JP2015222010A - Artificial lawn with cushioning layer - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide improved material and method for forming a reusable cushioning layer of artificial lawn that includes a cushioning layer of thermoplastic foam.SOLUTION: Non-crosslinked polyethylene foam is installed as a cushioning layer to be bonded on a backing material. An artificial lawn is installed on the backing material, and spaces between yarns are filled with a filler. The non-crosslinked polyethylene is reusable, so the material poses no environmental problem at all, and is especially effective as a weighty layer for reducing noises and vibrations.

Description

Embodiments disclosed herein generally relate to thermoplastic foam cushioning layers. In another aspect, embodiments described herein relate to a synthetic turf that includes a thermoplastic foam cushioning layer from which the foam can be reused.

An artificial turf is composed of a number of artificial turf ridges extending upwardly from a sheet substrate. The lawn is usually placed on a flat, leveled ground to form a stadium that mimics the ground of a natural turf stadium.

For some types of games, an elastic underpad is placed under the lawn and on a hard ground support surface to provide a cushioning effect. Also, in some cases, a layer of sand or other particulate material is on the top surface of the carpet base sheet,
And around the stranded wire. One example of this type of structure is January 21, 1983.
Frederick T. issued on the day. Haas, Jr. U.S. Pat. No. 4,389,43
It is shown in No.5. Another example is Seymour A, published January 20, 1987.
. As shown in US Pat. No. 4,637,942 to Tomarin et al.

In addition, an example of an artificial lawn formed by a lawn-like carpet placed on an elastic underpad discloses a polyurethane foam underpad, a Carter et al. Patent issued December 29, 1970. No. 3,551,263, 1967, 1 discloses PVC foam plastic or polyurethane foam plastic underpad
U.S. Pat. No. 3,332,828 to Faria et al., Issued on Jan. 25, Seymour A. et al. US Patent No. 4,637,942 to Tomarin, Hans-Urich Britschild, issued November 21, 1989, illustrating closed cell cross-linked polyethylene foam underpad
U.S. Pat. No. 4,882,208 to Theodore Buchholz et al., Issued August 3, 1971, which discloses a voided polyurethane underpad.
No. 597,297, James W., issued March 19, 1985, which discloses a cushioning pad made from an elastomeric foam such as polyvinyl chloride, polyethylene, polyurethane, polypropylene and the like. Leffingwell, U.S. Pat. No. 4,505,960.

Of course, the buffer layer can be widely used for other applications, for example, energy suppression in the floor. Therefore, what is further needed is an improved material and method for forming a buffer layer, such as a reusable buffer layer.

In one aspect, embodiments disclosed herein relate to a synthetic turf surface comprising an artificial turf carpet having a flexible substrate sheet and a cushioning pad,
The cushion pad includes a non-crosslinked polyolefin foam.

Other aspects and advantages of the invention will be apparent from the following description and the appended claims.

It is a figure which shows the measurement and experiment regarding a buffer test using a FIFA standard. FIG. 4 compares the results of a compressive stress strain behavior analysis of a foam according to embodiments disclosed herein with the results of a crosslinked polyethylene foam. FIG. 4 compares the results of a compressive stress strain behavior analysis of a foam according to embodiments disclosed herein with the results of a crosslinked polyethylene foam. FIG. 5 compares the results of a time test for compression strain for a foam according to embodiments described herein with results for a crosslinked polyethylene foam. FIG. 5 compares the results of a time test for compression strain for a foam according to embodiments described herein with results for a crosslinked polyethylene foam. FIG. 6 compares the results of a compression creep behavior test for a foam according to embodiments described herein with the results of a crosslinked polyethylene foam. FIG. 2 illustrates an artificial turf that can be formed using the non-crosslinked polyolefin foam embodiments described herein.

  General definitions and measurement methods

  The following terms have the meaning given for the purposes of the present invention.

“Polymer” means a substance composed of molecules having a large molecular weight composed of repeating structural units or monomers joined by covalent chemical bonds. The term “polymer” typically includes, but is not limited to, homopolymers, copolymers, such as block, graft, random, and alternating copolymers, terpolymers, and the like and mixtures and modifications thereof. Further, unless otherwise specifically limited, the term “polymer” is intended to include all possible geometrical configurations of the molecular structure. These configurations include isotactic, syndiotactic, random arrangement, and the like.

“Interpolymer” means a polymer prepared by the polymerization of at least two different types of monomers. The generic term “interpolymer” refers to the term “copolymer” (usually used to refer to a polymer prepared from two different monomers), as well as the term “terpolymer” (polymer prepared from three different types of monomers). Usually used to refer to). The class of materials known as “interpolymers” also includes polymers made by polymerizing four or more types of monomers.

  Resin and composition densities were measured according to ASTM D792.

  The density of the foam was measured according to ASTM D3575 / W / B.

“Melt Index (I2)” was determined according to ASTM D1238 using a weight of 2.16 kg at 190 ° C. for polymers containing ethylene as the major component in the polymer. “Melt Flow Rate (MFR)” is ASTM using a weight of 2.16 kg at 230 ° C. for polymers containing propylene as the major component in the polymer.
Determined according to D1238.

The molecular weight distribution of the polymer was determined using four linear mixed bed columns (Polymer Labora).
Polymer Laboratories with Tories (20 micron particle size)
Determined using gel permeation chromatography (GPC) with ies PL-GPC-220 high temperature chromatograph unit. The oven temperature is 160 ° C, the auto sampler hot zone is 160 ° C, the warm zone is 145 ° C
It is. The solvent is 1,2,4-trichlorobenzene containing 200 ppm 2,6-di-t-butyl-4-methylphenol. The flow rate is 1.0 millimeter / minute and the injection size is 100 microliters. 200 ppm 2,6-di-tert-butyl-4-
By gently mixing the sample in nitrogen purged 1,2,4-trichlorobenzene containing methylphenol and dissolving at 160 ° C. for 2.5 hours, an approximately 0.2% by weight solution of the sample is ready for injection. Prepared.

Molecular weight is determined by 10 narrow molecular weight distribution polystyrene standards (Polymer Lab).
EasiCal in the range of 580-7,500,000 g / mol from oratories
Estimated by using PS1) with its elution volume. Equivalent polypropylene molecular weight is obtained from polypropylene (Th. G. Scholte, N. L. J. Meijeri).
nk, H.M. M.M. Schoffeleers, and A.M. M.M. G. Brands, J. et al. Ap
pl. Polym. Sci. 29, 3763-3782 (1984)), and polystyrene (EP Otokka, RJ Roe, NY).
Hellman, P.M. M.M. Muglia, Macromolecules, 4,507 (
1971)) by using the appropriate Mark-Houwink coefficient {N} = KM ^a . However,
K _pp = 1.90E-04, a _pp = 0.725 and K _ps = 1.26E-04, a _p
s = 0.702. “Molecular weight distribution” or MWD is described in Williams, T .; , Wa
rd, I.D. M.M. , Journal of Polymer Science, Polym
er Letters Edition (1968), 6 (9), measured by conventional GPC through the technique described by 621-624. The coefficient B is 1. Factor A
Is 0.4316.

