JP2016530409A - Building insulation - Google Patents

Abstract

A building structure is provided that includes a building envelope that defines an interior. The building structure includes building insulation positioned adjacent to the face of the building envelope, interior, or a combination thereof. The building insulation can include a porous polymeric material formed from a thermoplastic composition containing a continuous phase that includes a matrix polymer. Micro-included additives and nano-included additives may also be dispersed within the continuous phase in the form of discrete regions, the material being a porous network comprising a plurality of nanopores having an average cross-sectional dimension of about 800 nanometers or less Defined in. [Selection figure] None

Description

(Claiming priority)
This application claims priority to US Provisional Application No. 61 / 834,038 (filed June 12, 2013), which is incorporated herein by reference in its entirety.

  Insulation materials are used in building structures for a wide variety of purposes, including heat transfer, moisture, noise, and protection from vibration. For example, one type of building insulation is a water-impermeable house wrap used in the manufacture of wall and roof assemblies. In addition to preventing water from entering the building, such house wraps are also typically breathable in that they are permeable to gases, without confining water vapor on the building surface, Can escape from insulation. Unfortunately, one common problem associated with many conventional types of building insulation, such as house wrap, is that they are generally not multifunctional. For example, a conventional breathable house wrap material is a flash spun polyolefin material that is commercially available from DuPont under the trademark Tyvek®. Although providing good water shielding properties, Tyvek® house wrap generally does not provide good thermal insulation. In order to achieve this goal, polymeric foams are often used for thermal insulation purposes. However, such materials do not always function well as breathable water shielding. Furthermore, the gas blowing agent used to form the foam leaches out of the insulation material over time resulting in environmental problems.

  Accordingly, there is a current need for improved insulation for use in building structures.

In accordance with one embodiment of the present invention, a building insulation for use in residential or commercial building structures is disclosed. Building insulation includes a porous polymeric material formed from a thermoplastic composition containing a continuous phase including a matrix polymer. The polymeric material exhibits a water vapor transmission rate of about 300 g / m ² -24 hours or more, a thermal conductivity of about 0.40 watts / meter Kelvin or less, and a water head value of about 50 centimeters or more.

  In accordance with one embodiment of the present invention, a building insulation for use in residential or commercial building structures is disclosed. Building insulation includes a porous polymeric material formed from a thermoplastic composition containing a continuous phase including a matrix polymer. The micro-included additive and the nano-included additive may be dispersed within the continuous phase in the form of discrete regions, wherein the porous network comprises a plurality of nanopores having an average cross-sectional dimension of about 800 nanometers or less Is defined in the material.

  In yet another embodiment, a building structure is disclosed that includes a building envelope that defines an interior. The building structure further comprises building insulation positioned adjacent to the face of the building envelope, interior, or a combination thereof, such as those described herein. For example, in one embodiment, the building insulation can be positioned adjacent to the face of the building envelope, such as adjacent to an exterior wall, roof, or combination thereof. If desired, building insulation may be positioned adjacent to an outer cover (eg, wallboard). Building insulation can also be positioned adjacent to interior surfaces, such as adjacent to interior walls, floors, ceilings, doors, or combinations thereof.

  Other features and aspects of the present invention are discussed in more detail below.

The complete and feasible disclosure of the present invention, which is directed to those skilled in the art, is more specifically described in the remainder of this specification, including its best mode, which is illustrated in the following attached drawings. refer.
FIG. 2 shows a partial representative view of a building structural wall made of building panels that can be formed according to the present invention. 2 is an average cross-sectional dimension of the building panel of FIG. 1 along line 2-2. 1 is a perspective view of one embodiment of a building structure in which the building insulation of the present invention is positioned adjacent to an outer wall. FIG. 1 is a perspective view of one embodiment of a building structure in which the building insulation of the present invention is positioned adjacent to an inner wall. FIG. It is a SEM micrograph of the unstretched film of Example 7 (The film was cut | disconnected in parallel with respect to flow direction orientation). It is a SEM micrograph of the unstretched film of Example 7 (The film was cut | disconnected in parallel with respect to flow direction orientation). It is a SEM micrograph of the stretched film of Example 7 (The film was cut | disconnected in parallel with respect to flow direction orientation). It is a SEM micrograph of the stretched film of Example 7 (The film was cut | disconnected in parallel with respect to flow direction orientation). 9 is a SEM micrograph of an unstretched film of Example 8, wherein the film was cut perpendicular to the flow direction in FIG. 9 and parallel to the flow direction in FIG. 9 is a SEM micrograph of an unstretched film of Example 8, wherein the film was cut perpendicular to the flow direction in FIG. 9 and parallel to the flow direction in FIG. It is a SEM micrograph of the stretched film of Example 8 (The film was cut | disconnected in parallel with respect to flow direction orientation). It is a SEM micrograph of the stretched film of Example 8 (The film was cut | disconnected in parallel with respect to flow direction orientation). It is a SEM micrograph (1,000X) of the fiber (polypropylene, polylactic acid, and polyepoxide) of Example 9 after freezing destruction in liquid nitrogen. It is a SEM micrograph (5,000X) of the fiber (polypropylene, polylactic acid, and polyepoxide) of Example 9 after freezing fracture in liquid nitrogen. It is a SEM micrograph (10,000X) of the fiber surface (polypropylene, polylactic acid, and polyepoxide) of Example 9.

  Repeat use of reference characters in the present specification and drawings is intended to indicate same or analogous features of the invention.

  Reference will now be made in detail to various embodiments of the invention, one or more examples of which are set forth below. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the scope or spirit of the invention. For example, features illustrated or described as part of one embodiment can be used in another embodiment to yield a still further embodiment. Accordingly, it is intended that the present invention cover modifications and variations that fall within the scope of the appended claims and their equivalents.

  In general, the present invention is directed to building insulation including porous polymeric materials (eg, films, fibrous materials, etc.). As used herein, “building insulation” refers to buildings used as insulation for any purpose, such as thermal insulation, soundproofing, shock isolation (eg, vibration), fireproofing, moistureproofing, etc., and combinations thereof. Broadly refers to any object within. Building insulation is a physical separator between the interior and exterior environment of a building, such as adjacent to the face of a building envelope that can include foundations, roofs, exterior walls, exterior doors, windows, skylights, etc. It can be located in a residential or commercial building structure. Building insulation can also be positioned adjacent to interior surfaces of buildings, such as interior walls, interior doors, floors, and ceilings.

Regardless of the specific location where building insulation is used, the porous polymeric material of the present invention performs multiple insulation functions within the building, and in some cases eliminates the need for certain types of conventional insulation there's a possibility that. For example, the polymeric material is porous, for example, from about 15% to about 80% / cm ³ , in some embodiments from about 20% to about 70%, and in some embodiments about per cubic centimeter of material. Define a porous network that is 30% to about 60%. Such a high pore volume allows the polymeric material to be generally water vapor permeable, thereby allowing such vapors to escape from the building surface during use, resulting in intermittent flooding. Limit the possibilities of Permeability to water vapor of the material, although it may be characterized by its relatively high moisture vapor transmission rate ( "WVTR"), which is measured in grams / square meter / 24 hours (g / m ^2/24 hours) Is the rate at which water vapor permeates through the material. For example, the polymeric material may be about 300 g / m ² -24 hours or longer, as determined by ASTM E96 / 96M-12, Procedure B or INDA test procedure IST-70.4 (01), etc., in some embodiments. About 500 g / m ² -24 hours or more, in some embodiments about 1,000 g / m ² -24 hours or more, and in some embodiments about 3,000 to about 15,000 g / m ² -24. It may indicate the WVTR of time. In addition to allowing the passage of vapor, the relatively high pore volume of the material can also significantly reduce the density of the material, which is lighter, more flexible and still achieves good insulating properties The use of materials may be possible. For example, the composition can be about 1.2 grams / cubic centimeter (“g / cm ³ ”) or less, in some embodiments about 1.0 g / cm ³ or less, and in some embodiments about 0.2 g / cm ^3. It may have a relatively low density, such as from about 0.8 g / cm ³ and in some embodiments from about 0.1 g / cm ³ to about 0.5 g / cm ³ . Because of its low density, lighter materials that still achieve good thermal resistance can be formed.

  Despite being highly porous and generally water vapor permeable, the porous network can be viewed as a “closed cell” network where the tortuous path is not defined between a significant portion of the pores. They discovered. Such a structure helps restrict the flow of fluid through the material and may be generally impermeable to fluid (eg, liquid water), whereby the material is water The surface can be protected from penetration. In this regard, the polymeric material, when determined in accordance with ATTCC 127-2008, is about 50 centimeters ("cm") or greater, in some embodiments about 100 cm or greater, in some embodiments about 150 cm or greater, And in some embodiments, may have a relatively high head value of about 200 cm to about 1000 cm.

  A significant portion of the pores of the porous network of polymeric material is about 800 nanometers or less, in some embodiments about 1 to 500 nanometers, in some embodiments about 5 to about 450 nanometers, Also “nanoscale” sizes (“nanopores”), such as those having an average cross-sectional dimension of about 5 to about 400 nanometers in some embodiments and about 10 to about 100 nanometers in some embodiments sell. The term “cross-sectional dimension” generally refers to the characteristic dimension (eg, width or diameter) of a pore, which is substantially perpendicular to its major axis (eg, length) and stress applied during stretching. Is generally substantially perpendicular to the direction of For example, such nanopores are about 15% or more by volume of the total pore volume of the polymeric material, in some embodiments about 20% or more, and in some embodiments about 30% to 100% by volume. %, In some embodiments, may comprise from about 40% to about 90% by volume. The presence of such a high level of nanopores can greatly reduce thermal conductivity because there are not many cell molecules in each pore that collide and conduct heat. Thus, the polymeric material can also serve as a thermal insulator and can help limit the degree of heat transfer through the building structure.

To achieve this goal, the polymeric material is about 0.40 Watts / meter Kelvin (“W / m-K”) or less, in some embodiments about 0.20 W / m-K or less, one In some embodiments, about 0.15 W / m-K or less, in some embodiments from about 0.01 to 0.12 W / m-K, and in some embodiments from about 0.02 to about 0.10 W May exhibit a relatively low thermal conductivity, such as /m-K.In particular, the material can achieve such a low thermal conductivity value at a relatively thin thickness, which makes the material more flexible and compatible And the space that the material occupies in the building can be reduced, so that polymeric materials can also exhibit relatively low “thermal properties”, which can reduce the thermal conductivity of the material. equals divided by thickness, watts / square meter - Kelvin ( "W / m 2 ^K" It is provided in the unit. For example, the material can be about 1000 W / m ² K or less, in some embodiments from about 10 to about 800 W / m ² K, in some embodiments from about 20 to about 500 W / m ² K, and in some implementations. The form can exhibit thermal properties of about 40-200 W / m ² K. The actual thickness of the polymeric material may depend on its particular shape, but is typically about 5 micrometers to about 100 millimeters, in some embodiments about 10 micrometers to about 50 millimeters, part In embodiments, the range is from about 200 micrometers to about 25 millimeters, and in some embodiments, from about 50 micrometers to about 5 millimeters.

  In contrast to the prior art for forming building insulation materials, the inventors have discovered that the porous material of the present invention can be formed without the use of a gas blowing agent. This is due in part to the unique nature of the material components and the materials in which the material is formed. More specifically, the porous material can be formed from a thermoplastic composition containing a continuous phase that includes a matrix polymer, a micro-included additive, and a nano-included additive. The additive can be selected to have a different modulus of elasticity than the matrix polymer. In this way, the micro-included additive and the nano-included additive can be dispersed within the continuous phase as separate microscale and nanoscale phase regions, respectively. When subjected to deformation and elongation strain (eg, stretching), microscale and nanoscale phase regions can interact in a unique way to create a network of pores, a significant portion of which is nanoscale sized We have found that there is. That is, as a result of stress concentrations resulting from material incompatibility, elongational strain can initiate strong local shear zones and / or stress intensity zones (eg, normal stress) near the microscale discrete phase regions. . These shear and / or stress intensity zones result in some initial delamination in the polymer matrix adjacent to the microscale region. In particular, however, local shear and / or stress intensity zones can also be created near nanoscale individual phase regions that overlap with microscale zones. Such overlapping shear and / or stress intensity zones cause further delamination in the polymer matrix, thereby producing a significant number of nanopores adjacent to the nanoscale and / or microscale regions.

  Various embodiments of the invention will now be described in detail.

