Thermoplastic polyurethane composition and process for producing the same Number:7,084,207 from the United States Patent and Trademark Office (PTO) owispatent The present invention provides a thermoplastic polyurethane composition which comprises an ethylene-vinyl alcohol copolymer and/or a polyamide, and a thermoplastic polyurethane, in which the retention of melt tension thereof, when kept in a molten state at 220.degree. C. for 1 hour, determined by the following equation (1), is not less than 10%. Retention of melt tension (%)=[Melt tension after being kept in a molten state/Melt tension before being kept in a molten state].times.100 (1)The thermoplastic polyurethane composition of the present invention is excellent in production stability of a molded article, and can provide a molded article excellent in appearance because the progress of gelation thereof is suppressed even in a molten state.<H Thermoplastic, polyurethane, Thermoplastic, p, 7084207.html, Patent, pto, 7084207

Title: Thermoplastic polyurethane composition and process for producing the same

Abstract: The present invention provides a thermoplastic polyurethane composition which comprises an ethylene-vinyl alcohol copolymer and/or a polyamide, and a thermoplastic polyurethane, in which the retention of melt tension thereof, when kept in a molten state at 220.degree. C. for 1 hour, determined by the following equation (1), is not less than 10%. Retention of melt tension (%)=[Melt tension after being kept in a molten state/Melt tension before being kept in a molten state].times.100 (1)The thermoplastic polyurethane composition of the present invention is excellent in production stability of a molded article, and can provide a molded article excellent in appearance because the progress of gelation thereof is suppressed even in a molten state.

Patent Number: 7,084,207 Issued on 08/01/2006 to Yamana, et al.

Inventors: Yamana; Yoshihiro (Okayama, JP); Ono; Hiroyuki (Kurashiki, JP)
Assignee: Kuraray Co., Ltd. (Kurashiki, JP)

Appl. No.: 10/352,945

Filed: January 29, 2003

Foreign Application Priority Data


Jan 29, 2002 [JP]			2002-19711

Current U.S. Class: 525/60 ; 525/130; 525/131; 525/524; 525/58

Current International Class: C08L 75/04 (20060101); C08F 116/06 (20060101); C08G 16/06 (20060101); C08L 77/00 (20060101)

Field of Search: 525/58,60,130,131,424

References Cited [Referenced By]

U.S. Patent Documents


4423185	December 1983	Matsumoto et al.
4464438	August 1984	Lu
6790391	September 2004	Watkins

Foreign Patent Documents


2123053	Nov., 1994	CA
0 624 463	Nov., 1994	EP
0 657 505	Jun., 1995	EP
0 748 829	Dec., 1996	EP
57-87447	May., 1982	JP
58-022163	Feb., 1983	JP
02-206634	Aug., 1990	JP
02-259341	Oct., 1990	JP
03-005143	Jan., 1991	JP
03-255288	Nov., 1991	JP
07-195635	Aug., 1995	JP
07-324162	Dec., 1995	JP
10-110154	Apr., 1998	JP
2000-248073	Sep., 2000	JP
WO 96/39886	Dec., 1996	WO

Other References

Patent Abstracts of Japan, JP 03-175032, Jul. 30, 1991. cited by other .
Derwent Abstracts, AN 2000-632246, XP-002240348, JP 2000-248073, Sep. 12, 2000. cited by other.

Primary Examiner: Woodward; Ana
Attorney, Agent or Firm: Oblon, Spivak, McClelland, Maier & Neustadt, P.C.

Claims

The invention claimed is:

1. A thermoplastic polyurethane composition comprising an ethylene-vinyl alcohol copolymer andlor a polyamide, and a thermoplastic polyurethane, wherein the retention of melt tension of said thermoplastic polyurethane composition, when kept in a molten state at 220.degree. C. for 1 hour, is not less than 10% wherein said thermoplastic polyurethane composition is produced by melt kneading an ethylene-vinyl alcohol copolymer and/or polyamide, a thermoplastic polyurethane, and in addition an organic compound having a hydroxy group and a molecular weight of not less than 50, wherein the organic compound having a hydroxyl group is used in an amount of from 0.5 to 20 parts by weight per a total weight of 100 parts by weight of the ethylene-vinyl alcohol copolymer, the polyamide and the thermoplastic polyurethane.

2. The thermoplastic polyurethane composition according to claim 1, wherein at least a part of the ethylene-vinyl alcohol copolymer, the polyamide or the polyurethane is at least one of (i) a scrap generated during the production of an article comprising at least one polymer selected from the group consisting of a thermoplastic polyurethane, an ethylene-vinyl alcohol copolymer and a polyamide, or (ii) a recycled article comprising at least one polymer selected from the group consisting of a thermoplastic polyurethane, an ethylene-vinyl alcohol copolymer and a polyamide.

3. The thermoplastic polyurethane composition according to claim 2, wherein the article comprises not less than two polymers selected from the group consisting of a thermoplastic polyurethane, an ethylene-vinyl alcohol copolymer and a polyamide.

4. The thermoplastic polyurethane composition according to claim 2, wherein the article is composed of a composition of not less than two polymers selected from the group consisting of a thermoplastic polyurethane, an ethylene-vinyl alcohol copolymer and a polyamide.

5. The thermoplastic polyurethane composition according to claim 2, wherein the article is a multi-layered structure having a layer of a thermoplastic polyurethane and a layer of at least one of an ethylene-vinyl alcohol copolymer or a polyamide.

6. A molded article comprising the thermoplastic polyurethane composition according to claim 2.

7. The thermoplastic polyurethane composition according to claim 1, wherein the thermoplastic polyurethane is produced with a high polymer polyol having a crystallization enthalpy (.DELTA.H) of not more than 70 J/g, an organic isocyanate and a chain extender.

8. The thermoplastic polyurethane composition according to claim 1, wherein the Shore A hardness of the thermoplastic polyurethane is from 60 to 97.

9. A method for producing the thermoplastic polyurethane composition according to claim 1, comprising melt kneading an ethylene-vinyl alcohol copolymer and/or a polyamide, a thermoplastic polyurethane and in addition an organic compound having a hydroxy group and a molecular weight of not less than 50.

10. The method according to claim 9, wherein the organic compound having a hydroxy group is at least one compound selected from the group consisting of diols, polyhydric alcohols and polymer polyols.

11. The method according to claim 9, wherein the thermoplastic polyurethane is produced with a high polymer polyol having a crystallization enthalpy (.DELTA.H) of not more than 70 J/g, an organic isocyanate and a chain extender.

12. The method according to claim 9, wherein the Shore A hardness of the thermoplastic polyurethane is 60 to 97.

13. A method for producing the thermoplastic polyurethane composition according to claim 1, comprising melt kneading (A) at least one of [A-1] a scrap generated during the production of an article comprising at least one polymer selected from the group consisting of a thermoplastic polyurethane, an ethylene-vinyl alcohol copolymer and a polyamide, or [A-2] a used article comprising at least one polymer selected from the group consisting of a thermoplastic polyurethane, an ethylene-vinyl alcohol copolymer and a polyamide, (B) at least one of an ethylene-vinyl alcohol copolymer or a polyamide, (C) a thermoplastic polyurethane and (D) an organic compound having a hydroxy group and a molecular weight of not less than 50.