The term high pressure low density type resin refers to peroxides (eg, US Pat. No. 4,599, incorporated herein by reference) at pressures greater than 14,500 psi (100 MPa) in an autoclave or tubular reaction vessel. No. 392), which is defined to mean partially or fully homopolymerized or copolymerized using free radical initiators such as “high pressure ethylene polymer” or “highly branched polyethylene” "LDPE" which may also be called. Cumulative detector frac of these materials
(CDF) is greater than about 0.02 for molecular weights greater than 1,000,000 g / mole as measured using light scattering. CDF is WO200, which is incorporated herein.
5/023912 A2 can be determined as described with respect to the teachings on CDF. Preferred high pressure low density polyethylene materials (LDPE) have a melt index MI (I2) of less than about 20, more preferably less than about 15, most preferably less than 10, and greater than about 0.1, more preferably about 0. .2, more preferably 0.
Greater than 3 g / 10 min. Preferred LDPE is about 0.915 g / cm ³ and 0.930 g.
/ Cm has a density of between ^3, less than 0.925 g / cm ³ is more preferable.

“Crystallinity” means the dimensional or structural degree of atoms in a polymer composition. Crystallinity is often expressed as a percentage or percentage of the volume of crystalline material, or as a measure of how much atoms or molecules tend to be arranged in a regular pattern, ie crystals. The crystallinity of the polymer can be tuned fairly accurately over a very wide range of heat treatments. "Crystalline" and "semi-crystalline" polymers are
It has a first order phase transition or crystalline melting point (Tm) as determined by a differential scanning calorimeter (DSC) or equivalent technique. This term can be used interchangeably with the term “semicrystalline”. The term “amorphous” refers to a polymer without a crystalline melting point as determined by differential scanning calorimetry (DSC) or equivalent technique.

Differential scanning calorimetry (DSC) is a common technique that can be used to test the melting and crystallization of semi-crystalline polymers. The general principles of DSC measurements and DSC application for the study of semicrystalline polymers are described in standard texts (eg EA Turi, ed., Ther.
mal Characterization of Polymer Material
als, Academic Press, 1981). DSC is a suitable method for determining the melt properties of a polymer.

DSC analysis was performed using TA Instruments, Inc. model Q1000 DSC
Made using. The DSC is calibrated by the following method. First, the baseline is D
Obtained by running the SC at -90 ° C to 290 ° C in an aluminum DSC pan without any sample. Then 7 milligrams of fresh indium sample was heated to 180 ° C., the sample was cooled to 140 ° C. at a cooling rate of 10 ° C./min, then the sample was kept isothermal at 140 ° C. for 1 minute, The samples are analyzed by heating from 140 ° C. to 180 ° C. at a heating rate of 10 ° C./min. The heat of fusion and onset of melting of the indium sample is in the range of 0.5 ° C. to 156.6 ° C. with respect to the onset of melting and within the range of 0.5 J / g to 28.71 J / g with respect to the heat of fusion. As determined and suppressed. The deionized water is then cooled from 25 ° C. to −3 at a cooling rate of 10 ° C./min.
A small amount of fresh sample was analyzed by cooling in a DSC pan at 0 ° C. The sample was kept isothermal at −30 ° C. for 2 minutes and heated to 30 ° C. at a heating rate of 10 ° C./min. The onset of melting was determined and suppressed to be in the range of 0.5 to 0 ° C.

The polymer sample was compressed into a thin film at an initial temperature of 190 ° C. (referred to as “initial temperature”). Approximately 5-8 mg from the sample was weighed and placed in the DCS pan. The lid was crimped to the pan to ensure a closed atmosphere. The DSC pan was placed in the DSC cell and then heated at a rate of about 100 ° C./min to a temperature (T ₀ ) of about 60 ° C. above the melting temperature of the sample. The sample was held at this temperature for about 3 minutes. The sample was then cooled to −40 ° C. at a rate of 10 ° C./min and kept isothermal at that temperature for 3 minutes. Thus, the sample is heated at a rate of 10 ° C./min until completely melted. The enthalpy curve resulting from this experiment was analyzed for peak melting temperature, onset and peak crystallization temperature, heat of fusion and heat of crystallization, and any other DSC analysis of interest.

Crystallinity is analyzed for a polymer with polypropylene and T ₀ is 230 ° C. The sample of polyethylene crystallinity is present in the case where polypropylene crystallinity does not exist at all, T _o is 190 ° C..

The weight percentage crystallinity is given by the following formula:
The heat of fusion (ΔH) divided by the heat of fusion for the complete polymer crystal (ΔH ₀ ), 1
Calculated by multiplying by 00%. For ethylene crystallinity, ΔH ₀ is 290 J /
g. For example, the crystallinity of an ethylene-octene copolymer upon melting of polyethylene was measured to have a heat of fusion of 29 J / g and the associated crystallinity was 10% by weight. Regarding the crystallinity of propylene, ΔH ₀ was assumed to be 165 J / g. For example, the propylene crystallinity of a propylene-ethylene copolymer upon melting has been determined to have a heat of fusion of 20 J / g and an associated crystallinity of 12.1% by weight.

As used herein, the term “non-cross-linked” refers to a polymer having a gel between 0-10%, more preferably 0-5%, more preferably 0-1%. Since some degree of cross-linking may inevitably occur during processing, it should not be construed that there is an absolute zero cross-linking, and the cross-linking is kept to a minimum to allow for reusability. There is a need.

Foam Buffer Layer In one aspect, the embodiments described herein relate to a thermoplastic foam buffer layer.
In another aspect, the embodiments described herein relate to artificial grass that includes a thermoplastic foam cushioning layer. In selected applications, the embodiments described herein relate to a foam buffer layer of a thermoplastic non-crosslinked polymer having the following characteristics.
1) Foam thickness, between 8mm and 30mm 2) Foam density, between 30kg / m3 and 150kg / m3 3) Foam cell size, between 0.2mm and 3mm 4) To avoid water absorption Low% open cell volume, typically less than 35%

  polymer

The thermoplastic polymer used to form the buffer layer can vary depending on the particular application and the desired result. For example, in one embodiment, the polymer is an olefin polymer. As used herein, olefin polymer generally refers to the type of polymer formed from hydrocarbon monomers having the general formula C _n H _2n . Olefin polymer is
It can exist as an interpolymer, a block copolymer, or a copolymer such as a multi-block interpolymer or copolymer.

For example, with one particular embodiment, the olefin _polymer, C 3 _{-C 20} linear,
An alpha olefin interpolymer of ethylene having at least one comonomer selected from the group consisting of branched or cyclic dienes or ethylene vinyl compounds such as vinyl acetate, and represented by the formula H ₂ C═CHR, , R is _C 1 _~C
It may include ₂₀ linear, branched, or cyclic alkyl group or a C ₆ -C ₂₀ aryl group composition. Examples of comonomers include propylene, 1-butene, 3-methyl-1-butene, 4-methyl-1-pentene, 3-methyl-1-pentene, 1-heptene, 1-hexene, 1-octene, 1-octene, Decene and 1-dodecene are included.

In another embodiment, the polymer is represented by ethylene, a C4-C20 linear, branched, or cyclic diene, and the formula H ₂ C═CHR, where R is a C ₁ -C ₂₀ linear, it can branched or an alpha-olefin interpolymer of propylene with at least one comonomer selected from the group consisting of compounds represented by alkyl or C ₆ -C ₂₀ aryl group cyclic. Examples of comonomers include ethylene, 1-butene,
3-methyl-1-butene, 4-methyl-1-pentene, 3-methyl-1-pentene, 1-
Heptene, 1-hexene, 1-octene, 1-decene, and 1-dodecene are included.
In some embodiments, the comonomer is present from about 5% to about 25% by weight of the interpolymer. In one embodiment, a propylene-ethylene interpolymer is used.

