Refrigerator liner structures

Abstract

A refrigerator cabinet is provided with a plastic liner, the inside wall of the refrigerator, which is resistant to chemical degradation by fluorocarbons. Freon and Freon substitutes used as blowing agents for foaming the insulation contained between an outer metal cabinet and on the inside wall of the refrigerator can cause blistering, cracking, and sometimes dissolution of materials used to form the plastic liner which is the inside wall of the refrigerator. There is provided a plastic liner which is resistant to those blowing agents and particularly to those blowing agents which are partially halogenated and tend to be more aggressive than Freon. The plastic liner wall maintains impact strength and toughness after exposure to fluorohydrocarbons conventionally employed in refrigerator units for in situ polyurethane foam production.

Description

FIELD OF THE INVENTION

The invention relates to a refrigerator cabinet appliance, the liner wall of which is resistant to attack by Freon and Freon substitutes.

BACKGROUND OF THE INVENTION

Typical refrigerator appliance cabinets consist of an outer metal cabinet, an inner plastic liner, typically ABS (acrylonitrile-butadiene-styrene) or HIPS (high impact polystyrene), and an insulating foam core, typically polyurethane foam. Blowing agents for the polyurethane foam are locked into the foam. Freon, a completely halogenated methane, fluorotrichloromethane, is presently employed commercially as the blowing agent. For environmental reasons, implemented by regulations, substitutes for Freon must be found. Proposed substitutes for Freon are halogenated hydrocarbons which contain at least one hydrogen atom.

Polyurethane blowing agents, such as Freon (CFC-11) and Freon substitutes, such as 2-fluoro-2,2-dichloroethane and 2,2-dichloro-1,1,1-trifluoroethane (HCFC 141b and HCFC 123, respectively), can cause liner blistering, catastrophic cracks, tiny cracks (crazing), and loss of impact properties (embrittlement), as well as stress whitening and/or dissolution. The blowing agents HCFC 141b and HCFC 123 appear to be more chemically aggressive than Freon (CFC-11) in attacking the liner. It is the common belief that blowing agent attack of the liner occurs on condensation of the blowing agent to liquid, which occurs on cooling. Cooling and condensation of the blowing agent does occur during shipping and storage. Shipping conditions are simulated during fabrication by cycling the appliance cabinet from hot to cold to cause evaporation and condensation of the blowing agent(s).

It is proposed to provide a plastic sheet structure to be thermoformed into a refrigeration liner that is resistant to chemical attack.

It is an object of the invention to provide a refrigeration appliance liner to be fabricated from a thermoformable, plastic sheet material exhibiting resistance to chemical attack (blistering, cracking, crazing, as mentioned above), by polyurethane foam blown with Freon (CFC-11) or potential Freon substitutes, including HCFC-123 and HCFC-141b, which are mentioned above.

It is an object of the invention to provide a refrigeration appliance liner to be fabricated from a thermoformable, plastic sheet material which retains a high level of toughness (impact properties) and strength (tensile properties), even at low temperatures (at 5.degree. F. or less).

It is another object of the invention to provide a liner made from a plastic sheet material that maintains processability similar to HIPS or ABS, including favorable extrusion conditions and similar thermoforming behavior.

It is another object of the invention to provide a liner made from a plastic sheet containing a layer of a special multi-functional blend that exhibits excellent chemical resistance to Freon or potential Freon substitutes, may additionally function as an adhesive layer between optional layers of HIPS (or ABS) and polyolefin, and finally acts as a compatibilizing agent when regrind plastic sheet scrap is recycled to virgin plastics resin being extruded into the core sheet layer.

SUMMARY OF THE INVENTION

In accordance with the invention, a refrigerator appliance is provided with a plastic liner which is substantially chemically inert to Freon and Freon substitutes. A conventional refrigerator appliance cabinet includes an outer metal cabinet, an inner plastic liner comprising ABS (acrylonitrile-butadiene-styrene) or HIPS (high impact polystyrene), and an insulating foam core, typically polyurethane foam. Blowing agent for the polyurethane foam is locked into the foam.

The plastic liner serves as the inner plastic wall of the refrigerator. The plastic wall is of variable thickness, as a result of thermoforming during fabrication. However, it is formed of a composite of relatively uniform thickness.

