continuous slot enables the polymer streams to merge together to form a dividing line in the coextruded polymer article between the die orifices.

Referring to fig. 8A and 8B, a plan view of a shim 800 is shown. The gasket 800 has a first hole 860a, a second hole 860b, a third hole 860c, and a fourth hole 860 d. When the shim 800 is assembled with other shims as shown in fig. 10 and 11, the aperture 860a helps define the first cavity 862a, the aperture 860b helps define the second cavity 862b, the aperture 860c helps define the third cavity 862c, and the aperture 860d helps define the third cavity 862 d. When the shims are assembled as shown in fig. 10 and 11, the passages 868a, 868b, 868c, and 868d cooperate with similar passages on adjacent shims to allow access from the cavities 862a, 862b, 862c, and 862d to the dispensing surfaces of the appropriate shims.

The shim 800 has several holes 847 to allow, for example, bolts to enter the assembly for holding the shim 800 and other components described below. Shim 800 also has a dispensing surface 867 and in this embodiment, dispensing surface 867 has an indexing groove 880 that can receive a suitably shaped key to ease assembly of the discrete shims into a die. The shim may also have an identification notch 882 to help verify that the die has been assembled in the desired manner. This embodiment has shoulders 890 and 892 that can facilitate mounting of an assembly die using a mount of the type shown in fig. 13. The gasket 800 has a dispensing opening 857 in the dispensing surface 867. Dispensing opening 857 can be seen more clearly in the enlarged view shown in FIG. 8B. It may appear that there is no path from cavity 862c to dispensing opening 857 via, for example, passage 868c, but when the sequence of fig. 8 is fully assembled, the flow has a path in the dimension perpendicular to the plane of the drawing. The shim 800 also has dispensing openings 858 and 856, but it should be noted that these openings have no connection between dispensing openings 858 and 856 and any of the cavities 862a, 862b, 862c, or 862 d. The openings 858 provide an expanded dispensing slot for the distal end of the protrusion. This is to minimize the effect of flow reduction typically seen at the ends of distribution slots such as this. The opening 856 provides a continuous dispensing slot for extrusion between the first and second orifices and allows for a demarcation line to be formed within the coextruded polymeric article.

Referring to fig. 9A and 9B, a plan view of a gasket 900 is shown. The gasket 900 has a first hole 960a, a second hole 960b, a third hole 960c, and a fourth hole 960 d. When the gasket 900 is assembled with other gaskets as shown in fig. 10 and 11, the aperture 960a helps define a first cavity 962a, the aperture 960b helps define a second cavity 962b, the aperture 960c helps define a third cavity 962c, and the aperture 960d helps define a third cavity 962 d. When the pads are assembled as shown in fig. 10 and 11, the channels 968a, 968b, 968c, and 968d cooperate with similar channels on adjacent pads to allow access from the cavities 962a, 962b, 962c, and 962d to the dispensing surfaces of the appropriate pads.

The shim 900 has several holes 947 to allow, for example, bolts to enter the assembly for holding the shim 900 and other components described below. Shim 900 also has a dispensing surface 967, and in this embodiment, dispensing surface 967 has an indexing groove 980 that can receive a key of an appropriate shape to easily assemble the discrete shims into a die. The shim may also have an identification notch 982 to help verify that the die has been assembled in the desired manner. This embodiment has shoulders 990 and 992 which may facilitate mounting of the assembly die using a mount of the type shown in fig. 13. The gasket 900 has a dispensing opening 956 in the dispensing surface 967. Dispensing opening 956 can be seen more clearly in the enlarged view shown in figure 9B. It may appear that there is no path from cavity 962b to dispensing opening 956 via, for example, channel 968b, but when the sequence of fig. 9 is fully assembled, the flow has a path in the dimension perpendicular to the plane of the drawing.