I. Thermoplastic Composition A. Matrix Polymer As noted above, the thermoplastic composition may comprise a continuous phase comprising one or more matrix polymers, typically from about 60% to about 99% by weight of the thermoplastic composition, In some embodiments, about 75 wt% to about 98 wt%, and in some embodiments, about 80 wt% to about 95 wt%. The nature of the matrix polymer used to form the continuous phase is not critical, and any suitable polymer such as polyester, polyolefin, synthetic polymer, polyamide, etc. can generally be used. In certain embodiments, for example, polyester may be used in the composition to form the polymer matrix. Aliphatic polyesters, etc., polycaprolactone, polyesteramide, polylactic acid (PLA) and copolymers thereof, polyglycolic acid, polyalkylene carbonate (for example, polyethylene carbonate), poly-3-hydroxybutyric acid (PHB), poly-3- Hydroxyvaleric acid (PHV), poly-3-hydroxybutyric acid-co-4-hydroxybutyric acid, poly-3-hydroxybutyric acid-co-3-hydroxyvaleric acid copolymer (PHBV), poly-3-hydroxybutyric acid-co -3-hydroxyhexanoic acid, poly-3-hydroxybutyric acid-co-3-hydroxyoctanoic acid, poly-3-hydroxybutyric acid-co-3-hydroxydecanoic acid, poly-3-hydroxybutyric acid-co-3-hydroxyoctadecane Acids, and succinic acid-based aliphatic polymers (eg, polybutylene succinate, polybutene Lensuccinate adipate, polyethylene succinate, etc.), aliphatic directional copolyesters (eg, polybutylene adipate terephthalate, polyethylene adipate terephthalate, polyethylene adipate isophthalate, polybutylene adipate isophthalate, etc.), aromatic polyesters (eg, polyethylene terephthalate) Any of a variety of polyesters such as polybutylene terephthalate) may be generally used.

In certain cases, the thermoplastic composition may include at least one polyester having a relatively high glass transition temperature due to its hard nature. For example, the glass transition temperature (“T _g ”) is about 0 ° C. or higher, in some embodiments from about 5 ° C. to about 100 ° C., in some embodiments from about 30 ° C. to about 80 ° C., and some In embodiments, it may be from about 50 ° C to about 75 ° C. The polyester may also have a melting temperature of about 140 ° C. to about 300 ° C., in some embodiments about 150 ° C. to about 250 ° C., and in some embodiments about 160 ° C. to about 220 ° C. Melting temperature may be determined using differential scanning calorimetry (“DSC”) according to ASTM D-3417. The glass transition temperature can be determined by dynamic mechanical analysis according to ASTM E1640-09.

  One particularly suitable hard polyester is polylactic acid, which can be any lactic acid, such as levorotatory lactic acid ("L-lactic acid"), dextrorotatory lactic acid ("D-lactic acid"), mesolactic acid, or mixtures thereof. Generally derived from the monomeric unit of the isomer. Monomer units can also be formed from the anhydride of any isomer of lactic acid, including L-lactide, D-lactide, meso-lactide, or mixtures thereof. Such cyclic dimers and / or lactides of lactic acid can also be used. Any known polymerization method, such as polycondensation or ring-opening polymerization, can be used for the polymerization of lactic acid. Small amounts of chain extenders (eg diisocyanate compounds, epoxy compounds or acid anhydrides) can also be used. The polylactic acid can be a homopolymer or a copolymer, such as those containing monomer units derived from L-lactic acid and monomer units derived from D-lactic acid. Although not essential, the content of one of the monomer units derived from L-lactic acid and the monomer units derived from D-lactic acid is about 85 mol% or more, and in some embodiments about 90 mol% or more, and one In some embodiments, it is preferably about 95 mol% or more. A plurality of polylactic acids each having a different ratio between monomer units derived from L-lactic acid and monomer units derived from D-lactic acid may be mixed in any percentage. Of course, the polylactic acid can also be mixed with other types of polymers (eg, polyolefins, polyesters, etc.).

  In one particular embodiment, the polylactic acid has the following general structure:

  One specific example of a suitable polylactic acid polymer that may be used in the present invention is the Biomer, Inc. under the name BIOMER ™ L9000. (Claying, Germany). Other suitable polylactic acid polymers are commercially available from Natureworks LLC (NATUREWORKS®) or Mitsui Chemicals, Inc. (LACEA ™), Minnetonka, Minnesota. Still other suitable polylactic acids are U.S. Pat. Nos. 4,797,468, 5,470,944, 5,770,682, 5,821,327, 5,880,254. , And 6,326,458.

The polylactic acid is generally about 40,000 to about 180,000 grams / mole, in some embodiments about 50,000 to about 160,000 grams / mole, and in some embodiments about 80,000. Having a number average molecular weight (“M _n ”) in the range of 000 to about 120,000 grams / mole. Similarly, the polymer generally also has from about 80,000 to about 250,000 grams / mole, in some embodiments from about 100,000 to about 200,000 grams / mole, and in some embodiments about It has a weight average molecular weight (“M _w ”) in the range of 110,000 to about 160,000 grams / mole. The ratio of the weight average molecular weight to the number average molecular weight (“M _w / M _n ”), ie “polydispersity index” is also relatively low. For example, the polydispersity index generally ranges from about 1.0 to 3.0, in some embodiments from about 1.1 to about 2.0, and in some embodiments from about 1.2 to About 1.8. Weight and number average molecular weight can be determined by methods known to those skilled in the art.

Polylactic acid is also about 50 to about 600 Pascal seconds (Pa · s), in some embodiments about 100 to 500 Pa · s, and one when measured at a temperature of 190 ° C. and a shear rate of 1000 s ^−1. Some embodiments may have an apparent viscosity of about 200 to 400 Pa · s. The melt flow rate (dry base) of polylactic acid is also about 0.1 to about 40 grams / 10 minutes, measured in 2160 grams load and 190 ° C., in some embodiments about 0.5 to about It can be 20 grams / 10 minutes, and in some embodiments from about 5 to about 15 grams / 10 minutes.

  Some types of pure polyester (eg, polylactic acid) have a moisture content of about 500-600 million parts per million (“ppm”) or higher based on the dry weight of the starting polylactic acid. Can absorb water from the environment. The moisture content can be determined in various ways known in the art, such as in accordance with ASTM D 7191-05, as described below. Because the presence of water during the melt process can hydrolyze the polyester and reduce its molecular weight, it may be desirable to dry the polyester prior to mixing. In most embodiments, for example, before mixing the micro inclusion additive and the nano inclusion additive, the polyester is less than about 300 parts per million (“ppm”), in some embodiments less than about 200 ppm, In some embodiments, it is desirable to have a moisture content of about 1-100 ppm. The drying of the polyester can occur, for example, at a temperature of about 50 ° C to about 100 ° C, and in some embodiments about 70 ° C to about 80 ° C.

B. Micro Inclusion Additives As noted above, in certain embodiments of the invention, micro inclusion additives and / or nano inclusion additives can be dispersed within the continuous phase of the thermoplastic composition. As used herein, the term “micro inclusion additive” refers to any amorphous, crystalline or semi-crystalline material that can be dispersed in the form of discrete regions of microscale size within a polymer matrix. Generally refers. For example, prior to stretching, the region is about 0.05 μm to about 30 μm, in some embodiments about 0.1 μm to about 25 μm, in some embodiments about 0.5 μm to about 20 μm, and some implementations. The form may have an average cross-sectional dimension of about 1 μm to about 10 μm. The term “cross-sectional dimension” generally refers to a characteristic dimension (eg, width or diameter) of a region, which is substantially perpendicular to its principal axis (eg, length) and is the stress applied during stretching. The direction is generally substantially orthogonal. Although typically formed from micro-included additives, it should be understood that the microscale region can also be formed from combinations of micro-included and nano-included additives and / or other components of the composition.

  In certain embodiments, the micro-included additive is generally polymeric in nature, has a relatively high molecular weight, and helps to improve the melt strength and stability of the thermoplastic composition. Typically, the micro-included polymer can be generally immiscible with the matrix polymer. Thus, the additive can be better dispersed as a discrete phase region within the continuous phase of the matrix polymer. The discrete regions can absorb energy resulting from external forces, increasing the overall toughness and strength of the resulting material. A region can have a variety of different shapes, such as oval, spherical, cylindrical, plate-like, tubular, and the like. For example, in one embodiment, the region has a substantially elliptical shape. The physical dimensions of the individual regions are generally small enough to minimize the propagation of cracks through the polymeric material when external stress is applied, but they initiate micro deformation of the plastic and contain particles. Large enough to allow shear and / or stress intensity zones around and around the object.

Although the polymer can be immiscible, the micro-included additive can nevertheless be selected to have a solubility parameter that is relatively similar to the matrix polymer. This improves the interfacial compatibility and physical interaction at the boundary between the individual and continuous phases, thus reducing the likelihood of the composition breaking. In this regard, the ratio of matrix polymer solubility parameter to additive is typically about 0.5 to about 1.5, and in some embodiments about 0.8 to about 1.2. For example, the micro-included additive may have a solubility parameter of about 15 to about 30 M Joule ^1/2 / m ^3/2 , in some embodiments, about 18 to about 22 M Joule ^1/2 / m ^3/2. On the other hand, polylactic acid can have a solubility parameter of about 20.5 M Joule ^1/2 / m ^3/2 . The term “solubility parameter” as used herein refers to the “Hilden brand solubility parameter”, which is the square root of the cohesive energy density and is calculated according to the following equation:

here,
ΔHv = heat of vaporization R = ideal gas constant T = temperature Vm = molar volume

  Many polymer Hilden brand solubility parameters are also available from Wyyech's Plastic Solubility Handbook (2004), which is incorporated herein by reference.

  The micro-included additive can also have a constant melt flow rate (or viscosity) to ensure that the individual regions and resulting pores are properly maintained. For example, if the melt flow rate of the additive is too high, it tends to flow and disperse uncontrolled through the continuous phase. This results in a layered plate-like region or co-continuous phase structure that is difficult to maintain and is more likely to break prematurely. Conversely, if the melt flow rate of the additive is too low, it tends to agglomerate to form very large elliptical regions that are difficult to disperse during mixing. This can result in a non-uniform distribution of the additive throughout the continuous phase. In this regard, the inventors have generally determined that the ratio of the melt flow rate of the micro-included additive to the flow rate of the matrix polymer is about 0.2 to about 8, and in some embodiments about 0.5 to about 6, and in some embodiments from about 1 to about 5. For example, the melt flow rate of the micro-included additive is about 0.1 to about 250 grams / 10 minutes when measured at a load of 2160 grams and 190 ° C., and in some embodiments about 0.5 to about 200. Grams / 10 minutes, and in some embodiments from about 5 to about 150 grams / 10 minutes.

  In addition to the properties described above, the mechanical properties of the micro-included additive can also be selected to achieve the desired increase in toughness. For example, when an external force is applied to the mixture of matrix polymer and micro inclusion additive, the stress concentration (eg, including normal or shear stress) and as a result of the stress concentration resulting from the difference in elastic modulus of the additive and matrix polymer and Shear and / or plastic yield zones can be initiated at and around the individual phase zones. A greater stress concentration promotes stronger local plastic flow in the region, which allows the region to stretch greatly when stress is transmitted. These stretch regions allow the composition to behave more supple and flexible than the matrix polymer when the composition is a hard polyester resin or the like. To increase the stress concentration, the micro inclusion additive can be selected to have a relatively low Young's modulus as compared to the matrix polymer. For example, the ratio of the elastic modulus of the matrix polymer to the elastic modulus of the additive is generally about 1 to about 250, in some embodiments about 2 to about 100, and in some embodiments about 2 to about 50. It is. The elastic modulus of the micro-included additive ranges, for example, from about 2 to about 1000 megapascals (MPa), in some embodiments from about 5 to about 500 MPa, and in some embodiments from about 10 to about 200 MPa. sell. In contrast, the elastic modulus of polylactic acid is, for example, generally about 800 MPa to about 3000 MPa.

  A wide variety of micro-include additives with the properties specified above may be used, but particularly suitable examples of such polymers include polyolefins (eg, polyethylene, polypropylene, polybutylene, etc.), styrene copolymers ( For example, styrene-butadiene-styrene, styrene-isoprene-styrene, styrene-ethylene-propylene-styrene, styrene-ethylene-butadiene-styrene, etc.), polytetrafluoroethylene, polyester (eg, recycled polyester, polyethylene terephthalate, etc.), poly Vinyl acetate (eg, poly (ethylene vinyl acetate), polyvinyl chloride-vinyl acetate, etc.), polyvinyl alcohol (eg, polyvinyl alcohol, poly (ethylene vinyl alcohol), etc.), polyvinyl butyral, Acrylic resins (e.g., polyacrylates, polymethyl acrylate, polymethyl methacrylate, etc.), polyamides (e.g., nylon), polyvinyl chloride, polyvinylidene chloride, polystyrene, may include synthetic polymers such as polyurethane. Suitable polyolefins include, for example, ethylene polymers (eg, low density polyethylene (“LDPE”), high density polyethylene (“HDPE”), linear low density polyethylene (“LLDPE”}, etc.), propylene homopolymers (eg, Syndiotactic, atactic, isotactic, etc.), propylene copolymers and the like.

  In one particular embodiment, the polymer is a propylene polymer, such as a homopolypropylene or a copolymer of propylene. The propylene polymer can be formed, for example, from a copolymer comprising substantially no more than about 10% by weight of isotactic polypropylene homopolymer or other monomer (ie, at least about 90% by weight of propylene). Such homopolymers can have a melting point of about 160 ° C to about 170 ° C.

