Patent Description:
<CIT> describes a polymeric netting useful as a filtration medium wherein the polymeric netting includes at least two different types of generally continuous elements, one of which is ribbon like and oriented on its edge within the netting and wherein the ribbon-like element can be at least partially held in place by a second element that typically has a smaller height. It is disclosed that the polymeric netting can be made in a continuous, one-step extrusion process.

Coextruded polymeric articles (including layers) having projections are known in the art. For example, it is known to provide a co-extruded, layer structures where the layer is partitioned, not as coextensive layers in the thickness direction, but as stripes or strands along the width dimension of the layer. This has sometimes been called "side-by-side" co-extrusion.

<CIT> describes a method for the manufacture of pressure sensitive adhesive tape comprising the steps of: a) providing first and second molten streams of pressure-sensitive adhesive composition; b) providing a molten stream of a backing-forming material; c) combining said streams into a single unified, molten structure having, in order, a first layer of pressure-sensitive adhesive composition, a layer of backing-forming material, and a second layer of pressure-sensitive adhesive composition, wherein at least one of said backing and said layers of adhesive is not coextensive; d) cooling said molten structure. It is disclosed that at least one of said adhesive layers may be discontinuous.

There is a need for films with projections where the projections are different than the film layer. These projections can provide second and third type performance as compared to the base film layer.

There is a desire for additional polymeric articles with projections that offer different configurations and/or properties (e.g., adhesive properties) over conventional articles. Some adhesive systems that switch from a state of relatively low or no adhesion to a state of much higher adhesion upon application of a certain trigger (commonly called "adhesion on demand" systems) are known. Many of these systems use triggers such as solvents, ultra violet light, heat, or magnetic forces, to create tiered adhesive performance once or repetitively. These systems are limited in applications for several reasons. For many of these triggers, the adhesive system must contain specific chemical groups, which restricts usage to applications where those chemical groups can be tolerated. These systems can be used only where a particular trigger is available and can be effectively applied to the adhesive system. Further, some triggers are difficult or inconvenient for consumers to use. Certain triggers, as well as the chemical groups in the adhesive that respond to such triggers, can be cost-prohibitive.

There is a continuing desire for new coextruded polymeric article constructions. Further, there is a need for "adhesion on demand" systems where the trigger is applicable to all adhesive chemistries, the trigger is more broadly or even universally available, the trigger is easy to apply, not only industrially, but by a consumer, and the adhesion-on-demand system is not exceedingly expensive.

In one aspect, the present disclosure describes a first continuous coextruded polymeric article comprising a layer comprising first and second opposed major surfaces, wherein a plurality of attached projection pairs comprising first and second projections extend from only the first major surface (i.e., the second major surface is free of any projections), wherein each first projection has at least first and second opposed sides and a height from the first major surface to a distal end, wherein each second projection has at least first and second opposed sides and a height from the first major surface to a distal end, wherein the second side of the first projection is in continuous contact with the first side of the second projection, wherein the height of the first projections is not greater than <NUM> (in some embodiments, not greater than <NUM>, or even not greater than <NUM>), and wherein there are at least <NUM> (in some embodiments, at least <NUM>, <NUM>, <NUM>, or even at least <NUM>) projection pairs per centimeter. The projections extend along the length of the coextruded polymeric article. Preferably the continuous coextruded polymeric article has a length of at least <NUM> millimeters.

In another aspect, the present disclosure describes a method for making the first continuous coextruded polymeric article described herein, the method comprising:.

In another aspect, the present disclosure describes a second continuous coextruded polymeric article comprising a layer comprising first and second opposed major surfaces, wherein a plurality of attached projection pairs comprising first and second projections extend from only the first major surface (i.e., the second major surface is free of any projections), wherein each first projection has at least first and second opposed sides and a height from the first major surface to a distal end, wherein each second projection has at least first and second opposed sides and a height from the first major surface to a distal end, wherein the second side of the first projection is in continuous contact with the first side of the second projection, wherein a majority by number (i.e., at least <NUM> percent by number; in some embodiments, at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or even <NUM> percent) of the projection pairs, the height of the second projection is greater than the height of the attached first projection, wherein at least one of the first or second projections comprise adhesive. The projections extend along the length of the coextruded polymeric article. Preferably the continuous coextruded polymeric article has a length of at least <NUM> millimeters.

In another aspect, the present disclosure describes a method for making the second continuous coextruded polymeric article described herein, the method comprising:.

In another aspect, the present disclosure describes a third continuous coextruded polymeric article comprising a layer comprising first and second opposed major surfaces, wherein a plurality of attached projection pairs comprising first and second projections extend from only the first major surface (i.e., the second major surface is free of any projections), wherein each first projection has at least first and second opposed sides and a height from the first major surface to a distal end, wherein each second projection has at least first and second opposed sides and a height from the first major surface to a distal end, wherein the second side of the first projection is in continuous contact with the first side of the second projection, and wherein there is a demarcation line between the attached projections. The projections extend along the length of the coextruded polymeric article. Preferably the continuous coextruded polymeric article has a length of at least <NUM> millimeters.