Referring to fig. 10, a perspective assembly view of several different gasket repeat sequences (collectively 1000) employing the gaskets of fig. 5-9 is shown for making the co-extruded polymeric article 100 shown in fig. 1, and showing the co-extruded polymeric article 200 shown in fig. 2. It should be noted that in fig. 10, the dispensing slot collectively formed by dispensing openings 556, 656, 756, 856, and 956 in the plurality of shims is a continuous opening across the die. The continuous opening is fed from three extrusion orifices as shown in fig. 3. There are no spacers without dispensing openings, which may form interruptions to cause the extruded polymer composition to form into separate strands.

Referring to fig. 11, an exploded perspective assembly view of a gasket repeat sequence employing the gaskets of fig. 5-9 is shown. In the illustrated embodiment, the repeating sequence includes one instance of shim 500, two instances of shim 600 forming the first orifice, one instance of shim 500, one instance of shim 800 forming the third orifice, one instance of shim 700, and two instances of shim 900 forming the second orifice, oriented as the figure. In this view, it can be understood how the three holes merge together at the extrusion slot to produce a continuous coextruded polymer article.

Referring to fig. 12A and 12B, a plan view of a shim 1200 is shown. The gasket 1200 has a first bore 1260a, a second bore 1260b, a third bore 1260c, and a fourth bore 1260 d. When gasket 1200 is assembled with other gaskets, bore 1260a helps define first cavity 1262a, bore 1260b helps define second cavity 1262b, bore 1260c helps define third cavity 1262c, and bore 1260d helps define third cavity 1262 d. The channels 1268a, 1268b, 1268c, and 1268d cooperate with similar channels on adjacent shims to allow passage from the cavities 1262a, 1262b, 1262c, and 1262d to the dispensing surfaces of the appropriate shims.

The gasket 1200 has several holes 1247 to allow, for example, bolts to enter the assembly for holding the gasket 1200 and other components described below. Shim 1200 also has a dispensing surface 1267, and in this embodiment, dispensing surface 1267 has an indexing groove 1280 that can receive a key of a suitable shape to ease assembly of the discrete shims into a die. The shim may also have an identification notch 1282 to help verify that the die has been assembled in the desired manner. This embodiment has shoulders 1290 and 1292 which can aid in mounting the assembly die using a mount of the type shown in fig. 13. The gasket 1200 also has a dispensing opening 1256 and a dispensing opening 1257 in the dispensing surface 1267 as well as a dispensing opening 1258. The dispensing openings 1256 and 1258 can be more clearly seen in the enlarged view shown in fig. 12B. It may appear that there is no path from cavity 1262c to dispensing opening 1257 and from 1262a to dispensing opening 1256 via, for example, channels 1268a and 1268c, but when the sequence of fig. 12 is fully assembled, the flow has a path in the dimension perpendicular to the plane of the drawing. The gasket 1200 may be used to create a dispensing orifice as shown in fig. 4. Opening 1258 is not connected to the cavity. Opening 1258 provides an expanded dispensing slot for the distal end of the tab. This is to minimize the effect of flow reduction typically seen at the ends of distribution slots such as this.

Shim 1200 is an alternative to shim 800. A die stack having shim sequences 500, 600, 500, 1200, 700, 900 produced the orifice configuration shown in fig. 4. A die stack having shim sequences 500, 600, 500, 800, 700, 900 produced the orifice configuration shown in fig. 3.

Referring to fig. 13, an exploded perspective view of a mount 2000 suitable for an extrusion die constructed from multiple repetitions of the shim repeat sequence of fig. 10 and 11 is shown. Mount 2000 is particularly suited for use with shims 500, 600, 700, 800, and 900 or shims 500, 600, 700, 1200, and 900 as shown in fig. 5-9 and 12. However, for visual clarity, only a single example of a shim is shown in fig. 13. Multiple repetitions of the gasket repetition sequence of fig. 10 and 11 are compressed between the two end blocks 2244a and 2244 b. Conveniently, through bolts may be used to assemble the shims to the end blocks 2244a and 2244b so as to pass through the holes 547 in the shims 500 or the like.