In accordance with the invention, the plastic liner comprises a barrier layer, which is substantially chemically inert to completely halogenated and partially halogenated hydrocarbons, e.g., chlorinated and/or fluorinated hydrocarbons used as blowing agents for polyurethane foam formation. In one embodiment of the invention, a core layer of ABS (acrylonitrile-butadiene-styrene) or HIPS (high impact polystyrene), for example by coextrusion or lamination, is affixed to the barrier layer. For visual attractiveness, a glossy patina on the barrier layer or the core layer must be present either due to the inherent properties of the core layer or by providing an independent layer of material which provides high gloss.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic drawing of a refrigerator cabinet.

FIG. 2 is a schematic drawing of the plastic liner serving as the inner plastic wall of the refrigerator.

FIG. 3 is a fragmentary cross section of the composite forming the plastic liner.

DETAILED DESCRIPTION OF THE INVENTION

The invention will be explained with reference to the appended drawings.

The refrigerator appliance of FIG. 1 includes a cabinet and is defined by an outer cabinet metal wall 1, an inner liner wall 2, and a body of foamed-in-place insulation 3 there between. In one popular design, the cabinet may define a freezer space 4 and an above-freezing refrigeration space 5.

Inner liner wall 2 is thermoformed into the desired configuration, as shown in FIG. 2. Inner liner wall 2 is a thermoformed product of liner sheet 6, one embodiment of which is illustrated in FIG. 3 as a multi-lamina composite. After being thermoformed into the desired configuration, the inner liner wall 2 is disposed into the outer cabinet wall 1 in a nested, spaced relationship for introduction of the foamed insulation by a conventional foaming-in-place operation. Usually, the outer cabinet wall 1 and the inner liner wall 2 are joined physically by mating of joints.

The barrier layer of the invention is substantially chemically inert to halogenated hydrocarbon(s) used as blowing agents in polyurethane foam production. If a core layer is employed, it is disposed on a surface of the core layer. During polyurethane in situ foam production, in one embodiment of the invention, it is the surface of the barrier layer of the composite which is contiguous to and bonds with the foam. However, it is not essential that the barrier layer of the invention be contiguous to the foam. In FIG. 3, the barrier layer is illustrated as numeral 8.

The barrier layer comprises 3.5 to 50 percent by weight of a composite which includes a core layer and comprises polymers or copolymers of ethylene or propylene which are selected from the group consisting of polypropylene, low density polyethylene, linear low density polyethylene, high density polyethylene (melt index of 1 to 10 and density of 0.935 to 0.960), high molecular weight high density polyethylene (melt index of 0.05 to 1.0), ethylene vinyl alcohol, certain high impact polystyrenes, nylon 66, and PVC. The barrier layer may comprise one or more lamina of the same or different polymer or copolymer.

The barrier layer may contain 0 to 40 weight percent, preferably 4 to 30 weight percent, based upon the weight of the barrier layer material, of a synthetic block copolymer. The synthetic block copolymer rubber can be selected from styrene-butadiene diblock; styrene-ethylene/propylene diblock copolymer; styrene-ethylene/butylene-styrene triblock; styrene-ethylene/butylene-styrene triblock functionalized with maleic anhydride, maleic acid or admixtures thereof, or combinations of any of the above.

The liner sheet may be formed of ABS (acrylonitrile-butadiene-styrene) or HIPS (high impact polystyrene) core layer which constitutes the major proportion of the composite. The core layer comprises 50 to 96 weight percent, preferably 55 to 85 weight percent, of the composite. Those core materials are chemically degradable by the completely or partially halogenated hydrocarbon blowing agent used in the polyurethane foam production. Both of these core materials are commercially available. In FIG. 3, the core layer chemically degradable by the fluorinated hydrocarbon is designated as 7.

The core layer which is (1) high impact polystyrene or (2) acrylonitrile-butadiene-styrene copolymer contains 5 to 35, preferably 5 to 20, and usually 5 to 15 weight percent rubber, in the form of particles. The rubber is usually polybutadiene and can be a styrene-butadiene copolymer. The rubber particles can have average diameters of at least 2 microns, and preferably at least 5 microns average diameters and generally up to 10 microns. When the rubber particles are 1 micron or less, as described in U.S. Pat. No. 4,513,120, high gloss polystyrene (medium impact) is produced. U.S. Pat. 4,513,120 is herein incorporated by reference.

Various alternatives are available for maximizing the adhesion of the core material to the barrier layer. Moreover, these alternatives can improve adhesion of the foam insulation to the barrier material. The core layer may be subjected to corona discharge treatment, or to ultraviolet light exposure, and by methods known in the art. In accordance with one embodiment of the invention, maximizing the adhesion of the barrier layer to the foam and optionally to a core layer appears to be achieved chemically. In a preferred embodiment, the material of the barrier layer contains maleic anhydride, maleic acid, and/or derivatives of maleic acid in an amount ranging from 0.05 to 10 weight percent of the barrier material. Conveniently, this can be achieved by inclusion of styrene-ethylene/butylene-styrene triblock functionalized with maleic anhydride, maleic acid or admixtures thereof; the triblock material is available from Shell Chemical Company as Kraton FG-1901X.