In yet another embodiment, the polyolefin can be a copolymer of ethylene or propylene and another α-olefin (such as a C ₃ -C ₂₀ α-olefin or C ₃ -C ₁₂ α-olefin). Specific examples of suitable α-olefins include 1-butene, 3-methyl-1-butene, 3,3-dimethyl-1-butene, 1-pentene, one or more methyl, ethyl or propyl substituents. 1-pentene, 1-hexene with one or more methyl, ethyl or propyl substituents, 1-heptene with one or more methyl, ethyl or propyl substituents, one or more methyl, ethyl or propyl substituents 1-octene having, 1-nonene having one or more methyl, ethyl or propyl substituents, ethyl, methyl or dimethyl substituted 1-decene, 1-dodecene, and styrene. Particularly preferred α-olefin comonomers are 1-butene, 1-hexene and 1-octene. Such copolymers have an ethylene or propylene content of about 60 mol% to about 99 mol%, in some embodiments about 80 mol% to about 98.5%, and in some embodiments about 87 mol%. % To about 97.5 mol%. The α-olefin content may also be from about 1 mol% to about 40 mol%, in some embodiments from about 1.5 mol% to about 15 mol%, and in some embodiments from about 2.5 mol% to It can range from about 13 mole percent.

Exemplary olefin copolymers for use in the present invention include ethylene-based copolymers commercially available under the name EXACT ™ from ExxonMobil Chemical Company of Houston, Texas. Other suitable ethylene copolymers are commercially available under the names ENGAGE ™, AFFINITY ™, DOWLEX ™ (LLDPE) and ATTANE ™ (ULDPE) from Dow Chemical Company, Midland, Michigan. . Other suitable ethylene polymers, Ewen et al., U.S. Pat. No. 4,937,299, Tsutsui et al No. 5,218,071, Lai et al No. 5,272,236, and Lai et fifth, 278,272. Suitable propylene copolymers are also available from ExxonMobil Chemical Co. (Houston, Texas) VISTAMAXX ™, Atofina Chemicals (Felai, Belgium) FINA ™ (eg, 8573), TAFMER ™ from Mitsui Petrochemical, and Dow Chemical Co. (Midland, Michigan) is sold under the name VERSIFY ™. Suitable polypropylene homopolymers may similarly include Exxon Mobil 3155 polypropylene, Exxon Mobil Achieve ™ resin and Total M3661 PP resin. Other examples of propylene polymers are described in Datta et al. , US Pat. No. 6,500,563, Yang et al ., 5,539,056, and Resconi et al ., 5,596,052.

Any of a variety of known techniques can be commonly used to form olefin copolymers. For example, olefin polymers can be formed using free radicals or coordination catalysts (eg, Ziegler-Natta). Preferably, the olefin polymer is formed from a single site coordination catalyst, such as a metallocene catalyst. Such a catalyst system produces an ethylene copolymer in which the comonomer is randomly distributed within the molecular chain and is uniformly distributed over different molecular weight fractions. Metallocene catalyzed polyolefins include, for example, McAlpin et al. , US Pat. No. 5,571,619, Davis et al . 5,322,728, Obijski et al . 5,472,775, Lai et al . 5,272, and the like. 236, and Wheat et al ., 6,090,325. Examples of metallocene catalysts include bis (n-butylcyclopentadienyl) titanium dichloride, bis (n-butylcyclopentadienyl) zirconium dichloride, bis (cyclopentadienyl) scandium chloride, bis (indenyl) Zirconium dichloride, bis (methylcyclopentadienyl) titanium dichloride, bis (methylcyclopentadienyl) zirconium dichloride, cobaltcene, cyclopentadienyltitanium trichloride, ferrocene, hafnocene dichloride, isopropyl (cyclopentadi) Enyl, -1-fluorenyl) zirconium dichloride, molybdocene dichloride, nickelocene, niovocene dichloride, ruthenocene, titanocene dichloride, zirconocene chloride hydride, zirco dichloride Sen, and the like. Polymers made using metallocene catalysts generally have a narrow molecular weight range. For example, a metallocene catalyzed polymer can have a polydispersity (M _w / M _n ) less than 4, a controlled short chain branching distribution, and a controlled isotacticity.

  Regardless of the material used, the relative percentage of micro-included additives in the thermoplastic composition is selected to achieve the desired properties without significantly affecting the basic properties of the composition. For example, the reinforcing additive is typically about 1% to about 30% by weight of the thermoplastic composition based on the weight of the continuous phase (matrix polymer), in some embodiments, the micro-included additive, Used in an amount of about 2% to about 25% by weight, and in some embodiments about 5% to about 20% by weight. The concentration of micro-included additives throughout the thermoplastic composition is also from about 0.1% to about 30%, in some embodiments from about 0.5% to about 25%, and in part In embodiments, it may comprise from about 1% to about 20% by weight.

C. Nano Inclusion Additive As used herein, the term “nano inclusion additive” refers to any amorphous, crystalline, or crystalline substance that can be dispersed in the form of nanoscale sized discrete regions within a polymer matrix. Generally refers to semi-crystalline material. For example, prior to stretching, the region has an average cross-sectional dimension of about 1 to about 500 nanometers, in some embodiments about 2 to about 400 nanometers, and in some embodiments about 5 to about 300 nanometers. Can have. It will be appreciated that the nanoscale region can also be formed from a combination of micro-included additives and nano-included additives and / or other components of the composition. The nano-included additive is generally from about 0.05% to about 20%, in some embodiments, about 0.1% by weight of the thermoplastic composition, based on the weight of the continuous phase (matrix polymer). % To about 10% by weight, and in some embodiments from about 0.5% to about 5% by weight. The concentration of the nano-included additive throughout the thermoplastic composition is also from about 0.01 wt% to about 15 wt%, in some embodiments from about 0.05 wt% to about 10 wt%, and in part In embodiments, it may be from about 0.3% to about 6% by weight.

  Nano-included additives are polymeric in nature, have a relatively high molecular weight and help improve the melt strength and stability of thermoplastic compositions. To enhance its ability to disperse in the nanoscale region, the nano-included additive can also be selected from materials that are generally compatible with matrix polymers and micro-included additives. This can be particularly useful when the matrix polymer or micro-included additive has a polar moiety such as polyester. In one example, such nano-included additives are functional polyolefins. For example, the polar component can be provided by one or more functional groups and the nonpolar component can be provided by an olefin. The olefin component of the nano-included additive can generally be formed from any linear or branched alpha-olefin monomer, oligomer, or polymer (including copolymers) derived from olefin monomers as described above.

  The functional group of the nano-included additive can be any group, molecular segment and / or block that provides a polar component for the molecule and is incompatible with the matrix polymer. Examples of molecular segments and / or blocks that are incompatible with polyolefins may include acrylates, styrenes, polyesters, polyamides, and the like. The functional group has ionic properties and can include charged metal ions. Particularly suitable functional groups are maleic anhydride, maleic acid, fumaric acid, maleimide, maleic hydrazide, reaction products of maleic anhydride and diamine, methyl nadic anhydride, dichloromaleic anhydride, maleic amide, etc. . Maleic anhydride modified polyolefins are particularly suitable for use in the present invention. Such modified polyolefins are generally formed by grafting maleic anhydride onto the polymer backbone material. Such maleated polyolefins are available from E.I. I. Du Pont de Nemours and Company under the name Fusbond (registered trademark), P series (chemically modified polypropylene), E series (chemically modified polyethylene), C series (chemically modified ethylene vinyl acetate), A series (chemical) Modified ethylene acrylate copolymer or terpolymer), or N series (chemically modified ethylene-propylene, ethylene-propylene diene monomer ("EPDM") or ethylene-octane). Alternatively, the maleated polyolefin can be obtained from Chemtura Corp. under the name Polybond®. From Eastman Chemical Company under the name Eastman G series.

  In certain embodiments, nano-included additives can also be reactive. An example of such a reactive nano-included additive is a polyepoxide containing an average of at least two oxylene rings per molecule. Without being limited by theory, such polyepoxide molecules induce matrix polymer (eg, polyester) reactions under certain conditions, thereby improving melt strength without significantly reducing the glass transition temperature. It is considered possible. The reaction can involve chain extension, side branching, grafting, copolymer formation, and the like. For example, chain extension can occur through a variety of different reaction pathways. For example, the modifier may allow a nucleophilic ring-opening reaction through the carbonyl end group of the polyester (esterification) or through the hydroxyl group (etherification). Oxazoline side reactions can occur as well to form ester amide moieties. Through such a reaction, the molecular weight of the matrix polymer can be increased to counter the degradation often seen during melt processing. While it may be desirable to induce a matrix polymer reaction as described above, the inventors have discovered that if the reaction proceeds too much, crosslinking between the polymer backbones can occur. When such cross-linking proceeds to a significant degree, the resulting polymer mixture can become brittle and difficult to process into a material with desirable strength and elongation properties.

  In this regard, the inventors have found that polyepoxides with relatively low epoxy functionality are particularly effective and can be quantified by their “epoxy equivalents”. Epoxy equivalent reflects the amount of resin containing one molecule of epoxy groups, which can be calculated by dividing the number average molecular weight of the modifier by the number of epoxy groups in the molecule. The polyepoxides of the present invention generally have from about 7,500 to about 250,000 grams / mole, in some embodiments from about 15,000 to about 150,000 grams / mole, and in some embodiments about With a number average molecular weight in the range of 20,000 to about 100,000 grams / mole, the polydispersity index is generally in the range of 2.5-7. The polyepoxide can comprise less than 50, in some embodiments 5-45, and in some embodiments 15-40 epoxy groups. Similarly, the epoxy equivalent weight is less than about 15,000 / mole, in some embodiments from about 200 to about 10,000 grams / mole, and in some embodiments from about 500 to about 7,000 grams / mole. sell.

  The polyepoxide can be a linear or branched homopolymer or copolymer (eg, random, graft, block, etc.) containing terminal epoxy groups, backbone oxylene units, and / or overhanging epoxy groups. The monomers used to form such polyepoxides can vary. In one particular embodiment, for example, the polyepoxide includes at least one epoxy functional (meth) acrylic monomer component. As used herein, the term “(meth) acryl” includes acrylic and methacrylic monomers, and salts or esters thereof, such as acrylate and methacrylate monomers. For example, suitable epoxy functional (meth) acrylic monomers can include, but are not limited to, those containing 1,2-epoxy groups, such as glycidyl acrylate and glycidyl methacrylate. Other suitable epoxy functional monomers include allyl glycidyl ether, glycidyl ethacrylate, and glycidyl itaconate.

  Polyepoxides generally have a relatively high molecular weight as described above to not only provide chain extension, but also help achieve the desired mixed form. Thus, the resulting melt flow rate of the polymer is about 10 to about 200 grams / 10 minutes when measured at a load of 2160 grams and 190 ° C., and in some embodiments about 40 to about 150 grams / 10 minutes, And in some embodiments from about 60 to about 120 grams / 10 minutes.

  If necessary, additional monomers may also be used in the polyepoxide to help achieve the desired molecular weight. Such monomers can be different and can include, for example, ester monomers, (meth) acrylic monomers, olefin monomers, amide monomers, and the like. In one particular embodiment, for example, the polyepoxide comprises at least one linear or branched α-olefin monomer, such as one having 2 to 20 carbon atoms, preferably 2 to 8 carbon atoms. Specific examples include ethylene, propylene, 1-butene, 3-methyl-1-butene, 3,3-dimethyl-1-butene, 1-pentene, 1- with one or more methyl, ethyl or propyl substituents. Pentene, 1-hexene with one or more methyl, ethyl or propyl substituents, 1-heptene with one or more methyl, ethyl or propyl substituents, 1 with one or more methyl, ethyl or propyl substituents -Octene, 1-nonene with one or more methyl, ethyl or propyl substituents, ethyl, methyl or dimethyl substituted 1-decene, 1-dodecene, and styrene. Particularly desirable α-olefin comonomers are ethylene and propylene.

  Another suitable monomer may include a (meth) acrylic monomer that is not epoxy functional. Examples of such (meth) acrylic monomers include methyl acrylate, ethyl acrylate, n-propyl acrylate, i-propyl acrylate, n-butyl acrylate, s-butyl acrylate, and i-acrylate. Butyl, t-butyl acrylate, n-amyl acrylate, i-amyl acrylate, isobornyl acrylate, n-hexyl acrylate, 2-ethylbutyl acrylate, 2-ethylhexyl acrylate, n-octyl acrylate, acrylic acid n-decyl, methyl cyclohexyl acrylate, cyclopentyl acrylate, cyclohexyl acrylate, methyl methacrylate, ethyl methacrylate, 2-hydroxyethyl methacrylate, n-propyl methacrylate, n-butyl methacrylate, i-propyl methacrylate, Methacrylic acid i-bu , N-amyl methacrylate, n-hexyl methacrylate, i-amyl methacrylate, s-butyl methacrylate, t-butyl methacrylate, 2-ethylbutyl methacrylate, methyl cyclohexyl methacrylate, cinnamyl methacrylate, crotyl methacrylate , Cyclohexyl methacrylate, cyclopentyl methacrylate, 2-ethoxyethyl methacrylate, isobornyl methacrylate, and the like, as well as combinations thereof.