14. The method according to claim 13, wherein the organic compound having a hydroxy group is at least one compound selected from the group consisting of diols, polyhydric alcohols and polymer polyols.

15. The method according to claim 13, wherein the thermoplastic polyurethane is produced with a high polymer polyoi having a crystallization enthalpy (.DELTA.H) of not more than 70 J/g, an organic isocyanate and a chain extender.

16. The method according to claim 13, wherein the Shore A hardness of the thermoplastic polyurethane is 60 to 97.

17. A method for producing the thermoplastic polyurethane composition according to claim 1, comprising melt kneading (I) at least one of [I-1] a scrap generated during the production of an article comprising at least one polymer selected from the group consisting of a thermoplastic polyurethane, an ethylene-vinyl alcohol copolymer and a polyamide, or [I-2] a used article comprising at least one polymer selected from the group consisting of a thermoplastic polyurethane, an ethylene-vinyl alcohol copolymer and a polyamide, and (II) an organic compound having a hydroxy group and a molecular weight of not less than 50 in the presence of (III) at least one polymer selected from the group consisting of an ethylene-vinyl alcohol copolymer, a polyamide and a thermoplastic polyurethane.

18. The method according to claim 17, wherein the organic compound having a hydroxy group is at least one compound selected from the group consisting of diols, polyhydric alcohols and polymer polyols.

19. The method according to claim 17, wherein the thermoplastic polyurethane is produced with a high polymer polyol having a crystallization enthalpy (.DELTA.H) of not more than 70 J/g, an organic isocyanate and a chain extender.

20. The method according to claim 17, wherein the Shore A hardness of the thermoplastic polyurethane is 60 to 97.

21. A method for producing the thermoplastic polyurethane composition according to claim 1, comprising melt kneading at least one of (i) at least one of [i-1] a scrap generated during the production of a multi-layered structure having a layer of a thermoplastic polyurethane and a layer of at least one of an ethylene-vinyl alcohol copolymer or a polyamide, or [i-2] a used multi-layered structure having a layer of a thermoplastic polyurethane and a layer of at least one of an ethylene-vinyl alcohol copolymer or a polyamide, or (ii) at least one of [ii-1] a scrap generated during the production of an article composed of a polymer composition comprising a thermoplastic polyurethane and at least one of an ethylene-vinyl alcohol copolymer or a polyamide, or [ii-2] a used article comprising at least one of a thermoplastic polyurethane, an ethylene-vinyl alcohol copolymer, or a polyamide, and (iii) an organic compound having a hydroxy group and a molecular weight of not less than 50, optionally in the presence of (iv) at least one polymer selected from the group consisting of an ethylene-vinyl alcohol copolymer, a polyamide and a thermoplastic polyurethane.

22. The method according to claim 21, wherein the organic compound having a hydroxy group is at least one compound selected from the group consisting of diols, polyhydric alcohols and polymer polyols.

23. The method according to claim 21, wherein the thermoplastic polyurethane is produced with a high polymer polyol having a crystallization enthalpy (.DELTA.H) of not more than 70 J/g, an organic isocyanate and a chain extender.

24. The method according to claim 21, wherein the Shore A hardness of the thermoplastic polyurethane is 60 to 97.

25. A molded article comprising the thermoplastic polyurethane composition according to claim 1.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a thermoplastic polyurethane composition comprising a thermoplastic polyurethane and an ethylene-vinyl alcohol copolymer and/or a polyamide.

2. Description of the Related Art

A thermoplastic polyurethane has been widely used because it is excellent in various properties such as mechanical strength, flexibility, elastic recovery from strain and abrasion resistance. A film, a sheet, a belt, a hose, a tube and other various articles may be produced with a thermoplastic polyurethane by extrusion molding or injection molding.

An article, made of a thermoplastic polyurethane and having good gas barrier property, has been required. For example, multi-layered structures having a layer of a thermoplastic polyurethane and a layer of an ethylene-vinyl alcohol copolymer or a polyamide, each of which is known as a polymer having excellent gas barrier property, are proposed [see Japanese Patent Application Laid-open Nos. 22163/1983 (JPA 58-022163), 258341/1990 (JPA 2-258341), 5143/1991 (JPA 3-005143) and 110154/1998 (JPA 10-110154)].

A process for producing an article made of a thermoplastic polyurethane and an ethylene-vinyl alcohol copolymer or a polyamide inevitably causes a scrap such as(i) a lug of a film which is involved by co-extrusion process, (ii) trimmings which is involved by co-extrusion blow molding process and (iii) defective moldings. It is desirable to reuse such a scrap from the viewpoint of production cost and resource saving.

In addition, it is also desirable to recycle an article made of a thermoplastic polyurethane and an ethylene-vinyl alcohol copolymer or a polyamide.

Various attempts have been applied for the recycle of an article made of an ethylene-vinyl alcohol copolymer. For example, Japanese Patent Application Laid-open No. 195635/1995 (JPA 7-195635) discloses a method for the recycle of a multi-layered structure having a layer of an ethylene-vinyl alcohol copolymer and a layer of a polyolefin. Also, U.S. Pat. No. 6,294,602 and Japanese Patent Application Laid-open No. 248073/2000 (JPA 2000-248073) disclose a method for the recycle of an article made of a polymer composition comprising an ethylene-vinyl alcohol copolymer, a polyamide and a copolymer of an olefin and an unsaturated carboxylic acid. However, these documents are silent with a method for the recycle of an article made of an ethylene-vinyl alcohol copolymer and a thermoplastic polyurethane.

A thermoplastic polyurethane composition comprising a thermoplastic polyurethane and an ethylene-vinyl alcohol copolymer and/or a polyamide may be formulated by melting [i] an article made of a thermoplastic polyurethane and an ethylene-vinyl alcohol copolymer and/or a polyamide or [ii] a scrap involved by a process for producing an article made of a thermoplastic polyurethane and an ethylene-vinyl alcohol copolymer and/or a polyamide. However, in most cases, a combined use of a thermoplastic polyurethane and an ethylene-vinyl alcohol copolymer and/or a polyamide tends to cause gelation upon melt molding.

Japanese Patent Application Laid-open Nos. 206634/1990 (JPA 2-206634) and 255288/1991 (JPA 3-255288) disclose a uniform thermoplastic polyurethane composition, which can be formulated without gelation, comprising a thermoplastic polyurethane and an ethylene-vinyl alcohol copolymer having specific ethylene content. Japanese Patent Application Laid-open No. 324162/1995 (JPA 7-324162) also discloses a polymer composition comprising a thermoplastic polyurethane dispersed in a matrix of a polyamide. The present inventors have found that, even with such a uniform composition, gelation may proceed at a molten state to cause a reduction of melt tension of the composition, which leads to lesser processability upon extrusion molding or injection molding.