Other examples of polymers that can be used in the present disclosure generally include polyethylene, polypropylene, poly-1-butene, poly-3-methyl-1-butene, poly-3-methyl-1-
Ethylene, propylene, 1-butene, 3-methyl-1 as represented by pentene, poly-4-methyl-1-pentene, ethylene-propylene copolymer, ethylene-1-butene copolymer, and propylene-1-butene copolymer -Butene, 4-methyl-1-
Pentene, 3-methyl-1-pentene, 1-heptene, 1-hexene, 1-octene, 1
-Decene, and homo- and copolymers of olefins (including elastomers) such as 1-dodecene, generally alpha-olefins having conjugated and non-conjugated dienes as represented by ethylene-butadiene copolymers and ethylene-ethylidene norbornane copolymers Copolymers (including elastomers), and generally represented by ethylene-propylene-butadiene copolymers, ethylene-propylene-dicyclopentadiene copolymers, ethylene-propylene-1,5-hexadiene copolymers, and ethylene-propylene-ethylidene norbornane copolymers Polyolefins (including elastomers) such as copolymers of two or more alpha-olefins having such conjugated or non-conjugated dienes, and N-mes Roll-functional comonomers, N- methylol functional ethylenically having a comonomer - vinyl alcohol copolymers, ethylene vinyl chloride copolymer, ethylene acrylic acid or ethylene - (meth) acrylic acid copolymer, and ethylene - (
Ethylene-vinyl composite copolymers such as ethylene-vinyl acetate copolymers with (meth) acrylate copolymers, styrene copolymers (including elastomers) such as polystyrene, ABS, acrylonitrile-styrene copolymers, methylstyrene-styrene copolymers, styrene-butadiene copolymers and their Hydrates and polyvinyls such as styrene block copolymers (including elastomers) such as styrene-isoprene-styrene triblock copolymers, polyvinyl chloride, polyvinylidene chloride, vinyl chloride-vinylidene chloride copolymers, polymethyl acrylate, and polymethyl methacrylate Composite,
Polyamides such as nylon 6, nylon 6,6 and nylon 12, thermoplastic polyesters such as polyethylene terephthalate and polybutylene terephthalate, polycarbonate, polyphenylene oxide, and the like are included. These resins can be used alone or in combination of two or more.

In certain embodiments, polypropylene, polyethylene, and copolymers thereof, and mixtures thereof, and polyolefins such as ethylene-propylene-diene terpolymers can be used. In some embodiments, the olefinic polymer includes a homogeneous polymer as described in Elston US Pat. No. 3,645,992, a high density as described in Anderson US Pat. No. 4,076,698. Polyethylene (HDPE), heterogeneous branched linear low density polyethylene (LLDPE), heterogeneous branched linear ultra-low density (ULDPE), eg, US Pat. No. 5,272, the disclosure of which process is incorporated herein by reference. 2
36, and homogeneously branched linear ethylene / alpha-olefin copolymers that can be prepared by the processes disclosed in US Pat. No. 5,278,272, heterogeneously branched substantially linear ethylene / alpha-olefin polymers, And low density polyethylene (LDPE)
And high pressure free radical polymerized ethylene polymers and copolymers.

In another embodiment, the polymer as well as PRIMA from, for example, Dow Chemical Company.
COR ™, NUCREL ™ from DuPont, and ExxonMob
U.S. Pat. Nos. 4,599,392, 4,988,781, each sold under the trade name ESCOR ™ from il, each of which is incorporated herein by reference in its entirety.
Ethylene-vinyl acetate (EVA) copolymers such as those described in 59,384,373, ethylene-carboxylic acid copolymers such as ethylene-acrylic acid (EAA) and ethylene-methacrylic acid copolymers, and the like. Exemplary polymers include polypropylene (both impact modified polypropylene, isotactic polypropylene, atactic polypropylene, and ethylene / propylene random copolymers), US Pat. Nos. 6,545,088, 6,538,070. No.6,566,446, No.5
, 844, 045, 5,869,575, and 6,448,341 products such as Ziegler-Natta PE and metallocene PE multi-reactor PE ("in-reactor") mixtures. Various types of polyethylene are included, including high pressure free radical LDPE, Ziegler-Natta LLDPE, metallocene PE. Olefin plastomers and elastomers, ethylene and propylene-based copolymers (eg, a polymer available from Dow Chemical Company under the trade name VERSIFY ™, and ExxonMobi
Homogeneous polymers such as VISTAMAXX ™, commercially available from the company l, can also be useful in some embodiments. Of course, a mixture of polymers can be used as well. In some embodiments, the mixture includes two different Ziegler Natta polymers. In other embodiments, the mixture can include a mixture of Ziegler Natta and metallocene polymers. In another embodiment, the thermoplastic resin used herein can be a mixture of two different metallocene polymers.

In one particular embodiment, the polymer can comprise an alpha-olefin interpolymer of ethylene with a comonomer comprising an alkene such as 1-octene. The ethylene and octene copolymers can be present alone or in combination with another polymer such as an ethylene-acrylic acid copolymer. When present together, the weight ratio between the ethylene and octene copolymer and the ethylene-acrylic acid copolymer is about 3: 2.
From about 1:10 to about 10: 1, such as from about 2: 3. A polymer such as an ethylene-octene copolymer can have a crystallinity of less than about 50%, such as less than about 25%. In some embodiments, the crystallinity of the polymer can be 5 to 35 percent. In another embodiment, the crystallinity can range from 7 to 20 percent.

In one particular embodiment, the polymer is at least one low density polyethylene (LD
PE). The polymer is an autoclave process
s), or LDPE made by tubular processes. A suitable LDPE for this embodiment is defined elsewhere in this document.

In one particular embodiment, the polymer can include at least two low density polyethylenes. The polymer can include LDPE made by an autoclave process, a tube process, or a combination thereof. LDPE suitable for this embodiment is
Defined anywhere in this document.

In one particular embodiment, the polymer can comprise an alpha-olefin interpolymer of ethylene with a comonomer comprising an alkene such as 1-octene. The ethylene and octene copolymers can be present alone or in combination with another polymer such as low density polyethylene (LDPE). When present together, the weight ratio between the ethylene and octene copolymer and the LDPE can be from about 60:40 to about 97: 3, such as from about 80:20 to about 96: 4. A polymer such as an ethylene-octene copolymer can have a crystallinity of less than about 50%, such as less than about 25%. In some embodiments, the crystallinity of the polymer can be 5 to 35 percent.
In another embodiment, the crystallinity can range from 7 to 20 percent. LDPE suitable for this embodiment is defined anywhere in this document.

In one particular embodiment, the polymer can comprise an alpha-olefin interpolymer of ethylene with a comonomer comprising an alkene such as 1-octene. The ethylene and octene copolymers can be present alone or in combination with at least two other polymers from the group of low density polyethylene, medium density polyethylene, and high density polyethylene (HDPE). When present together, the weight ratio between ethylene and octene copolymer, LDPE, HDPE is 1 to 3 to 97% by weight of the total composition.
It can be such that it contains one component and the rest contain the other two components. A polymer such as an ethylene-octene copolymer can have a crystallinity of less than about 50%, such as less than about 25%. In some embodiments, the crystallinity of the polymer can be 5 to 35 percent. In other embodiments, the crystallinity can range from 7 to 20 percent.