  In one particularly desirable embodiment of the invention, the polyepoxide is an epoxy functional (meth) acrylic monomer component, an α-olefin monomer component, and a non-epoxy functional (meth) acrylic monomer component. is there. For example, the polyepoxide may be poly (ethylene-co-methyl acrylate-co-glycidyl methacrylate), which has the following structure:

  Here, x, y, and z are 1 or more.

  Various known techniques can be used to make the epoxy functional monomer into a polymer. For example, monomers containing polar functional groups can be grafted onto the polymer backbone to form a graft copolymer. Such grafting techniques are well known in the art and are described, for example, in US Pat. No. 5,179,164. In other embodiments, the monomer containing an epoxy functional group is obtained by using known free radical polymerization techniques, such as high pressure reactions, Ziegler-Natta catalysis systems, single site catalysis (eg, metallocene) reaction systems, and the like. Can be copolymerized to form block or random copolymers.

  The relative portion of the monomer component can be selected to achieve a balance between epoxy reactivity and melt flow rate. More specifically, a high epoxy monomer content can result in good reactivity with the matrix polymer, but if the content is too high, the melt flow rate is reduced so that the polyepoxide adversely affects the melt strength of the polymer mixture. sell. Thus, in most embodiments, the epoxy-functional (meth) acrylic monomer is about 1% to about 25% by weight of the copolymer, in some embodiments about 2% to about 20%, and one Some embodiments comprise from about 4% to about 15% by weight. Similarly, the α-olefin monomer is about 55% to about 95% by weight of the copolymer, about 60% to about 90% by weight in some embodiments, and about 65% to about 50% by weight in some embodiments. It may account for about 85% by weight. When used, other monomer components (eg, non-epoxy functional (meth) acrylic monomers) are about 5% to about 35% by weight of the copolymer, and in some embodiments about 8% by weight. To about 30% by weight, and in some embodiments about 10% to about 25% by weight. One specific example of a suitable polyepoxide that can be used in the present invention is commercially available from Arkema under the name LOTADER® AX8950 or AX8900. For example, LOTADER® AX8950 has a melt flow rate of 70-100 g / 10 min, 7 wt% to 11 wt% glycidyl methacrylate monomer content, 13 wt% to 17 wt% methyl acrylate monomer content And an ethylene monomer content of 72% to 80% by weight. Another suitable polyepoxide is commercially available from DuPont under the name ELVALOY® PTW, which is a terpolymer of ethylene, butyl acrylate, and glycidyl methacrylate with a melt flow rate of 12 g / 10 min.

  In addition to controlling the type and relative content of monomers used to form the polyepoxide, the overall weight percent can also be controlled to achieve the desired benefits. For example, if the modification level is too low, the desired increase in melt strength and mechanical properties may not be achieved. However, the inventors have also discovered that if the modification level is too high, the process can be limited due to strong intermolecular interactions (eg, crosslinking) and physical network formation by the epoxy functionality. Thus, the polyepoxide is generally from about 0.05 wt% to about 10 wt%, and in some embodiments from about 0.1 wt% to about 10 wt%, based on the weight of the matrix polymer used in the composition. 8% by weight, in some embodiments from about 0.5% to about 5% by weight, and in some embodiments from about 1% to about 3% by weight. Also, the polyepoxide is from about 0.05% to about 10%, in some embodiments from about 0.05% to about 8%, in some embodiments, from about 0.05% to about 10%, based on the total weight of the composition. It may comprise from 0.1 wt% to about 5 wt%, and in some embodiments from about 0.5 wt% to about 3 wt%.

  Other reactive nano-included additives such as oxazoline functionalized polymers, cyanide functionalized polymers may also be used in the present invention. When used, such reactive nano-included additives can be used within the concentrations described above for polyepoxides. In one particular embodiment, an oxazoline grafted polyolefin, which is a polyolefin grafted with a monomer containing an oxazoline ring, can be used. Oxazolines include 2-vinyl-2-oxazoline (eg, 2-isopropenyl-2-oxazoline), 2-fatty-alkyl-2-oxazolines (eg, oleic acid, linolenic acid, palmitooleic acid, gadoleic acid, 2-oxalolin, such as erucic acid and / or arachidonic acid ethanolamide) and combinations thereof. In another embodiment, the oxazoline may be selected from, for example, ricinol oxazoline maleate, undecyl-2-oxazoline, soya-2-oxazoline, ricinus-2-oxazoline, and combinations thereof. In yet another embodiment, the oxazoline is selected from 2-isopropenyl-2-oxazoline, 2-isopropenyl-4,4-dimethyl-2-oxazoline and combinations thereof.

Nanofillers such as carbon black, carbon nanotubes, carbon nanofibers, nanoclays, metal nanoparticles, nanosilica, nanoalumina can also be used. Nanoclay is particularly suitable. The term “nanoclay” generally refers to nanoparticles of clay materials (natural minerals, organically modified minerals, or materials with synthetic names), which typically have a plate-like structure. Examples of nanoclays include, for example, montmorillonite (2: 1 layered smectite clay structure), bentonite (aluminum phyllosilicate mainly formed of montmorillonite), kaolinite (1: 1 plate structure and A1 ₂ Si ₂ O ₅ ( Aluminosilicate) having an empirical formula of OH) ₄ ), aluminosilicate having halloysite (1: 1 tubular structure and A1 ₂ Si ₂ O ₅ (OH) ₄ ), and the like. One example of a suitable nanoclay is Cloisite®, which is a montmorillonite nanoclay and is manufactured by Southern Clay Products, Inc. Commercially available. Other examples of synthetic nanoclays include, but are not limited to, mixed metal hydroxide nanoclays, layered double hydroxide nanoclays (eg, sepiosite), laponite, hectorite, saponite, indonite, and the like.

  If desired, the nanoclay can include a surface treatment that helps improve compatibility with the matrix polymer (eg, polyester). The surface treatment agent can be organic or inorganic. In one embodiment, an organic surface treating agent obtained by reaction of an organic cation and clay is used. Suitable organic cations include, for example, dimethyl bis [hydrogenated tallow] ammonium chloride (2M2HT), methylbenzyl bis [hydrogenated tallow] ammonium chloride (MB2HT), methyltris [hydrogenated tallow alkyl] chloride (M3HT), and the like. And an organic quaternary ammonium compound capable of exchanging cations. Examples of commercially available organic nanoclays can include, for example, Dellite® 43B (Laviosa Chimica, Livorno, Italy), a montmorillonite clay modified with dimethylbenzyl hydrogenated tallow ammonium salt. Other examples include Cloisite (R) 25A and Cloisite (R) 30B (Southern Clay Products) and Nanofil 919 (Svd Chemie). If desired, the nanofiller can be mixed with a carrier resin to form a masterbatch that improves the compatibility of the additive with other polymers of the composition. Particularly suitable carrier resins include, for example, polyesters (eg, polylactic acid, polyethylene terephthalic acid, etc.), polyolefins (eg, ethylene polymers, propylene polymers, etc.), etc., as further described above.

  In certain embodiments of the invention, a plurality of nano-included additives may be used in combination. For example, the first nano-included additive (eg, polyepoxide) is about 50 to about 500 nanometers, in some embodiments about 60 to about 400 nanometers, and in some embodiments about 80 to about 300. It can be dispersed in the form of regions having an average cross-sectional dimension of nanometers. The second nano-included additive (eg, nanofiller) is about 1 to about 50 nanometers, in some embodiments about 2 to about 45 nanometers, and in some embodiments about 5 to about 40 nanometers. It can also be dispersed in the form of regions smaller than the first nano-included additive, such as those having an average cross-sectional dimension of meters. When used, the first and / or second nano-included additive is generally about 0.05% to about 20% by weight of the thermoplastic composition, based on the weight of the continuous phase (matrix polymer), In some embodiments, it comprises an amount of about 0.1 wt% to about 10 wt%, and in some embodiments about 0.5 wt% to about 5 wt%. The concentration of the first and / or second nano-included additive throughout the thermoplastic composition is also about 0.01% to about 15% by weight of the thermoplastic composition, and in some embodiments about 0%. 0.05% to about 10% by weight, and in some embodiments about 0.1% to about 8% by weight.

D. Various other ingredients may be used in the composition for a variety of different reasons. For example, in one particular embodiment, an interphase modifier is used in the thermoplastic composition to help reduce the degree of friction and bonding between the micro-included additive and the matrix polymer, so that the degree of delamination and uniformity Can be improved. In this way, the pores can be distributed in a substantially uniform manner throughout the composition. The modifier can be in liquid or semi-solid form at room temperature (eg, 25 ° C.) so that it has a relatively low viscosity, can be easily incorporated by the thermoplastic composition, and can be easily transferred to the polymer surface. In this regard, the kinematic viscosity of the interphase modifier is typically about 0.7 to about 200 centistokes (“cs”), measured in 40 ° C., and in some embodiments about 1 to 100 cs. , And in some embodiments from about 1.5 to about 80 cs. In addition, interphase modifiers have an affinity for micro-included additives and are generally also hydrophobic, for example, to cause a change in interfacial tension between the matrix polymer and the additive. It is believed that by reducing the physical force at the interface between the matrix polymer and the micro inclusion additive, the low viscosity, hydrophobic nature of the modifier can help promote exfoliation. As used herein, the term “hydrophobic” generally refers to a material having a contact angle of water in air of about 40 degrees or greater, and in some cases about 60 degrees or greater. In contrast, the term “hydrophilic” generally refers to a material that has a contact angle of water in air of less than about 40 degrees. One suitable test for contact angle measurement is ASTM D 5725-99 (2008).

  Suitable hydrophobic, low viscosity interphase modifiers include, for example, silicon, silicone-polyester copolymers, aliphatic polyesters, aromatic polyesters, alkylene glycols (eg, ethylene glycol, diethylene glycol, triethylene glycol, tetraethylene). Glycol, propylene glycol, polyethylene glycol, polypropylene glycol, polybutylene glycol, etc.), alkane diol (for example, 1,3-propanediol, 2,2-dimethyl-1,3-propanediol, 1,3-butanediol, 1 , 4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 2,2,4-trimethyl-1,6hexanediol, 1,3-cyclohexanedimethanol, 1,4-cyclohexanedimethanol 2,2,4,4-tetramethyl-1,3-cyclobutanediol), amine oxides (eg octyldimethylamine oxide), fatty acid esters, fatty acid amides (eg oleamide, erucamide, stearamide, ethylenebis ( Stearamide)), minerals, vegetable oils and the like. One particularly suitable liquid and semi-solid is a polyether polyol, which is available from BASF Corp. Are commercially available under the trade name Pluriol (registered trademark) WI. Another suitable modifier is a partially renewable ester, such as that commercially available from Hallstar under the name HALLGREEN® IM.

  When used, the interphase modifier is about 0.1% to about 20%, in some embodiments, about 0.5% by weight of the thermoplastic composition, based on the weight of the continuous phase (matrix polymer). % To about 15% by weight, and in some embodiments about 1% to about 10% by weight. The concentration of interphase modifiers throughout the thermoplastic composition may also be from about 0.05% to about 20%, in some embodiments from about 0.1% to about 15%, and some In embodiments, it may comprise from about 0.5% to about 10% by weight.

  When used in the above amounts, the interphase modifier has characteristics that allow it to easily migrate to the polymer interface and promote exfoliation without interfering with the overall dissolution properties of the thermoplastic composition. For example, interphase modifiers generally do not have a plasticizing effect on the polymer by lowering the glass transition temperature. In contrast, the inventors have discovered that the glass transition temperature of the thermoplastic composition can be substantially the same as the initial matrix polymer. In this regard, the ratio of the glass transition temperature of the composition to the glass transition temperature of the matrix polymer is generally about 0.7 to 1.3, and in some embodiments about 0.8 to about 1.2, and In some embodiments from about 0.9 to about 1.1. The thermoplastic composition has a glass transition temperature of, for example, from about 35 ° C to about 80 ° C, in some embodiments from about 40 ° C to about 80 ° C, and in some embodiments from about 50 ° C to about 65 ° C. sell. The melt flow rate of the thermoplastic composition can also be similar to the melt flow rate of the matrix polymer. For example, the melt flow rate (dry base) of the composition is also about 0.1 to about 70 grams / 10 minutes, measured in some embodiments about 0.5 when measured at a load of 2160 grams and 190 ° C. To about 50 grams / 10 minutes, and in some embodiments about 5 to about 25 grams / 10 minutes.

  Compatibilizers may also be used that improve interfacial adhesion and reduce interfacial tension between the region and the matrix, thereby allowing the formation of smaller regions during mixing. Examples of suitable compatibilizers include, for example, copolymers functionalized with epoxy or maleic anhydride chemical moieties. An example of a maleic anhydride compatibilizer is polypropylene-grafted-maleic anhydride, which is commercially available from Arkema under the trademarks Orevac ™ 18750 and Orevac ™ CA 100. When used, the compatibilizer is from about 0.05% to about 10%, in some embodiments, from about 0.1% to about 10% by weight of the thermoplastic composition, based on the weight of the continuous phase matrix. It may account for 8% by weight, and in some embodiments about 0.5% to about 5% by weight.