SUMMARY OF THE INVENTION

It is desired to give a thermoplastic polyurethane composition comprising a thermoplastic polyurethane and an ethylene-vinyl alcohol copolymer and/or a polyamide, which can be formulated without gelation and is suppressed in the progress of gelation even at a molten state. The object of the present invention is to provide such a thermoplastic polyurethane composition and a process for producing thereof.

The present inventors have made intensive studies to find that a melt kneading of a specific compound together with a thermoplastic polyurethane and an ethylene-vinyl alcohol copolymer and/or a polyamide can give a uniform thermoplastic polyurethane composition without gelation and can suppress the progress of gelation of the resulting composition in a molten state. The present invention is made upon such findings.

The present invention provides a thermoplastic polyurethane composition comprising a thermoplastic polyurethane and an ethylene-vinyl alcohol copolymer and/or a polyamide, in which the retention of melt tension thereof, when kept in a molten state at 220.degree. C. for 1 hour, is not less than 10%.

The thermoplastic polyurethane composition of the present invention includes, as a preferred embodiment, ones that is formulated using, as at least a part of its raw material, (i) a scrap which is involved by the production of an article made of at least one polymer selected from the group consisting of a thermoplastic polyurethane, an ethylene-vinyl alcohol copolymer and a polyamide and/or (ii) a used article which is made of at least one polymer selected from the group consisting of a thermoplastic polyurethane, an ethylene-vinyl alcohol copolymer and a polyamide, wherein said article can include {i} an article which is made of at least two kinds of polymer selected from the group consisting of a thermoplastic polyurethane, an ethylene-vinyl alcohol copolymer and a polyamide and {ii} a multi-layered structure having a layer of a thermoplastic polyurethane and a layer of an ethylene-vinyl alcohol copolymer and/or a polyamide.

The present invention also provides a process for producing the thermoplastic polyurethane composition of the present invention comprising melt kneading a compound having a hydroxy group and molecular weight not lower than 50 together with a thermoplastic polyurethane and an ethylene-vinyl alcohol copolymer and/or a polyamide.

The process of the present invention includes, as a preferred embodiment, ones that employ, as at least a part of its raw material, (i) a scrap which is involved by the production of an article made of at least one polymer selected from the group consisting of a thermoplastic polyurethane, an ethylene-vinyl alcohol copolymer and a polyamide and/or (ii) a used article which is made of at least one polymer selected from the group consisting of a thermoplastic polyurethane, an ethylene-vinyl alcohol copolymer and a polyamide.

In addition, the present invention provides a molded article made of the thermoplastic polyurethane composition of the present invention, wherein said molded article can include a multi-layered structure having a layer of a thermoplastic polyurethane, a layer of an ethylene-vinyl alcohol copolymer and/or a polyamide and a layer of the thermoplastic polyurethane composition of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A conventionally known thermoplastic polyurethane can be used as a component of the thermoplastic polyurethane composition of the present invention. From the viewpoint of flexibility and mechanical properties, the Shore A hardness of the thermoplastic polyurethane falls preferably between 60 and 97, more preferably between 65 and 95.

The thermoplastic polyurethane, which is employed in the present invention, can be prepared from a high polymer polyol, an organic isocyanate and a chain extender.

A conventionally known high polymer polyol can be used as a high polymer polyol constituting the thermoplastic polyurethane. From the viewpoint of the properties of the thermoplastic polyurethane, and from the viewpoint of the suppression of the molding failure such as a fish-eye and a granular structure, and the suppression of the failure of a molding machine during the continuous melt molding of the thermoplastic polyurethane for a long time, the number average molecular weight of the high polymer polyol preferably falls within a range of 300 to 10000, and more preferably within a range of 500 to 8000. Here, the number-average molecular weight of the high polymer polyol referred to in this specification means, in any case, the number-average molecular weight based on its hydroxyl value as measured in accordance with JIS K-1577.

Whereas, from the viewpoint of the interlaminar strength between the layer of the thermoplastic polyurethane composition of the present invention and a layer of an ethylene-vinyl alcohol copolymer or a polyamide, when formulated into a multi-layered structure, the crystallization enthalpy (.DELTA.H) of the high polymer polyol is preferably not more than 70 J/g. Here, the crystallization enthalpy (.DELTA.H) referred to in the present invention can be determined by means of a differential scanning calorimetry [DSC]. Specifically, it means the value determined in accordance with the method described in the following examples. The crystallization enthalpy (.DELTA.H) of the high polymer polyol is more preferably not more than 50 J/g.

In addition, the present inventors have found that a thermoplastic polyurethane made of a high polymer polyol having a crystallization enthalpy of not more than 70 J/g shows excellent interlaminar strength when formulated into a multi-layered structure having a layer of said thermoplastic polyurethane and an ethylene-vinyl alcohol copolymer or a polyamide. Especially, a thermoplastic polyurethane which is made of a high polymer diol having a crystallization enthalpy of not more than 70 J/g and having a number average molecular weight of from 300 to 1800 is found to be preferable because it can continuously produce, for a long time and without an operational failure of a molding machine, a multi-layered structure having a layer of said thermoplastic polyurethane and a layer of an ethylene-vinyl alcohol copolymer or a polyamide without causing a fish-eye or a granular structure.

The high polymer polyol can include, for example, polyester polyols, polycarbonate polyols, polyester-polycarbonate polyols, polyether polyols, polyolefin polyols, conjugated diene polymer based polyols, castor oil based polyols, silicone based polyols and vinylic polymer based polyols. Among them, polyester polyols, polycarbonate polyols, polyester-polycarbonate polyols and polyether polyols are preferred.

The polyester polyols can be prepared from a dicarboxylic acid component and a diol component, and if necessary, together with another component by a conventional polymerization method such as an esterification and an ester interchange. The polyester polyols can be also prepared by a ring-opening polymerization of lactones under the presence of a diol component.

The dicarboxylic acid component can include an aliphatic dicarboxylic acid having 4 to 12 carbon atoms such as succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, dodecane dicarboxylic acid, methyl succinic acid, 2-methylglutaric acid, 3-methylglutaric acid, trimethyladipic acid, 2-methyloctane dicarboxylic acid, 3,8-dimethyldecane dicarboxylic acid and 3,7-dimethyldecane dicarboxylic acid; a cycloaliphatic dicarboxylic acid such as cyclohexane dicarboxylic acid, dimer acid and hydrogenated product of dimer acid; an aromatic dicarboxylic acid such as terephthalic acid, isophthalic acid, orthophthalic acid and naphthalene dicarboxylic acid; a polyfunctionalized carboxylic acid such as trimellitic acid and pyromellitic acid; and derivatives thereof which can form esters, such as carboxylic acid esters and acid anhydrides. One or more of these compounds can be used as a dicarboxylic acid component.