In this embodiment, the inlet fitting provides a flow path for three streams of molten polymer to reach the cavities 562a, 562b, 562c and 562d through the end blocks 2244a and 2244 b. The compression blocks 2204 have notches 2206 that conveniently engage shoulders on the shim (e.g., 590 and 592 on 500). When mount 2230 is fully assembled, compression blocks 2204 are attached to back plate 2208 by, for example, mechanical bolts. A hole is conveniently provided in the assembly for insertion of the cartridge heater 52.

Referring to fig. 14, a perspective view of mount 2000 of fig. 13 is shown in a partially assembled state. Several shims (e.g., 500) in their assembled position show how they fit within mount 2000, but most of the shims that would make up the assembled die have been omitted for visual clarity.

In some embodiments, at least one of the first adhesive, the second adhesive, or the third adhesive of the second coextruded polymeric article described herein is independently at least one of an acrylate copolymer pressure sensitive adhesive, a rubber-based adhesive (e.g., those based on at least one of natural rubber, polyisobutylene, polybutadiene, butyl rubber, or styrene block copolymer rubber), a silicone polyurea-based adhesive, a silicone polyoxamide-based adhesive, a polyurethane-based adhesive, or a poly (alkenyl ether) adhesive, including copolymers and blends thereof.

In some embodiments, the first material and the second material of the second coextruded polymer article described herein are the same. In some embodiments, the first material and the third material of the second coextruded polymer article described herein are the same.

In some embodiments, there are at least 5 protrusions per centimeter (in some embodiments, at least 10, 15, 20, 25, 30, 35, or even up to 40).

In some embodiments, the protrusions of the coextruded polymeric articles described herein are substantially parallel to each other and substantially perpendicular to the first major surface.

In some embodiments, the protrusion has a surface that contacts a protrusion associated with the protrusion, wherein the surface is planar. In some embodiments, the protrusion has a surface that contacts a protrusion associated with the protrusion, wherein the surface exhibits at least one depression. In some embodiments, the protrusion has a surface that contacts a protrusion associated with the protrusion, wherein the surface exhibits at least one protuberance.

In some embodiments, the protrusions of the coextruded polymer articles described herein have a high to thickness ratio (i.e., height to thickness) of at least 2:1 (in some embodiments, at least 3:1, or even at least 4: 1).

In some embodiments, the protrusions of the coextruded polymer articles described herein are spaced no more than 2mm apart (in some embodiments, no more than 1 mm).

In some embodiments, the protrusions of the coextruded polymer articles described herein have a height and a thickness, and the thickness is along the length of each respective protrusion.

In some embodiments, the protrusions of the coextruded polymeric articles described herein do not contact the first major surface.

In some embodiments, the height of the protrusions of the coextruded polymer articles described herein is in the range of 0.1mm to 5mm (in some embodiments, in the range of 0.1mm to 2mm or even 0.1mm to 1 mm).

In some embodiments, the protrusions of the coextruded polymer articles described herein have a longest cross-sectional dimension in a direction perpendicular to the protrusions in the range of 0.05mm to 0.5mm (in some embodiments, in the range of 0.05mm to 0.2mm or even 0.05mm to 0.1 mm).

In some embodiments, the distance between the protrusions of a region of the coextruded polymer article described herein is in the range of 0.25mm to 5mm (in some embodiments, in the range of 0.25mm to 2mm or even 0.25mm to 1 mm).

In some embodiments of the coextruded polymeric articles described herein, the distance between the first major surface and the second major surface is in the range of 0.05mm to 5mm (in some embodiments, in the range of 0.05mm to 3mm, 0.05mm to 2mm, or even 0.1mm to 1 mm).

In some embodiments, the protrusions of the coextruded polymer articles described herein extend from no more than the first major surface to less than the height of the protrusion (in some embodiments, in the range of 1% of the length of the protrusion to 75% of the length of the protrusion, 1% of the length of the protrusion to 50% of the length of the protrusion, or even 10% of the length of the protrusion to 50% of the length of the protrusion).