In one embodiment of the invention, the composite is formed with a barrier layer disposed on one surface of the core layer with a third layer of medium impact high gloss polystyrene on the exposed surface of the core layer. The third layer of medium impact high gloss polystyrene comprises 0.5 to 8 weight percent of the composite. The third layer is depicted in FIG. 3 as element 9.

The composite is formed by coextrusion of the materials of the laminae described above. The composite sheet can then be cut into suitable lengths for thermoforming into any desired configuration, one of which is illustrated by FIG. 2. The resulting liner wall 2 is then assembled with the outer cabinet wall 1 and in situ foaming of the insulation material is performed. The resulting structure exhibits impact strength and substantial elimination of thermal cracking and of blistering.

In situ foaming involves admixing an isocyanate with a masterbatch. The masterbatch comprises 60 to 60 percent of a polyol; 0.3 to 1.5 percent of a surfactant; 0.5 to 3.0 percent of a catalyst; 0.4 to 2.5 percent of water; and 12 to 30 percent of the blowing agent. The isocyanates used in appliances include TDI and PMDI. TDI comprises an 80:20 mixture of 2,4- and 2,6- isomers of products produced by dinitration of toluene, catalytic hydrogenation to the diamines, and phosgenation. CF. Kirk Othmer, Encyclopedia of Chemical Technology, Vol. 23, page 581 (Third Edition). PMDI is the reaction product formed by nitration of benzene and reduction to produce aniline; reacting aniline with formaldehyde in the presence of hydrochloric acid to produce a mixture of oligomeric amines, which are phosgenated to yield PMDI. Cf. Kirk Othmer, Encyclopedia of Chemical Technology, Vol. 23, page 581 (Third Edition). The blowing agent can be Freon or Freon substitutes which are partially halogenated lower hydrocarbons of 1 to 5 carbon atom, usually of 2 to 4 carbon atoms; halogenated includes fluorinated and/or chlorinated. By "partially halogenated" is meant that the Freon substitutes of the invention preferably contain at least one hydrogen atom. Illustrative of the partially halogenated lower hydrocarbons are 1,1-dichloro-1-fluoroethane and 2,2-dichloro-1,1,1-trifluoroethane, chlorodifluoromethane (HCFC-22),1,1,1,2-tetrafluoro-2-chloro-ethane (HCFC-124),1,1,1,2-tetrafluoroethane (HFC-134a), and pentafluoroethane (HFC-125). The foams produced contain in their cellular structure residual amounts of the blowing agent. The foam is formed in situ by foaming in a high pressure mixhead equipped to a nozzle for introducing the foam and foaming components into the cavity formed by the nesting of outer metal cabinet 1 and the plastic liner.

EXAMPLES

Example 1

Plastic sheets of composition described in Table 1 were fabricated into test plaques (15".times.15".times.0.050") and Brett-type test panels (783/4".times.77/8".times.0.050"). These test sheets were then positioned as pairs into closed foaming jigs with a 2" space between the sheets. Polyurethane foam chemicals were then introduced into the jigs to fill the space between the plastic sheets, to produce plastic/foam/plastic composite structures. These composite structures were thermally cycled several times between -20.degree. F. and 140.degree. F., to cause condensation and vaporization of liquid blowing agent along the exposed plastic sheet surfaces.

Several blowing agents (CFC-11 and HCFC-123) at several levels (9-15 percent) were evaluated in separate tests. CFC-11 is trichlorofluoromethane (CCl.sub.3 F); HCFC-123 is 2,2-dichloro-1,1,1-trichloroethane, HCFC-141b is 1,1-dichloro-1-fluoroethane (CHCl.sub.2 CF.sub.3). The thermally cycled composite structures were then tested, as summarized in Table 1, and inspected for signs of chemical attack.