Embodiments disclosed herein can also include a polymer component that can include at least one multi-block olefin interpolymer. Suitable multi-block olefin interpolymers are described, for example, in US Provisional Patent Application No. 60 / 818,911.
Can be included. The term "multiblock copolymer" is preferably joined in a linear fashion, ie the polymer is end-to-end joined to the polymerized ethylene functionality, rather than suspended or branched. Two or more chemically distinct regions or segments (“blocks”) that are polymers containing chemically identified units
The polymer containing). In some embodiments, the block comprises the amount or type of comonomer incorporated therein, the density, the amount of crystallinity, the crystallite size attributed to the polymer of such composition, the type or degree of tacticity (isolation). Tactic or syndiotactic), regio-regularity, or regio-irregu
larity), the amount of branching, including long chain branching or hyperbranching, uniformity, or any other chemical or physical property. Multi-block copolymers are characterized by a unique distribution of polydispersity index (PDI or M _w / M _n ), block length distribution, and / or block number distribution due to the copolymer's unique fabrication process. More specifically, when produced in a continuous process, polymer embodiments have from about 1.7 to about 8, in other embodiments from about 1.7 to about 3.5, in other embodiments. It may have a PDI in the range of about 1.7 to about 2.5, in another embodiment about 1.8 to about 2.5 or about 1.8 to about 2.1. When produced in a batch or semi-batch process, the polymer embodiment is from about 1.0 to about 2.9, in another embodiment from about 1.3 to about 2.5, in another embodiment from about 1. It may have a PDI ranging from 4 to about 2.0, and in another embodiment from about 1.4 to about 1.8.

One example of a multiblock olefin interpolymer is an ethylene / alpha olefin block interpolymer. Another example of a multiblock olefin interpolymer is a propylene / alpha olefin interpolymer. The following description focuses on interpolymers having ethylene as the main monomer, but applies in the same way as propylene-based multiblock interpolymers in terms of general polymer properties.

An ethylene / alphaolefin multiblock interpolymer is a plurality (ie, two or more) blocks or segments (block interpolymers), preferably multiblocks, of two or more polymerized monomer units that differ in chemical or physical properties. It can include ethylene in polymerized form, characterized by an interpolymer, and one or more copolymerizable alpha olefin comonomers. In some embodiments, the multi-block interpolymer is represented by the following formula: (A
B) _n n is at least 1, preferably 2, 3, 4, 5, 10, 15, 20, 30, 40
, 50, 60, 70, 80, 90, 100, or more, such as “A” represents a hard block or segment, and “B” represents a soft block or segment. Preferably, the plurality of A and the plurality of B are connected in a linear manner rather than a branched or star-like manner. A “hard” segment refers to a plurality of blocks of polymerized units in which ethylene is present in an amount greater than 95 weight percent in some embodiments and greater than 98 weight percent in another embodiment. . In other words, the comonomer content in the hard segment is less than 5 weight percent of the total weight of the hard segment in some embodiments, and less than 2 weight percent of the total weight of the hard segment in some embodiments. . In some embodiments, the hard segments are all
Or substantially all ethylene. On the other hand, the “soft” segment has a comonomer content greater than 5 weight percent of the total weight of the soft segment in some embodiments and greater than 8 weight percent of the soft segment in various other embodiments. Refers to multiple blocks of polymerized units that are greater than 10 weight percent and greater than 15 weight percent. In some embodiments, the comonomer content in the soft segment is greater than 20 weight percent, and in various other embodiments, greater than 25 weight percent, greater than 30 weight percent, greater than 35 weight percent, greater than 40 weight percent. More 4
It can be greater than 5 weight percent, greater than 50 weight percent, or greater than 60 weight percent.

In some embodiments, the plurality of A blocks and the plurality of B blocks are randomly distributed along the polymer chain. In other words, the block copolymer is AAA-AA-
It is not a structure like BBB-BB.

In another embodiment, the block copolymer does not have a third block. In another embodiment, neither block A nor block B comprises two or three segments (or sub-blocks) such as chip segments.

Multiblock interpolymers can be characterized by an average block index ranging from greater than 0 to about 1.0, ABI, molecular weight distribution Mw / Mn greater than about 1.3. The average block index, ABI, is the average weight of the block index (“Br”) per polymer fraction obtained with a preparative TREF of 20 ° C. to 110 ° C. in 5 ° C. increments. ABI = Σ _(w i B
I _i ) where BI _i is the block index for the i-th fraction of the multi-block interpolymer obtained with preparative TERF, and w _i is the weight percentage of the i-th fraction.

Similarly, the square root of the second moment around the mean, referred to below as the second moment weight average block index, can be defined as:

For each polymer fraction, BI is defined by one of two following formulas, both of which give the same BI value.
Where T _x is the analytical temperature rising elution fractionation (ATREF) elution temperature (preferably expressed in Kelvin) for the i th fraction and P _x is the NMR as shown below
Or the ethylene mole fraction for the i-th fraction that can be measured by IR. P _AB is the ethylene mole fraction of the total ethylene / alpha olefin interpolymer (before fractionation), which can also be measured by NMR or IR. T _A and P _A
Is the ATREF elution temperature and ethylene mole fraction for pure “hard segments” (which refer to the crystalline segments of the interpolymer). As an approximation, or with respect to the polymer "hard segment" composition is unknown, the value of T _A and P _A is set to a value related to a high density polyethylene homopolymer.

T _AB is the ATREF elution temperature for a random copolymer of the same composition (having an ethylene mole fraction of P _AB ) and molecular weight as the multiblock interpolymer. T _A
B can be calculated from the mole fraction of ethylene (measured by NMR) using the following formula:
LnP _AB = α / T _AB + β
Where α and β are determined by several well-characterized, broad composition random copolymer preparative TREF fractions and / or calibration using well-characterized narrow composition random ethylene copolymers There are two constants that can be. Note that α and β vary between instruments. In addition, an appropriate calibration curve should be created for the polymer composition of interest using the appropriate molecular weight range and comonomer type for the preparative TREF fraction and / or random copolymer used to create the calibration. There will be. There is a slight molecular weight effect. Such effects are essentially negligible if calibration curves are obtained from similar molecular weight ranges. In some embodiments, the random ethylene copolymer and / or the preparative TREF fraction of the random copolymer satisfy the following relationship: LnP = −237
. 83 / T _ATREF +0.639

The above calibration equation relates the mole fraction P of ethylene to the analytical TREF elution temperature T _ATREF for preparative TREF fractions of narrow and / or wide composition random copolymers. T _XO is the ATREF temperature for a random copolymer of the same composition having an ethylene mole fraction of _{P X.} T _XO is LnP _X
= Α / T _XO + β. Conversely, P _XO is the ethylene mole fraction for a random copolymer of the same composition and is calculated from LnP _XO = α / T _X + β, AT of T _X
Has a REF temperature.

After the block index (BI) for each preparative TREF fraction is obtained, the weight average block index, ABI, for the entire polymer can be calculated. In some embodiments, ABI is greater than 0 but less than about 0.4, or about 0.1
To about 0.3. In another embodiment, ABI is greater than about 0.4 and up to about 1.0. Preferably, ABI should be in the range of about 0.4 to about 0.7, about 0.5 to about 0.7, or about 0.6 to about 0.9. In some embodiments, ABI is about 0.
. 3 to about 0.9, about 0.3 to about 0.8, about 0.3 to about 0.7, about 0.3 to about 0.00.
6, about 0.3 to about 0.5, about 0.3 to about 0.4. In another embodiment, A
BI is about 0.4 to about 1.0, about 0.5 to about 1.0, about 0.6 to about 1.0, about 0.00.
The range is from 7 to about 1.0, from about 0.8 to about 1.0, from about 0.9 to about 1.0.