One exemplary use of the articles described herein is as a coextruded polymeric adhesive article, wherein the adhesive is not initially exposed to contact with a substrate in the vicinity of the article, and may be subsequently exposed to contact with the substrate after mechanical movement of the protrusions of the article (such as by hand pressure in a shear mode).

In some embodiments, the polymeric materials used to prepare the coextruded polymeric articles described herein can include colorants (e.g., pigments and/or dyes) for functional purposes (e.g., optical effects) and/or aesthetic purposes (e.g., each having a different color/shade). Suitable colorants are those known in the art for use in a variety of polymeric materials. Exemplary colors imparted by the colorant include white, black, red, pink, orange, yellow, green, aqua, purple, and blue. In some embodiments, the desired level is a degree of opacity for one or more of the polymeric materials. The amount of colorant used in a particular embodiment can be readily determined by one skilled in the art (e.g., to achieve a desired color, shade, opacity, transmission, etc.). The polymeric materials can be formulated to have the same or different colors, if desired.

Another exemplary use of the co-extruded polymeric articles described herein is as a household cleaning product (e.g., a mop, duster, brush, cleaning cloth, or lint roller) whose effectiveness is increased by the motion inherent in its use.

Another exemplary use of the co-extruded polymeric articles described herein is as an adhesive article that can be attached to a substrate (e.g., a wall attachment that can be positioned without any adhesion) with a slight shear movement, and then adhered to a wall by gentle hand pressure with a slight shear movement. The wall attachment may then be removed by peeling. Another exemplary coextruded polymeric adhesive article has two levels of adhesion, which can be applied to a substrate at a low adhesion level, repositioned as desired, and then subsequently rendered highly adhesive by applying gentle hand pressure with slight shear movement. Another exemplary coextruded polymeric adhesive article has three levels of adhesion and double-sided adhesion. Such a coextruded polymer article may be characterized as any of those described above, and then may exhibit adhesion to another substrate or article on the still-exposed surface (the surface opposite the surface that has been adhered to the substrate). For example, the co-extruded polymeric article can be positioned against a wall and freely repositioned without tack or with minimal tack. Gentle hand pressure may be applied with slight shear movement to provide a high level of adhesion. Other objects, such as posters, flyers, and other decorative materials, may then be attached to the wall using a third level of adhesion (which may be the same or different than either of the first two levels of adhesion) present on the side of the coextruded polymeric adhesive article opposite the side adhered to the wall, which attachment may be permanent or removable, disposable, or repeated.

In embodiments of the coextruded polymer articles described herein, it is also within the scope of the present disclosure that properties other than adhesion can be triggered to exhibit delamination behavior. For example, various chemistries may also be utilized to provide the channel web or tape. Exemplary co-extruded polymeric articles may have hydrophobic protrusions and hydrophilic protrusions. For example, water gently encountering such a coextruded polymer article from the side having the projections will form beads on the coextruded polymer article unless the water is approached at a determined level of force or pressure, whereby the water will penetrate deep enough between the projections to encounter the hydrophilic projections and will form wicking channels downward due to hydrostatic forces while still not penetrating through the layer to any measurable extent.

Exemplary embodiments

A coextruded polymeric article comprising first and second opposing major surfaces, wherein a plurality of protrusions extend only from the first major surface (i.e., the second major surface is free of any protrusions), wherein each protrusion has at least first and second opposing sides and a height from the first major surface to the distal end, wherein at least a majority by number (i.e., at least 50% by number; in some embodiments, at least 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or even 100%) of the protrusions have protrusions that extend only from the first side and in one direction to no more than the first major surface and in an opposite direction to less than the height of the respective protrusion (i.e., less than the distal end of the respective protrusion), wherein the protrusions extend to the second major surface, wherein there is a region extending from the first major surface and the second major surface and located between the protrusions, wherein the region comprises a first material, the protrusions comprise a second material, and the protrusions comprise a third material, wherein the second material and the third material are different, and wherein at least one of the second material or the third material comprises an adhesive.