  Other suitable materials that can be used in the thermoplastic composition include catalysts, antioxidants, stabilizers, surfactants, waxes, solid solvents, fillers, nucleating agents (eg, calcium carbonate, etc.), particulates, As well as other materials added to enhance the processability and mechanical properties of the thermoplastic composition. In any event, one beneficial aspect of the present invention is that blowing agents (eg, chlorofluorocarbons, hydrochlorofluorocarbons, hydrocarbons, carbon dioxide, supercritical carbon dioxide, nitrogen, etc.) and plasticizers (eg, solid or semi-solid) Good properties can be provided without the need for various conventional additives such as solid polyethylene glycol). In fact, thermoplastic compositions may generally be free of blowing agents and / or plasticizers. For example, the blowing agent and / or plasticizer may be about 1 wt% or less of the thermoplastic composition, in some embodiments about 0.5 wt% or less, and in some embodiments about 0.001 wt% or less. It can be present in an amount of about 0.2% by weight. In addition, due to its stress whitening properties detailed below, the resulting composition can achieve an opaque color (eg, white) without the need for conventional pigments such as titanium dioxide. In certain embodiments, for example, the pigment is about 1 wt% or less of the thermoplastic composition, in some embodiments about 0.5 wt% or less, and in some embodiments about 0.001 wt% to It can be present in an amount of about 0.2% by weight.

II. Polymeric Materials The polymeric materials of the present invention can be formed by stretching a thermoplastic composition that can include matrix polymers, micro-included additives, nano-included additives, and other optional components. To form the initial thermoplastic composition, the components are typically mixed using any of a variety of known techniques. In one embodiment, for example, the compositions can be supplied separately or in combination. For example, the composition may first be dry mixed to form an essentially uniform dry mixture, and may be fed simultaneously or sequentially to a melt processing apparatus that also mixes the materials in a dispersive manner. Batch and / or continuous melt processing techniques can be used. For example, the materials can be mixed and melt processed using a mixer / kneader, Banbury mixer, Farrell continuous mixer, single screw extruder, twin screw extruder, roll mill, and the like. Particularly suitable melt processing equipment is a co-rotating, twin screw extruder (eg, ZSK-30 extruder available from Werner & Pfleiderer Corporation (Ramsey, NJ) or Thermo Electron Corp. (Stone, UK). Possible Thermo Prism ™ USALAB 16 extruder, which includes a feed port and a ventilation port to provide strong distribution and dispersive mixing, for example, the ingredients are the same as in a twin screw extruder Alternatively, it can be fed to different feed ports and melt mixed to form a substantially uniform melt mixture, optionally with other additives injected into the polymer melt and / or along the length of the extruder. Can be fed separately to the extruder at different points .

Regardless of the particular processing technique selected, the resulting melt-mixed composition can include a microscale region of the micro-included additive and a nanoscale region of the nano-included additive as described above. The degree of shear / pressure and heat can be controlled to ensure sufficient dispersion but not to detrimentally reduce the size of the region such that the desired properties cannot be achieved. For example, mixing generally occurs at a temperature of about 180 ° C to about 300 ° C, in some embodiments about 185 ° C to about 250 ° C, and in some embodiments about 190 ° C to about 240 ° C. Similarly, the apparent shear rate during the melting process is from about 10 seconds ⁻¹ to about 3000 seconds ⁻¹ , in some embodiments from about 50 seconds ⁻¹ to about 2000 seconds ⁻¹ , and in some embodiments. It can range from about 100 seconds- ¹ to about 1200 seconds- ¹ . The apparent shear rate may be equal to 4Q / πR ³ , where Q is the volume flow rate of the polymer melt (“m ³ / sec”) and R is the capillary through which the molten polymer flows (eg, The radius ("m") of the extruder die. Of course, other variables, such as residence time during the melt process, which is inversely proportional to the amount of extrusion, can also be controlled to achieve a uniform desired degree.

  In order to achieve the desired shear conditions (eg, speed, residence time, shear rate, melt processing temperature, etc.), the extruder screw speed can be selected in a specific range. In general, there is an increase in product temperature with increasing screw speed due to the addition of additional mechanical energy to the system. For example, screw speeds can range from about 50 to about 600 revolutions per minute (“rpm”), in some embodiments from about 70 to 500 rpm, and in some embodiments from about 100 to about 300 rpm. This can result in a sufficiently high temperature to disperse the micro-included additive without adversely affecting the size of the resulting region. The melt shear rate, and also the extent to which the additive is dispersed, can be increased through the use of one or more dispensing and / or dispersed mixing components within the mixing section of the extruder. Suitable dispensing mixers for single screw extruders can include, for example, Saxon, Dulage, Cavity Transfer mixers, and the like. Similarly, suitable dispersive mixers may include Blister rings, Leroy / Maddock, CRD mixers and the like. As is well known in the art, mixing produces folding and rearrangement of polymer melts, such as those used in Buss Kneader extruders, Cavity Transfer mixers, and Vortex Intersecting Pin (VIP) mixers Further improvement can be achieved by the use of barrel pins.

  Once mixed, a porous network can be introduced by stretching the composition in the machine direction (eg, flow direction), the cross direction (eg, width direction), etc., and combinations thereof. To achieve the desired stretching, the thermoplastic composition can be formed into a precursor shape and then stretched and then converted to the desired material (eg, film, fiber, etc.). In one embodiment, the precursor shape is about 1 to 5000 micrometers, in some embodiments about 2 to 4000 micrometers, in some embodiments about 5 to 2500 micrometers, and some embodiments. Then, it may be a film having a thickness of about 10 to 500 micrometers. As an alternative to forming a precursor shape, the thermoplastic composition can be stretched in situ as it is molded into the desired form of the polymeric material. In one embodiment, for example, the thermoplastic composition can be stretched as it is formed into a film or fiber.

  In any case, various drawing techniques such as suction (eg, fiber drawing unit), tensile frame drawing, biaxial drawing, multiaxial drawing, profile drawing, vacuum drawing, etc. can be used. In one embodiment, for example, the composition can be obtained from Marshall and Willams, Co. Stretched with a flow direction orienter ("MDO"), such as those commercially available from Providence, Rhode Island. The MDO unit typically has a plurality of draw rolls (e.g., 5-8) that gradually stretch the film in the flow direction to make it thinner. The composition can be drawn in either a single or multiple individual stretching operations. It should be noted that some of the rolls of the MDO device may not be operating at progressively higher speeds. It is generally desirable that the MDO roll not be heated in order to stretch the material in the manner described above. In any event, if desired, one or more rolls can be heated to a slight extent to facilitate the stretching process as long as the temperature of the composition remains below the above range.

  The degree of stretching depends in part on the nature of the material being stretched (eg, fiber or film), but is generally selected to ensure that the desired porous network is achieved. In this regard, the composition can be from about 1.1 to about 3.5, in some embodiments from about 1.2 to about 3.0, and in some embodiments from about 1.3 to about 2.5. (For example, in the flow direction). The “stretch ratio” can be determined by dividing the length of the stretched material by its length before stretching. Stretch rates may also be achieved, for example, from about 5% to 1500% / deformation, in some embodiments from about 20% to about 1000% / deformation, and in some embodiments about 25 to help achieve desirable properties. % To about 850% / variation. The composition can be kept at a temperature below the glass transition temperature of the matrix polymer and the micro-included additive during stretching. Among other things, this helps to ensure that the polymer chains cannot be changed to the extent that the porous network becomes unstable. For example, the composition can be stretched at a temperature at least about 10 ° C., in some embodiments about 20 ° C., and in some embodiments about 30 ° C. below the glass transition temperature of the matrix polymer. For example, the composition may be stretched at a temperature from about 0 ° C. to about 50 ° C., in some embodiments from about 15 ° C. to about 40 ° C., and in some embodiments, from about 20 ° C. to about 30 ° C. The composition is typically stretched without the application of external heat (eg, heated rolls), but such heat is optionally utilized to improve processability, reduce stretch force, and stretch Speed can be increased and fiber uniformity can be improved.

  Stretching in the manner described above results in the formation of pores with “nanoscale” dimensions (“nanopores”). For example, the nanopore is about 800 nanometers or less, in some embodiments about 1 to about 500 nanometers, in some embodiments about 5 to about 450 nanometers, and in some embodiments about 5 to about 5 nanometers. It may have an average cross-sectional dimension of about 400 nanometers, and in some embodiments about 10 to about 100 nanometers. Locations of microscale regions having an average cross-sectional dimension of about 0.5 to about 30 micrometers, in some embodiments about 1 to about 20 micrometers, and in some embodiments about 2 to about 15 micrometers; A plurality of micropores around it may also be formed during stretching. The micropores and / or nanopores can have any regular or irregular shape, such as spherical, elongated shapes. In certain cases, the aspect ratio (ratio of axial dimension to cross-sectional dimension) is from about 1 to about 30, in some embodiments from about 1.1 to about 15, and in some embodiments from about 1.2 to about 5. As such, the micropore and / or nanopore axial dimensions may be larger than the cross-sectional dimensions. An “axial dimension” is a dimension in the direction of the main axis (eg, length), which is generally the direction of stretching.

  The inventor has also discovered that pores (eg, micropores, nanopores, or both) can be distributed in a substantially uniform manner throughout the material. For example, the pores can be distributed in columns that are oriented generally perpendicular to the direction in which the stress is applied. These columns can be generally parallel to each other across the width of the material. While not intending to be bound by theory, such a uniformly distributed porous network provides high thermal resistance and good mechanical properties (eg, energy dissipation and impact strength under load). Is believed to be able to bring. This is in stark contrast to the prior art of pore formation, which involves the use of blowing agents and tends to result in uncontrolled pore distribution and reduced mechanical properties. In particular, the formation of a porous network by the process described above does not necessarily result in a substantial change in the cross-sectional size (eg, width) of the material. That is, the material is substantially neckless, which may allow the material to retain a greater degree of strength characteristics.

  In addition to forming a porous network, the stretching can also increase the axial dimension of the microscale region significantly to have a generally straight and elongated shape. For example, the elongated microscale region is about 10% or more than the axial dimension of the region prior to stretching, in some embodiments from about 20% to about 500%, and in some embodiments from about 50% to about 250. % Can have a larger average axial dimension. The axial dimension after stretching is, for example, from about 0.5 to about 250 micrometers, in some embodiments from about 1 to about 100 micrometers, in some embodiments from about 2 to about 50 micrometers, and one Some embodiments can range from about 5 to about 25 micrometers. The microscale region may be relatively thin, and thus about 0.05 to about 50 micrometers, in some embodiments about 0.2 to about 10 micrometers, and in some embodiments 0.5 to It can have a small cross-sectional dimension, such as about 5 micrometers. This is the aspect ratio (ratio of axial dimension to cross-sectional dimension) of the first region of about 2 to about 150, in some embodiments about 3 to about 100, and in some embodiments about 4 to about 50. ).

  As a result of the porous, elongated region structure, the inventors have discovered that when stretched in the machine direction, the resulting polymeric material can expand uniformly in volume, which is determined according to the following equation: Reflected by the low “Poisson's ratio”:

Here, E _horizontal is a lateral deformation of the material, and E _vertical is a vertical deformation of the material. More specifically, the Poisson's ratio of the material can be about zero or negative. For example, the Poisson's ratio can be about 0.1 or less, in some embodiments about 0.08 or less, and in some embodiments about −0.1 to about 0.04. When the Poisson's ratio is 0, there is no lateral shrinkage when the material expands in the vertical direction. If the Poisson's ratio is negative, the transverse or transverse dimension of the material also expands when the material is stretched in the longitudinal direction. Thus, materials with a negative Poisson's ratio show an increase in width when stretched in the machine direction, which can cause an increase in energy absorption in the transverse direction.

  The polymeric materials of the present invention generally come in different forms depending on the specific application, such as films, fibrous materials, molded articles, contours, etc., and composites and laminates for use in building insulation. Can have. In one embodiment, for example, the polymeric material is in the form of a film or a layer of film. The multilayer film can include 2 to 15 layers, and in some embodiments 3 to 12 layers. Such multilayer films typically include at least one base layer and at least one additional layer (eg, a skin layer), but may include any number of layers desired. For example, a multilayer film may be formed from a base layer and one or more skin layers, where the base layer and / or skin layer is formed from the polymeric material of the present invention. However, it will be appreciated that other polymeric materials such as polyolefin polymers may be used for the base layer and / or skin layer.

