JP-2022531375-A5 -

Dates

Publication Date

20230511

Application Date

20200428

Description

Various embodiments of the present invention have been described. These embodiments and other embodiments are within the scope of the following claims. The present invention encompasses the following aspects. (1) A method comprising reactively extruding a polymer composition to form a film, wherein the polymer composition comprises a polyisocyanate and at least one dimeric aliphatic diol. (2) The method according to item 1, wherein the polymer composition is extruded at a temperature of less than about 200°C. (3) The method according to item 1 or 2, wherein the polyisocyanate comprises an isocyanate having at least two functionalities. (4) The method according to item 3, wherein the isocyanate is aromatic and is selected from tolylene diisocyanate, m-phenylenediisocyanate, p-phenylenediisocyanate, xylylene diisocyanate, 4,4'-diphenylmethane diisocyanate (MDI), 2,4'-diphenylmethane diisocyanate, polymethylene polyphenyl diisocyanate, 3,3'-dimethyl-4,4'-biphenylenediisocyanate, 3,3'-dimethyl-4,4'-diphenylmethane diisocyanate, 3,3-dichloro-4,4'-biphenylenediisocyanate, 1,5-naphthalene diisocyanate, hydrogenated MDI (4,4'-methylenebis(cyclohexyl isocyanate)), and uretonimine-modified compounds thereof. (5) The method according to item 4, wherein the isocyanate is 4,4'-diphenylmethane diisocyanate (MDI). (6) The method according to any one of items 1 to 5, wherein the dimeric aliphatic diol is derived from a fatty acid having a C10 to C30 alkyl chain. (7) The method according to item 6, wherein the fatty acid is selected from oleic acid, linoleic acid, linolenic acid, palmitoleic acid, elaidic acid, and mixtures and combinations thereof. (8) The method according to any one of items 1 to 7, wherein the polymer composition further comprises a hydroxyl functional chain extender selected from aliphatic polyols, and the polyol is an alkyl polyol. (9) The method according to any one of items 1 to 8, wherein the polymer composition comprises about 20% to about 80% by weight of polyisocyanate and about 5% to about 70% by weight of the dimeric aliphatic diol. (10) The method according to item 9, wherein the polymer composition comprises about 0% to about 35% by weight of the chain extender. (11) The method according to any one of items 1 to 10, further comprising crosslinking the film. (12) The polymer composition is of the formula HX-R-XH (In the formula, X is O, S, NH, or NR1, R1 is an alkylene group containing 1 to 4 carbon atoms, and R is an organovinyl linking group containing 1 to 50 carbon atoms.) The method according to any one of items 1 to 11, further comprising a crosslinking agent selected from vinyl diols having the property. (13) The method of any one of items 1 to 12, further comprising thermoforming the film to create a cavity therein configured to receive one or more teeth, thereby forming a dental appliance. (14) The method according to item 13, wherein the dental appliance has at least one of a tensile modulus of about 0.8 GPa to about 2.0 GPa and a coffee stain index of less than about 3. (15) A first film layer comprising a film formed by any of the methods described in item 1 to 14, A polymer film structure comprising a second film layer containing polyester, polycarbonate, and mixtures and combinations thereof. (16) The polymer film structure according to item 15, wherein the film structure is co-extruded. (17) A polymer film structure, The first film layer, The second film layer, The present invention includes an intermediate film layer between the first film layer and the second film layer, Each of the first and second film layers comprises polyester, polycarbonate, and mixtures and combinations thereof, and the intermediate film layer is a thermoplastic polyurethane comprising polyisocyanate and at least one dimeric aliphatic diol, or A polymer film structure in which each of the first and second film layers comprises a thermoplastic polyurethane containing a polyisocyanate and at least one dimeric aliphatic diol, and the intermediate film layer comprises polyester, polycarbonate, and mixtures and combinations thereof. (18) The polymer film structure according to item 17, wherein the first film layer is different from the second film layer. (19) The polymer film structure according to item 17, wherein the first film layer and the second film layer are independently selected from polyethylene terephthalate (PET), polyethylene terephthalate glycol (PETG), polycyclohexylenedimethylene terephthalate (PCT), polycyclohexylenedimethylene terephthalate glycol (PCTG), Tritan, polycarbonate (PC), and mixtures and combinations thereof. (20) A method for manufacturing dental appliances, A first polymer film composition comprising a polyisocyanate and at least one dimeric aliphatic diol, Co-extrude a second polymer film composition containing at least one polyester to form a multilayer film having at least one film layer of the first polymer film composition and at least one film layer of the second polymer