The co-extruded polymeric article of exemplary embodiment 1A, having a (machine direction) length of at least 5mm (in some embodiments, at least 10mm, 25mm, 50mm, 1cm, 5cm, 10cm, 50cm, 75cm, 1m, 5m, 10m, 25m, 50m, 100m, 500m, or even at least 1000 m).

The co-extruded polymeric article of exemplary embodiment 2A, wherein the protrusions and projections extend along a length of the co-extruded polymeric article (i.e., have a respective length of at least 5mm (in some embodiments, at least 10mm, 25mm, 50mm, 1cm, 5cm, 10cm, 50cm, 75cm, 1m, 5m, 10m, 25m, 50m, 100m, 500m, or even at least 1000 m)).

The co-extruded polymeric article of any of the preceding exemplary embodiments of a, wherein there is a line of demarcation between the connected projections and adjacent projections.

The co-extruded polymeric article of any of the foregoing exemplary embodiments of a, wherein there is a line of demarcation between the connected projections and adjacent projections, the connected regions and projections.

The coextruded polymeric article of any of the previous exemplary embodiments of a, wherein the protrusions are substantially parallel to each other and substantially perpendicular to the first major surface.

The coextruded polymer article of any preceding a exemplary embodiment, wherein the protrusions have a height to thickness ratio (i.e., height to thickness) of at least 2:1 (in some embodiments, at least 3:1, or even at least 4: 1).

The coextruded polymer article of any preceding exemplary embodiment of a, wherein the protrusions are spaced apart by no more than 2mm (in some embodiments, no more than 1 mm).

The co-extruded polymeric article of any previous exemplary embodiment of a, wherein the protrusions have a height and a thickness, and the thickness is along a length of each respective protrusion.

The coextruded polymer article of any of the preceding exemplary embodiments a, wherein the first material and the second material are the same.

The co-extruded polymeric article of any of exemplary embodiments 1A-9A, wherein the first material and the second material are different.

12a. the coextruded polymer article of any preceding exemplary embodiment of a, wherein the first material and the third material are the same.

The co-extruded polymeric article of any one of exemplary embodiments 1A-11A, wherein the first material and the third material are different.

14a. the coextruded polymer article of any preceding exemplary embodiment of a, wherein the first material comprises a first binder.

The coextruded polymeric article of exemplary embodiment 14A, wherein the first adhesive is at least one of an acrylate copolymer pressure sensitive adhesive, a rubber-based adhesive (e.g., those based on at least one of natural rubber, polyisobutylene, polybutadiene, butyl rubber, or styrene block copolymer rubber), a silicone polyurea-based adhesive, a silicone polyoxamide-based adhesive, a polyurethane-based adhesive, or a poly (alkenyl ether) adhesive.

The coextruded polymer article of any preceding a exemplary embodiment, wherein the second material comprises a second binder.

The coextruded polymeric article of exemplary embodiment 16A, wherein the second adhesive is at least one of an acrylate copolymer pressure sensitive adhesive, a rubber-based adhesive (e.g., those based on at least one of natural rubber, polyisobutylene, polybutadiene, butyl rubber, or styrene block copolymer rubber), a silicone polyurea-based adhesive, a silicone polyoxamide-based adhesive, a polyurethane-based adhesive, or a poly (alkenyl ether) adhesive.

18a. the coextruded polymer article of any preceding exemplary embodiment of a, wherein the third material comprises a third binder.

The co-extruded polymeric article of any of the preceding exemplary embodiments a, wherein the protrusions do not contact the first surface.

The coextruded polymer article of any preceding a exemplary embodiment, wherein the height of the protrusions is in the range of 0.1mm to 5mm (in some embodiments, in the range of 0.1mm to 2mm or even 0.1mm to 1 mm).

21a. the coextruded polymer article of any preceding a exemplary embodiment, wherein the longest cross-sectional dimension of the projections is in the range of 0.05mm to 0.5mm (in some embodiments, in the range of 0.05mm to 0.2mm or even 0.05mm to 0.1 mm).