Another feature of multi-block interpolymers is that the interpolymer is preparative T
At least one polymer fraction obtainable by REF, wherein the fraction has a block index greater than about 0.1 and up to about 1.0, and the polymer has a molecular weight distribution greater than about 1.3, It has _Mw / _Mn . In some embodiments, the polymer fraction is greater than about 0.6 to about 1.0, about 0.7
Greater than about 1.0, greater than about 0.8 to about 1.0, greater than about 0.9 to about 1.
It has a block index up to zero. In another embodiment, the polymer fraction is
Greater than about 0.1 to about 1.0, greater than about 0.2 to about 1.0, greater than about 0.3 to about 1.0, greater than about 0.4 to about 1.0, about 0 A block index greater than .4 up to about 1.0. In another embodiment, the polymer fraction is about 0.1
Greater than about 0.5, greater than about 0.2, up to about 0.5, greater than about 0.3, about 0.
Up to 5, with a block index greater than about 0.4 and up to about 0.5. In another embodiment, the polymer fraction is greater than about 0.2 to about 0.9, greater than about 0.3 to about 0.8, greater than about 0.4 to about 0.7, about 0.5. It has a larger block index up to about 0.6.

The ethylene alpha olefin multiblock interpolymer used in embodiments of the present invention can be an ethylene interpolymer having at least one C _{3 to} C ₂₀ alpha olefin. Interpolymers may further comprise a diolefin and / or alkenyl benzene C ₄ -C _18. Suitable unsaturated comonomers useful for polymerization with ethylene include, for example, ethylenically unsaturated monomers,
Conjugated or non-conjugated dienes, polyenes, alkenylbenzenes and the like are included. Examples of such comonomers include propylene, isobutylene, 1-butene, 1-hexene, 1-pentene, 4-methyl-1-pentene, 1-heptene, 1-octene, 1-nonene, 1-decene and the like. include alpha olefins C ₃ -C _20. 1-butene and 1-octene are particularly preferred. Other suitable monomers include styrene, halo or alkyl substituted styrenes, vinyl benzocyclobutane, 1,4-hexadiene, 1,7-octadiene, and naphthenes (eg cyclopentane, cyclohexene, good cyclooctene, etc.) It is.

The multi-block interpolymers disclosed herein include conventional random copolymers, physical mixtures of polymers, continuous monomer additions, fluxional catalysts,
It can be a block copolymer prepared via anionic or cationic living polymerization techniques. In particular, compared to random copolymers of the same monomer and monomer content in equal crystallinity or modules, interpolymers have better (higher) heat resistance measured by melting point and are determined by dynamic mechanical analysis Having a higher TMA penetration temperature, higher high temperature tensile strength, and / or higher high-temperature torsion storage modulus. The characteristics of the filler can benefit from the use of the multi-block interpolymer embodiment compared to a random copolymer containing the same monomer and monomer content, the multi-block interpolymer being especially at elevated temperatures, Lower compression set, lower stress relaxation, higher creep resistance, higher tear strength, higher blocking resistance, faster cure due to higher crystallization (solidification) temperature, higher recovery (especially elevated temperature) so),
Has better wear resistance, higher shrinkage, and better oil and filler tolerance.

Other olefin interpolymers include polymers comprising monovinylidene aromatic monomers including styrene, o-methyl styrene, p-methyl styrene, t-butyl styrene and the like. In particular, interpolymers comprising ethylene and styrene can be used. In another embodiment, ethylene, styrene, and _C 3 of _{-C 20} alpha-olefins, copolymers containing diene _C 4 _{-C 20} optionally may be used.

Suitable non-conjugated diene monomers can include linear, branched, or cyclic hydrocarbon dienes having 6 to 15 carbon atoms. Examples of suitable non-conjugated dienes include, but are not limited to, linear acyclic dienes such as 1,4 hexadiene, 1,6-octadiene, 1,7-octadiene, 1,9-decadiene, 5-methyl-1,4-hexadiene, 3
Branched acyclic dienes such as 1,7-dimethyl-1,6-octadiene, 3,7-dimethyl-1,7-octadiene and mixed isomers of dihydromyricene and dihydroosinene, 1,3
-Cyclopentadiene, 1,4-cyclohexadiene, 1,5-cyclooctadiene and 1
Monocyclic alicyclic dienes such as 1,5-cyclododecadiene, tetrahydroindene, methyltetrahydroindene, dicyclopentadiene, bicyclo- (2,2,1) -hepta-2,5
-Polycyclic alicyclic fused and bridged cyclic dienes such as dienes, 5-methylene-2-norbornene (MNB), 5-propenyl-2-norbornene, 5-isopropylidene-2-norbornene, 5- (4-cyclo Pentenyl) -2-norbornene, 5-cyclohexylidene-2
-Alkenyl such as norbornene, 5-vinyl-2-norbornene, and norbornadiene, alkylidene, cycloalkenyl, and cycloalkylidene norbornene. Of the dienes commonly used to prepare EPDM, particularly preferred dienes are 1,4-hexadiene (HD), 5-ethylidene-2-norbornene (ENB), 5
-Vinylidene-2-norbornene (VNB), 5-methylene-2-norbornene (MNB)
And dicyclopentadiene (DCPD).

One type of desirable polymers that may be used in accordance with embodiments disclosed herein, elastomeric interpolymers of ethylene, alpha-olefin C ₃ -C _20, one or more particular propylene, and optionally Of diene monomers. Preferred alpha olefins used in this embodiment are designated by the formula CH ₂ —CHR ^* , where R ^* is a linear or branched alkyl group of 1 to 12 carbon atoms. Examples of suitable alpha olefins include, but are not limited to, propylene, isobutylene, 1-butene, 1-pentene, 1-hexene, 4-methyl-1-pentene, and 1-octene. A particularly preferred alpha olefin is propylene. Propylene-based polymers are commonly referred to in the art as EP or EPDM polymers. Dienes suitable for use in preparing such polymers, particularly multiblock EPDs
M type polymers include linear or branched, cyclic, or polycyclic dienes with 4 to 20 carbons, conjugated or non-conjugated. Preferred dienes include 1,4-pentadiene, 1,4-hexadiene, 5-ethylidene-2-norbornene, dicyclopentadiene,
Cyclohexadiene and 5-butylidene-2-norbornene are included. A particularly preferred diene is 5-ethylidene-2-norbornene.

The polymers disclosed herein (homopolymers, copolymers, interpolymers, and multi-block interpolymers), in some embodiments, are from 0.01 to 20
00g / 10 minutes, in another embodiment 0.01 to 1000 g / 10 minutes, in another embodiment 0.01 to 500 g / 10 minutes, in another embodiment 0.01 to 100 g / 10 minutes melt index, it may have _{I 2.} In some embodiments, the polymer is 0.01 to 10 g / 10 minutes, 0.5 to 50 g / 10 minutes, 1 to 30 g / 10 minutes,
The melt index of from 1 to 6 g / 10 min, or from 0.3 10 g / 10 min may have an _{I 2.} In some embodiments, the melt index for the polymer is:
It can be about 1 g / 10 min, 3 g / 10 min, or 5 g / 10 min. In another embodiment, the polymer can have a melt index greater than 20 dg / min, in another embodiment greater than 40 dg / min, and in yet another embodiment greater than 60 dg / min.

The polymers disclosed herein, in some embodiments, range from 1,000 g to 5,000.
00,000 g / mol, in another embodiment from 1000 g to 1,000,000 g / mol, in another embodiment, from 10,000 g to 500,000 g / mol, in another embodiment,
It may have 300,000 g / mol molecular weight _{M w} of from 10,000 g. The density of the polymers disclosed herein can be from 0.80 to 0.99 g / in some embodiments.
cm ³ , for ethylene-containing polymers, from 0.85 to 0.97 g / cm ³ , and in some embodiments, from 0.87 to 0.94 g / cm ³ .