In another aspect, the present disclosure describes a method for making the third continuous coextruded polymeric article described herein, the method comprising:.

Embodiments of coextruded polymeric articles described herein can include adhesive articles, household cleaning products (e.g., a mop, a duster, a brush, a cleaning cloth, or a lint roller), and wall attachments.

Embodiments of coextruded polymeric articles described herein can provide a tiered performance, such that for some property of merit (e.g., an adhesive level), the coextruded polymeric article exhibits one level of or value for that property in a base condition or state of use, and at least one different level of or value for that property when in at least one triggered condition or state of use.

Referring to <FIG>, exemplary continuous coextruded polymeric article <NUM> comprises layer <NUM> comprising first and second opposed major surfaces <NUM>, <NUM>. Plurality of attached projection pairs <NUM> comprise first and second projections <NUM>, <NUM> extend from only first major surface <NUM>. Each first projection <NUM> has at least first and second opposed sides <NUM>, <NUM> and height, h<NUM>, from first major surface <NUM> to distal end <NUM>. Height, h<NUM>, of first projections <NUM> is not greater than <NUM>. There are at least <NUM> projection pairs per centimeter. Distance, d<NUM>, measured from the respective midpoints of two projections, is used to express the number of projections in a given distance. Distance, d<NUM>, which is measured from the closest sides of two projections, is used to express the distance between projections.

In some embodiments of the first continuous coextruded polymeric article, the first projections comprise first material, the second projections comprise second material, and the layer comprises a third material. In some embodiments of the first coextruded polymeric article, at least one of the first, second, or third materials comprise adhesive. In some embodiments of the first coextruded polymeric article, at least one of the first, second, or third materials independently comprise at least one of a thermoplastic resin (e.g., at least one of, including copolymers and blends thereof, a polyolefin (e.g., polypropylene and polyethylene), polyvinyl chloride, a polystyrene, nylon, a polyester (e.g., polyethylene terephthalate) or an elastomer (e.g., an ABA block copolymer, a polyurethane, a polyolefin elastomer, a polyurethane elastomer, a metallocene polyolefin elastomer, a polyamide elastomer, an ethylene vinyl acetate elastomer, and a polyester elastomer)). In some embodiments, at least one of the first, second, or third materials of the first continuous coextruded polymeric article described herein independently comprise an adhesive. In some embodiments, at least one of the first, second, or third adhesives of the first continuous coextruded polymeric article described herein are independently at least one of, including copolymers and blends thereof, 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(vinyl ethyl ether)-based adhesive.

In some embodiments of the first coextruded polymeric article, the first and second materials are the same. In some embodiments of the first coextruded polymeric article, the first and second materials are different. In some embodiments of the first coextruded polymeric article, the first and third materials are the same. In some embodiments of the first coextruded polymeric article, the first and third materials are the different. In some embodiments of the first coextruded polymeric article, the second and third materials are the same. In some embodiments of the first coextruded polymeric article, the second and third materials are the different. "Different" as used herein means at least one of (a) a difference of at least <NUM>% in at least one infrared peak, (b) a difference of at least <NUM>% in at least one nuclear magnetic resonance peak, (c) a difference of at least <NUM>% in the number average molecular weight, or (d) a difference of at least <NUM>% in polydispersity. Examples of differences in polymeric materials that can provide the difference between polymeric materials include composition, microstructure, color, and refractive index. The term "same" in terms of polymeric materials means not different.

Referring to <FIG>, exemplary continuous coextruded polymeric article <NUM> comprising layer <NUM> comprising first and second opposed major surfaces <NUM>, <NUM>. Plurality of attached projection pairs <NUM> comprise first and second projections <NUM>, <NUM> extend from only first major surface <NUM>. Each first projection <NUM> has at least first and second opposed sides <NUM>, <NUM> and height, h<NUM>, h<NUM>, from first major surface <NUM> to distal end <NUM>. Majority by number of projection pairs <NUM>. Height, h<NUM>, of second projection <NUM> is greater than height, h<NUM>, of attached first projection <NUM>. At least one of first or second projections <NUM>, <NUM> comprise first or second materials, respectively, at least one of which is adhesive. Distance, d<NUM>, measured from the respective midpoints of two projections, is used to express the number of projections in a given distance. Distance, d<NUM>, which is measured from the closest sides of two projections, is used to express the distance between projections.

In some embodiments of the second continuous coextruded polymeric article, the layer comprises at least one of a thermoplastic resin (e.g., at least one of, including copolymers and blends thereof, a polyolefin (e.g., polypropylene and polyethylene), polyvinyl chloride, a polystyrene, nylon, a polyester (e.g., polyethylene terephthalate) or an elastomer (e.g., an ABA block copolymer, a polyurethane, a polyolefin elastomer, a polyurethane elastomer, a metallocene polyolefin elastomer, a polyamide elastomer, an ethylene vinyl acetate elastomer, and a polyester elastomer)). The layer of the second coextruded polymeric article comprises a third material, wherein in some embodiments, the third materials comprises a third adhesive. In some embodiments, at least one of the first, second, or third adhesives of the first coextruded polymeric article described herein are independently at least one of, including copolymers and blends thereof, 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(vinyl ethyl ether)-based adhesive.