The diol component can include an aliphatic diol having 2 to 15 carbon atoms such as ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, 1,3-propanediol, 2-methyl-1,3-propanediol, 2,2-diethyl-1,3-propanediol, 1,3-butanediol, 1,4-butanediol, 2-methyl-1,4-butanediol, neopentylglycol, 1,5-pentanediol, 3-methyl-1,5-pentanediol, 1,6-hexanediol, 1,7-heptanediol, 1,8-octanediol, 2-methyl-1,8-octanediol, 2,7-dimethyl-1,8-octanediol, 1,9-nonanediol, 2-methyl-1,9-nonanediol, 2,8-dimethyl-1,9-nonanediol and 1,10-decanediol; a cycloaliphatic diol such as 1,4-cyclohexanediol, cyclohexanedimethanol and cyclooctanedimethanol; an aromoatic diol such as 1,4-bis(.beta.-hydroxyethoxy)benzene; and a polyhydric alcohol having not less than 3 hydroxy groups such as trimethylolpropane, trimethylolethane, glycerin, 1,2,6-hexanetriol, pentaerythritol and diglycerin. One or more of these compounds can be used as a diol component.

The lactones can include, for example, .epsilon.-caprolactone and .beta.-methyl-.delta.-valerolactone.

In order to produce the polyester polyol having a crystallization enthalpy (.DELTA.H) of not more than 70 J/g, at least one of the following conditions (1) and (2) is preferably satisfied.

(1) At least a part of the dicarboxylic acid component for the polyester polyol is a dicarboxylic acid having a side chain; and

(2) At least a part of the diol component for the polyester polyol is a diol having a side chain.

The total number of moles of the dicarboxylic acid having a side chain and the diol having a side chain is preferably not less than 10%, more preferably not less than 30%, and still more preferably not less than 50% based on the total number of moles of the dicarboxylic acid component and the diol component for the polyester polyol.

An aliphatic dicarboxylic acid, having 5 to 14 carbon atoms and a saturated or unsaturated branched aliphatic hydrocarbon chain with two carboxyl groups on both ends thereof, or its derivative is preferable for the dicarboxylic acid having a side chain. The dicarboxylic acid having a side chain can include 2-methylsuccinic acid, 3-methylglutaric acid, 2-methyladipic acid, 3-methyladipic acid, 3-methylpentane dicarboxylic acid, 2-methyloctane dicarboxylic acid, 3,7-dimethylsebacic acid, 3,8-dimethylsebacic acid, citraconic acid, mesaconic acid and derivatives thereof such as carboxylic acid diesters and dicarboxylic acid anhydrides. One or more of these compounds can be used.

An aliphatic diol, having 4 to 10 carbon atoms and a saturated or unsaturated branched aliphatic hydrocarbon chain with two hydroxy groups on both ends thereof is preferable for the diol having a side chain. The diol having a side chain can include 2methyl-1,3-propanediol, 2,2-diethyl-1,3-propanediol, 2-methyl-1,4-butanediol, neopentylglycol, 3-methyl-1,5-pentanediol, 2-methyl-1,8-octanediol, 2,7-dimethyl-1,8-octanediol, 2-methyl-1,9-nonanediol, 2,8-dimethyl-1,9-nonanediol and 2-methyl-2-butene-1,4-diol. One or more of these compounds can be used. Among them, 3-methyl-1,5-pentanediol, 2-methyl-1,8-octanediol or a mixture of 3-methyl-1,5-pentanediol and 2-methyl-1,8-octanediol is more preferred.

One or more of these polyester polyols can be used as a raw material for the thermoplastic polyurethane.

Polyester polyols can be prepared under the presence of a catalyst such as a titanium catalyst and a tin catalyst. Titanium catalyst can include titanic acid, tetraalkoxy titanium compounds such as tetraisopropyl titanate, tetra-n-butyl titanate, tetra-2-ethylhexyl titanate and tetrastearyl titanate; titanium acylates such as polyhydroxytitanium stearate and polyisopropoxytitanium stearate; titanium chelate compounds such as titanium acetylacetonate, triethanoamine titanate, titanium ammonium lactate and titanium ethyl lactate; etc.

Tin catalyst includes dialkyl tin diacetates such as dibutyl tin diacetate, dialkyl tin dilaurate such as dibutyl tin dilaurate, dialkyl tin bismercaptocarboxylates such as dibutyl tin bis(ethoxybutyl-3-mercaptopropionate); etc.

The amount of the titanium catalyst, if used, is preferably from 0.1 to 50 ppm, more preferably from 1 to 30 ppm, relative to the total weight of the reactants. The amount of the tin catalyst, if used, is preferably from 1 to 200 ppm, more preferably from 5 to 100 ppm, relative to the total weight of the reactants.

Where polyester polyols are produced in the presence of a titanium catalyst, it is desirable that the titanium catalyst remaining in the polyester polyols produced is deactivated. The polyester polyol, in which the remaining titanium catalyst is deactivated, can give a thermoplastic polyurethane having excellent properties such as resistance to hydrolysis.

To deactivate the titanium catalyst remaining in the polyester polyols, for example, employable are [1] a method of bringing the polyester polyols into contact with water under heat to deactivate the titanium catalyst remaining therein, and [2] a method of treating the polyester polyols with phosphorus compounds such as phosphoric acid, phosphates, phosphorous acid and phosphites. Where the titanium catalyst is deactivated through contact with water, 1% by weight or more of water may be added to the polyester polyols and heated at 70.degree. C. to 150.degree. C., preferably 90.degree. C. to 130.degree. C., for from 1 to 3 hours. The deactivation of the titanium catalyst can be effected at atmospheric pressure or under elevated pressure. It is desirable that the pressure in the system is reduced after the deactivation of the titanium catalyst since water as added to the system for the deactivation can be removed quickly.

The polycarbonate polyols can include those obtained by the reaction of a diol component and a carbonate compound. The diol component, which constitutes the polycarbonate polyols, can include ones illustrated above as a diol component for the polyester polyols. The carbonate compound can include dialkyl carbonates such as dimethyl carbonate and diethyl carbonate; alkylene carbonates such as ethylene carbonate; and diaryl carbonates such as diphenyl carbonate. One or more of these polycarbonate polyols can be used as a raw material for the thermoplastic polyurethane.

In order to produce the polycarbonate polyol having a crystallization enthalpy (.DELTA.H) of not more than 70 J/g, at least a part of the diol component is preferably a diol having a side chain. The diol component having a side chain can include ones illustrated above as a component for the polyester polyols. The amount of the diol having a side chain is preferably not less than 10 mol %, more preferably not less than 30 mol %, and still more preferably not less than 50 mol % based on the diol component.