22a. the coextruded polymer article of any preceding a exemplary embodiment, wherein the distance of the regions between the protrusions is in the range of 0.25mm to 5mm (in some embodiments, in the range of 0.25mm to 2mm or even 0.25mm to 1 mm).

23a. the coextruded polymeric article of any preceding a exemplary embodiment having a distance between the first and second major surfaces in the range of 0.05mm to 5mm (in some embodiments, in the range of 0.05mm to 3mm, 0.05mm to 2mm, or even 0.1mm to 1 mm).

The coextruded polymer article of any of the preceding a exemplary embodiments, wherein the protrusions extend from no more than the first major surface to less than the height of the protrusions (in some embodiments, in the range of 1% of the length of the protrusions to 75% of the length of the protrusions, 1% of the length of the protrusions to 50% of the length of the protrusions, or even 10% of the length of the protrusions to 50% of the length of the protrusions).

The co-extruded polymeric article of any of the foregoing a exemplary embodiments, wherein the protrusions have a surface that contacts the protrusions associated with the protrusions, wherein the surface is planar.

The co-extruded polymeric article of any of exemplary embodiments 1A-24A, wherein the protrusions have a surface that contacts the protrusions associated with the protrusions, wherein the surface exhibits at least one depression.

The co-extruded polymeric article of any of exemplary embodiments 1A-24A, wherein the protrusions have a surface that contacts the protrusions associated with the protrusions, wherein the surface exhibits at least one protrusion.

28a. the coextruded polymer article of any preceding exemplary embodiment of a, wherein there are at least 5 protrusions per centimeter (in some embodiments, at least 10, 15, 20, 25, 30, 35, or even up to 40).

A method of making a coextruded polymer article according to any preceding exemplary embodiment of a, comprising:

providing an extrusion die comprising a plurality of shims positioned adjacent to one another, the shims together defining a first cavity, a second cavity, a third cavity, and a die slot, wherein the die slot has a distal opening, wherein the die slot is comprised of a first plurality of apertures, a second plurality of apertures, and a third plurality of apertures, wherein the plurality of shims comprises: a first plurality of repeating sequences of shims that together provide a fluid channel between the second cavity and the second orifice; a second plurality of repeating sequences of shims that together provide a fluid passage between the first cavity and the first aperture and that also together provide a fluid passage between the third cavity and the third aperture; and a third plurality of shims that together provide a fluid passage between the first cavity and the first orifice;

providing a first material to the first cavity of the extrusion die via extrusion, a second material to the second cavity of the extrusion die, and a third material to the third cavity of the extrusion die, wherein the second material and the third material are different, and wherein at least one of the second material and the third material comprises a binder;

extruding a layer from the distal opening of the die slot; and

quenching the extruded layer.

A method of making a coextruded polymer article according to any preceding exemplary embodiment of a, comprising:

providing an extrusion die comprising a plurality of shims positioned adjacent to one another, the shims together defining a first cavity, a second cavity, a third cavity, and a die slot, wherein the die slot has a distal opening, wherein the die slot is comprised of a first plurality of apertures, a second plurality of apertures, and a third plurality of apertures, wherein the plurality of shims comprises: a first plurality of repeating sequences of shims that together provide a fluid channel between the second cavity and a second orifice; a second plurality of repeating sequences of shims providing fluid passageways between the third cavity and third orifice; and a third plurality of shims that together provide a fluid passage between the first cavity and the first orifice;

providing a first material to the first cavity of the extrusion die via extrusion, a second material to the second cavity of the extrusion die, and a third material to the third cavity of the extrusion die, wherein the second material and the third material are different, and wherein at least one of the second material and the third material comprises a binder;

extruding a layer from the distal opening of the die slot; and

quenching the extruded layer.