TABLE 1__________________________________________________________________________POLYSTYRENE/POLYOLEFIN BLENDSMIS-ESCR AND PHYSICAL PROPERTIES__________________________________________________________________________ MOBIL PS7100 BLEND 1 BLEND 2 BLEND 3 BLEND 4 BLEND 5 BLEND BLEND__________________________________________________________________________ 7Composition (%)*HIPS/**PS, % 100 80 80 80 80 80 80 80Polyolefin, % 0 10 10 10 10 10 10 10Compatabilizer, % 0 10 10 10 10 10 10 10HIPS/PS, Type 7100 7100 7100 7100 7100 7100 7100Polyolefin, Type Hilmont Aristech Himont Mobil Mobil Himont Himont 6231 FF-028N SA-747M HMA-045 MMA-169 SA-747M SA-747M LLDPE Rand Rand PPCompatibilizer, Type Homo PP Homo PP Rand PP HDPE G1657 50:50 FG1901X G1657 G1657 G1657 G1657 S-EB-S 1657:1901 SEBS/MA S-EB-S S-EB-S S-EB-S S-EB-SMIS-ESCR, 1000 psi (min)Chiffon 63 138 394 125 63 2 600 630COOA 115 441 1186 491 256 4 5963 1708CFC-11 9 7 9 8 6 0 12 14HCFC-123 5 4 14 10 2 0 14 20HCFC-141b 6 8 13 10 6 0 17 18MIS-ESCR, 400 psi (min)CFC-11 22 37 44HCFC-123 13 65 69HCFC-141b 23 51 60Physical Properties:MFI (G), g/10 min 2.9 9.3 6.8 8.2 8.7 12.1 5.8 5.7Vicat, C 103 103 103 101 100 92 101 101Tensile Yield, psi 2500 2200 2500 2100 2100 1600 2600 2800Tensile Fail, psi 3500 2200 2500 2100 2100 1600 2600 2800Tensile Modulus, PSI 182,000 97,000 109,000 99,000 96,000 58,000 112,000 116,000Elongation, % 41 31 41 31 29 28 40 40Izod Impact, ft.lb/in 2.1C 1.0C 1.4C 1.2C 1.1C 1.1C 1.5C 1.6HGardner Impact, in.lb 123 49 95 69 18 6 93 99__________________________________________________________________________ BLEND 8 BLEND 9 BLEND 10 BLEND 11 BLEND 12 BLEND 13 BLEND BLEND__________________________________________________________________________ 15Composition (%)HIPS/PS, % 85 80 80 70 60 50 60 60Polyolefin, % 10 10 10 20 30 40 30 30Compatabilizer, % 10 10 10 10 10 10 10 10HIPS/PS, Type 7100 7100 7100 7100 7100 7100 7100 7100Polyolefin, Type Hilmont Himont OxyChem OxyChem OxyChem OxyChem OxyChem Himont SA-747M SA-747M L5005 L5005 L5005 L5005 L5005 SA-747M Rand PP Rand PP HMW- HMW- HMW- HWM- HWM- Rand PP HDPE HDPE HDPE HDPE HDPECompatibilizer, Type G1702 G1702 FG1901X FG1901X FG1901X FG1901X G1657 G1657 S-EP S-EP SEBS/MA SEBS/MA SEBS/MA SEBS/MA S-EB-S S-EB-SMIS-ESCR, 1000 psi (min)Chiffon 147 90 342 753 1700 2887 37 22COOA 7026 4995CFC-11 7 5 8 13 25 31 3 4HCFC-123 4 3HCFC-141b 5 4MIS-ESCR, 400 psi (min)CFC-11 41 48 80 130 51 48HCFC-123 56 74 142 270 93 146HCFC-141b 48 63 115 218 73 88Physical Properties:MFI (G), g/10 min 2.8 2.7 3.5 2.9 2.2 1.8 3.6 11.1Vicat, C 101 101 100 101 102 103 99 101Tensile Yield, psi 2400 2400 3000 3070 3020 2940 2500 2200Tensile Fail, psi 2400 2400 3000 3070 3020 2940 2500 2040Tensile Modulus, psi 152,000 145,000 138,000 130,000 124,000 118,000 106,000 79,000Elongation, % 12 7 50 46 36 33 34 39Izod Impact, ft.lb/in 2.1C 2.1C 2.1C 2.0C 