The polyester polycarbonate polyols can include (a) those obtained by the reaction of a diol component, a dicarboxylic acid component and a carbonate compound; (b) those obtained by the reaction of a carbonate compound and a previously prepared polyester polyol and/or polycarbonate polyol; and (c) those obtained by the reaction of a previously prepared polycarbonate polyol, a diol component and a dicarboxylic acid component.

The diol component and dicarboxylic acid component each for constituting the polyester polycarbonate polyol can include those illustrated above as components each for constituting the polyester polyol.

One or more of these polyester polycarbonate polyols can be used as a raw material for the thermoplastic polyurethane.

In order to produce the polyester polycarbonate polyol having a crystallization enthalpy (.DELTA.H) of not more than 70 J/g, it is preferable to use a polyester polyol having a crystallization enthalpy (.DELTA.H) of not more than 70 J/g, and/or a polycarbonate polyol having a crystallization enthalpy (.DELTA.H) of not more than 70 J/g, for the case (b) or (c). Alternatively, for the case (a), at least one of the following conditions (3) and (4) is satisfied.

(3) At least a part of the dicarboxylic acid component for the polyester polycarbonate polyol is a dicarboxylic acid having a side chain; and

(4) At least a part of the diol component for the polyester polyol is a diol having a side chain.

The total number of moles of the dicarboxylic acid having a side chain and the diol having a side chain is preferably not less than 10%, more preferably not less than 30%, and still more preferably not less than 50% based on the total number of moles of the dicarboxylic acid component and the diol component for the polyester polycarbonate polyol.

The polyether polyols can include polyether diols prepared by the ring-opening polymerization of a cyclic ether such as ethylene oxide, propylene oxide, trimethylene oxide tetrahydrofuran and methyltetrahydrofuran; and polyether diols prepared by the polymerization of a glycol such as ethylene glycol, propylene glycol, 1,4-butanediol, neopentyl glycol, 1,6-hexanediol, 3-methyl-1,5-pentanediol, 2-methyl-1,8-octanediol, 1,9-nonanediol or 1,10-decanediol. One or more of these polyether polyols can be used as a raw material for the thermoplastic polyurethane.

To obtain the polyether polyol having a crystallization enthalpy (.DELTA.H) of not more than 70 J/g, it is preferred to use a branched compound for the cyclic ether or the glycol.

The conjugated diene polymer based polyols or the polyolefin polyols can include a polyisoprene polyol, a polybutadiene polyol, a poly(butadiene/isoprene) polyol, a poly(butadiene/acrylonitrile) polyol, a poly(butadiene/styrene) polyol, and a hydrogenated product thereof, prepared by polymerizing a conjugated diene such as butadiene or isoprene, or a conjugated diene and another monomer, by a living polymerization method, or the like in the presence of a polymerization initiator, followed by a reaction with an epoxy compound. One or more of these conjugated diene polymer based polyols or the polyolefin polyols can be used as a raw material for the thermoplastic polyurethane.

The organic isocyanate for the thermoplastic polyurethane can include aromatic diisocyanates such as 4,4'-diphenylmethane diisocyanate, phenylene diisocyanate, toluylene diisocyanate, xylylene diisocyanate, 1,5-naphthylene diisocyanate and 3,3'-dichloro-4,4'-diphenylmethane diisocyanate; aliphatic or alicyclic diisocyanates such as hexamethylene diisocyanate, isophorone diisocyanate, 4,4'-dicyclohexylmethane diisocyanate and hydrogenated xylylene diisocyanate; etc. One or more of these organic isocyanates can be used. Among them, preferred is 4,4'-diphenylmethane diisocyanate. If required, small amounts of tri-functional or higher poly-functional polyisocyanates, such as triphenylmethane triisocyanate, can be added to the organic diisocyanate.

The chain extender for the thermoplastic polyurethane can include, as a preferred example, a compound having a molecular weight of not more than 300 and having two or more active hydrogen atoms capable of reacting with isocyanate group, examples of which are diols such as ethylene glycol, propylene glycol, 1,4-butanediol, 1,6-hexanediol, 1,4-bis (.beta.-hydroxyethoxy)benzene, 1,4-cyclohexanedimethanol, bis (.beta.-hydroxyethyl) terephthalate, xylylene glycol; diamines such as hydrazine, ethylenediamine, propylenediamine, isophoronediamine, piperazine, piperazine derivatives, phenylenediamine, toluylenediamine, xylylenediamine, adipic acid dihydrazide and isophthalic acid dihydrazide; aminoalcohols such as aminoethyl alcohol and aminopropyl alcohol; etc. One or more of these compounds can be used. Among them, preferred is an aliphatic diol having 2 to 10 carbon atoms. More preferred is 1,4-butanediol, because it can give a thermoplastic polyurethane having excellent properties such as heat resistance and hot water resistance.

The method for producing the thermoplastic polyurethane can include conventional method such as "prepolymer process" and "one-shot process" utilizing melt polymerization or solution polymerization. In particular, it is preferable to employ the melt polymerization substantially in the presence of no solvent to give the intended thermoplastic polyurethane. More preferred is continuous melt polymerization using multi-screw extruders.

The preparation of the thermoplastic polyurethane can be conducted in the presence of a urethanating tin catalyst. It is desirable to conduct the preparation of the thermoplastic polyurethane in the presence of a urethanating tin catalyst in an amount of 0.5 to 15 ppm, calculated as the tin atom, based on the total weight of the raw materials used, because the thermoplastic polyurethane having a high molecular weight can be obtained. The thermoplastic polyurethane thus obtained in the presence of a urethanating tin catalyst shows excellent processability and gives a molded article having high transparency and good appearance with little fish-eye.

The urethanating tin catalyst includes dibutyltin diacetate, dibutyltin dilaurate, dibutyltin bis (3-ethoxybutyl-3-mercaptopropionate), etc.

The degree of polymerization of the thermoplastic polyurethane is, in consideration of the mechanical properties and processability, preferably such that the thermoplastic polyurethane as dissolved in N,N-dimethylformamide at a concentration of 0.5 dl/g can have an inherent viscosity at 30.degree. C. of at least 0.3 dl/g, more preferably at least 0.5 dl/g.

The thermoplastic polyurethane can contain a crosslinking agent curable by ultraviolet or electron rays such as trimethylolpropane trimethacrylate, trimethylolpropane triacrylate and trimethylolpropane triglycidyl ether.

The thermoplastic polyurethane can contain other polymers such as a styrene-butadiene rubber [SBR], a natural rubber, an ethylene propylene diene terpolymer [EPDM], a liquid polyisoprene, a block copolymer of styrene and butadiene, an olefin-based elastomer, soft acrylic resin and polyvinylchloride. The thermplastic polyurethane can also contain fillers such as glass beads, glass fibers, talc, calcium carbonate, mica and clay. In addition, the thermoplastic polyurethane can contain, if necessary, conventionally used additives such as heat stabilizers, antioxidants, ultraviolet absorbents, flame retardants, lubricants, colorants, hydrolysis inhibitors, nucleating agents, weather resistance improving agents and antifungal agents.