In some embodiments of the second coextruded polymeric article, the first and second materials are the same. In some embodiments of the second coextruded polymeric article, the first and second materials are different. In some embodiments of the second coextruded polymeric article, the first and third materials are the same. In some embodiments of the second coextruded polymeric article, the first and third materials are the different. In some embodiments of the second coextruded polymeric article, the second and third materials are the same. In some embodiments of the second coextruded polymeric article, the second and third materials are the different.

Referring to <FIG>, exemplary continuous coextruded polymeric article <NUM> comprises layer <NUM> comprises first and second opposed major surfaces <NUM>, <NUM>. Plurality of attached projection pairs <NUM> comprises first and second projections <NUM>, <NUM> extend from only first major surface <NUM>. Each first projection <NUM> has at least first and second opposed sides <NUM>, <NUM> and height, h<NUM>, from first major surface <NUM> to distal end <NUM>. There is demarcation line <NUM> between attached projections <NUM>, <NUM>. Distance, ds, measured from the respective midpoints of two projections, is used to express the number of projections in a given distance. Distance, d<NUM>, which is measured from the closest sides of two projections, is used to express the distance between projections.

In some embodiments of the third continuous coextruded polymeric article, the first projections comprise first material, and the second projections comprise second material, and the layer comprises the third material. In some embodiments of the third coextruded polymeric article, at least one of the first, second, or third materials comprise adhesive. In some embodiments of the third coextruded polymeric article, at least one of the first, second, or third materials independently comprise at least one of a thermoplastic resin (e.g., at least one of, including copolymers and blends thereof, a polyolefin (e.g., polypropylene and polyethylene), polyvinyl chloride, a polystyrene, nylon, a polyester (e.g., polyethylene terephthalate) or an elastomer (e.g., an ABA block copolymer, a polyurethane, a polyolefin elastomer, a polyurethane elastomer, a metallocene polyolefin elastomer, a polyamide elastomer, an ethylene vinyl acetate elastomer, and a polyester elastomer)). In some embodiments, at least one of the first, second, or third materials of the first coextruded polymeric article described herein independently comprise an adhesive. In some embodiments, at least one of the first, second, or third adhesives of the first coextruded polymeric article described herein are independently at least one of, including copolymers and blends thereof, 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(vinyl ethyl ether)-based adhesive.

In some embodiments of the third coextruded polymeric article, the first and second materials are the same. In some embodiments of the third coextruded polymeric article, the first and second materials are different. In some embodiments of the third coextruded polymeric article, the first and third materials are the same. In some embodiments of the third coextruded polymeric article, the first and third materials are the different. In some embodiments of the third coextruded polymeric article, the second and third materials are the same. In some embodiments of the third coextruded polymeric article, the second and third materials are the different.

In some embodiments, the first, second, and third continuous coextruded polymeric articles described herein have a (machine direction) length of at least <NUM> (in some embodiments, at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or even at least <NUM>). The projections extend along the length of the coextruded polymeric article (i.e., have respective lengths of at least <NUM> (in some embodiments, at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or even at least <NUM>)).

In some embodiments of the first and second continuous coextruded polymeric articles and in the third continuous coextruded polymeric articles, connected projections have a demarcation line therebetween. This construction can be formed by methods described herein where materials are coextruded in a manner that results in a distinct line of orientation visible at the polymer boundary between connected projections. This demarcation line or boundary region between connected projections can be detected using Differential Scanning Calorimetry. Comparing by temperature modulated differential scanning calorimetry a region containing mostly a demarcation line (Region <NUM>) versus a region that does not substantially contain material from the demarcation line (Region <NUM>) a difference in heat flow/heat capacity is observed that is believed to be consistent with an energy release or reduction in molecular orientation/internal stress. That is, although not wanting to be bound by theory, it is believed that the thermal signatures of the regions may be a combination of material thermal transitions and the material response to retained thermal/processing history. In some embodiments, there is a demarcation line between the layer and at least the first of second projections.

Coextruded polymeric articles described herein (including those shown in <FIG> and <FIG>), each of the layer, respective first projections, and respective second projections may be considered monolithic (i.e., having a generally uniform composition) and are not fibrous. The projection material does not pass into the layer, but, is rather bonded to one side of the layer, and thus, the layer is a continuous formation of a single material. This is accomplished by formation of weld lines, called demarcation lines at the die region where the dispensing orifices merge together at the distal opening. Further, the projections are not nonwoven materials, nor are they coated or added via as a secondary step. In some embodiments described below, however, portions of the articles may be apertured. Typically, the projections are co-extruded and melt bonded together to form coextruded, continuous, polymeric articles with projections formed together as a pair. Referring again to <FIG>, coextruded polymeric article <NUM> can be prepared, for example, by extrusion from a die having a variety of passageways from cavities within the die to a dispensing slot, including exemplary dies described herein (see, e.g., <FIG>). The die may conveniently be comprised of a plurality of shims. In some embodiments a first plurality of a repeating sequence of shims that together provide a fluid passageway between the third cavity and a third orifice, a second plurality of a repeating sequence of shims that together provide a fluid passageway between the first cavity and a first orifice and also together provide a fluid passageway between the third cavity and a third orifice, and a third plurality of shims that together provide a fluid passageway between the second cavity and a second orifice and also together provide a fluid passageway between the third cavity and a third orifice.