1.8C 1.5H 1.4C 1.0CGardner Impact, in.lb 66 66 121 127 109 55 100 136__________________________________________________________________________ BLEND 16 BLEND 17 BLEND 18 BLEND 19 BLEND 20 BLEND 21 BLEND BLEND__________________________________________________________________________ 23Composition (%)HIPS/PS, % 60 60 60 60 50 50 40 40Polyolefin, % 30 30 30 30 40 40 50 50Compatabilizer, % 10 10 10 10 10 10 10 10HIPS/PS, Type 7100 7100 7100 7100 9524 7800 7800 1800Polyolefin, Type Himont Chevron Chevron Chevron OxyChem OxyChem OxyChem OxyChem SA-747M PE5280T PE5280T PE5272 L5005 L5005 L5005 L5005 Rand PP PE/EVA PE/EVA PE/EVA HMW- HMW- HMW- HMW- 8% 8% 4% HDPE HDPE HDPE HDPECompatibilizer, Type FG1901X FG1901X G1657 G1657 G1657 G1657 FG1901X FG1901X SEBS/MA SEBS/MA S-EB-S S-EB-S S-EB-S S-EB-S SEBS/MA SEBS/MAMIS-ESCR, 1000 psi (min)Chiffon 914 >10000 >1000 >1000 >1000 >1000COOA (400 psi) (400 psi) (400 psi)CFC-11 16HCFC-123HCFC-141bMIS-ESCR, 400 psi (min)CFC-11 88 75 68 53 96 88 311 346HCFC-123 230 150 160 126 197 170 642 627HCFC-141b 159 105 103 74 135 108 >1000 495Physical Properties:MFI (G), g/10 min 6.3 4.6 6.1 7.7 1.9 1.7 1.8 1.6Vicat, C 103 88 77 103 104 104 106 109Tensile Yield, psi 2790 2520 2000 1930 2500 2500 2790 3890Tensile Fail, psi 2770 2520 2000 1930 2000 2300 2830 3460Tensile Modulus, PSI 101,000 84,000 65,000 61,000 102,000 103,000 122,000 174,000Elongation, % 36 54 42 42 46 48 82 23Izod Impact, ft.lb/in 1.4C 2.6H 2.1H 1.9H 1.9C 1.7C 1.7C 0.8CGardner Impact, in.lb 154 242 215 240 104 89 67 14__________________________________________________________________________ BLEND 24 BLEND 25 BLEND 26 BLEND 27 BLEND BLEND__________________________________________________________________________ 29 Composition (%) HIPS/PS, % 60 60 60 50 0 20 Polyolefin, % 30 30 30 40 80 65 Compatabilizer, % 10 10 10 10 20 15 HIPS/PS, Type 1800 1800 7800 7100 7100 7100 Polyolefin, Type Mobil Mobil OxyChem Mobil Mobil Mobil HYA-301 HCX-002 L5005 HMX-034 HMX-034 HMX-034 HDPE HDPE HMW- HDPE HDPE HDPE HDPE Compatibilizer, Type FG1901X FG1901X FG1901X FG1901X FG1901X FG1901X SEBS/MA SEBS/MA SEBS/MA SEBS/MA SEBS/MA SEBS/MA MIS-ESCR, 1000 psi (min) Chiffon 223 >1000 734 >1000 >1000 >1000 COOA CFC-11 HCFC-123 HCFC-141b MIS-ESCR, 400 psi (min) CFC-11 62 679 83 351 >1000 >1000 HCFC-123 76 523 120 630 >1000 >1000 HCFC-141b 87 496 97 544 >1000 >1000 Physical Properties: MFI (G), g/10 min 4.7 9.4 3.7 9.3 9.8 10.8 Vicat, C 106 103 103 105 115 108 Tensile Yield, psi 5160 4140 2950 2890 1830 2170 Tensile Fail, psi 5160 4140 2950 2890 1830 2170 Tensile Modulus, psi 229,000 192,000 151,000 126,000 58,000 71,000 Elongation, % 5 15 121 18 500 477 Izod Impact, ft.lb/in 1.1H 0.7H 4.3H 0.6C 13.8 1.4C Gardner Impact, in.lb 38 44 207 48 >320 294__________________________________________________________________________ *high impact polystyrene **polystyrene