Such crosslinking agents, other polymers, fillers and additives can be added during or after the preparation of the thermoplastic polyurethane.

As the ethylene-vinyl alcohol copolymer, which is another component of the thermoplastic polyurethane composition of the present invention, the one having an ethylene content of 10 to 60 mol % is preferably used, and the one having an ethylene content of 20 to 60 mol % is more preferably used, from the viewpoint of the gas barrier property, the processability and the compatibility with the thermoplastic polyurethane, and further from the viewpoint of the interlaminar strength when formulated into a multi-layered structure with a thermoplastic polyurethane. Further, as the ethylene-vinyl alcohol copolymer, the one having a degree of saponification of not less than 90% is preferably used.

The ethylene-vinyl alcohol copolymer may be the one prepared from the copolymerization of components other than ethylene and vinyl acetate, as long as it does not depart from the scope of the present invention.

The ethylene-vinyl alcohol copolymer preferably has a melt index determined in accordance with ASTM D-1238-65T of 0.1 to 25 g/10 min [determined at 190.degree. C. and under the load of 2160 g] from the viewpoint of the processability. The melt index is more preferably 0.3 to 20 g/10 min.

The ethylene-vinyl alcohol copolymer can be used alone. Also, a mixture of not less than two of the ethylene-vinyl alcohol copolymers having different ethylene content, degree of saponification, melt index and the like may be used.

The ethylene-vinyl alcohol copolymer can contain carboxylic acids such as acetic acid, propionic acid and lactic acid; alkali metal salts of carboxylic acids such as sodium acetate, potassium acetate, sodium propionate, potassium propionate, sodium lactate and potassium lactate; phosphoric acid compounds and alkali metal salts thereof such as phosphoric acid, phosphorous acid, sodium phosphate, lithium phosphate, sodium dihydrogenphosphate and potassium dihydrogenphosphate; boric acid compound and alkali metal salts or ester derivatives thereof such as orthoboric acid, metaboric acid, tetraboric acid, sodium borate, lithium borate, triethylborate, trimethylborate and borax; etc.

Examples of the method for allowing the ethylene-vinyl alcohol copolymer to contain the above-described compound can include (1) a method in which an ethylene-vinyl alcohol copolymer in powdery, granular, spherical or cylindrical pellet form is immersed in an aqueous solution of the above-described compound, if required, followed by drying; (2) a method in which an ethylene-vinyl alcohol copolymer and the above-described compound are melt blended; and (3) a method in which an ethylene-vinyl alcohol copolymer is dissolved in an appropriate solvent, and the above-described compound are mixed therein.

The ethylene-vinyl alcohol copolymer can contain, if necessary, additives such as softening agents, heat stabilizers, antioxidants, ultraviolet absorbents, flame retardants, lubricants, colorants, hydrolysis inhibitors, nucleating agents, weather resistance improving agents and antifungal agents.

The polyamide can include ones obtained by the ring-opening polymerization of a cyclic lactam, ones obtained by the polymerization of an .omega.-aminocarboxylic acid, and ones obtained by the polymerization of a dicarboxylic acid component and a diamine component. One or more of these polyamides can be used.

The lactam can contain .epsilon.-caprolactam, enanthlactam, caprilactam, laurolactam and .alpha.-pyrolidone. The .omega.-aminocarboxylic acid can include 6-aminocaproic acid, 7-aminoheptanoic acid, 9-aminononanoic acid and 11-aminoundecanoic acid.

The dicarboxylic acid component can include aliphatic dicarboxylic acids such as malonic acid, dimethylmalonic acid, succinic acid, 3,3-diethylsuccinic acid, glutaric acid, 2,2-dimethylglutaric acid, adipic acid, sebacic acid and suberic acid; alicyclic dicarboxylic acids such as 1,3-cyclopentanedicarboxylic acid and 1,4-cyclohexanedicarboxylic acid; aromatic dicarboxylic acids such as terephthalic acid, isophthalic acid, 2,6-naphthalenedicarboxylic acid, 2,7-naphthalenedicarboxylic acid, 1,4-naphthalenedicarboxylic acid, 1,4-phenylenedioxy-diacetic acid, 1,3-phenylenedioxy-diacetic acid, diphenic acid, 4,4'-oxydibenzoic acid, diphenylmethane-4,4'-dicarboxylic acid, diphenylsulfone-4,4'-dicarboxylic acid and 4,4'-biphenyldicarboxylic acid.

The diamine component can include aliphatic diamines such as ethylenediamine, propylenediamine, 1,4-tetramethylenediamine, 1,6-hexanediamine, 1,8-octanediamine, 1,9-nonanediamine, 1,10-decanediamine, 1,12-dodecanediamine, 2-methyl-1,5-pentanediamine, 3-methyl-1,5-pentanediamine, 2,2,4-trimethyl-1,6-hexanediamine, 2-methyl-1,8-octanediamine and 5-methyl-1,9-nonanediamine; cycloaliphatic diamines such as cyclohexanediamine, methylcyclohexanediamine and isophoronediamine; aromatic diamines such as p-phenylenediamine, m-phenylenediamine, xylylenediamine, 4,4'-diaminodiphenylmethane, 4,4'-diaminodiphenylsulfone and 4,4'-diaminodiphenylether.

The polyamide can contain fillers such as glass beads, glass fibers, talc, calcium carbonate, mica and clay. In addition, the polyamide can contain, if necessary, conventionally used additives such as heat stabilizers, antioxidants, ultraviolet absorbents, flame retardants, lubricants, colorants, hydrolysis inhibitors, nucleating agents, weather resistance improving agents and antifungal agents.

With respect to the thermoplastic polyurethane composition of the present invention, the weight ratio of the thermoplastic polyurethane based on the total weight of the ethylene-vinyl alcohol copolymer and the polyamide falls between 98/2 and 2/98.

The thermoplastic polyurethane composition of the present invention is required to have a retention of melt tension thereof, when kept in a molten state at 220.degree. C. for 1 hour, of not less than 10%.

The retention of melt tension is the value calculated in accordance with the following equation (I), and corresponds to the degree of progress of gelation when the thermoplastic polyurethane composition is kept in a molten state. When the retention of melt tension is less than 10%, the gelation remarkably proceeds when the thermoplastic polyurethane composition comprising an ethylene-vinyl alcohol copolymer and/or a polyamide, and a thermoplastic polyurethane is kept in a molten state, which does not meet the object of the present invention. Retention of melt tension (%)=[Melt tension after being kept in a molten state/Melt tension before being kept in a molten state].times.100 (I)

The retention of melt tension of the thermoplastic polyurethane composition of the present invention, when kept in a molten state at 220.degree. C. for 1 hour, is preferably not less than 15%, and more preferably not less than 20%.

The melt tension referred to in the present invention means the tension observed when the thermoplastic polyurethane composition has been molten, the resulting melt has been extruded in the air as a strand, and the strand is taken back at a given rate.