  The film thickness may be relatively small to increase flexibility. For example, the film can be from about 1 to about 200 micrometers, in some embodiments from about 2 to about 150 micrometers, in some embodiments from about 5 to about 100 micrometers, and in some embodiments about 10 Can have a thickness of ˜about 60 micrometers. Despite having such a small thickness, the film can still retain good mechanical properties during use. For example, the film can be relatively ductile. One parameter that indicates the ductility of the film is the elongation at break of the film as shown by a stress-strain curve, such as that obtained at 23 ° C. according to ASTM standard D638-10. For example, the elongation in the direction of flow (“MD”) at the break of the film is about 10% or more, in some embodiments 50% or more, in some embodiments about 80% or more, and some implementations. In the form, the elongation at break in the width direction (“CD”) of the film can be about 15% or more, and in some embodiments about 40% or more, In some embodiments, it can be about 70% or more, and in some embodiments, from about 100% to about 400%. Another parameter indicative of ductility is the tensile modulus of the film, which is equal to the ratio of tensile stress to tensile strain and is determined from the slope of the stress-strain curve. For example, the film is typically about 2500 megapascals (“MPa”) or less, in some embodiments about 2200 MPa or less, in some embodiments about 50 MPa to about 2000 MPa, and in some embodiments about 100 MPa. An MD and / or CD tensile modulus of ˜about 1000 MPa is indicated. The tensile modulus can be determined at 23 ° C. according to ASTM D638-10.

  Although the film is ductile, it can still be relatively strong. One parameter that indicates the relative strength of the film is the tensile strength, which is equal to the peak stress obtained in the stress-strain curve, such as that obtained according to ASTM standard DD638-10. For example, the film can exhibit an MD and / or CD peak stress of about 5 to about 65 MPa, in some embodiments about 10 MPa to about 60 MPa, and in some embodiments about 20 MPa to about 55 MPa. The film may exhibit an MD and / or CD breaking stress of about 5 to about 60 MPa, in some embodiments about 10 MPa to about 50 MPa, and in some embodiments about 20 MPa to about 45 MPa. Peak stress and rupture stress may be determined at 23 ° C. according to ASTM D638-10.

  In addition to films, polymeric materials may also be in the form of fibrous materials or layers or components of fibrous materials, which are formed from individual short fibers or filaments (continuous fibers) and such fibers. Yarns, fabrics and the like can be included. For example, yarns can be arranged together with a number of short fibers twisted together (“spun yarn”), filaments placed together without twisting (“zero twist yarn”), with some twisting Filaments, single filaments with or without twisting ("monofilaments"), and the like. The yarn may or may not be bulky. Similarly suitable fabrics include, for example, woven fabrics, knitted fabrics, nonwoven fabrics (eg, spunbond webs, meltblown webs, bonded carded webs, wet webs, airlaid webs, coform webs, hydroentangled webs, etc.). sell.

  Fibers formed from thermoplastic compositions are generally arbitrary, including single and multicomponent (eg, sheath core configurations, side-by-side configurations, segmented pie configurations, underwater island configurations, etc.) May have a desirable configuration. In some embodiments, the fibers can include one or more additional polymers as components (eg, two components) or components (eg, two components) to enhance strength and other mechanical properties. . For example, the thermoplastic composition may form the sheath component of the sheath / core bicomponent fiber while the additional polymer may form the core component or vice versa. Additional polymers include polyesters (eg, polylactic acid, polyethylene terephthalic acid, polybutylene terephthalic acid, etc.), polyolefins (eg, polyethylene, polypropylene, polybutylene, etc.), polytetrafluoroethylene, polyvinyl acetate, polyvinyl chloride-acetic acid, Polyvinyl butyral, acrylic resin (eg, polyacrylate, polymethyl acrylate, polymethyl methacrylate, etc.), polyamide (eg, nylon), polyvinyl chloride, polyvinylidene chloride, polystyrene, polyvinyl alcohol, and polyurethane sell.

  When used, the fiber can deform without breaking when strain is applied. Thus, the fiber can continue to function as a load bearing member even after the fiber exhibits significant elongation. In this regard, the fibers of the present invention can exhibit “maximum stretch properties”, ie an improvement in the percent elongation of the fiber at maximum load. For example, the fibers of the present invention have about 50% or more, in some embodiments about 100% or more, and in some embodiments about 200% to about 1500% when measured at 23 ° C. according to ASTM D638-10. , And in some embodiments, may exhibit a maximum elongation of about 400% to about 800%. Such stretching is, for example, from about 0.1 to about 50 micrometers, in some embodiments from about 1 to about 40 micrometers, in some embodiments from about 2 to about 25 micrometers, and some Embodiments can be achieved for fibers having a wide range of average diameters, such as those in the range of about 5 to about 15 micrometers.

While having the ability to extend under strain, the fibers of the present invention can remain relatively strong. For example, the fiber is about 25 to about 500 megapascals (“MPa”), measured in some embodiments from about 50 to 300 MPa, and in some embodiments when measured at 23 ° C. according to ASTM D638-10. A maximum tensile stress of about 60-200 MPa can be exhibited. Another parameter indicative of the relative strength of the fiber of the present invention is “tensile strength”, which indicates the tensile strength of the fiber expressed in force per unit linear density. For example, the fibers of the present invention is from about 0.75 to about 6.0 g - force ( _{"g f")} / denier, in some embodiments from about 1.0 to about 4.5 g _f / denier, and single in the embodiment of the parts may have a tensile strength of about 1.5 to about 4.0 g _f / denier. The fiber denier can vary depending on the desired application. Generally, the fibers are formed to have a denier per filament of less than about 6, in some embodiments less than about 3, and in some embodiments from about 0.5 to about 3. The unit of linear density is equal to the mass of grams per 9000 meters of fiber).

  If desired, the polymeric material of the present invention may undergo one or more additional processing steps before and / or after being stretched. Examples of such processes include, for example, grooved roll drawing, embossing, coating, and the like. In certain embodiments, the polymeric material may be annealed to ensure that it retains the desired shape. Annealing is above the glass transition temperature of the polymeric matrix, such as about 40 ° to about 120 ° C., in some embodiments about 50 ° C. to about 100 ° C., and in some embodiments about 70 ° C. to about 90 ° C. Generally occurs. The polymeric material can also be surface treated using any of a variety of known techniques to improve its properties. For example, high energy beams (eg, plasma, x-rays, electron beams, etc.) can be used to remove or reduce any skin layer, change surface polarity, porosity, topography, or break the surface layer. It can be made easier. If desired, such a surface treatment can be used prior to stretching the thermoplastic composition.

III. Building Insulation As noted above, the building insulation of the present invention can be used for a wide variety of purposes such as thermal insulation, soundproofing, shock isolation (eg, vibration), fireproofing, moistureproofing, and the like, and combinations thereof. In certain embodiments, building insulation can be used in structures formed entirely from the polymeric material of the present invention. However, in other embodiments, the building insulation is for various purposes, such as a polymeric material as one layer and one or more additional layers of material, for example, as additional insulation, barrier properties, or a cover. Can be included. Additional layers may include other conventional types of materials such as polymeric foam, films or sheets, nonwoven webs, glass fiber materials, cellulosic materials, scrims, foils and the like. Regardless of its particular structure, building insulation can be positioned in residential or commercial building structures so as to be adjacent to the face of the building envelope and / or adjacent to the interior surface of the building.

  For example, a building panel is formed from the polymeric material of the present invention, a structural wall, a frost wall (eg, a building without a basement), a basic curtain wall of a prefab house, a floor assembly, a ceiling system, a roof assembly, an external ground It can be used without limitation on architecture such as walls, curtain walls, and outer walls of areas using stone exteriors. 1-2, one embodiment of a building panel (e.g., a structural wall panel) that can be formed in accordance with the present invention is shown in greater detail. As shown, the building includes internal and external structural walls 10 that collectively define a foundation 12. Each structural wall 10 is then defined by one or more structural wall panels 14. Illustratively, each structural wall panel 14 includes a bottom plate 16, an upright wall section 18 and a top plate 20. Each upright wall section 18 is secured to or integral with the main enclosure wall section 22 and the main enclosure wall section, is regularly spaced along the wall section, and extends from the inner surface of the main enclosure section. It includes an upright alignment reinforcing pillar 23 extending in the direction. In the embodiment shown in FIG. 1, wedge-shaped securing brackets 24 are attached to the studs at the top and bottom of the wall section to attach the bottom and top plates, and / or other fasteners to the main enclosure portion of the upright wall section. Assist in fixing to.

  As shown, a conventional beam 26 (eg, I-steel) is attached to the wall section as needed to maintain the covering floor length. Such beams can be supported by posts 28 and / or pads 30 as needed. Additional struts can also be used at or adjacent to the beam ends to meet building design specific and individual load bearing requirements. A non-hollow reinforced stud 23 can be used to attach the beam to each panel of the structural wall. As shown in FIG. 2, the main enclosure wall section 22 is generally defined between the inner and outer surfaces of the wall panel 14. According to one embodiment of the present invention, the wall section 22 may comprise the polymeric material of the present invention as a building insulation 32, between the inward facing surface and the outward facing surface of the wall. Provides thermal insulation. The bottom plate 16 and top plate 20 can be secured to the main enclosure section 22 by support of a wedge bracket 24 or other support bracket structure. The bottom plate 16 may support the building superstructure that overlies the structural walls and lower assembly base, such as the concrete legs 55.

  In yet other embodiments of the present invention, the building insulation of the present invention serves as an exterior covering (eg, wall, roof, etc.) of the building and is disposed adjacent to the exterior surface of the building. Can be used as For example, such materials can be applied to and positioned adjacent to external surfaces and / or external coverings (eg, wallboard, brick, stone, masonry, plaster, concrete veneer, etc.) prior to installation. For example, referring to FIG. 3, one embodiment is shown in which building insulation is applied to the outer wall. Typically, building insulation is used after the walls have been built and all covering and rain diversion details have been installed. The building insulation is preferably applied before the door and window are installed in the internal framed opening and before the primary wall cover is installed. In the exemplary embodiment, first building insulation 100 is applied to wall assembly 140. As shown in the figure, the roll of insulating material can be spread. The building insulating material 100 is fixed to the outer wall assembly 140 with a fastener such as a U-shaped nail or a cap nail. Building insulation may be cut around each framed opening with appropriate additional details applied according to the window / door manufacturer and / or standards. Once installed, an outer cover can be applied / installed over the building insulation if desired.

  In addition to insulating the exterior of the building structure, building insulation can also be used inside the building. In such embodiments, the building insulation is typically positioned adjacent to an interior surface of the building, such as a ceiling, floor, stud wall, or internal door. For example, referring to FIG. 4, one embodiment of an interior surface 250 that can be insulated in accordance with the present invention is shown. More specifically, FIG. 4 is intended to show a cross-sectional view of an insulated wall cavity. In this embodiment, surface 250 includes walls attached to a pair of studs 252 and 254. Between the pair of studs 252 and 254 is a layer of the building insulation material 256 of the present invention applied to the face 250. In the embodiment shown in FIG. 4, building insulation 256 is positioned directly adjacent to surface 250. However, it should be appreciated that in other embodiments, additional types of insulation may be positioned between the surface 250 and the building insulation 256.

  The invention can be better understood with reference to the following examples.

Test method

Hydrostatic pressure test ("water head"):
The hydrostatic pressure test is a measure of the resistance of a material to penetration by liquid water under static pressure and is performed according to AATCC test method 127-2008. Results for each specimen are averaged and recorded in centimeters (cm). Higher values indicate higher resistance to water penetration.

Water vapor transmission rate (“WVTR”)
The test used to determine the WVTR of a material can vary based on the nature of the material. One technique for measuring WVTR values is ASTM E96 / 96M-12, Procedure B. Another method involves the use of INDA test procedure IST-70.4 (01). The INDA test procedure is summarized as follows. Depending on the permanent guard film and the sample material being tested, the dry chamber is separated from the wet chamber at a known temperature and humidity. The purpose of the guard film is to define a well-defined air gap and to calm or calm the air in the air gap while the air gap is characterized. The dry chamber, guard film, and wet chamber constitute a diffusion cell in which the test film is sealed. Sample holders are available from Mocon / Modem Controls, Inc. It is known as Permatran-W model 100K manufactured by (Minneapolis, Minnesota). The first test consists of the WVTR of the air gap between the guard film and the evaporator assembly producing 100% relative humidity. Water vapor diffuses through the voids and guard film and mixes with the flow of dry gas proportional to the water vapor concentration. An electrical signal is sent to the computer for processing. The computer calculates the permeation rate of the air gap and guard film and saves the value for future use.

   The permeation speed of the guard film and the gap is stored in the computer as CalC. The sample material is then sealed in the test cell. Again, the water vapor diffuses through the voids to the guard film and the test material and mixes with the dry gas that carries the test material away. Again, this mixture is carried to the vapor sensor. The computer then calculates the permeation rate for the combination of void, guard film and test material. This information is then used to calculate the permeability that moisture permeates through the test material according to the following equation:

  The water vapor transmission rate (“WVTR”) is then calculated as follows:

here,
F = flow of water vapor (cm ³ / min)
ρ _{sat (T)} = density of water in saturated air at temperature T RH = relative humidity at a specific location of the cell A = cell cross-sectional area P _{sat (T)} = saturated vapor pressure of water vapor at temperature T

Conduction characteristics:
Thermal conductivity (W / mK) and thermal resistance (m ² K / W) are measured according to ASTM E-1530-11 (“resistance to thermal flow of materials with protective heat flow technology”). Can be determined using. The target test temperature can be 25 ° C. and the applied load can be 0.17 MPa. Prior to testing, the samples can be conditioned for 40+ hours at a temperature of 23 ° C. (± 2 ° C.) and a relative humidity of 50% (± 10%). Thermal properties (W / m ² K) can also be calculated by dividing 1 by thermal resistance.