In some embodiments, the polymers disclosed herein can have a tensile strength greater than 10 MPa, in another embodiment, a tensile strength ≧ 11 MPa, and in another embodiment, a tensile strength ≧ 13 MPa. . In some embodiments, the polymers disclosed herein are at least 600 percent at a crosshead separation rate of 11 cm / min, in other embodiments at least 700 percent, in other embodiments at least 800 percent, Embodiments can have an elongation at break of at least 900 percent.

In some embodiments, the polymers disclosed herein have a storage module ratio G ′ (25 ° C.) / G of 1 to 50, in another embodiment 1 to 20, and in another embodiment 1 to 10.
'(100 ° C). In some embodiments, the polymer is less than 80 percent, in another embodiment less than 70 percent, in another embodiment less than 60 percent, in another embodiment less than 50 percent, less than 40 percent, in another embodiment. It can have a compression set of up to 0 percent.

In some embodiments, the ethylene / alpha-olefin interpolymer is 85
It can have a heat of fusion of less than J / g. In another embodiment, the ethylene / alpha-olefin interpolymer is 100 pounds / ft ² (4800 Pa) or less, in another embodiment, 50 pounds / ft ² (2400 Pa) or less, and in another embodiment, 5 pounds / ft. ² (240 Pa) or less, and can have pellet blocking strength as low as 0 lb / ft ² (0 Pa).

In some embodiments, a block polymer made with two catalysts that incorporate different amounts of comonomer can have a weight ratio of blocks formed thereby ranging from 95: 5 to 5:95. In some embodiments, the elastomeric interpolymer has an ethylene content of 20 to 90 percent, based on the total weight of the polymer,.
It has a diene content of 1 to 10 percent and an alpha-olefin content of 10 to 80 percent. In some embodiments, the multi-block elastomeric interpolymer has an ethylene content of from about 60 to 90 percent, based on the total weight of the polymer,.
It has a diene content of 1 to 10 percent and an alpha-olefin content of 10 to 40 percent. In another embodiment, the interpolymer can have a Mooney viscosity (ML (1 + 4) 125 ° C.) in the range of 1 to 250. In some embodiments, such polymers can have an ethylene content of 65 to 75 percent, a diene content of 0 to 6 percent, and an alpha-olefin content of 20 to 35 percent.

In some embodiments, the polymer has an ethylene content between 5 wt% and 20 wt%,
And 0.5 to 300 g / 10 min melt flow rate (230 ° C at 2.16 kg weight)
Propylene-ethylene copolymer or interpolymer having
In another embodiment, the propylene-ethylene copolymer or interpolymer has an ethylene content between 9% and 12% by weight and a melt flow rate of 1 to 100 g / 10 min (230 ° C. at 2.16 kg weight). Can have.

In some specific embodiments, the polymer is a propylene-based copolymer or interpolymer. In some embodiments, the propylene / ethylene copolymer or interpolymer is characterized as having a substantially isotactic propylene sequence. The term "substantially isotactic propylene sequence" and similar terms are used when the sequence is greater than about 0.85, preferably greater than about 0.90, more preferably greater than about 0.92, most preferably Greater than about 0.93, ¹
Means having an isotactic triad (mm) measured by ³ C NMR. Isotactic triads are well known in the art, for example, US Pat. No. 5,504,172 and WO00 which refer to isotactic sequences in terms of triad units within the copolymer molecular chain as determined by ¹³ C NMR spectra. / 01745. In another specific embodiment, the ethylene-alpha olefin copolymer can be ethylene-butene, ethylene-hexene, or an ethylene-octene copolymer or interpolymer. In another specific embodiment, the propylene-alpha olefin copolymer can be propylene-ethylene, or a propylene-ethylenebutene copolymer or interpolymer.

The polymers disclosed herein (homopolymers, copolymers, interpolymers, multiblock interpolymers) can be produced using single site catalysts,
It can have a weight average molecular weight of about 15,000 to about 5 million, such as about 20,000 to about 1 million. The molecular weight distribution of the polymer can be from about 1.01 to about 80, such as from about 1.5 to about 40, such as from about 1.8 to about 20.

In some embodiments, the polymer can have a Shore A hardness of 30 to 100. In another embodiment, the polymer is from 40 to 90, in another embodiment from 30 to 80.
In another embodiment, it can have a Shore A hardness of 40 to 75.

Olefin polymers, copolymers, interpolymers, and multiblock interpolymers can be functionalized by incorporating at least one functional group within the polymer structure. Exemplary functional groups can include, for example, ethylenically unsaturated monofunctional and bifunctional carboxylic acids, ethylenically unsaturated monofunctional and bifunctional carboxylic acid anhydrides, salts thereof, and esters thereof. Such functional groups can be grafted onto the olefin polymer or can be copolymerized with ethylene and any additional comonomers to form ethylene interpolymers, functional comonomers, and optionally other comonomers. . Means for grafting functional groups onto polyethylene are described, for example, in U.S. Pat. Nos. 4,762,890, 4,927,888, and 4,950, the disclosures of which are incorporated herein by reference in their entirety. , 541. One particularly useful functional group is maleic anhydride.

The amount of functional groups present in the functional polymer can vary. The functional group is at least about 1.0 weight percent in some embodiments and at least about 5 in another embodiment.
The weight percent, in another embodiment, can be present in an amount of at least about 7 weight percent. Functional groups can be present in some embodiments in amounts of less than about 40 weight percent, in other embodiments about 30 weight percent, and in other embodiments about 25 weight percent.

Foam sheets according to embodiments described herein can include a single layer or multiple layers as desired. Foam articles can be produced in any manner that forms at least one foam layer. The foam layer disclosed herein is
It can be produced by a pressurized melt processing method such as an extrusion method. The extrusion device can be a tandem system, a single screw extruder, a twin screw extruder, or the like. Extruders are commercially available from Multilayer Circular Dies, Flat Film Dies and Feed Blocks, Multilayer Feed Blocks as disclosed in US Pat. No. 4,908,278 (Bland et al.), Cloeren of Orange, Texas 3
Multiple vanes such as layer vane dies or multiple manifold dies can be equipped. The foamable composition can also be produced by combining the chemical blowing agent and the polymer at a temperature below the decomposition temperature of the chemical blowing agent and then foaming. In some embodiments,
The foam can be coextruded with one or more barrier layers.

One method of producing the foam disclosed herein is by using the extruder described above. In this case, a foamable mixture (polymer + foaming agent) is extruded. When the mixture exits the die of the extruder and is exposed to the reduced pressure, the deviating gas nucleates and forms cells within the polymer, forming a foam article. The resulting foam article can then be deposited on a temperature controlled casting drum. The speed of the casting drum (ie caused by the drum RPM) can affect the overall thickness of the foam article. As the speed of the casting roll increases, the overall thickness of the foam article can be reduced. However, the thickness of the barrier layer at the die exit where foaming occurs is the diffusion distance to the system. As the foam article is stretched and cooled on the casting drum, the thickness of the barrier layer can be reduced until the foam article solidifies. In other words, an important factor in controlling the diffusion of deviant gases is
This is the barrier layer diffusion distance (ie thickness) at the die exit.

Blowing agents suitable for use in forming the foams disclosed herein, it is a general, for example, chemical blowing agents to produce a deviation gas or departing gases, such as CO ₂ It can be a physical blowing agent that is the same material. Two or more physical or chemical blowing agents can be used, and both physical and chemical blowing agents can be used.

