Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • Y10T428/249978—Voids specified as micro

Definitions

• the present invention relates to microporous derived from renewable polymers, and multilayer articles prepared therefrom.
• Synthetic substrates offer significant advantages over natural wood pulp paper including, for example, improved print quality, water resistance, tear resistance, and tensile strength.
• Such materials typically are comprised of polymeric materials such as polyolefins or polyesters.
• the present invention is directed to microporous materials comprising:
• the present invention additionally provides multilayer articles prepared from the above-described microporous materials.
• the multilayer articles comprise at least one layer of a microporous material and at least one layer of a material that may be the same as or different from the microporous material.
• any numerical range recited herein is intended to include all sub-ranges subsumed therein.
• a range of “1 to 10” is intended to include all sub-ranges between (and including) the recited minimum value of 1 and the recited maximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value of equal to or less than 10.
• polymer is meant a polymer including homopolymers and copolymers, and oligomers.
• composite material is meant a combination of two or more differing materials.
• composition “formed from” denotes open, e.g., “comprising,” claim language. As such, it is intended that a composition “formed from” a list of recited components be a composition comprising at least these recited components, and can further comprise other, nonrecited components, during the composition's formation.
• polymeric inorganic material means a polymeric material having a backbone repeat unit based on an element or elements other than carbon.
• polymeric organic materials means synthetic polymeric materials, semisynthetic polymeric materials and natural polymeric materials, all of which have a backbone repeat unit based on carbon.
• An “organic material,” as used herein, means carbon containing compounds wherein the carbon is typically bonded to itself and to hydrogen, and often to other elements as well, and excludes binary compounds such as the carbon oxides, the carbides, carbon disulfide, etc.; such ternary compounds as the metallic cyanides, metallic carbonyls, phosgene, carbonyl sulfide, etc.; and carbon-containing ionic compounds such as metallic carbonates, for example calcium carbonate and sodium carbonate. See R. Lewis, Sr., Hawley's Condensed Chemical Dictionary, (12th Ed. 1993) at pages 761-762, and M. Silberberg, Chemistry The Molecular Nature of Matter and Change (1996) at page 586, which are specifically incorporated by reference herein.
• organic material means any material that is not an organic material.
• thermoplastic is a material that softens when exposed to heat and returns to its original condition when cooled to room temperature.
• thermoset a material that solidifies or “sets” irreversibly when heated.
• biodegradable has been defined by the industry and as used herein is defined as: “ . . . capable of undergoing decomposition into CO 2 , methane, water, inorganic compounds or biomass in which the predominant mechanism is the enzymatic action of micro-organisms, that can be measured by standardized tests, in a specified period of time, reflecting available disposal conditions.”
• compostable material has been defined by the industry and as used herein is defined as: “ . . . capable of undergoing biological decomposition in a compost site as part of an available program, such that the material (that is, feedstock) is not visually distinguishable and breaks down to CO 2 , water, inorganic compounds, and biomass, at a rate consistent with known compostable materials.”
• Typical composting conditions time: 12 weeks; temperature: >140° F. (>50° C.).
• a compostable plastic is one that will biodegrade completely in a composting situation, i.e., when combined with other plant material in an aerobic atmosphere. Compostable plastics can be put into industrial composting facilities and will biodegrade completely. Not all compostable plastics will biodegrade completely in a home compost bin.
• degradation is meant that a substance will break down. It does not mean that a substance will break down naturally in the soil, or that it will necessarily break down completely to CO 2 and water.
• the products of a degradable substance may not necessarily be usable by living organisms as food or energy.
• “Renewable” polymers and plastics are manufactured from renewable resources; i.e., theoretically, the raw materials used to manufacture the polymers and plastics will not run out.
• ASTM D6866 Standard Test Methods for Determining the Biobased Content of Natural Range Materials Using Radiocarbon and Isotope Ratio Mass Spectrometry Analysis” is a test method which determines the percentage of a product that comes from renewable resources.
• Biomass is renewable; more plants can be grown to replace those that are used. Chemicals, including monomers for polymer production, may be derived from biomass. Polymers made from these monomers are, therefore, renewable polymers; they can be replaced by growing more biomass and then repeating the manufacturing process. Examples of commonly used renewable polymers include starch and polylactic acid.
• Biobased material refers to an organic material in which the carbon is derived from a renewable resource via biological processes.
• Biobased materials include all plant and animal mass derived from CO 2 recently fixed via photosynthesis, per definition of a renewable resource. Biobased materials may or may not be biodegradable or compostable.
• microporous material or “microporous sheet material” means a material having a network of interconnecting pores, wherein, on a coating-free, printing ink-free, impregnant-free, and pre-bonding basis, the pores have a volume average diameter ranging from 0.001 to 0.5 micrometer, and constitute at least 5 percent by volume of the material as discussed herein below.