1D. a coextruded polymeric article comprising first and second opposing major surfaces, wherein a plurality of protrusions extend only from the first major surface (i.e., the second major surface is free of any protrusions), wherein each protrusion has at least first and second opposing sides and a height from the first major surface to the distal end, wherein at least a majority by number (i.e., at least 50% by number; in some embodiments, at least 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or even 100%) of the protrusions have protrusions that extend only from the first side and in one direction do not extend beyond the first major surface and in the opposite direction extend less than the height of the respective protrusion (i.e., less than the distal end of the respective protrusion), wherein the protrusions extend to the second major surface, wherein there is a region extending between the first major surface and the second major surface and located between the protrusions, wherein the region comprises a first material, the protrusions comprise a second material, and the protrusions comprise a third material, wherein at least two of the first material, the second material, or the third material are different, and wherein the first material, the second material, and the third material each comprise an adhesive.

The co-extruded polymeric article of exemplary embodiment 1D, having a (machine direction) length of at least 5mm (in some embodiments, at least 10mm, 25mm, 50mm, 1cm, 5cm, 10cm, 50cm, 75cm, 1m, 5m, 10m, 25m, 50m, 100m, 500m, or even at least 1000 m).

3d. the coextruded polymer article of exemplary embodiment 2D, wherein the projections and protrusions extend along a length of the coextruded polymer article (i.e., have a respective length of at least 5mm (in some embodiments, at least 10mm, 25mm, 50mm, 1cm, 5cm, 10cm, 50cm, 75cm, 1m, 5m, 10m, 25m, 50m, 100m, 500m, or even at least 1000 m)).

The co-extruded polymeric article of any of the preceding D exemplary embodiments, wherein there is a demarcation line between the connected projections and the adjacent projections.

The co-extruded polymeric article of any of the preceding D exemplary embodiments, wherein there is a line of demarcation between the connected projections and adjacent projections, the connected regions and projections.

The coextruded polymer article of any preceding D exemplary embodiment, wherein the first material and the second material are the same.

The coextruded polymer article of any preceding D exemplary embodiment, wherein the first material and the third material are the same.

The coextruded polymeric article of any preceding D exemplary embodiment, wherein the first adhesive is at least one of an acrylate copolymer pressure sensitive adhesive, a rubber-based adhesive (e.g., those based on at least one of natural rubber, polyisobutylene, polybutadiene, butyl rubber, or styrene block copolymer rubber), a silicone polyurea-based adhesive, a silicone polyoxamide-based adhesive, a polyurethane-based adhesive, or a poly (alkenyl ether) adhesive.

The coextruded polymeric article of any preceding D exemplary embodiment, wherein the second adhesive is at least one of an acrylate copolymer pressure sensitive adhesive, a rubber-based adhesive (e.g., those based on at least one of natural rubber, polyisobutylene, polybutadiene, butyl rubber, or styrene block copolymer rubber), a silicone polyurea-based adhesive, a silicone polyoxamide-based adhesive, a polyurethane-based adhesive, or a poly (alkenyl ether) adhesive.

The coextruded polymeric article of any preceding D exemplary embodiment, wherein the third adhesive is at least one of an acrylate copolymer pressure sensitive adhesive, a rubber-based adhesive (e.g., those based on at least one of natural rubber, polyisobutylene, polybutadiene, butyl rubber, or styrene block copolymer rubber), a silicone polyurea-based adhesive, a silicone polyoxamide-based adhesive, a polyurethane-based adhesive, or a poly (alkenyl ether) adhesive.

The co-extruded polymeric article of any of the preceding D exemplary embodiments, wherein the protrusions do not contact the first surface.

The coextruded polymer article of any preceding D exemplary embodiment, wherein the height of the protrusions is in the range of 0.1mm to 5mm (in some embodiments, in the range of 0.1mm to 2mm or even 0.1mm to 1 mm).

The coextruded polymer article of any preceding D exemplary embodiment, wherein the longest cross-sectional dimension of the projections is in the range of 0.05mm to 0.5mm (in some embodiments, in the range of 0.05mm to 0.2mm or even 0.05mm to 0.1 mm).