In some embodiments, the shims will be assembled according to a plan that provides a sequence of shims of diverse types. Since different applications may have different requirements, the sequences can have diverse numbers of shims. The sequence may be a repeating sequence that is not limited to a particular number of repeats in a particular zone. Or the sequence may not regularly repeat, but different sequences of shims may be used. The shape of the passageways within, for example, a sequence of shims, may be identical or different. Examples of passageway cross-sectional shapes include round, square, and rectangular shapes. In some embodiments, the shims that provide a passageway between one cavity and the dispensing slot might have a flow restriction compared to the shims that provide a passageway between another cavity and the dispensing slot. The width of the distal opening within, for example, a different sequence of shims, may be identical or different. For example, the portion of the distal opening provided by the shims that provide a passageway between one cavity and the dispensing slot could be narrower than the portion of the distal opening provided by the shims that provide a passageway between another cavity and the dispensing slot. In general, the distal opening to create the projections is much longer than the distal opening to create the layer.

Individual cavities and passageways provide a conduit for polymer to orifices to create the layer and protrusions. These individual flow streams merge together to form a continuous, solid coextruded polymeric article, at the die slot portion of the die. Spacer shims provide connecting slots to form demarcation lines connecting the layer and projections.

In some embodiments, extrusion dies described herein include a pair of end blocks for supporting the plurality of shims. In these embodiments, it may be convenient for one, or even all, of the shims to each have at least one through-holes for the passage of connectors between the pair of end blocks. Bolts disposed within such through-holes are one convenient approach for assembling the shims to the end blocks, although the ordinary artisan may perceive other alternatives for assembling the extrusion die. In some embodiments, the at least one end block has an inlet port for introduction of fluid material into one, or both, of the cavities.

In some embodiments, the shims will be assembled according to a plan that provides a repeating sequence of shims of diverse types. The repeating sequence can have diverse numbers of shims per repeat. For a first example, repeating sequence of five shim patterns is described below to create the orifice pattern shown in <FIG> to create the coextruded polymeric article shown in <FIG>. When that five-shim repeating sequence is properly provided with molten polymer, it extrudes a continuous film through the die slot to create the coextruded polymeric article with the layer and projections.

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

Typically, the passageway between cavity and dispensing orifice is up to <NUM> in length. Sometimes the fluid passageways leading to one array has greater fluid restriction than the fluid passageways leading to one or more of the other arrays.

The shims for dies described herein typically have thicknesses in the range from <NUM> micrometers to <NUM> micrometers, although thicknesses outside of this range may also be useful. Typically, the fluid passageways have thicknesses in a range from <NUM> micrometers to <NUM> micrometers, and lengths less than <NUM> (with generally a preference for smaller lengths for decreasingly smaller passageway thicknesses), although thicknesses and lengths outside of these ranges may also be useful. For large diameter fluid passageways, several smaller thickness shims may be stacked together, or single shims of the desired passageway width may be used.

The shims are tightly compressed to prevent gaps between the shims and polymer leakage. For example, <NUM> (<NUM> inch) diameter bolts are typically used and tightened, at the extrusion temperature, to their recommended torque rating. Also, the shims are aligned to provide uniform extrusion out the extrusion orifice, as misalignment can lead to strands extruding at an angle out of the die which inhibits desired bonding of the net. To aid in alignment, an alignment key can be cut into the shims. Also, a vibrating table can be useful to provide a smooth surface alignment of the extrusion tip.

In practicing methods described herein, the polymeric materials might be solidified simply by cooling. This can be conveniently accomplished passively by ambient air, or actively, for example, by quenching the extruded polymeric materials on a chilled surface (e.g., a chilled roll). In some embodiments, the first and/or second and/or third polymeric materials are low molecular weight polymers that need to be cross-linked to be solidified, which can be done, for example, by electromagnetic or particle radiation. In some embodiments, it is desirable to maximize the quenching time to increase the bond strength.

<FIG> is a schematic cross-sectional view of an exemplary die orifice pattern just upstream from the dispensing slot of the die employed in the formation of an exemplary coextruded polymeric article described herein. Orifice plan <NUM> shows first orifices <NUM>, second orifices <NUM>, and third orifices <NUM>. As will be described in detail later, the orifices are spaced apart to provide passageway sidewalls between passageways. The individual flowstreams are merged together, with demarcation lines to form a continuous coextruded polymeric article in the final slot orifice of the die, not shown. The demarcation lines are created at orifices separated by a minimal amount, by spacer shims. These shims typically have thicknesses in a range from <NUM> to <NUM> micrometers. The depth of the final slot is long enough, and the distance between the orifices are close, such that a continuous article, a created sum of all orifices, is formed within the final slot of the die.