Physical blowing agents useful in the present invention include any naturally occurring atmospheric material that is a vapor at the temperature and pressure at which the foam exits the die. The physical blowing agent can be introduced or injected into the polymer material as a gas, supercritical fluid, or liquid, preferably a supercritical fluid or liquid, most preferably a liquid. The physical blowing agent used is
Depends on the properties required for the resulting foam article. Other factors considered when selecting a blowing agent are its toxicity, vapor pressure properties, ease of handling, and solubility in the polymer material used. For example, non-flammable, non-toxic, non-ozone destructive foams are preferred because they are easier to use due to fewer environmental and safety issues and are generally less soluble in thermoplastic polymers. Suitable physical blowing agents include carbon dioxide, nitrogen, SF
sub6, nitrogen dioxide, C ₂ F ₆ , argon, helium, xenon and other rare gases, air (
Perfluorinated fluids, such as mixtures of nitrogen and oxygen, and mixtures of these materials.

Chemical blowing agents that can be used in the present invention include, for example, a mixture of sodium bicarbonate and citric acid, dinitrosopentamethylenetetraamine, p-toluenesulfonyl hydrazide, 4-4 ′ oxybiz (benzenesulfonyl hydrazide), azodicarbonamide ( 1-
1'-azobisformamide), p-toluenesulfonyl semicarbazide, 5-phenyltetrazole, 5-phenyltetrazole analogues, diisopropylhydrazodicarboxylate, 5-phenyl-3,6-dihydro-1,3,4-oxadiazone 2-one and sodium borohydride are included. Preferably, the blowing agent is 0.689 at 0 ° C.
One or more deviant gases having a vapor pressure higher than MPa, or produce it.

The total amount of blowing agent used will depend on conditions such as the extrusion process conditions in mixing, the blowing agent used, the composition of the extrudate, and the desired density of the foam article. Extrudates are defined herein as including a blowing agent mixture, one or more polyolefin resins, and optional additives. For foams having a density of about 1 to about 15 lb / ft ³ , the extrudate typically contains about 18 to about 1 wt% blowing agent.
In another embodiment, 1% to 10% blowing agent can be used.

The blowing agent mixture used in the present invention comprises less than about 99 mole percent isobutane. The blowing agent mixture generally comprises from about 10 mole percent to about 60 or 75 mole percent isopentane. The blowing agent mixture more typically comprises from about 15 mole percent to about 40 mole percent isopentane. More specifically, the blowing agent mixture comprises from about 25 or 30 mole percent to about 40 mole percent isobutane. The blowing agent mixture generally includes at least about 15 or 30 mole percent of one or more co-blowing agents. More specifically, the blowing agent mixture is from about 40 to about 85 or 90.
Contains mol% of one or more co-blowing agents. More typically, the blowing agent mixture comprises from about 60 mole percent to about 70 or 75 mole percent of one or more co-blowing agents.

Nucleating agents, or combinations of such agents, can be used in the present invention for advantages such as their ability to modulate cell formation and cell morphology. The nucleating agent or cell size control agent can be any conventional or useful one or more nucleating agents. The amount of nucleating agent used is
Depends on the desired cell size, the selected blowing agent mixture, and the desired foam density. The nucleating agent is generally added in an amount of about 0.02 to about 20 wt% polyolefin resin composition.

Some contemplated nucleating agents include inorganic materials (in small particle form) such as clay, talc, siliceous earth, and diatomaceous earth. Other contemplated nucleating agents include organic nucleating agents that decompose or react at heating temperatures in the extruder to release gases such as carbon dioxide, water, and / or nitrogen. One example of an organic nucleating agent is a combination of an alkali metal salt of a polycarboxylic acid with carbonic acid or bicarbonate. Some examples of alkali metal salts of polycarboxylic acids include, but are not limited to, monosodium salt of 2,3 dihydroxybutanedioic acid (commonly referred to as sodium hydrogen tartrate), monopotassium butanedioic acid salt(
Commonly referred to as potassium hydrogen succinate), trisodium and tripotassium salts of 2-hydroxy-1,2,3-propanetricarboxylic acid (commonly referred to as sodium citrate and potassium citrate, respectively), and diethane of ethanedioic acid Sodium salts (commonly referred to as sodium oxalate) or polycarboxylic acids such as 2-hydroxy-1,2,3-propanetricarboxylic acid are included. Some examples of carbonic acid or bicarbonate include, but are not limited to, sodium carbonate, sodium bicarbonate, potassium carbonate, potassium bicarbonate, and calcium carbonate.

It is contemplated that a mixture of different nucleating agents can be added to the present invention. Some more desirable nucleating agents include talc, cristobalite, and a stoichiometric mixture of citric acid and sodium bicarbonate (a stoichiometry having a concentration of 1 to 100 percent where the carrier is a suitable polymer such as polyethylene) Theoretical mixture). Talc can be added in the form of a carrier or powder.

Gas permeation agents or stability control agents can be used in the present invention to help prevent or prevent the foam from breaking. Stability control agents suitable for use in the present invention are described in US Pat. No. 3,214,054, partial esters of long chain fatty acids with polyols described in US Pat. No. 3,644,230. Saturated higher alkyl amines, saturated higher fatty acid amides, full esters of higher fatty acids, and combinations thereof as described in US Pat. No. 5,750,584.

Partial esters of fatty acids that may be desirable as stability control agents include generic class elements known as surfactants or surfactants. A preferred class of surfactants includes partial esters of fatty acids having 12 to 18 carbon atoms and polyols having 3 to 6 hydroxy groups. More preferably,
The partial ester of the long chain fatty acid having the polyol component of the stability control agent is glycerol monostearate, glycerol distearate, or a mixture thereof. It is contemplated that other gas permeation agents or stability control agents can be used in the present invention to help prevent or prevent the foam from breaking.

  Additive

If desired, fillers, colorants, light and heat stabilizers, antioxidants, scavengers, flame retardants, processing aids, extrusion aids, and foaming additives can be used to make the foam. it can. The foams of the present invention can include filler materials in amounts ranging from about 2 to 100 percent (on a dry basis) of the weight of the polymer components, depending on the application for which they are designed. These optional ingredients include, but are not limited to, calcium carbonate, titanium dioxide powder, polymer particles, hollow glass spheres, polyolefin based staple monofilaments.
polymer fibers such as ilaments).

In selected embodiments, foams useful for the disclosed embodiments are 1 mm and 500 mm.
Between 5 mm and 100 mm in some embodiments, 8 mm and 3 in some embodiments
It can have a thickness between 0 mm. In selected embodiments, the foam is about 20k.
between g / m ³ and 600 kg / m ³ , preferably between 25 kg / m ³ and 300 kg / m ³ ,
More preferably it can have a density between 30 kg / m ³ and 150 kg / m ³ . In selected embodiments, the foam may have a cell size between about 0.1 mm and 6 mm, preferably between 0.2 mm and 4.5 mm, preferably between 0.2 mm and 3 mm.

In some embodiments, the foam layer can be perforated to facilitate drainage so that it can drain water from the competition ground when it rains.

In some embodiments, the foam described above can be used as a buffer layer in artificial turf. In addition, tests can be performed to analyze the resulting temperature performance and aging of the lawn, as well as bounce and spin characteristics. In short, FIFA Qu
Significant tests and desired results regarding the performance of the artificial lawn as specified by theity Concept Manual (March 2006 edition) are shown in the table below. Those skilled in the art will recognize that this is one application of the foam disclosed herein, and that the artificial lawn and foam disclosed herein are several others such as rugby and field hockey. It will be appreciated that it can be useful in a number of other applications in sports.