Melt flow rate:
Melt flow rate (“MFR”) is extruded through an extrusion rheometer port (0.0825 inch diameter) when loaded at 2160 grams / 10 minutes, typically at 190 ° C., 210 ° C., or 230 ° C. The weight of the polymer in grams. Unless otherwise indicated, melt flow rate is measured according to ASTM test method D1239 on a Tinius Olsen Extension Plasometer.

Thermal properties:
Glass transition temperature _{(T g),} according to ASTM E1640-09, can be determined by dynamic mechanical analysis (DMA). A TA Instruments A Q800 instrument may be used. The experiment can be performed in tension / tensile shape, at a temperature sweep mode of -120 ° C to 150 ° C, and a heating rate of 3 ° C / min. The strain vibration amplitude frequency can be kept constant (2 Hz) during the test. Three independent samples are tested to obtain the average glass transition temperature, which is defined by the maximum value of the tan δ curve, where δ is the ratio of loss modulus to storage modulus (tan δ = E ″ / E ′).

  The melting temperature can be determined by differential scanning calorimetry (DSC). The differential scanning calorimeter can be a DSC Q100 differential scanning calorimeter, which can be fitted with a liquid nitrogen cooling accessory and a UNIVERSAL ANALYSIS 2000 (version 4.6.6) analysis software program, which are Both T.W. A. Instruments Inc. (Newcastle, Delaware). Tweezers or other tools can be used to avoid handling the sample directly. Samples are placed in an aluminum pan and weighed to a precision of 0.01 milligrams on a chemical balance. A lid can be crimped onto the pan of the material sample. In general, the resin pellets may be placed directly on the weighing pan.

  The differential scanning calorimeter can be calibrated using an indium metal standard and a baseline correction can be performed, as described in the differential scanning calorimeter operating manual. Material samples can be placed in a differential scanning calorimeter test chamber for testing, and an empty pan can be used as a control. All tests can be performed with a nitrogen (industrial grade) purge of 55 cubic centimeters / minute into the test chamber. For resin pellet samples, the heating and cooling program is a two-cycle test, starting with chamber equilibration to -30 ° C, then the first heating period to a temperature of 200 ° C at a heating rate of 10 ° C / min Followed by equilibration of the sample at 200 ° C. for 3 minutes, followed by a first cooling period to −30 ° C. at a cooling rate of 10 ° C./min, followed by equilibration of the sample to −30 ° C. for 3 minutes Followed by a second heating period at a heating rate of 10 ° C./min to a temperature of 200 ° C. For fiber samples, the heating and cooling program is a one cycle test, starting with the equilibration of the chamber to -25 ° C, followed by a heating period to a temperature of 200 ° C at a heating rate of 10 ° C / min, followed by 200 The sample is equilibrated for 3 minutes at 0 ° C., followed by a cooling period to a temperature of −30 ° at a cooling rate of 10 ° C./min. All tests can be performed with a nitrogen (industrial grade) purge of 55 cubic centimeters / minute into the test chamber.

The results can be evaluated using the UNIVERSAL ANALYSIS 2000 analysis software program that identifies and quantifies the glass transition temperature (T _g ) of the inflection point, endothermic and exothermic peaks, and the area under the peak of the DSC plot. The glass transition temperature can be identified as the area on the plot line where a clear change in slope occurs, and the melting temperature can be determined using automatic inflection point calculation.

Film tensile properties:
Films can be tested with the MTS Synergyie 200 tensile frame for tensile properties (peak stress, modulus, fracture strain, and energy per volume at break). The test can be performed according to ASTM D638-10 (about 23 ° C.). Film samples can be cut into dog bone shapes with a central width of 3.0 mm prior to testing. A dog bone-shaped film sample can be held in place at a gauge length of 18.0 mm using the grips of the MTS Synergie 200 device. Film samples can be stretched at a crosshead speed of 5.0 inches / minute until breakage occurs. Five samples for each film can be tested in both the flow direction (MD) and the width direction (CD). A computer program (eg TestWorks 4) is used to collect the data under test and generate a stress versus strain curve from which many properties including modulus, peak stress, elongation, and energy to failure are determined. sell.

Fiber tensile properties:
Fiber tensile properties can be measured at 23 ° C. according to ASTM 638-10. For example, individual fiber specimens can be initially shortened to a length of 38 millimeters (eg, cut with scissors) and placed separately on a black velvet cloth. Ten to fifteen specimens are collected in this way. The fiber specimen can then be mounted substantially straight on a rectangular paper frame having an outer dimension of 51 millimeters x 51 millimeters and an inner dimension of 25 millimeters x 25 millimeters. The end of each fiber specimen can be operably attached to the frame by fixing the fiber end to the side of the frame with adhesive tape. Each fiber specimen can be measured for its relatively short fiber cross-sectional dimensions using a conventional laboratory microscope that can be properly calibrated and set at a magnification of 40X. This fiber cross-sectional dimension can be recorded as the diameter of an individual fiber specimen. The frame serves to attach the ends of the sample fiber specimen to the upper and lower grips of a constant rate extension type tensile tester in a manner that avoids excessive damage to the fiber specimen.

  A constant rate extension type tensile tester and a suitable load cell may be used for testing. The load cell may be selected such that the test value is within 10-90% of full scale load (eg, 10N). Tensile testers (ie, MTS SYNERGY 200) and load cells may be obtained from MTS Systems Corporation (Eden Prairie, MI). The fiber specimen in the frame assembly is then mounted between the tensile tester grips such that the end of the fiber is held operably by the tensile tester grips. Thereafter, the side of the paper frame that extends parallel to the length of the fiber can be cut or separated so that the tensile tester applies a test force only to the fiber. The fiber can be pulled up at a pulling speed of 12 inches / minute and a gripping speed. The resulting data can be analyzed using the TESTWORKS 4 software program from MTS Corporation with the following test setup:

[table]

  Tensile strength values are expressed in grams · force / denier. Maximum elongation (% fracture strain) and maximum stress can also be measured.

Stretch rate, density, and percent pore volume:
To determine stretch rate, density, and percent pore volume, the width (W _i ) and thickness (T _i ) of the specimen can be first measured prior to stretching. The length before stretching (L _i ) was also determined by measuring the distance between two marks on the surface of the specimen. Thereafter, the specimen can be stretched to initiate voiding. Next, the width (W _f ), thickness (T _f ), and length (L _f ) of the specimen were measured to the nearest 0.01 mm using a Digimatic Caliper (Mitutoyo Co., Ltd.). The volume (V _i ) before stretching can be calculated as W _i × T _i × L _i = V _i . The stretched volume (V _f ) can also be calculated as W _f × T _f × L _f = V _f . The stretch ratio (Φ) can be calculated as Φ = V _f / V _i and the density (P _f ) is calculated as P _f = P _i / Φ, where P _i is the density of the precursor material and the pore volume The percentage (% V _v ) can be calculated as% V _v = (1-1 / Φ) × 100.

Water content:
Moisture content can be determined substantially in accordance with ASTM D 7191-05 using an Arizona Instruments Computrac Vapor Pro moisture analyzer (Model No. 3100), which is incorporated by reference in its entirety for all purposes. Incorporated herein. The test temperature (§X2.1.2) can be 130 ° C., the sample size (§X2.1.1) can be 2-4 grams, and the vial purge time (§X2.1.4) can be 30 seconds. In addition, the termination criterion (§X2.1.3) can be defined as a “predictive” mode, which means that the test is performed when the programmed built-in criterion (which mathematically calculates the endpoint moisture content) is satisfied. Means to end.

The ability to form polymeric materials for use in building insulation has been demonstrated. First, 85.3% by weight polylactic acid (PLA 6201D, Natureworks®), 9.5% by weight micro inclusion additive, 1.4% by weight nano inclusion additive, and 3.8% by weight A mixture of various interfacial modifiers was demonstrated. The micro inclusion additive was Vistamaxx ™ 2120 (ExxonMobil), which was a polyolefin copolymer / elastomer with a melt flow rate of 29 g / 10 min (190 ° C., 2160 g) and a density of 0.866 g / cm ³ . Nano-included additives include 5-6 g / 10 min (190 ° C./2160 g) melt flow rate, 7-11 wt% glycidyl methacrylate content, 13-17 wt% methyl acrylate content, and 72-80 wt% % Poly (ethylene-co-methyl acrylate-co-glycidyl methacrylate) (Lotader (R) AX8900, Arkema). The internal interfacial modifier was a BASF PLURIOL® WI 285 lubricant, a polyalkylene glycol functional fluid. The polymer was fed for mixing to a co-rotating, twin screw extruder (ZSK-30, 30 mm diameter, 1328 mm length) from Werner and Pfleiderer Corporation (Ramsey, NJ). The extruder has 14 thorns, which are numbered sequentially from 1 to 14 from the feed hopper to the mold. The first barrel zone number 1 received the resin through the gravimetric feeder at a total throughput of 15 pounds / hour. PLURIOL® WI285 was added to barrel zone number 2 with an infusion pump. The mold used to extrude the resin had three mold openings (6 mm in diameter) that were 4 mm apart. Once formed, the extruded resin was cooled on a fan cooling conveyor and formed into pellets with a Conair pelletizer. The extruder screw speed was 200 revolutions per minute (“rpm”). The pellets are then fed into a single screw extruder heated to 212 ° C. where the molten mixture is discharged through a 4.5 inch wide slit to a film thickness in the range of 0.54 to 0.58 mm. It was stretched.

  The sheet produced in Example 1 was cut to a length of 6 inches and stretched to 100% elongation using a hydraulic tension frame of 50 mm / min MTS 820 tension mode.

  The sheet produced in Example 1 was cut to a length of 6 inches and stretched to 150% elongation using a hydraulic tension frame of 50 mm / min MTS 820 tension mode.

  The sheet produced in Example 1 was cut to a length of 6 inches and stretched to 200% elongation using a hydraulic tension frame in the MTS 820 tension mode at 50 mm / min.

  Thereafter, the thermal properties of Examples 1-4 were determined. The results are listed in the table below.

[table]

  Pellets were formed as described in Example 1 and fed to a Rheomix 252 single screw extruder at an L / D ratio of 25: 1 and heated to a temperature of 212 ° C., where the molten mixture was Haake It was discharged through a 6 inch wide s-cast film die and stretched to a film thickness ranging from 39.4 μm to 50.8 μm by a Haake take-up roll. The film was stretched in the flow direction using a MTS Synergie 200 tensile frame with a 75 mm gauge length to a longitudinal deformation of 160% (67% / min deformation rate) at a pulling speed of 50 mm / min.

  The film is described in Example 5, except that the film was stretched in the width direction to 100% deformation at a grip length of 50 mm and a tensile speed of 50 mm / min (deformation rate of 100% / min). Formed as it was.

  Various properties of the films of Examples 5-6 were tested as described above. The results are listed in Tables 1-2 below.

  The pellets were formed as described in Example 1 and then fed to a single screw extruder heated to 212 ° C., where the molten mixture was discharged through a 4.5 inch wide slit, 36 μm to 54 μm. Stretched to a range of film thickness. The film was stretched about 100% in the flow direction to initiate cavitation and void formation. Film morphology was analyzed by scanning electron microscopy (SEM) before and after stretching. The results are shown in FIGS. As shown in FIGS. 5-6, the micro-included additive begins with a region having an axial size (flow direction) of about 2 to about 30 micrometers and a lateral dimension (width direction) of about 1 to 3 micrometers. Whereas the nano-included additive was initially dispersed as a hemisphere or spheroid region with an axial size of about 100 to about 300 nanometers. Figures 7-8 show the film after stretching. As shown, pores were formed around the micro inclusion additive and the nano inclusion additive. The micropores formed around the micro inclusion additive generally had an elongated or slit-like shape with a wide size distribution ranging from about 2 to about 20 micrometers in the axial direction. Nanopores associated with nano-included additives were generally about 50 to about 500 nanometers in size.

  The composite pellet of Example 7 was dry mixed with another nano-included additive, which was a halloysite clay masterbatch containing 22 wt% styrene copolymer modified nanoclay and 78 wt% polypropylene (Exxon Mobil 3155). (MacroComp MNH-731-36, MacroM). The mixing ratio was 90% pellets and 10% clay masterbatch, which resulted in a total clay content of 2.2%. The dry mixture was then fed into a single screw extruder heated to 212 ° C. where the molten mixture was discharged through a 4.5 inch wide slit and stretched to a film thickness in the range of 51-58 μm. . The film was stretched about 100% in the flow direction to initiate cavitation and void formation.