Referring now to <FIG>, a plan view of shim <NUM> is illustrated. Shim <NUM> has first aperture 560a, second aperture 560b third aperture 560c, and fourth aperture 560d. When shim <NUM> is assembled with others as shown in <FIG> and <FIG>, aperture 560a aids in defining first cavity 562a, aperture 560b aids in defining second cavity 562b, aperture 560c aids in defining third cavity 562c, and aperture 560d aids in defining third cavity 562d. Passageways 568a, 568b, 568c, and 568d cooperate with analogous passageways on adjacent shims to allow passage from cavities 562a, 562b, 562c, and 562d to the dispensing surfaces of the appropriate shims when the shims are assembled as shown in <FIG> and <FIG>.

Shim <NUM> has several holes <NUM> to allow the passage of, for example, bolts, to hold shim <NUM> and others to be described below into an assembly. Shim <NUM> also has dispensing surface <NUM>, and in this embodiment, dispensing surface <NUM> has indexing groove <NUM> which can receive an appropriately shaped key to ease assembling diverse shims into a die. The shim may also have identification notch <NUM> to help verify that the die has been assembled in the desired manner. This embodiment has shoulders <NUM> and <NUM> which can assist in mounting the assembled die with a mount of the type shown in <FIG>. Shim <NUM> has dispensing opening <NUM>, but it will be noted that this shim has no connection between dispensing opening <NUM> and any of cavities 562a, 562b, 562c, or 562d. Shim <NUM> serves as a spacer shim and provides a sidewall for passageways of adjacent shims. Opening <NUM> provides a continuous dispensing slot for extrusion. This continuous slot enables polymer streams to merge together to form demarcation lines in the coextruded polymeric article between die orifices.

Referring to <FIG>, a plan view of shim <NUM> is illustrated. Shim <NUM> has first aperture 660a, second aperture 660b, third aperture 660c, and fourth aperture 660d. When shim <NUM> is assembled with others as shown in <FIG> and <FIG>, aperture 660a aids in defining first cavity 662a, aperture 660b aids in defining second cavity 662b, aperture 660c aids in defining third cavity 662c, and aperture 660d aids in defining third cavity 662d. Passageways 668a, 668b, 668c, and 668d cooperate with analogous passageways on adjacent shims to allow passage from cavities 662a, 662b, 662c, and 662d to the dispensing surfaces of the appropriate shims when the shims are assembled as shown in <FIG> and <FIG>.

Shim <NUM> has several holes <NUM> to allow the passage of, for example, bolts, to hold shim <NUM> and others to be described below into an assembly. Shim <NUM> also has dispensing surface <NUM>, and in this embodiment, dispensing surface <NUM> has indexing groove <NUM> which can receive an appropriately shaped key to ease assembling diverse shims into a die. The shim may also have identification notch <NUM> to help verify that the die has been assembled in the desired manner. This embodiment has shoulders <NUM> and <NUM> which can assist in mounting the assembled die with a mount of the type shown in <FIG>. Shim <NUM> has dispensing opening <NUM>, in dispensing surface <NUM>. Dispensing opening <NUM> may be more clearly seen in the expanded view shown in <FIG>. Dispensing opening <NUM> has connection to cavity 662d. It might seem that there is no path from cavity 662d to dispensing opening <NUM>, via, for example, passageway 668d, but the flow has a route in the perpendicular-to-the-plane-of-the-drawing dimension when the sequence of <FIG> is completely assembled.

Referring to <FIG>, a plan view of shim <NUM> is illustrated. Shim <NUM> has first aperture 760a, second aperture 760b, third aperture 760c, and fourth aperture 760d. When shim <NUM> is assembled with others as shown in <FIG> and <FIG>, aperture 760a aids in defining first cavity 762a, aperture 760b aids in defining second cavity 762b, aperture 760c aids in defining third cavity 762c, and aperture 760d aids in defining third cavity 762d. Passageways 768a, 768b, 768c, and 768d cooperate with analogous passageways on adjacent shims to allow passage from cavities 762a, 762b, 762c, and 762d to the dispensing surfaces of the appropriate shims when the shims are assembled as shown in <FIG> and <FIG>.

Shim <NUM> has several holes <NUM> to allow the passage of, for example, bolts, to hold shim <NUM> and others to be described below into an assembly. Shim <NUM> also has dispensing surface <NUM>, and in this embodiment, dispensing surface <NUM> has indexing groove <NUM> which can receive an appropriately shaped key to ease assembling diverse shims into a die. The shim may also have identification notch <NUM> to help verify that the die has been assembled in the desired manner. This embodiment has shoulders <NUM> and <NUM> which can assist in mounting the assembled die with a mount of the type shown in <FIG>. Shim <NUM> has dispensing opening <NUM>, with connection to cavities 762b, and 762d. Shim <NUM> creates a portion of the first layer with connection pathway 768d and also forms a projection with connection pathway 768b. These <NUM> streams merge together to form demarcation lines in the coextruded polymeric article between die orifices.