• plastomer is meant a polymer exhibiting both plastic and elastomeric properties.
• microporous material comprising:
• renewable polymers may be suitable for use in the preparation of the microporous materials of the present invention.
• specific examples of renewable polymers include starch-based polymers; an example is Materbi®, manufactured by Novamont; polylactic acid (PLA), for example, NatureWorks PLA®, manufactured by NatureWorks; cellulose such as Natureflex®, manufactured by Innovia films; polyhydroxyalkanoates including plant-derived sugars or lipids; polyesters derived from corn resins; polyurethane derived from natural oils such as soy and/or castor oil; polyethylene derived from sugar cane; thermoplastic starch (TPS), polylactides (PLA), poly- ⁇ -hydroxybutyric acid (PHB), and the like.
• Combinations of renewable polymers are also suitable, as well as mixtures of one or more renewable polymers with one or more polyolefins, including plastomers, such as any of those discussed above as suitable in the biodegradable microporous material.
• Up to 100 percent by weight of the matrix may comprise the renewable polymer, although typically the renewable polymer constitutes 1 to 50 percent by weight, such as 1 to 10 percent by weight, of the matrix.
• the polymeric matrix (a) may optionally comprise a polyolefin that is the same as or different from the renewable polymer.
• Polyolefins are polymers derived from at least one ethylenically unsaturated monomer.
• the matrix comprises a plastomer.
• the matrix may comprise a plastomer derived from butene, hexene, and/or octene. Suitable plastomers are available from ExxonMobil Chemical under the tradename “EXACT”.
• the matrix comprises a different polymer derived from at least one ethylenically unsaturated monomer, which may be used in combination with the plastomer.
• examples include polymers derived from ethylene, propylene, and/or butene, such as polyethylene, polypropylene, and polybutene. High density and/or ultrahigh molecular weight polyolefins are also suitable.
• the polyolefin matrix comprises a copolymer of ethylene and butene.
• Ultrahigh molecular weight (UHMW) polyolefin can include essentially linear UHMW polyethylene or polypropylene. Inasmuch as UHMW polyolefins are not thermoset polymers having an infinite molecular weight, they are technically classified as thermoplastic materials.
• the ultrahigh molecular weight polypropylene can comprise essentially linear ultrahigh molecular weight isotactic polypropylene. Often the degree of isotacticity of such polymer is at least 95 percent, e.g., at least 98 percent.
• the intrinsic viscosity of the UHMW polyethylene can range from 18 to 39 deciliters/gram, e.g., from 18 to 32 deciliters/gram. While there is no particular restriction on the upper limit of the intrinsic viscosity of the UHMW polypropylene, in one non-limiting example, the intrinsic viscosity can range from 6 to 18 deciliters/gram, e.g., from 7 to 16 deciliters/gram.
• intrinsic viscosity is determined by extrapolating to zero concentration the reduced viscosities or the inherent viscosities of several dilute solutions of the UHMW polyolefin where the solvent is freshly distilled decahydronaphthalene to which 0.2 percent by weight, 3,5-di-tert-butyl-4-hydroxyhydrocinnamic acid, neopentanetetrayl ester [CAS Registry No. 6683-19-8] has been added.
• the reduced viscosities or the inherent viscosities of the UHMW polyolefin are ascertained from relative viscosities obtained at 135° C. using an Ubbelohde No. 1 viscometer in accordance with the general procedures of ASTM D 4020-81, except that several dilute solutions of differing concentration are employed.
• the nominal molecular weight of UHMW polyethylene is empirically related to the intrinsic viscosity of the polymer in accordance with the following equation:
• M is the nominal molecular weight and [ ⁇ acute over ( ⁇ ) ⁇ ] is the intrinsic viscosity of the UHMW polyethylene expressed in deciliters/gram.
• the nominal molecular weight of UHMW polypropylene is empirically related to the intrinsic viscosity of the polymer according to the following equation:
• M is the nominal molecular weight and [ ⁇ acute over ( ⁇ ) ⁇ ] is the intrinsic viscosity of the UHMW polypropylene expressed in deciliters/gram.
• a mixture of substantially linear ultrahigh molecular weight polyethylene and lower molecular weight polyethylene can be used.
• the UHMW polyethylene has an intrinsic viscosity of at least 10 deciliters/gram
• the lower molecular weight polyethylene has an ASTM D 1238-86 Condition E melt index of less than 50 grams/10 minutes, e.g., less than 25 grams/10 minutes, such as less than 15 grams/10 minutes
• the amount of UHMW polyethylene used (as weight percent) in this embodiment is described in column 1, line 52 to column 2, line 18 of U.S.