Example 2

Sheets of several different compositions described in Table 2 invention were exposed to the liquid blowing agents by sealing a glass ball joint to the sheet samples and adding the specific liquid blowing agent being evaluated (CFC-11, HCFC-123, and HCFC-141b). The samples were exposed to the blowing agents for 30 minutes each, then exposed to heat (60.degree. C. for 30 minutes to drive off the blowing agents, and finally inspected for chemical attack. Several sheet samples displayed no signs of chemical attack at all, and most samples showed at least some reduction in chemical attack when compared to sheets of HIPS or ABS. The results are set forth in Table 2.

TABLE 2______________________________________LIQUID BLOWING AGENT CONTACT STUDY CFC-11 HCFC-123 HCFC-141b______________________________________UNMODIFIEDRESINS:Mobil PS7100 Severe Severe SevereHIPS Blistering Blistering BlisteringMobil PS7800 Severe Severe SevereMIPS Blistering Blistering BlisteringMobil PS5350 Severe Severe SevereHIPS Blistering Blistering BlisteringDow 469 HIPS Severe Severe Severe Blistering Blistering BlisteringMonsanto ABS Unaffected Cracking Cracking Severe No Blistering BlisteringPS/POLYOLEFINBLENDSCOEX. ON PS7100:CA10 Severe Severe Severe(10% Random PP) Blistering Blistering BlisteringCB30 Moderate Moderate Moderate(30% Random PP) Blistering Blistering BlisteringLB40 (40% Skin Skin SkinHMW-HDPE) Delamination Delamination Delamination Moderate No Blistering No Blistering BlisteringBASF KR2773 Skin Slim Skin(30% HDPE) Delamination Delamination Delamination(10% CaCO3 filled) No Slight Slight Blistering Blistering BlisteringBASF KR2774 Severe Moderate Moderate(30% LDPE) Blistering Blistering BlisteringBARRIER FILMSLAMINATED ONPS7100:Mobil MMA-169 Moderate Unaffected UnaffectedLLDPE (2 mil) BlisteringMobil HMA-045 Unaffected Unaffected UnaffectedHDPE(2 mil)Oxy L5005 Unaffected Unaffected UnaffectedHMW-HDPE(2 mil)DuPont EVOH Unaffected Unaffected Unaffected(5 mil)______________________________________

Example 3

The invention is illustrated by use in a top mount (freezer on top) refrigerator of 15 cu. ft. capacity, with HCFC-123 as the polyurethane blowing agent at an estimated 18 percent level weight. The layers of the composite are described below.

______________________________________Pre-Thermoformed Sheet:______________________________________Sheet Total Thickness 202 mil (0.202")Barrier Layer Thickness 10 mil (0.010")Core Layer Thickness 190 mil (0.190")Gloss Layer Thickness 2 mil (0.002")Barrier Layer Percent 5 percentof Total SheetPre-Thermoformed 77.75 .times. 46.75 .times. 0202 inchesSheet DimensionsBarrier Layer Material*Core Layer Material Mobil ES7100 Refrigeration Grade HIPSGloss Layer Material Mobil ES7800 Medium Impact, High Gloss PS______________________________________ *Barrier Material used had the following:High Density Mobil HMX-034 HDPEPolyethylene Type (Melt Flow = 4.0, Density = 0.954)Rubber Type Shell Chemical Co., Kraton FG-1901X Styrene-Ethylene/Butylene- Styrene Triblock (functionalized with 2 percent maleic anhydride)withPolyethylene Level 80 percentRubber Level 20 percentIrganox 1010 Antioxidant 500 ppm

The barrier layer material was compounded in a Werner & Pfleiderer ZSK 30/30 mm twin screw extruder at a temperature profile which ranged from 225.degree. F. to 400.degree. F.

The composite was formed from a two-layer system including the core layer (ES7100) and the barrier layer, which were coextruded. The gloss layer of medium impact polystyrene (Mobile ES7800) was laminated thereto. The temperature profile for coextrusion is set forth below.

______________________________________Coextrusion Temperature Profile:______________________________________ES 7100 ExtruderProfile (345-380-350-300-390-400).degree. F.Die 415.degree. F.Melt Temp. 440.degree. F.Barrier Material ExtruderProfile (275-300-325-330).degree. F.Die 415.degree. F.Melt Temp. 340.degree. F.______________________________________

The thermoformed product assembled in a metal cabinet with subsequent in situ insulation formation was subjected to 12 temperature cycles ranging from -40.degree. F. to +150.degree. F. Polyurethane foam adhesion to the barrier layer was good and better than the adhesion of the barrier layer to the core material. The liner wall exhibited satisfactory impact strength, no signs of cracking during thermal blistering, and de minimus blistering.

Example 4

A 22 cu. ft. refrigerator, a side-by-side model (configuration of refrigerator and freezer compartments), was fitted with a liner and then insulated with polyurethane foam produced by CFC-11 blowing agent at an estimated 16 weight percent level. The compositions and dimensions of the preformed sheet components are described below.