Referring to <FIG>, a plan view of shim <NUM> is illustrated. Shim <NUM> has first aperture 860a, second aperture 860b, third aperture 860c, and fourth aperture 860d. When shim <NUM> is assembled with others as shown in <FIG> and <FIG>, aperture 860a aids in defining first cavity 862a, aperture 860b aids in defining second cavity 862b, aperture 860c aids in defining third cavity 862c, and aperture 860d aids in defining third cavity 862d. Passageways 868a, 868b, 868c, and 868d cooperate with analogous passageways on adjacent shims to allow passage from cavities 862a, 862b, 862c, and 862d to the dispensing surfaces of the appropriate shims when the shims are assembled as shown in <FIG> and <FIG>.

Shim <NUM> has several holes <NUM> to allow the passage of, for example, bolts, to hold shim <NUM> and others to be described below into an assembly. Shim <NUM> also has dispensing surface <NUM>, and in this embodiment, dispensing surface <NUM> has indexing groove <NUM> which can receive an appropriately shaped key to ease assembling diverse shims into a die. The shim may also have identification notch <NUM> to help verify that the die has been assembled in the desired manner. This embodiment has shoulders <NUM> and <NUM> which can assist in mounting the assembled die with a mount of the type shown in <FIG>. Shim <NUM> has dispensing opening <NUM>, in dispensing surface <NUM>. There is a pathway connection between opening <NUM> and cavities 860a and 860d. Shim <NUM> creates a portion of the first layer with connection pathway 868d, and also forms a projection with connection pathway 868a. Dispensing opening <NUM> may be more clearly seen in the expanded view shown in <FIG>. It might seem that there is no path from cavity 862a and 862d to dispensing opening <NUM>, via, for example, passageway 868a and 868d, but the flow has a route in the perpendicular-to-the-plane-of-the-drawing dimension when the sequence of <FIG> is completely assembled.

Referring to <FIG>, a plan view of shim <NUM> is illustrated. Shim <NUM> has first aperture 960a, second aperture 960b, third aperture 960c, and fourth aperture 960d. When shim <NUM> is assembled with others as shown in <FIG> and <FIG>, aperture 960a aids in defining first cavity 962a, aperture 960b aids in defining second cavity 962b, aperture 960c aids in defining third cavity 962c, and aperture 960d aids in defining third cavity 962d. Passageways 968a, 968b, 968c, and 968d cooperate with analogous passageways on adjacent shims to allow passage from cavities 962a, 962b, 962c, and 962d to the dispensing surfaces of the appropriate shims when the shims are assembled as shown in <FIG> and <FIG>.

Shim <NUM> has several holes <NUM> to allow the passage of, for example, bolts, to hold shim <NUM> and others to be described below into an assembly. Shim <NUM> also has dispensing surface <NUM>, and in this embodiment, dispensing surface <NUM> has indexing groove <NUM> which can receive an appropriately shaped key to ease assembling diverse shims into a die. The shim may also have identification notch <NUM> to help verify that the die has been assembled in the desired manner. This embodiment has shoulders <NUM> and <NUM> which can assist in mounting the assembled die with a mount of the type shown in <FIG>. Shim <NUM> has dispensing opening <NUM>, in dispensing surface <NUM>. Dispensing opening <NUM> may be more clearly seen in the expanded view shown in <FIG>. Shim <NUM> serves as a spacer shim, there is not a connection between opening <NUM> and any of the cavities.

Referring to <FIG>, a perspective assembly drawing of a several different repeating sequences of shims, collectively <NUM>, employing the shims of <FIG> to produce coextruded polymeric article <NUM> shown in <FIG>, and coextruded polymeric article <NUM> shown in <FIG>, and coextruded polymeric article <NUM> shown in <FIG> is shown. It should be noted in <FIG> that the dispensing slot, formed by dispensing openings <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> collectively in the plurality of shims, is a continuous opening across the die. This continuous opening is fed from the three extrusion cavities and orifices as shown in <FIG>. There are no shims without dispensing openings, which may form breaks to cause the extruded polymeric compositions to form into separated strands.

Referring to <FIG>, an exploded perspective assembly drawing of a repeating sequence of shims employing the shims of <FIG> is illustrated. In the illustrated embodiment, the repeating sequence includes, from bottom to top as the drawing is oriented, one instance of shim <NUM>, two instances of shim <NUM> which forms the first orifice, one instance of shim <NUM>, two instances of shim <NUM>, one instance of shim <NUM>, two instances of shim <NUM>, one instance of shim <NUM>, and two instances of shim <NUM>. In this view, it can be appreciated how the three orifices are merged together at the extrusion slot to generate a continuous a coextruded polymeric article.