• LMWPE lower molecular weight polyethylene
• ASTM D 1248-84 Reapproved 1989.
• Non-limiting examples of the densities of LMWPE are found in the following Table 1.
• any or all of the polyethylenes listed in Table 1 above may be used as the LMWPE in the matrix of the microporous material.
• HDPE may be used because it can be more linear than MDPE or LDPE.
• Processes for making the various LMWPE's are well known and well documented. They include the high pressure process, the Phillips Petroleum Company process, the Standard Oil Company (Indiana) process, and the Ziegler process.
• the ASTM D 1238-86 Condition E (that is, 190° C. and 2.16 kilogram load) melt index of the LMWPE is less than about 50 grams/10 minutes. Often the Condition E melt index is less than about 25 grams/10 minutes.
• the Condition E melt index can be less than about 15 grams/10 minutes.
• the ASTM D 1238-86 Condition F (that is, 190° C. and 21.6 kilogram load) melt index of the LMWPE is at least 0.1 gram/10 minutes. In many cases the Condition F melt index is at least 0.5 gram/10 minutes such as at least 1.0 gram/10 minutes.
• the UHMWPE and the LMWPE may together constitute at least 65 percent by weight, e.g., at least 85 percent by weight, of the polyolefin polymer of the microporous material. Also, the UHMWPE and LMWPE together may constitute substantially 100 percent by weight of the polyolefin polymer of the microporous material.
• the microporous material can comprise a polyolefin comprising ultrahigh molecular weight polyethylene, ultrahigh molecular weight polypropylene, high density polyethylene, high density polypropylene, or mixtures thereof.
• thermoplastic organic polymers also may be present in the matrix of the microporous material provided that their presence does not materially affect the properties of the microporous material substrate in an adverse manner.
• the amount of the other thermoplastic polymer which may be present depends upon the nature of such polymer. In general, a greater amount of other thermoplastic organic polymer may be used if the molecular structure contains little branching, few long side chains, and few bulky side groups, than when there is a large amount of branching, many long side chains, or many bulky side groups.
• the microporous material comprises at least 70 percent by weight of UHMW polyolefin, based on the weight of the matrix.
• the above-described other thermoplastic organic polymer are substantially absent from the matrix of the microporous material.
• microporous materials of the present invention further comprise finely divided, particulate filler (b) distributed throughout the matrix.
• the particulate filler can be a substantially water-insoluble filler material.
• the particulate filler comprises particles that can be formed from materials selected from polymeric and nonpolymeric inorganic materials, polymeric and nonpolymeric organic materials, composite materials, and mixtures of any of the foregoing.
• the surface of the particle can be modified in any manner well known in the art, including, but not limited to, chemically or physically changing its surface characteristics using techniques known in the art.
• a particle can be formed from a primary material that is coated, clad or encapsulated with one or more secondary materials to form a composite particle that has a softer surface.
• particles formed from composite materials can be formed from a primary material that is coated, clad or encapsulated with a different form of the primary material.
• the particles suitable for use in the microporous materials of the invention can comprise inorganic elements or compounds known in the art.
• Suitable particles can be formed from ceramic materials, metallic materials, and mixtures of any of the foregoing.
• Suitable ceramic materials comprise metal oxides, metal nitrides, metal carbides, metal sulfides, metal silicates, metal borides, metal carbonates, and mixtures of any of the foregoing.
• metal nitrides are, for example boron nitride; specific, nonlimiting examples of metal oxides are, for example zinc oxide; nonlimiting examples of suitable metal sulfides are, for example molybdenum disulfide, tantalum disulfide, tungsten disulfide, and zinc sulfide; nonlimiting suitable examples of metal silicates are, for example aluminum silicates and magnesium silicates such as vermiculite.
• the particles can comprise, for example a core of essentially a single inorganic oxide such as silica in colloidal, fumed, or amorphous form, alumina or colloidal alumina, titanium dioxide, cesium oxide, yttrium oxide, colloidal yttria, zirconia, e.g., colloidal or amorphous zirconia, and mixtures of any of the foregoing; or an inorganic oxide of one type upon which is deposited an organic oxide of another type.
• a single inorganic oxide such as silica in colloidal, fumed, or amorphous form, alumina or colloidal alumina, titanium dioxide, cesium oxide, yttrium oxide, colloidal yttria, zirconia, e.g., colloidal or amorphous zirconia, and mixtures of any of the foregoing; or an inorganic oxide of one type upon which is deposited an organic oxide of another type.