The thermoplastic polyurethane composition of the present invention has, in general, a melt tension of not less than 0.1 g when extruded in the air at a rate of 2 m/min from a nozzle having a diameter of 1 mm at 220.degree. C. and taken back at a rate of 5 m/min.

The thermoplastic polyurethane composition of the present invention can be prepared by subjecting [a] a thermoplastic polyurethane, [b] an ethylene-vinyl alcohol copolymer and/or a polyamide and [c] an organic compound having a hydroxy group and molecular weight of not less than 50 to melt kneading.

When the molecular weight of the organic compound having a hydroxy group is less than 50, the organic compound is so volatile that it becomes difficult to melt knead it together with an ethylene-vinyl alcohol copolymer and/or a polyamide, and a thermoplastic polyurethane.

The upper limit of the molecular weight of the organic compound having a hydroxy group is, in general, not more than about 20000. The molecular weight of the organic compound having a hydroxy group preferably falls within a range of 60 to 18000.

The organic compound having a hydroxy group is preferably an organic compound having an alcoholic hydroxy group. Further, the average number of hydroxy groups per molecule of the compound falls within a range of preferably 1 to 5, more preferably 1.5 to 4, and still more preferably 2 to 3.5.

Organic compound having a hydroxy group can include monoalcohols having not less than 3 carbon atoms such as n-propanol, n-butanol, n-pentanol, n-octanol and benzylalcohol; diols having not less than 2 carbon atoms such as ethylene glycol, propylene glycol, butanediol, 2-methyl-1,4-butanediol, pentanediol, 3-methyl-1,5-pentanediol, hexanediol, heptanediol, octanediol, 2-methyl-1,8-octanediol, nonanediol, decanediol and cyclohexanedimethanol; polyhydric alcohols having not less than 3 carbon atoms such as glycerin, trimethylolpropane, butanetriol, hexanetriol, trimethylolbutane, trimethylolpentane and pentaerythritol; styrene-conjugated diene coplymer having hydroxy group at a polymer end and the hydrogenated product thereof; high polymer polyols such as polyesyer polyols, polyether polyols, polycarbonate polyols, polyester polycarbonate polyols and polyplefin polyols. High polymer polyols can include ones illustrated above as a raw material for the thermoplastic polyurethane. The polyurethane prepolymer, which can be obtained by the reaction of the high polymer polyol, the chain extender and the organic isocyanate in such an amount that the total moles of the hydroxy group of the reactant is higher than the total moles of the isocyanate group of the reactant, can be also used as the organic compound having a hydroxy group. One or more of these organic compounds can be used. Among them, diols, polyhydric alcohols and high polymer polyols are preferred.

The amount of the organic compound having a hydroxy group falls preferably between 0.5 and 50 part by weight based on the 100 part by weight of the sum of the thermoplastic polyurethane, the ethylene-vinyl alcohol copolymer and the polyamide.

The melt kneading of an ethylene-vinyl alcohol copolymer and/or a polyamide, a thermoplastic polyurethane and an organic compound having a hydroxy group and a molecular weight of not less than 50 can be carried out by a known apparatus such as a single-screw or twin-screw extruder, a mixing roll or a kneader. It is preferably carried out by a twin-screw extruder.

The melt kneading can be carried out at a temperature in the range of preferably 150 to 250.degree. C., and more preferably 180 to 230.degree. C.

The respective components may be dry blended prior to melt kneading.

And the respective components are, prior to melt kneading, desirably subjected to a drying treatment by means of a dryer or the like in order to suppress the moisture absorption. Further, the hopper opening of the molding machine is desirably sealed with an inert gas such as dried air or nitrogen.

The thermoplastic polyurethane composition of the present invention can be formulated, by various molding methods such as extrusion molding, injection molding, blow molding, calendar molding, press molding, compression molding, vacuum forming and air pressure forming, into molded articles having various shapes such as a film, a sheet or a pipe; a bag-like article obtained from a film or a sheet, an article obtained by thermally processing a sheet, an article obtained by blow molding, an article obtained by pressing and stacking [i.e. dry lamination] with previously molded films or sheets, and a molded article obtained from injection molding.

A composite article can be formulated from the thermoplastic polyurethane composition of the present invention and another material. The another material can include polyolefins such as a polyethylene, a polypropylene, an ethylene-propylene copolymer and a polybutene; olefin based copolymers such as an ethylene-vinyl acetate copolymer, an ethylene-ethyl acetate copolymer and an ionomer resin; thermoplastic polymers such as a thermoplastic polyurethane, an ethylene-vinyl alcohol copolymer, a polyamide, a polyvinylidene chloride, a polyvinyl chloride, a polyester, a polycarbonate, an acrylic polymer, an ABS resin and a polyacrylonitrile; metals such as aluminum, copper and nickel; papers; non-woven fabrics; etc. Among them, a thermoplastic polyurethane, an ethylene-vinyl alcohol copolymer and a polyamide are preferred.

Examples of the method for producing a composite article can include an extrusion lamination, a dry lamination, an extrusion blow molding, a co-extrusion lamination, a co-extrusion sheet molding, a co-extrusion pipe molding, a co-extrusion blow molding, a co-injection molding and a solution coating. The composite article may also be subjected to secondary processing by vacuum forming, air pressure forming, blow molding and the like, if desired.

The composite article can include multi-layered structures formed of a plurality of layers. Such composite article include the ones having various shapes such as a multi-layered sheet, a multi-layered film and a tube of a multi-layered structure.

Specific examples of the multi-layered structure include multi-layered structures having a layer made of a thermoplastic polyurethane, a layer made of an ethylene-vinyl alcohol copolymer and/or a polyamide, and a layer made of the thermoplastic polyurethane composition of the present invention. Among them, the one having a layer made of the thermoplastic polyurethane composition of the present invention as its outermost layer has a high practical utility.

The number of the layers (A) made of a thermoplastic polyurethane, the layers (B) made of an ethylene-vinyl alcohol copolymer and/or a polyamide, and the layers (C) made of the thermoplastic polyurethane composition of the present invention in such a multi-layered structure has no particular restriction. Further, the multi-layered structure may include a layer (D) made of another material.

Examples of another material can include other resins such as polyester based resins, polycarbonate based resins, polyether based resins, polyvinyl chloride based resins, ethylene-vinyl acetate copolymer resins, polyalkyl acrylate based resins and polyolefin based resins; papers; fabrics; and metals such as aluminum, copper and nickel.

The layer (A) of a thermoplastic polyurethane and the layer (B) of an ethylene-vinyl alcohol copolymer and/or a polyamide are desirably stacked directly one on another. However, the interposition of a layer (AD) of an interlaminar adhesive therebetween is not excluded if it does not depart from the scope of the present invention.