14d. the coextruded polymer article of any preceding D exemplary embodiment wherein the distance of the regions between the protrusions is in the range of 0.25mm to 5mm (in some embodiments, in the range of 0.25mm to 2mm or even 0.25mm to 1 mm).

15d. the coextruded polymer article of any preceding D exemplary embodiment having a distance between the first and second major surfaces in the range of 0.05mm to 5mm (in some embodiments, in the range of 0.05mm to 3mm, 0.05mm to 2mm, or even 0.1mm to 1 mm).

The coextruded polymer article of any of the preceding D exemplary embodiments, wherein the protrusions extend from no more than the first major surface to less than the height of the protrusions (in some embodiments, in the range of 1% of the length of the protrusions to 75% of the length of the protrusions, 1% of the length of the protrusions to 50% of the length of the protrusions, or even 10% of the length of the protrusions to 50% of the length of the protrusions).

The co-extruded polymeric article of any of the preceding D exemplary embodiments, wherein the protrusions have a surface that contacts the protrusions associated with the protrusions, wherein the surface is planar.

18d. the coextruded polymer article of any of exemplary embodiments 1D to 16D, wherein the protrusions have a surface that contacts the protrusions associated with the protrusions, wherein the surface exhibits at least one depression.

The co-extruded polymeric article of any of exemplary embodiments 1D-16D, wherein the protrusions have a surface that contacts the protrusions associated with the protrusions, wherein the surface exhibits at least one protrusion.

The co-extruded polymeric article of any of the preceding D exemplary embodiments, wherein there are at least 5 protrusions per centimeter (in some embodiments, at least 10, 15, 20, 25, 30, 35, or even up to 40).

A method of making a coextruded polymer article according to any preceding D exemplary embodiment, comprising:

providing an extrusion die comprising a plurality of shims positioned adjacent to one another, the shims together defining a first cavity, a second cavity, a third cavity, and a die slot, wherein the die slot has a distal opening, wherein the die slot is comprised of a first plurality of apertures, a second plurality of apertures, and a third plurality of apertures, wherein the plurality of shims comprises: a first plurality of repeating sequences of shims that together provide a fluid channel between the second cavity and the second orifice; a second plurality of repeating sequences of shims that together provide a fluid passage between the first cavity and the first aperture and that also together provide a fluid passage between the third cavity and the third aperture; and a third plurality of shims that together provide a fluid passage between the first cavity and the first orifice;

providing a first material to the first cavity of the extrusion die via extrusion, providing a second material to the second cavity of the extrusion die, and providing a third material to the third cavity of the extrusion die, wherein at least two of the first, second, and third materials are different, and wherein each of the first, second, and third materials comprises an adhesive;

extruding a layer from the distal opening of the die slot; and

quenching the extruded layer.

A method of making a coextruded polymer article according to any preceding D exemplary embodiment, comprising:

providing an extrusion die comprising a plurality of shims positioned adjacent to one another, the shims together defining a first cavity, a second cavity, a third cavity, and a die slot, wherein the die slot has a distal opening, wherein the die slot is comprised of a first plurality of apertures, a second plurality of apertures, and a third plurality of apertures, wherein the plurality of shims comprises: a first plurality of repeating sequences of shims that together provide a fluid channel between the second cavity and a second orifice; a second plurality of repeating sequences of shims providing fluid passageways between the third cavity and third orifice; and a third plurality of shims that together provide a fluid passage between the first cavity and the first orifice;

providing a first material to the first cavity of the extrusion die via extrusion, providing a second material to the second cavity of the extrusion die, and providing a third material to the third cavity of the extrusion die, wherein at least two of the first, second, and third materials are different, and wherein each of the first, second, and third materials comprises an adhesive;

extruding a layer from the distal opening of the die slot; and

quenching the extruded layer.

Advantages and embodiments of this invention are further illustrated by the following examples, but the particular materials and amounts thereof recited in these examples, as well as other conditions and details, should not be construed to unduly limit this invention. All parts and percentages are by weight unless otherwise indicated.