• Nonpolymeric, inorganic materials useful in forming the particles used in the present invention comprise inorganic materials selected from graphite, metals, oxides, carbides, nitrides, borides, sulfides, silicates, carbonates, sulfates, and hydroxides.
• a nonlimiting example of a useful inorganic oxide is zinc oxide
• suitable inorganic sulfides include molybdenum disulfide, tantalum disulfide, tungsten disulfide, and zinc sulfide.
• Nonlimiting examples of useful inorganic silicates include aluminum silicates and magnesium silicates, such as vermiculite.
• suitable metals include molybdenum, platinum, palladium, nickel, aluminum, copper, gold, iron, silver, alloys, and mixtures of any of the foregoing.
• the particles are selected from fumed silica, amorphous silica, colloidal silica, alumina, colloidal alumina, titanium dioxide, cesium oxide, yttrium oxide, colloidal yttria, zirconia, colloidal zirconia, and mixtures of any of the foregoing.
• a particle can be formed from a primary material that is coated, clad or encapsulated with one or more secondary materials to form a composite material that has a harder surface.
• a particle can be formed from a primary material that is coated, clad or encapsulated with a differing form of the primary material to form a composite material that has a harder surface.
• an inorganic particle formed from an inorganic material such as silicon carbide or aluminum nitride can be provided with a silica, carbonate or nanoclay coating to form a useful composite particle.
• a silane coupling agent with alkyl side chains can interact with the surface of an inorganic particle formed from an inorganic oxide to provide a useful composite particle having a “softer” surface.
• Other examples include cladding, encapsulating or coating particles formed from nonpolymeric or polymeric materials with differing nonpolymeric or polymeric materials.
• DUALITETM is a synthetic polymeric particle coated with calcium carbonate that is commercially available from Pierce and Stevens Corporation of Buffalo, N.Y.
• the particles are formed from solid lubricant materials.
• solid lubricant means any solid used between two surfaces to provide protection from damage during relative movement and/or to reduce friction and wear.
• the solid lubricants are inorganic solid lubricants.
• inorganic solid lubricant means that the solid lubricants have a characteristic crystalline habit which causes them to shear into thin, flat plates which readily slide over one another and thus produce an antifriction lubricating effect. See R. Lewis, Sr., Hawley's Condensed Chemical Dictionary, (12th Ed. 1993) at page 712, which is specifically incorporated by reference herein. Friction is the resistance to sliding one solid over another. F. Clauss, Solid Lubricants and Self-Lubricating Solids (1972) at page 1, which is specifically incorporated by reference herein.
• the particles may have a lamellar structure.
• Particles having a lamellar structure are composed of sheets or plates of atoms in hexagonal array, with strong bonding within the sheet and weak van der Waals bonding between sheets, providing low shear strength between sheets.
• a nonlimiting example of a lamellar structure is a hexagonal crystal structure.
• Inorganic solid particles having a lamellar fullerene (i.e., buckyball) structure also are useful in the present invention.
• Nonlimiting examples of suitable materials having a lamellar structure that are useful in forming the particles used in the present invention include boron nitride, graphite, metal dichalcogenides, mica, talc, gypsum, kaolinite, calcite, cadmium iodide, silver sulfide, and mixtures of any of the foregoing.
• suitable metal dichalcogenides include molybdenum disulfide, molybdenum diselenide, tantalum disulfide, tantalum diselenide, tungsten disulfide, tungsten diselenide, and mixtures of any of the foregoing.
• the particles can be formed from nonpolymeric, organic materials.
• nonpolymeric, organic materials useful in the present invention include, but are not limited to, stearates (such as zinc stearate and aluminum stearate), diamond, carbon black, and stearamide.
• the particles can be formed from inorganic polymeric materials.
• useful inorganic polymeric materials include polyphosphazenes, polysilanes, polysiloxane, polygeremanes, polymeric sulfur, polymeric selenium, silicones, and mixtures of any of the foregoing.
• a specific, nonlimiting example of a particle formed from an inorganic polymeric material suitable for use in the present invention is TOSPEARL 20 , which is a particle formed from cross-linked siloxanes and is commercially available from Toshiba Silicones Company, Ltd. of Japan.
• the particles can be formed from synthetic, organic polymeric materials.
• suitable organic polymeric materials include, but are not limited to, thermoset materials and thermoplastic materials.
• suitable thermoplastic materials include thermoplastic polyesters such as polyethylene terephthalate, polybutylene terephthalate, and polyethylene naphthalate, polycarbonates, polyolefins such as polyethylene, polypropylene, and polyisobutene, acrylic polymers such as copolymers of styrene and an acrylic acid monomer, and polymers containing methacrylate, polyamides, thermoplastic polyurethanes, vinyl polymers, and mixtures of any of the foregoing.