  Film morphology was analyzed by scanning electron microscopy (SEM) before and after stretching. The results are shown in FIGS. As shown in FIGS. 9-10, some of the nanoclay particles (visible as bright areas) were dispersed in the form of very small areas (ie, axial dimensions in the range of about 50 to about 300 nanometers). The masterbatch itself also formed a microscale size (axial dimension of about 1 to about 5 micrometers) region. Also, the micro inclusion additive (Vistamaxx ™) formed elongated regions, while the nano inclusion additive (Lotader® visible as a very small dark spot and the nanoclay masterbatch visible as a bright plate) was spheroidal. The region was formed. The stretched film is shown in FIGS. As shown, the void structure is further open, indicating the breadth of the pore diameter. In addition to the very elongated micropores formed by micro inclusions (Vistamaxx ™), the nanoclay masterbatch inclusions are more open with an axial size of about 10 microns or less and a lateral size of about 2 microns. A spheroidal micropore was formed. Spherical nanopores are also formed by nano-included additives (Lotader® and nanoclay particles).

  Various tensile properties (flow direction) of the films of Examples 1 and 2 were also tested. The results are shown in Table 3 below.

  As shown, the addition of nanoclay filler resulted in a slight increase in break stress and a significant increase in elongation at break.

  The ability to form fibers for use in building insulation has been demonstrated. First, 91.8% by weight of isotactic propylene homopolymer (M3661, melt flow rate of 14 g / 10 at 210 ° C. and melting temperature of 150 ° C., Total Petrochemicals), 7.4% by weight of polylactic acid (PLA A precursor mixture was formed from 6252, a melt flow rate of 70-85 g / 10 min at 210 ° C., Natureworks®), and 0.7 wt% polyepoxide. The polyepoxide has a melt flow rate of 6 g / 10 min (190 ° C./2160 g), a glycidyl methacrylate content of 8 wt%, a methyl acrylate content of 24 wt%, and an ethylene content of 68 wt%. Co-methyl acrylate-co-glycidyl methacrylate) (LOTADER® AX8900, Arkema). The ingredients were mixed in a co-rotating twin screw extruder (Werner and Pfleiderer ZSK-30 with a diameter of 30 mm and L / D = 44). The extruder had 7 heating zones. The temperature of the extruder was in the range of 180 ° C to 220 ° C. The polymer was fed gravimetrically at 15 pounds / hour at the hopper and the liquid was poured into the barrel using a peristaltic pump. The extruder was operated at 200 revolutions per minute (“RPM”). In the last section of the barrel (front), a 6 mm diameter 3 hole die was used to form the extrudate. The extrudate was air cooled with a conveyor belt and pelletized using a Conair Pelletizer.

  Fibers were then produced from the precursor mixture using a Davis standard spinning line equipped with a 0.75 inch single screw extruder and a 0.6 hole diameter 16 hole spinneret. Fibers were collected at different drawdown ratios. The winding speed was in the range of 1-1000 m / min. The temperature of the extruder was in the range of 175 ° C to 220 ° C. The fiber was drawn to 400% elongation at 25 ° C. and 300 mm / min on a tensile tester. To analyze the material morphology, the fibers were freeze fractured in liquid nitrogen and analyzed with a high vacuum scanning electron microscope Jeol 6490LV. The results are shown in FIGS. As shown, elongated ellipsoidal pores are formed in the stretching direction. Both nanopores (~ 50 nanometer wide, ~ 500 nanometer long) and micropores (~ 0.5 micrometer wide, ~ 4 micrometer long) were formed.

  Pellets were formed as described in Example 1, then filled into a single screw extruder at 240 ° C., melted, and 0.40 grams / hole / minute through a 0.6 mm diameter spinneret. It was passed through a melt pump at speed. The fibers were recovered by free fall (stretching force was only gravity) and tested for mechanical properties at a pulling speed of 50 millimeters / minute. The fiber was then cold drawn at 23 ° C. in an MTS Synergie Tensile frame at a speed of 50 mm / min. The fibers were drawn to a predetermined strain of 50%, 100%, 150%, 200% and 250%. After stretching, stretch rate, void volume and density were calculated for various strain rates as shown in the table below.

[table]

[table]

  The fiber was formed as described in Example 10, except that the fiber was collected at a collection roll speed of 100 meters / minute, resulting in a drawdown ratio of 77. The fibers were then tested for mechanical properties at a pulling rate of 50 millimeters / minute. The fiber was then cold drawn at 23 ° C. in an MTS Synergie Tensile frame at a speed of 50 mm / min. The fibers were drawn to a predetermined strain of 50%, 100%, 150%, 200% and 250%. After stretching, stretch rate, void volume and density were calculated for various strain rates as shown in the table below.

[table]

[table]

  The fibers consisted of 83.7% polylactic acid (PLA 6201D, Natureworks®), 9.3% by weight Vistamaxx ™ 2120, 1.4% by weight Lotader® AX8900, 3 Formed as described in Example 10, except that it consisted of 7 wt% PLURIOL® WI 285, and 1.9% hydrophilic surfactant (Masil SF-19). It was. PLURIOL® WI285 and Masil SF-19 were premixed at a ratio of 2: 1 (WI-285: SF-19) and added to barrel zone number 2 with an infusion pump. The fiber was recovered by free fall at 240 ° C. and 0.40 ghm.

  The fiber was formed as described in Example 12, except that the fiber was collected at a collection roll speed of 100 meters / minute, resulting in a drawdown ratio of 77. The fibers were then tested for mechanical properties at a pulling rate of 50 millimeters / minute. The fiber was then cold drawn at 23 ° C. in an MTS Synergie Tensile frame at a speed of 50 mm / min. The fiber was drawn to a predetermined strain of 100%. After stretching, the stretch ratio, void volume and density were calculated as shown in the table below.

[table]

[table]

  The fiber of Example 12 was stretched to 250% strain at a rate of 50 millimeters / minute in an MTS Synergy Tensile frame. This opened the void structure and whitened the fibers. A 1 inch sample was then cut from the stressed white area of the fiber. The new fiber was then tested as described above. The density was predicted to be 0.75 grams / cubic centimeter and the pull rate for the tensile test was 305 mm / min.

  The fiber of Example 11 was heated in an oven at 50 ° C. for 30 minutes to anneal the fiber.

  The fiber of Example 11 was heated in a 90 ° C. oven for 5 minutes to anneal the fiber and induce crystallization.

  The fibers of Examples 10-16 were then tested for mechanical properties at a pulling speed of 50 millimeters / minute. The results are listed in the table below.

[table]

  Although the present invention has been described in detail with respect to particular embodiments thereof, it will be appreciated that those skilled in the art will appreciate modifications to these embodiments, variations thereof, and The equivalent can be conceived immediately. Accordingly, the scope of the invention should be assessed as that of the appended claims and any equivalents thereto.

  Regardless of whether or not “about” is described in the numerical limitation recited in the claims, it is intended to include substantially the same range in view of the technical idea of the present invention.

Claims (44)

A building insulation for use in a residential or commercial building structure, wherein the building insulation is a porous polymeric material formed from a thermoplastic composition containing a continuous phase comprising a matrix polymer Wherein the polymeric material has a water vapor transmission rate of about 300 g / m ² -24 hours or more, a thermal conductivity of about 0.40 watts / meter · Kelvin or less, and / or a head value of about 50 centimeters or more. Showing building insulation.   The polymeric material further includes a micro-inclusion additive and a nano-inclusion additive dispersed in the continuous phase in the form of discrete regions, and includes a plurality of nanopores having an average cross-sectional dimension of about 800 nanometers or less The building insulation of claim 1, wherein a porous network is defined in the material.   A porous polymeric material formed from a thermoplastic composition containing a continuous phase comprising a matrix polymer, wherein the polymeric material is a building insulation for use in a residential or commercial building structure And a micro inclusion inclusion and a nano inclusion additive dispersed within the continuous phase in the form of discrete regions, wherein the porous inclusion includes a plurality of nanopores having an average cross-sectional dimension of about 800 nanometers or less. Building insulation in which a quality network is defined in the material. 4. The polymeric material exhibits a water vapor transmission rate of about 300 g / m < ² > -24 hours or more, a thermal conductivity of about 0.40 watts / meter-Kelvin or less, and a water head value of about 50 centimeters or more. Building insulation as described in.   The building insulation according to claim 2 or 3, wherein the micro inclusion additive is a polymer.   6. A building insulation according to claim 5, wherein the micro inclusion additive comprises a polyolefin.   The building insulating material according to claim 6, wherein the polyolefin is a propylene homopolymer, a propylene / α-olefin copolymer, an ethylene / α-olefin copolymer, or a combination thereof.   The ratio of the matrix polymer solubility parameter to the solubility parameter of the micro inclusion additive is about 0.5 to about 1.5, and the ratio of the melt flow rate of the matrix polymer to the melt flow rate of the micro inclusion additive is about 0. 4. The building insulation of claim 2 or 3, wherein the ratio of Young's modulus of the matrix polymer to Young's modulus of the micro-inclusion additive is from about 1 to about 250.   The building insulating material according to claim 2 or 3, wherein the nano-included additive is a polymer.   The building insulation of claim 9, wherein the nano-included additive is a functional polyolefin.   The building insulation according to claim 9 or 10, wherein the nano-included additive is reactive.   The building insulation according to claim 11, wherein the nano-included additive is a polyepoxide.   4. A building insulation according to claim 2 or 3, wherein the micro-included additive comprises from about 1% to about 30% by weight of the composition, based on the weight of the continuous phase.   4. The building insulation of claim 2 or 3, wherein the nano-included additive comprises about 0.05% to about 20% by weight of the composition, based on the weight of the continuous phase.   The building insulation according to claim 2 or 3, wherein the thermoplastic composition further comprises an interphase modifier.   The building insulation of claim 15, wherein the interphase modifier has a kinematic viscosity of about 0.7 to about 200 centistokes when measured at a temperature of 40 ° C.   The building insulation according to claim 15 or 16, wherein the interphase modifier is hydrophobic.   The interphase modifier is silicon, silicone polyether copolymer, aliphatic polyester, aromatic polyester, alkylene glycol, alkanediol, amine oxide, fatty acid ester, or a combination thereof. The building insulation described.   19. Building insulation according to any one of claims 14 to 18, wherein the interphase modifier comprises from about 0.1% to about 20% by weight of the composition, based on the weight of the continuous phase. .   The building insulation of claim 2 or 3, wherein the porous network further comprises micropores having an average cross-sectional dimension of about 0.5 to about 30 micrometers.   21. The building insulation of claim 20, wherein the micropore has an aspect ratio of about 1 to about 30.   The building insulation according to claim 2 or 3, wherein the porous network is distributed in a substantially uniform form throughout the material.   Building insulation according to any one of the preceding claims, wherein the nanopores are distributed in generally parallel columns.   The micro-included additive is in the form of a microscale region, the nano-included additive is in the form of a nanoscale region, the microscale region has an average cross-sectional dimension of about 0.5 to about 250 micrometers; The building insulation of claim 2 or 3, wherein the nanoscale region has an average cross-sectional dimension of about 1 nanometer to about 500 nanometers.   25. A building insulation according to any one of claims 1 to 24, wherein the insulation is formed entirely from the polymeric material.   25. Building insulation according to any one of the preceding claims, further comprising an additional layer of material.   27. The building insulation according to any one of claims 1 to 26, wherein the insulation is in the form of a panel.   27. The building insulation according to any one of claims 1 to 26, wherein the insulation is in the form of a wrap.   The building insulation according to any one of the preceding claims, wherein the total pore volume of the polymeric material is about 15% to about 80% per cubic centimeter.   The building insulation according to any one of the preceding claims, wherein the nanopores constitute about 20 vol% or more of the total pore volume of the polymeric material.   A building insulation according to any preceding claim, wherein the continuous phase comprises from about 60% to about 99% by weight of the thermoplastic composition.   Building insulation according to any one of the preceding claims, wherein the matrix polymer comprises polyester or polyolefin.   33. The building insulation of claim 32, wherein the polyester has a glass transition temperature of about 0 ° C. or higher.   The building insulation according to claim 32 or 33, wherein the polyester comprises polylactic acid.   Building insulation according to any one of the preceding claims, wherein the polymeric material generally does not contain a gas blowing agent.   The building insulation according to any preceding claim, wherein the thermoplastic composition has a density of about 1.2 grams cubic centimeter or less.   The polymer material according to any one of claims 1 to 36, wherein the polymer material is a film or a layer of a film.   37. The polymeric material according to any one of claims 1-36, wherein the polymeric material is a fibrous material or a layer or component of a fibrous material.   A building structure comprising a building envelope defining an interior, wherein the building structure further comprises a building insulation according to any of the preceding claims, which is the building envelope, an inner surface, or a combination thereof The building structure is located adjacent to the surface of the building.   40. The building structure of claim 39, wherein the building insulation is positioned adjacent to a surface of the building envelope.   41. The building structure of claim 40, wherein the building insulation is positioned adjacent to an outer wall, a roof, or a combination thereof.   42. The building structure of claim 41, wherein the building insulation is positioned adjacent to an outer cover.   40. The building structure of claim 39, wherein the building insulation is positioned adjacent to the interior surface. 44. The building structure of claim 43, wherein the building insulation is positioned adjacent to an interior wall, wall, floor, ceiling, door, or combination thereof.