______________________________________Sheet Total Thickness 198 mil (0.198")Barrier Layer Thickness 6 mil (0.006")Glue/Compat. Layer 2 mil (0.002")ThicknessCore Layer Thickness 188 mil (0.188")Gloss Layer Thickness 2 mil (0.002")Glue plus Barrier Layers 5 percentPercent of SheetPre-Thermoformed Sheet 78.75 .times. 36.00 .times. 0.198 inchesDimensionsBarrier Layer Material* Mobil HMX-034 HDPEGlue/Compatibilizer Mobil Developmental LB40Layer**Core Layer Material Mobil ES7100 Refrigeration Grade HIPSGloss Layer Material Mobil ES7800 Medium Impact, High Gloss PS______________________________________*Barrier Layer Mobil HMX-034 HDPEMaterial Used (high Density Polyethylene) (Melt Flow = 4.0, Density = 0.954).**Glue/Compat. LayerComposition:Polyethylene Type OxyChem Alathon L5005; HMW-HDPE (Melt Flow = 0.055 Cond. F, Density = 0.95)Rubber Type Shell Chemical Co. Kraton FG-1901X; Styrene-Ethylene/Butylene-Styrene Triblock (functionalized with 2 percent maleic anhydride)HIPS Type Mobil ES7100 Refrigeration Grade (Melt Flow = 2.5).Polyethylene Level 40 percent.Rubber Level 10 percent.HIPS Level 50 percent.

The glue/compatibilizer layer materials were compounded in a Werner Pfleiderer 30 mm twin screw extruder at a temperature profile ranging from 225.degree. F. to 450.degree. F. The ES7800 gloss layer was laminated to the remaining laminate which were coextruded in a Welex Coextrusion System.

The unit(s) were subjected 12 times to a temperature cycle of -40.degree. to 150.degree. F. The unit exhibited satisfactory impact strength and de minimus blistering.

Thus, it is apparent that there has been provided in accordance with the invention a refrigerator plastic liner wall that fully satisfies the objects, aims, and advantages set forth above. While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims.

Claims

1. A refrigerator appliance cabinet comprising an inner plastic liner molded from a thermoformable composite, disposed into an outer metal cabinet, said composite comprising:

a) a core layer comprising high impact polystyrene or an acrylonitrile-butadiene-styrene copolymer, said core layer containing 5 to 35 weight percent rubber, based on the weight of the core layer, in the form of particles having average diameters of at least 2 microns, said core layer having two surfaces;

b) a gloss patina on a first of said two surfaces;

c) a barrier material on a second of said two surfaces of said core layer, said barrier material comprising a polymer or copolymer of ethylene or propylene containing 0 to 40 percent of a block copolymer rubber, based upon the weight of the barrier material;

wherein the core layer comprises from 50 to 96 weight percent of the composite and said barrier material comprises 3.5 to less than 50 percent by weight of the composite.

2. The cabinet of claim 1, wherein the polymer or copolymer of ethylene or propylene is selected from the group consisting of polypropylene, low density polyethylene, linear low density polyethylene, high density polyethylene, high molecular weight high density polyethylene.

3. The cabinet of claim 2, wherein the block copolymer rubber in said barrier layer is a styrene-butadiene diblock; a styrene-ethylene/propylene diblock copolymer; a styrene-ethylene/butylene-styrene triblock; or a styrene-ethylene/butylene-styrene triblock functionalized with maleic anhydride, maleic acid or admixtures thereof.

4. The cabinet of claim 3, wherein the barrier material contains maleic anhydride, maleic acid, and/or derivatives of maleic acid in an amount ranging from 0.05 to 10 weight percent of the barrier material.

5. The cabinet of claim 4, wherein the block copolymer rubber comprises a styrene-ethylene/propylene diblock copolymer.

6. The cabinet of claim 4, wherein the gloss patina is provided by a layer of medium impact, high gloss polystyrene comprising 0.5 to 8 weight percent of the composite.

7. The cabinet of claim 1, wherein the barrier material contains maleic acid, maleic anhydride, and/or derivatives of maleic acid in an amount ranging from 0.05 to 10 weight percent of the barrier material.

8. The cabinet of claim 7, wherein the core layer comprises 55 to 85 weight percent of said composite.

9. The cabinet of claim 8, wherein the barrier material comprises high density polyethylene.

10. The cabinet of claim 9, wherein the barrier material includes at least 5 weight percent of said block copolymer rubber based on the weight of the barrier material.

11. The cabinet of claim 10, wherein the block copolymer rubber is functionalized with maleic anhydride, maleic acid, or derivatives of maleic acid.

12. The cabinet of claim 11, wherein the block copolymer rubber is a styrene-ethylene/propylene diblock copolymer.

13. The cabinet of claim 1, wherein said barrier material contains 4 to 30 weight percent, based on the weight of the barrier material, of a styrene-ethylene/propylene diblock copolymer rubber particle.