• thermoset materials include thermoset polyesters, vinyl esters, epoxy materials, phenolics, aminoplasts, thermoset polyurethanes, and mixtures of any of the foregoing.
• a specific, nonlimiting example of a synthetic polymeric particle formed from an epoxy material is an epoxy microgel particle.
• a thermoset material has formed a crosslinked network.
• a polymeric material is “crosslinked” if it at least partially forms a polymeric network.
• crosslink density can be determined by a variety of methods, such as dynamic mechanical thermal analysis (DMTA) using a TA Instruments DMA 2980 DMTA analyzer conducted under nitrogen. This method determines the glass transition temperature and crosslink density of free films of coatings or polymers.
• the length, width, and thickness of a sample to be analyzed are first measured, the sample is tightly mounted to the Polymer Laboratories MK III apparatus, and the dimensional measurements are entered into the apparatus.
• a thermal scan is run at a heating rate of 3.degree. C./min, a frequency of 1 Hz, a strain of 120%, and a static force of 0.01N, with sample measurements occurring every two seconds.
• the mode of deformation, glass transition temperature and crosslink density of the sample can be determined according to this method. Higher crosslink density values indicate a higher degree of crosslinking in the coating.
• the particles also can be hollow particles formed from materials selected from polymeric and nonpolymeric inorganic materials, polymeric and nonpolymeric organic materials, composite materials, and mixtures of any of the foregoing.
• suitable materials from which the hollow particles can be formed are described above.
• the hollow particles are hollow glass spheres.
• the filler can comprise a siliceous filler, talc, carbon black, charcoal, graphite, titanium oxide, iron oxide, copper oxide, zinc oxide, antimony oxide, zirconia, magnesia, alumina, molybdenum disulfide, zinc sulfide, barium sulfate, strontium sulfate, calcium carbonate, and/or magnesium carbonate.
• Non-limiting examples of siliceous fillers that may be used to prepare the microporous material include silica, mica, montmorillonite, kaolinite, nanoclays such as cloisite available from Southern Clay Products, talc, diatomaceous earth, vermiculite, natural and synthetic zeolites, calcium silicate, aluminum silicate, sodium aluminum silicate, aluminum polysilicate, alumina silica gels and glass particles.
• the filler typically comprises a hydrophilic material. Hydrophilic fillers allow for greater moisture content distributed throughout the microporous material, which in turn aids degradation of the material.
• the filler comprises silica such as precipitated silica.
• silica such as precipitated silica.
• precipitated silicas may be employed in the present invention but the precipitated silicas obtained by precipitation from an aqueous solution of sodium silicate using a suitable acid such as sulfuric acid, hydrochloric acid, or carbon dioxide are used most often.
• Such precipitated silicas are themselves known and processes for producing them are described in detail in the U.S. Pat. No. 2,940,830 and in West German Offenlegungsschrift No. 35 45 615.
• precipitated silica When precipitated silica is used, it typically has an average ultimate particle size of less than about 0.1 micrometer.
• the filler particles can constitute from 20 to 90 percent by weight of the microporous material.
• such filler particles can constitute from 20 to 90 percent by weight of the microporous material, such as from 30 percent to 90 percent by weight of the microporous material, or from 40 to 90 percent by weight of the microporous material, or from 50 to 90 percent by weight of the microporous material and even from 60 percent to 90 percent by weight of the microporous material.
• the filler is typically present in the microporous material of the present invention in an amount of 50 percent to about 85 percent by weight of the microporous material.
• the microporous material of the present invention further comprises a network of interconnecting pores (c) communicating throughout the microporous material.
• such pores can comprise at least 15 percent by volume, e.g. from at least 20 to 95 percent by volume, or from at least 25 to 95 percent by volume, or from 35 to 70 percent by volume of the microporous material. Often the pores comprise at least 35 percent by volume, or even at least 45 percent by volume of the microporous material.
• Such high porosity provides higher surface area and allows distribution of moisture throughout the microporous material.
• the porosity (also known as void volume) of the microporous material is determined according to the following equation:
• d 1 is the density of the sample, which is determined from the sample weight and the sample volume as ascertained from measurements of the sample dimensions
• d 2 is the density of the solid portion of the sample, which is determined from the sample weight and the volume of the solid portion of the sample.
• the volume of the solid portion of the same is determined using a Quantachrome stereopycnometer (Quantachrome Corp.) in accordance with the accompanying operating manual.
• the volume average diameter of the pores of the microporous material can be determined by mercury porosimetry using an Autopore III porosimeter (Micromeretics, Inc.) in accordance with the accompanying operating manual.
• the volume average pore radius for a single scan is automatically determined by the porosimeter.