  Buffer

Principle, mass (20 Kg) is incorporated by reference in its entirety FIFA Quali
Fall as discussed in ty Concept Manual (March 2006 edition). The maximum force applied is recorded. The reduction in% of this force relative to the maximum force measured on the concrete surface is reported as “force reduction”.

  FIFA requirements

  FIFA2Star, 60% -70%

  FIFA1Star, 55% -70%

  Vertical deformation

  The principle mass is dropped onto the placed spring and the maximum deformation of the surface is measured.

  FIFA requirements

  FIFA2Star, 4mm-8mm

  FIFA1Star, 4mm-9mm

Examples The usefulness of polyolefin resins with selected foam density and thickness was investigated.
Specifically, several polyethylene resins commercially available from Dow Chemical Company of Midland, Michigan were studied. Tables 1 and 2 show some composites used. In Table 1, uncrosslinked polyethylene (Examples 1 to 4) was investigated against the performance of the crosslinked polyethylene (Comparative Examples 1c to 4c). In particular, for Table 1, LDPE300E and LDPE
PG7004, and mixtures thereof, LDPE 620I and XU 60021.2
4 was used to generate the data. The formulation used to create the table is shown below.
' ^* ' Refers to a foam commercially available from Qycell, Inc. (Ontario, Calif.).

The performance of the uncrosslinked polyethylene foams in Table 1 commercially available from Dow Chemical Company of Midland, Michigan was investigated for buffering, vertical deformation, and energy resilience. The results of this survey are summarized in FIG. With respect to FIG. 1, compressive stress strain, compressive creep, and compressive stress strain behavior are shown in the Universal Testing Machine (Norwood, Mass.) Equipped with a compression plate and a 2 kN load cell.
The analysis is performed using a ne Instron Model 5565. If the test is performed at 65 ° C, the Instron environmental chamber (Model 31)
19-405-21) was also used.

Samples 2.5 to 5 cm wide by 5 cm deep were cut from the foam sheet. To measure the compressive stress-strain behavior, a sample was inserted between the centers of the compression plates. The thickness direction of the foam was aligned parallel to the crosshead movement. 2.5N preload is 5
Added at mm / min and the crosshead position was zeroed back. The sample was then compressed at 10 mm / min until the load reached the load capacity of the load cell. Stress is the measured compressive force
Calculated by dividing by the product of the width and depth of the foam. Stress is megapascal (MPa)
Quantified in units of. The stress in percent was calculated by dividing the crosshead displacement by the foam starting thickness and multiplying by 100. The results for the compressive stress-strain behavior test are shown in FIGS. 2 and 2c (comparative sample).

In order to measure the hysteretic behavior of compression, the foam sample was analyzed in the same manner as above.
loaded into tron. A preload of 2.5 N was applied at 5 mm / min and the crosshead position was returned to zero. The sample was then compressed at 10 mm / min until the stress reached 0.38 MPa and designated as the compression step. Then, immediately after, the crosshead is 0.00
It was reversed until a load of 38 MPa was reached and designated as reduced pressure. Without interruption
The sample was compressed and decompressed for 10 cycles.

To measure the compression creep behavior, the foam sample was loaded into the Instron in the same manner as described above, except that the environmental chamber was in place and preheated to a temperature of 65 ° C. Samples were placed between compression plates at 65 ° C. After the foam sample was allowed to equilibrate in the chamber for 1 hour, a preload of 2.5 N was applied at 5 mm / min to bring the crosshead position back to zero. A load was then applied at 0.16 MPa. The crosshead position was then automatically adjusted by an Instron computer to maintain a stress of 0.16 MPa for 12 hours. The time for compressive stress was measured and the results are shown in FIGS. 3 and 3c. After 12 hours, the crosshead returns to the starting position. After an additional 2 hours, the foam is removed and placed in ambient conditions (20 ° C., 50% relative humidity) to cool. The foam thickness is then re-measured. The corresponding strain was designated as “strain at release, 2 hours”. The result of the compression creep behavior test is shown in FIG.

To measure the energy absorption behavior of foam, FIFA is a FIFA handbook of test methods and requirements for artificial grass for soccer, "March 2006 FIFA Quality Concept", which is hereby incorporated by reference in its entirety.
Requirements for Artificial Turf Surfac
Establishes a quality concept method system as described in “es”. These foams
Tested according to this methodology, it has been found that, for example, a foam with a density of 144 kg / m ³ works to some extent. More detailed test results on buffering are given below. Returning to compression performance, the following graph shows that foam performance is not compromised by the elimination of cross-linking. Furthermore, embodiments of the present invention can be useful in any arena where an artificial lawn such as rugby or field hockey can be used.

Figures 3, 3c, and 4 show that essentially the same compression creep performance and subsequent recovery can be achieved despite the removal of the crosslinks.

An artificial turf using an embodiment of the present invention is shown in FIG. Specifically, a non-crosslinked polyethylene foam is provided as a buffer layer that can be adhered to the backing. Artificial grass is attached to the lining and the space between the grasses is filled with filler.

Embodiments using non-crosslinked polyethylene can be advantageous because non-crosslinked polyethylene is reusable and thus has no environmental issues. The polymer foam embodiments disclosed herein can also be useful as heavy layers for noise and vibration damping, among others.

Although the invention has been described with respect to a limited number of embodiments, those skilled in the art having the benefit of this disclosure will recognize other embodiments that do not depart from the scope of the invention as disclosed herein. It will be understood that it can be devised. Accordingly, the scope of the invention should be limited only by the attached claims.

All the most important documents are fully incorporated herein by reference with respect to all the rights that are allowed to be incorporated. In addition, all documents cited herein, including test procedures,
Such disclosure is hereby fully incorporated by reference with respect to all powers that may be incorporated to the extent consistent with the description of the invention.

In some embodiments, the polymers disclosed herein have a storage module ratio G ′ (25 ° C.) / G of 1 to 50, in another embodiment 1 to 20, and in another embodiment 1 to 10. '(100 ° C). In some embodiments, the polymer is compressed at 70 ° C. at less than 80 percent, in another embodiment less than 70 percent, in another embodiment less than 60 percent, in another embodiment less than 50 percent, less than 40 percent. The permanent set may have a compression set of up to 0 percent in another embodiment.

Claims (11)

a. An artificial turf carpet having a flexible base sheet;
b. With a cushion pad,
The artificial turf surface layer body, wherein the buffer pad includes a non-crosslinked polyolefin foam.   The artificial turf surface layer according to claim 1, wherein the foam thickness is between 8 mm and 30 mm. The artificial turf surface layer according to claim 1, wherein the foam density is between 20 kg / mm ³ and 600 kg / mm ³ . The artificial turf surface layer according to claim 3, wherein the foam density is between 30 kg / mm ³ and 150 kg / mm ³ . The artificial turf surface layer according to claim 1, wherein the foam has a cell size between 0.2 mm and 3 mm. The artificial turf surface layer according to claim 1, wherein the polyolefin foam includes a polyethylene foam. The polyethylene has a density of 0.865 g / cc and 0.96 g / cc.
The artificial turf surface layer described in 1. The artificial turf surface layer according to claim 1, wherein the turf has a vertical ball rebound of 0.60 to 1 m as measured according to FIFA regulations. The artificial turf surface layer according to claim 1, wherein the turf has a buffer of 55% to 70% as measured according to FIFA regulations. The artificial turf surface layer according to claim 1, wherein the turf has a vertical deformation of 4 mm to 9 mm, measured according to FIFA regulations. The artificial turf surface layer according to claim 1, wherein the polyolefin foam comprises at least two foam layers.