14. A refrigerator appliance cabinet comprising an outer metal cabinet and an inner plastic liner, said plastic liner containing a fluorinated hydrocarbon blowing agent and molded from a thermoformable composite comprising:

a) a core layer comprising a high impact polystyrene or acrylonitrile-butadiene-styrene copolymer, said core layer containing 5 to 35 weight percent rubber, based on the weight of the core layer, in the form of particles having average diameters of at least 2 microns, said core layer having two surfaces;

b) a gloss patina on a first of said two surfaces, which comprises 0.5 to less than 10 weight percent of the composite; and,

c) a barrier material on a second of said two surfaces of said core layer, said barrier material comprising a polymer or copolymer of ethylene or propylene selected from the group consisting of polypropylene, low density polyethylene, linear low density polyethylene, high density polyethylene, high molecular weight high density polyethylene,

wherein the core layer comprises at least 50 weight percent of the composite, said polymer or copolymer of ethylene or propylene contains from 0 to 40 weight percent, based on the weight of the barrier material, of a block copolymer rubber, and said barrier material comprises from 4 to 50 weight percent of the composite.

15. The cabinet of claim 14, wherein the block copolymer rubber is a styrene-butadiene diblock; a styrene-ethylene/propylene diblock copolymer; a styrene-ethylene/butylene-styrene triblock; or a styrene-ethylene/butylene-styrene triblock functionalized with maleic anhydride, maleic acid or admixtures thereof.

16. The cabinet of claim 15, wherein the barrier material contains maleic acid, maleic anhydride, and/or derivatives of maleic acid in an amount ranging from 0.5 to 10 weight percent of the barrier material.

17. The cabinet of claim 16, wherein the patina comprises a layer of medium impact, high gloss polystyrene, comprising 0.5 to 8 weight percent of the composite.

18. The cabinet of claim 17, wherein the barrier material comprises high density polyethylene.

19. The cabinet of claim 18, wherein the barrier material includes at least 5 weight percent of said block copolymer rubber based on the weight of the barrier material.

20. The cabinet of claim 19, wherein the rubber is functionalized with maleic acid, maleic anhydride, or derivatives of maleic acid.

21. The cabinet of claim 14, wherein the barrier material contains maleic acid, maleic anhydride, and/or derives of maleic acid in an amount ranging from 0.05 to 10 weight percent of the barrier material.

22. The cabinet of claim 14, wherein the block copolymer is a styrene-ethylene/propylene diblock copolymer in an amount of from 4 to 30 weight percent based on the weight of the barrier layer material.

23. A thermoformable composite comprising:

a) a core layer comprising high impact polystyrene or an acrylonitrile-butadiene-styrene copolymer, said core layer containing 5 to 35 weight percent rubber, based on the weight of the core layer, in the form of particles having average diameters of at least 2 microns, said core layer having two surfaces;

b) a high gloss layer on a first of said two surfaces;

c) a barrier material on a second of said two surfaces, said barrier material comprising a polymer or copolymer of ethylene or propylene containing 0 to 40 percent of a block copolymer rubber;

wherein the core layer comprises 50 to 96 weight percent of the composite and said barrier material comprises 3.5 to 50 percent by weight of the composite.

24. The composite of claim 23, wherein the polymer or copolymer of ethylene or propylene is selected from the group consisting of polypropylene, low density polyethylene, linear low density polyethylene, high density polyethylene, and high molecular weight high density polyethylene.

25. The composite of claim 24, wherein the block copolymer rubber is a styrene-butadiene diblock; styrene-ethylene/propylene diblock copolymer; styrene-ethylene/butylene-styrene triblock; or a styrene-ethylene/butylene-styrene triblock functionalized with maleic anhydride, maleic acid, or admixtures thereof.

26. The composite of claim 25, wherein the block copolymer rubber is a styrene-ethylene/propylene diblock copolymer.

27. The composite of claim 25, wherein the barrier material contains maleic acid, maleic anhydride, and/or derivatives of maleic acid in an amount ranging from 0.05 to 10 weight percent of the barrier material.

28. The composite of claim 23, wherein the barrier material contains maleic anhydride, maleic acid, and/or derivatives of maleic acid in an amount ranging from 0.05 to 10 weight percent of the barrier material.

29. The composite of claim 28, wherein the high gloss layer is medium impact, high gloss polystyrene, comprising 0.5 to 8 weight percent of the composite.

30. The composite of claim 29, wherein the barrier material comprises high density polyethylene.

31. The composite of claim 30, wherein the barrier material includes at least 5 weight percent of said block copolymer rubber based on the weight of the barrier material.

32. The composite of claim 31, wherein the block copolymer rubber is functionalized with maleic acid, maleic anhydride, or derivatives of maleic acid.