• a scan is made in the high pressure range (from 138 kilopascals absolute to 227 megapascals absolute). If approximately 2 percent or less of the total intruded volume occurs at the low end (from 138 to 250 kilopascals absolute) of the high pressure range, the volume average pore diameter is taken as twice the volume average pore radius determined by the porosimeter. Otherwise, an additional scan is made in the low pressure range (from 7 to 165 kilopascals absolute) and the volume average pore diameter is calculated according to the equation:
• d is the volume average pore diameter
• v 1 is the total volume of mercury intruded in the high pressure range
• v 2 is the total volume of mercury intruded in the low pressure range
• r 1 is the volume average pore radius determined from the high pressure scan
• r 2 is the volume average pore radius determined from the low pressure scan
• w 1 is the weight of the sample subjected to the high pressure scan
• w 2 is the weight of the sample subjected to the low pressure scan.
• the volume average diameter of the pores can be in the range of from 0.001 to 0.50 micrometers, e.g., from 0.005 to 0.30 micrometers, or from 0.01 to 0.25 micrometers.
• the maximum pore radius detected is sometimes noted. This is taken from the low pressure range scan, if run; otherwise it is taken from the high pressure range scan.
• the maximum pore diameter is twice the maximum pore radius.
• some production or treatment steps e.g., coating processes, printing processes, impregnation processes and/or bonding processes, can result in the filling of at least some of the pores of the microporous material, and since some of these processes irreversibly compress the microporous material, the parameters in respect of porosity, volume average diameter of the pores, and maximum pore diameter are determined for the microporous material prior to the application of one or more of such production or treatment steps.
• the microporous material of the present invention may further comprise a biodegradation promoting material distributed throughout the matrix, thereby rendering the microporous material compostable and/or biodegradable.
• a biodegradation promoting material known in the art may be used.
• materials that attract microorganisms in the environment and then enable the microorganisms to metabolize the molecular structure of polymers such as those disclosed in United States Patent Application Publication No. 2008/0103232 A1, are suitable. Such materials are disclosed in paragraphs [0058 through 0071] of the cited published patent application, incorporated herein by reference.
• biodegradation promoting materials include catalytic transition metal compounds, metal stearates such as cobalt stearate and manganese stearate, and/or a metal chelate.
• the biodegradation promoting material is present in the microporous material of the present invention at least in an amount sufficient to render the material biodegradable.
• filler polymer powder (polyolefin and/or renewable polymer), processing plasticizer, biodegradation promoting material (if used) and minor amounts of lubricant and antioxidant are mixed until a substantially uniform mixture is obtained.
• the weight ratio of filler to polymer powder employed in forming the mixture is essentially the same as that of the microporous material substrate to be produced.
• the mixture, together with additional processing plasticizer, is introduced to the heated barrel of a screw extruder. Attached to the extruder is a die, such as a sheeting die, to form the desired end shape.
• a continuous sheet or film formed by a die is forwarded to a pair of heated calender rolls acting cooperatively to form continuous sheet of lesser thickness than the continuous sheet exiting from the die.
• the final thickness may depend on the desired end-use application.
• the product passes to a first extraction zone where the processing plasticizer is substantially removed by extraction with an organic liquid which is a good solvent for the processing plasticizer, a poor solvent for the organic polymer, and more volatile than the processing plasticizer.
• an organic liquid which is a good solvent for the processing plasticizer, a poor solvent for the organic polymer, and more volatile than the processing plasticizer.
• both the processing plasticizer and the organic extraction liquid are substantially immiscible with water.
• the product then passes to a second extraction zone where the residual organic extraction liquid is substantially removed by steam and/or water.
• the product is then passed through a forced air dryer for substantial removal of residual water and remaining residual organic extraction liquid. From the dryer the microporous material may be passed to a take-up roll, when it is in the form of a sheet.
• the processing plasticizer has little solvating effect on the thermoplastic organic polymer at 60° C., only a moderate solvating effect at elevated temperatures on the order of about 100° C., and a significant solvating effect at elevated temperatures on the order of about 200° C. It is a liquid at room temperature and usually it is processing oil such as paraffinic oil, naphthenic oil, or aromatic oil. Suitable processing oils include those meeting the requirements of ASTM D 2226-82, Types 103 and 104. Those oils which have a pour point of less than 22° C., or less than 10° C., according to ASTM D 97-66 (reapproved 1978) are used most often.
• suitable oils include Shellflex® 412 and Shellflex® 371 oil (Shell Oil Co.) which are solvent refined and hydrotreated oils derived from naphthenic crude. It is expected that other materials, including the phthalate ester plasticizers such as dibutyl phthalate, bis(2-ethylhexyl) phthalate, diisodecyl phthalate, dicyclohexyl phthalate, butyl benzyl phthalate, and ditridecyl phthalate will function satisfactorily as processing plasticizers.