Referring to <FIG>, an exploded perspective view of a mount <NUM> suitable for an extrusion die composed of multiple repeats of the repeating sequence of shims of <FIG> and <FIG> is illustrated. Mount <NUM> is particularly adapted to use shims <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> as shown in <FIG>. For visual clarity, however, only a single instance of shims is shown in <FIG>. The multiple repeats of the repeating sequence of shims of <FIG> and <FIG> are compressed between two end blocks 2244a and 2244b. Conveniently, through bolts can be used to assemble the shims to end blocks 2244a and 2244b, passing through holes <NUM> in shims <NUM> et al.

In this embodiment, inlet fittings provide a flow path for three streams of molten polymer through end blocks 2244a and 2244b to cavities 562a, 562b, and 562d. Cavity 562c is not used. Compression blocks <NUM> have notch <NUM> that conveniently engages the shoulders on shims (e.g., <NUM> and <NUM>) on <NUM>. When mount <NUM> is completely assembled, compression blocks <NUM> are attached by, for example, machine bolts to backplates <NUM>. Holes are conveniently provided in the assembly for the insertion of cartridge heaters <NUM>.

Referring to <FIG>, a perspective view of the mount <NUM> of <FIG> is illustrated in a partially assembled state. A few shims, for example, <NUM> are in their assembled positions to show how they fit within mount <NUM>, but most of the shims that would make up an assembled die have been omitted for visual clarity.

In the first continuous coextruded polymeric articles and in some embodiments of the second and third continuous coextruded polymeric articles, there are at least <NUM> (in some embodiments, at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or even up to <NUM>) projections pairs per cm.

In some embodiments, the projections of a coextruded polymeric article described herein are generally parallel to each other and generally perpendicular to the first major surface.

In some embodiments, the projections of a coextruded polymeric article described herein have an aspect ratio (i.e., height to thickness) of at least <NUM>:<NUM> (in some embodiments, at least <NUM>:<NUM>, or even at least <NUM>:<NUM>).

In some embodiments of the second and third continuous coextruded polymeric articles, the projection pairs of are spaced apart not more than <NUM> (in some embodiments, not more than <NUM>).

In some embodiments, the projections of a coextruded polymeric article described herein have a height and thickness and the thickness is along the length of each respective projections.

In the first continuous coextruded polymeric articles and in some embodiments of the second and third continuous coextruded polymeric articles, each first projection has at least first and second opposed sides and a height from the first major surface to a distal end, wherein the height of the first projections is not greater than <NUM> (in some embodiments, not greater than <NUM>, or even not greater than <NUM>), and wherein there are at least <NUM> (in some embodiments, at least <NUM>, <NUM>, <NUM>, or even at least <NUM>) projection pairs per centimeter.

In the second continuous coextruded polymeric articles and in some embodiments of the first and third continuous coextruded polymeric articles, for a majority by number (i.e., at least <NUM> percent by number; in some embodiments, at least <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or even <NUM> percent) of the projection pairs, the height of the second projection is greater than the height of the attached first projection.

In some embodiments of the first continuous coextruded polymeric articles, the height of the second projections is in a range from <NUM> to <NUM> (in some embodiments, in a range from <NUM> to <NUM>, or even <NUM> to <NUM>) and the height of first projections is independently in a range from <NUM> to <NUM>, or even <NUM> to <NUM>. In some embodiments of the second and third continuous coextruded polymeric articles, the height of the projections are independently in a range from <NUM> to <NUM> (in some embodiments, in a range from <NUM> to <NUM>, or even <NUM> to <NUM>).

In some embodiments, the projections of a coextruded polymeric article described herein have a longest cross-sectional dimension in the direction normal to the projections in a range from <NUM> to <NUM> (in some embodiments, in a range from <NUM> to <NUM>, or even <NUM> to <NUM>).

In some embodiments, regions of a coextruded polymeric article described herein have a distance between projection pairs in a range from <NUM> to <NUM> (in some embodiments, in a range from <NUM> to <NUM>, or even <NUM> to <NUM>).

In some embodiments of a coextruded polymeric article described herein, there is a distance between the first and second major surfaces are in a range from <NUM> to <NUM> (in some embodiments, in a range from <NUM> to <NUM>, <NUM> to <NUM>, or even <NUM> to <NUM>).

One exemplary use for articles described herein is as a coextruded polymeric adhesive article, wherein an adhesive is initially not exposed to contact to a substrate brought into proximity of the article, and can subsequently be exposed to contact to the substrate after mechanical movement of the projections of the article, such as through hand-pressure in a shearing mode.

In some embodiments, polymeric materials used to make coextruded polymeric articles described herein may comprise a colorant (e.g., pigment and/or dye) for functional (e.g., optical effects) and/or aesthetic purposes (e.g., each has different color/shade). Suitable colorants are those known in the art for use in various polymeric materials. Exemplary colors imparted by the colorant include white, black, red, pink, orange, yellow, green, aqua, purple, and blue. In some embodiments, it is desirable level to have a certain degree of opacity for one or more of the polymeric materials. The amount of colorant(s) to be used in specific embodiments can be readily determined by those skilled in the art (e.g., to achieve desired color, tone, opacity, transmissivity, etc.). If desired, the polymeric materials may be formulated to have the same or different colors.