Examples of such an interlaminar adhesive can include polyolefins such as a polyethylene and a polypropylene, prepared by adding or grafting an ethylenically unsaturated carboxylic acid or an anhydride thereof such as maleic anhydride; ethylene-vinyl acetate copolymers and copolymers of ethylene and an ethylene-acrylic acid ester such as methyl ester and ethyl ester.

Examples of the configuration of the multi-layered structure can include (C)/(A)/(B), (A)/(B)/(A)/(C), (C)/(A)/(B)/(A)/(C), (C)/(A)/(B)/(D)/(B)/(A)/(C), (C)/(AD)/(A)/(B), and (C)/(AD)/(A)/(B)/(A)/(AD)/(C), wherein (A) is the abbreviation of the layer (A) of a thermoplastic polyurethane; (B), the layer (B) made of an ethylene-vinyl alcohol copolymer and/or a polyamide; (C), the layer (C) made of the thermoplastic polyurethane composition of the present invention; (D), the layer (D) made of another material; and (AD), the layer (AD) of an interlaminar adhesive.

The thickness of such layers constituting the multi-layered structure has no particular restriction. It is adjusted according to the properties of the thermoplastic polyurethane, the ethylene-vinyl alcohol copolymer or the polyamide, constituting the multi-layered structure, the number of the layers of the multi-layered structure, the molding method of the multi-layered structure, the intended use of the multi-layered structure, and the like. However, in general, it is preferably so configured that, the layer (A) of a thermoplastic polyurethane has a thickness within a range of 10 to 5000 .mu.m per layer, the layer (B) of an ethylene-vinyl alcohol copolymer and/or a polyamide has a thickness within a range of 1 to 1000 .mu.m per layer, and the layer (C) made of the thermoplastic polyurethane composition of the present invention has a thickness within a range of 50 to 10000 .mu.m per layer from the viewpoint of the ease of production of the multi-layered structure, the interlaminar strength between the respective layers and so on.

The ratio of the thicknesses of the layer (A) of a thermoplastic polyurethane to the layer (B) of an ethylene-vinyl alcohol copolymer and/or a polyamide is, in general, falls within the range of 100/1 to 1/100.

The multi-layered structure is efficiently produced by co-extrusion of a polyurethane, an ethylene-vinyl alcohol copolymer, a polyamide and the thermoplastic polyurethane composition of the present invention. Alternatively, it can also be produced by the following steps in which a multi-layered structure having the layer (A) made of a polyurethane and the layer (B) made of an ethylene-vinyl alcohol copolymer and/or a polyamide is produced [step 1], and the layer (C) made of the thermoplastic polyurethane composition of the present invention is formed on the surface of the resulting multi-layered structure by extrusion molding, injection molding, solution coating or the like [step 2].

The thermoplastic polyurethane composition of the present invention can be used for various applications in which the gas barrier property or the flexibility is required. For example, the thermoplastic polyurethane compositions of the present invention are useful as materials for various uses such as packaging materials for oxygen-sensitive food and medicals; packaging materials for apparel; packaging materials for other products; construction materials such as window frame materials, wallpapers and decorative sheets; electrical insulating films; base materials for adhesive films and tapes; marking films; agricultural films; films for lamination with metal sheets or other materials; uses of apparel and sundry goods such as table cloths, rain coats, umbrellas, curtains, mats and coverings; various industrial parts with packings for sealing purpose or other purposes; automobile interior components such as assist grips, handles and air bag coverings; sport goods such as goggles; bag-like goods such as shoes, trunks and bags; box-like goods; decorative materials for a furniture; tubes, belts, hoses, tires, various rolls, screens, casters, gears, packing materials, linings, electric wire cladding materials, various joints, valve components and machine parts.

In the present invention, as a preferred embodiment, it is possible to use (i) a scrap generated during the production of an article made of a thermoplastic polyurethane, an ethylene-vinyl alcohol copolymer or a polyamide and/or (ii) a used article made of a thermoplastic polyurethane, an ethylene-vinyl alcohol copolymer or a polyamide, as at least a part of the raw materials for the thermoplastic polyurethane composition.

Example of the article can include (I) an article made of one polymer such as a foam, a fiber, a sheet or a film of a thermoplastic polyurethane; or a foam, a fiber, a sheet or a film of a polyamide; (II) various articles composed of a polymer composition comprising not less than two polymers such as a thermoplastic polyurethane and an ethylene-vinyl alcohol copolymer, or a thermoplastic polyurethane and a polyamide; and (III) a multi-layered structure having a layer made of a thermoplastic polyurethane, and a layer made of an ethylene-vinyl alcohol copolymer and/or a polyamide.

The molded article can be produced by various molding methods such as extrusion molding, injection molding, blow molding, and calender molding. Examples of the scrap generated during the production process of the article can include a discharged product generated upon start-up or upon completion of production of an article or a multi-layered structure, trimmings at opposite ends of a film or a sheet generated during production thereof, sprue generated during production of a multi-layered structure by injection molding or blow molding, and low quality goods in the production of an article and a multi-layered structure.

Examples of the used article can include products after having been used by common consumers, recovered products from industrial wastes and crushed pieces thereof.

The melt kneading of such a scrap and/or a used article together with an ethylene-vinyl alcohol copolymer or a polyamide, a thermoplastic polyurethane and an organic compound having a hydroxy group and a molecular weight of not lower than 50 can give the thermoplastic polyurethane composition of the present invention.

When the scrap or the used article contains an ethylene-vinyl alcohol copolymer or a polyamide as an ingredient, it is possible to omit the use of an ethylene-vinyl alcohol copolymer or a polyamide in the foregoing melt kneading. Whereas, when the scrap or the used article contains a thermoplastic polyurethane as an ingredient, it is possible to omit the use of a thermoplastic polyurethane in the foregoing melt kneading. Further, when the scrap or the used article contains a thermoplastic polyurethane and an ethylene-vinyl alcohol copolymer and/or a polyamide as ingredients, if desired, it is also possible to omit the use of both an ethylene-vinyl alcohol copolymer and/or a polyamide and a thermoplastic polyurethane.

The thermoplastic polyurethane composition of the present invention can be produced by melt kneading of the scrap and/or the used article together with only an organic compound having a hydroxy group and a molecular weight not lower than 50 with respect to the following cases.

Case 1: The scrap is the one generated during the production of an article made of {a} a thermoplastic polyurethane and an ethylene-vinyl alcohol copolymer and/or a polyamide or made of {b} a polymer composition comprising a thermoplastic polyurethane, an ethylene-vinyl alcohol copolymer and/or a polyamide.

Case 2: The used article is the used one made of {a} a thermoplastic polyurethane and an ethylene-vinyl alcohol copolymer and/or a polyamide or made of {b} a polymer composition comprising a thermoplastic polyurethane, an ethylene-vinyl alcohol copolymer and/or a polyamide.

The proportion of the scrap or the used article in the raw materials for the thermoplastic polyurethane composition of the present invention can be determined according to the various conditions such as the compositions of the scrap and the used