• phthalate ester plasticizers such as dibutyl phthalate, bis(2-ethylhexyl) phthalate, diisodecyl phthalate, dicyclohexyl phthalate, butyl benzyl phthalate, and ditridecyl phthalate will function satisfactorily as processing plasticizers.
• organic extraction liquids there are many organic extraction liquids that can be used.
• suitable organic extraction liquids include 1,1,2-trichloroethylene, perchloroethylene, 1,2-dichloroethane. 1,1,1-trichloroethane, 1,1,2-trichloroethane, methylene chloride, chloroform, isopropyl alcohol, diethyl ether and acetone.
• the filler In the above described process for producing microporous material substrate, extrusion and calendering are facilitated when the filler carries much of the processing plasticizer.
• the capacity of the filler particles to absorb and hold the processing plasticizer is a function of the surface area of the filler. Therefore the filler typically has a high surface area.
• High surface area fillers are materials of very small particle size, materials having a high degree of porosity or materials exhibiting both characteristics.
• the surface area of the filler itself is in the range of from about 20 to about 400 square meters per gram as determined by the Brunauer, Emmett, Teller (BET) method according to ASTM C 819-77 using nitrogen as the adsorbate but modified by outgassing the system and the sample for one hour at 130° C.
• BET Brunauer, Emmett, Teller
• the surface area is in the range of from about 25 to 350 square meters per gram.
• the filler should be substantially insoluble in the processing plasticizer and substantially insoluble in the organic extraction liquid when microporous material substrate is produced by the above process.
• the residual processing plasticizer content is usually less than 15 percent by weight of the resulting microporous material and this may be reduced even further to levels such as less than 5 percent by weight, by additional extractions using the same or a different organic extraction liquid.
• microporous materials of the present invention are printable using any of a wide variety of printing media and printing processes known in the art.
• the term “printable”, as used herein means that the subject material can be printed using some printing media, for example, printing inks, and one or more printing methods.
• Non-limiting examples of such printing methods include, but are not limited to, typographic printing, e.g., rubber stamp printing, letterpress printing, flexography, and letterset printing (also known as dry offset printing and offset letterpress printing); intaglio printing, and gravure printing; planographic printing, e.g., lithography, hectograph printing and xerography; stencil printing, e.g., screen printing and mimeographic printing; typewriting and dot matrix printing; ink jet printing and electrophotographic printing.
• Suitable printing inks can include, for example, water-based inks and toners, oil-based inks and toners. The inks and toners may be in liquid form or in solid form.
• microporous materials of the present invention are suitable for a wide variety of end uses, especially those applications where a printable surface is required.
• the microporous materials may be formed into sheets for durable documents such as maps, menus and cards.
• the microporous material is capable of maintaining its shape and supporting any subsequently applied layers.
• the microporous material is suitable for use as one or more layers in a multilayer article, for example, labels, such pressure sensitive labels, in-mold labels, RFID labels, RFID inlays and cards, identification cards, smart cards, loyalty cards, passports, drivers licenses, flexible packaging, and the like.
• Multilayer articles of the present invention comprise:
• the material (b) may comprise a nonporous material such as poly vinyl chloride (PVC), polycarbonate, polyethylene terephthalate (PET) and rubber, and may be transparent, translucent, or opaque.
• PVC poly vinyl chloride
• PET polyethylene terephthalate
• rubber may be transparent, translucent, or opaque.
• the material (b) comprises an adhesive.
• a pressure sensitive label may be prepared wherein at least one outermost layer comprises an adhesive (which may be separate from a removable backing layer).
• an adhesive layer may be between one or more layers of microporous materials, one or more layers of other materials, or between a layer of microporous material and another material.
• Data transmission devices, electronic circuitry, antennae, and/or magnetic materials may be incorporated into at least one layer of the multilayer articles of the present invention to prepare RFID labels, cards, and inlays, smart cards, data storage devices, electroluminescent displays, and the like.
• Ultraviolet light absorbers and/or other additives may be incorporated into at least one layer of the multilayer articles of the present invention to prepare multilayer articles having outdoor exposure durability, suitable for use in or as articles such as outdoor signs, banners, etc.
• Example mixes presented in Table 1 are described.
• Part 2 the methods used to extrude, calender and extract the sheets prepared from the mixes of Part 1 are described.
• Part 3 the methods used to determine the physical properties reported in Table 2 are described.
• Part 4 a scale-up of the procedure described in Part 2 was used.
• the materials used in the Scale-up Control and Examples 8 and 9 are listed in Table 3 as percentages of the total mix.