Another exemplary use for coextruded polymeric articles described herein is as a household cleaning product (e.g., a mop, a duster, a brush, a cleaning cloth, or a lint roller) whose effectiveness is increased by the movement inherent to its use.

Another exemplary use for coextruded polymeric articles described herein is as an adhesive article that can be adhesively attached to a substrate by slight shearing motion (e.g., a wall attachment that can be positioned without any adhesion), and subsequently adhered to the wall by gentle hand pressure accompanied by a slight shearing movement. The wall attachment can be subsequently removable by peeling. Another exemplary coextruded polymeric adhesive article has two levels of adhesiveness, which can be applied to a substrate at a low level of adhesiveness, repositioned as needed, and then subsequently be made to be highly adhesive by applying gentle hand pressure accompanied by a slight shearing movement. Yet another exemplary coextruded polymeric adhesive article has three levels of adhesiveness and two-sided adhesiveness. Such coextruded polymeric articles can behave as any described above, and then, on the still exposed surface (the surface opposing the surface already adhered to a substrate) can exhibit adhesiveness with respect to an additional substrate or article. For example, the coextruded polymeric article can be positioned against a wall, repositioned freely in a state of no or little adhesiveness. A gentle hand pressure can be applied accompanied with a slight shearing movement to provide a high level of adhesiveness. Then use of a third level of adhesiveness existing on the side of the coextruded polymeric adhesive article opposite the side adhered to the wall (which may be the same or different from either of the first two levels of adhesiveness) can be made to affix other objects to the wall such as posters, handbills, and other decorative materials, either permanently or removably, either once or repeatedly.

It is also within the scope of the present disclosure that properties in addition to adhesiveness can be triggered to exhibit tiered behavior in embodiments of coextruded polymeric articles described herein. For example, various chemical properties can also be utilized to provide channeling webs or tapes. An exemplary coextruded polymeric article could have hydrophobic projections and hydrophilic protrusions. Water, for instance, gently encountering such a coextruded polymeric article from the side having the projections would bead-up on the coextruded polymeric article, unless it approached with a determinate level of force or pressure, whereupon it would penetrate between projections deeply enough to encounter hydrophilic protrusions, and would be wicked down-channel due to hydrostatic forces, while still unable to penetrate through the layer to any appreciable extent.

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.

A co-extrusion die as generally depicted in <FIG> and <FIG> can be assembled with a multi shim repeating pattern of extrusion orifices as generally illustrated in <FIG>. The thickness of the shims in the repeat sequence can be <NUM> mils (<NUM>) for shims <NUM>, <NUM>, and <NUM> and <NUM> mils (<NUM>) for shim <NUM>, and <NUM>. These shims can be formed from stainless steel, with perforations cut by a wire electron discharge machining. The shims can be stacked in a repeating sequence <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> and <NUM>. The extrusion orifices can be aligned in a collinear, alternating arrangement. The total width of the shim setup can be about <NUM>. (<NUM> inches).

The inlet fittings on the two end blocks can be each connected to three conventional single-screw extruders. The extruders feeding the three cavities can be loaded with a thermoplastic polymer such as polyethylene copolymer (available, for example, under the trade designation "ELVALOY <NUM>" from DuPont Company, Wilmington, DE). The thermoplastic polymer for the first cavity can be dry blended with a color concentrate such as yellow color concentrate (available, for example, under the trade designation "<NUM>" from PolyOne Distribution, Romeoville, IL). The thermoplastic polymer for the second cavity can be dry blended with a second color concentrate such as green color concentrate (available, for example, under the trade designation "PP64643536" from Clariant, Minneapolis, MN). The extruder feeding the third cavity can be dry blended with a third color concentrate such as white color concentrate (available, for example obtained under the trade designation "PP1015100S" from Clariant).

The melt can be extruded vertically into an extrusion quench takeaway. The quench roll can be a smooth temperature controlled chrome plated <NUM> diameter steel roll or similar devise. The quench temperature can be controlled with internal water flow. The web path can be wrapped <NUM> degrees around a chrome steel roll and then to a windup roll.

Other process conditions that can be used are listed below:.

Prophetic Example <NUM> can be made the as described for Prophetic Example <NUM>, except that an adhesive can be used as the third polymer for the second projection. The extruder feeding the third cavity can be loaded with acrylate copolymer adhesive (available, for example, under the trade designation "R <NUM>" from <NUM> Company, St. Paul, MN), or other acrylates for suitable adhesive performance.

Claim 1:
A continuous coextruded polymeric article comprising a layer comprising first and second opposed major surfaces, wherein a plurality of attached projection pairs comprising first and second projections extend from only the first major surface, wherein each first projection has at least first and second opposed sides and a height from the first major surface to a distal end, wherein each second projection has at least first and second opposed sides and a height from the first major surface to a distal end, wherein the second side of the first projection is in continuous contact with the first side of the second projection, wherein the height of the first projections is not greater than <NUM>, wherein there are at least <NUM> projection pairs per centimeter, and wherein the projections extend along the length of the coextruded polymeric article.