• the dry ingredients were weighed into a FM-130D LITTLEFORD plough blade mixer with one high intensity chopper style mixing blade in the order and amounts (grams (g)) specified in Table I.
• the dry ingredients were premixed for 15 seconds using the plough blades only.
• the process oil was then pumped in via a hand pump through a spray nozzle at the top of the mixer, with only the plough blades running.
• the high intensity chopper blade was turned on, along with the plough blades, and the mix was mixed for 30 seconds.
• the mixer was shut off and the internal sides of the mixer were scrapped down to insure all ingredients were evenly mixed.
• the mixer was turned back on with both high intensity chopper and plough blades turned on, and the mix was Mixed for an additional 30 seconds.
• the mixer was turned off and the mix dumped into a storage container.
• the mixes of the Examples and Control were extruded and calendered into final sheet form using an extrusion system including a feeding, extrusion and calendering system described as follows.
• a gravimetric loss in weight feed system K-TRON model # K2MLT35D5
• the extruder barrel was comprised of eight temperature zones and a heated adaptor to the sheet die.
• the extrusion mixture feed port was located just prior to the first temperature zone.
• An atmospheric vent was located in the third temperature zone.
• a vacuum vent was located in the seventh temperature zone.
• the mix was fed into the extruder at a rate of 90 g/minute. Additional processing oil also was injected at the first temperature zone, as required, to achieve the desired total oil content in the extruded sheet.
• the oil contained in the extruded sheet (extrudate) being discharged from the extruder is referenced herein as the “extrudate oil weight percent”.
• Extrudate from the barrel was discharged into a 15-centimeter wide sheet MASTERFLEX® die having a 1.5 millimeter discharge opening.
• the extrusion melt temperature was 203-210° C. and the throughput was 7.5 kilograms per hour.
• the calendering process was accomplished using a three-roll vertical calender stack with one nip point and one cooling roll. Each of the rolls had a chrome surface. Roll dimensions were approximately 41 cm in length and 14 cm in diameter.
• the top roll temperature was maintained between 135° C. to 140° C.
• the middle roll temperature was maintained between 140° C. to 145° C.
• the bottom roll was a cooling roll wherein the temperature was maintained between 10-21° C.
• the extrudate was calendered into sheet form and passed over the bottom water cooled roll and wound up.
• a sample of sheet cut to a width up to 25.4 cm and length of 305 cm was rolled up and placed in a canister and exposed to hot liquid 1,1,2-trichloroethylene for approximately 7-8 hours to extract oil from the sheet sample. Afterwards, the extracted sheet was air dried and subjected to test methods described hereinafter.
• Handle-O-Meter Stiffness was measured on a Handle-O-Meter, instrument available from Thwing-Albert Instrument Company. Two 4 ⁇ 4 inch (10.16 ⁇ 10.16 cm) specimens were cut from samples of the sheets prepared as described in Part 2. The machine direction was noted for each sample sheet. The first specimen was inserted in the machine direction under the penetrator beam covering the gap in the specimen platform and aligned with the corresponding line on the specimen platform. The test mode was set to single and the beam size was 1000 g. The load reading was zeroed. The peak load, measured as grams (g), was noted as value 1 and the sample was turned 180 degrees and retested to determine value 2. This test procedure was repeated for a second specimen cut from the same sample. The resulting two values from specimen 1 and the two values from specimen 2 were added together and then divided by four to yield an arithmetic average Handle-O-Meter value for the sample.
• Thickness was determined using an ONO SOKKI thickness gauge EG-225. Two 4.5 ⁇ 5 inch (11.43 cm ⁇ 12.7 cm) specimens were cut from each sample and the thickness for each specimen was measured in nine places (at least 3 ⁇ 4 of an inch (1.91 cm) from any edge). The arithmetic average of the readings was recorded in mils to 2 decimal places and converted to microns.
• the density of the Examples was determined by dividing the average anhydrous weight of two specimens measuring 4.5 ⁇ 5 inches (11.43 cm ⁇ 12.7 cm) that were cut from each sample by the average volume of those specimens. The average volume was determined by boiling the two specimens in deionized water for 10 minutes, removing and placing the two specimens in room temperature deionized water, weighing each specimen suspended in deionized water after it has equilibrated to room temperature and weighing each specimen again in air after the surface water was blotted off. The average volume of the specimens was calculated as follows:
• volume(avg.) [(weight of lightly blotted specimens weighed in air ⁇ sum of immersed weights) ⁇ 1.002]/2
• the anhydrous weight was determined by weighing each of the two specimens on an analytical balance and multiplying that weight by 0.98 since it was assumed that the specimens contained 2 percent moisture.

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