US20120267368A1 - Disposable lid having polymer composite of polyolefin and mineral filler - Google Patents

Disposable lid having polymer composite of polyolefin and mineral filler Download PDF

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Publication number
US20120267368A1
US20120267368A1 US13/449,632 US201213449632A US2012267368A1 US 20120267368 A1 US20120267368 A1 US 20120267368A1 US 201213449632 A US201213449632 A US 201213449632A US 2012267368 A1 US2012267368 A1 US 2012267368A1
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Prior art keywords
mineral filler
polymer composite
disposable lid
polyolefin
aspect ratio
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Abandoned
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US13/449,632
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English (en)
Inventor
Wen Pao Wu
Alan H. Forbes
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Pactiv LLC
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Pactiv LLC
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Priority to US13/449,632 priority Critical patent/US20120267368A1/en
Assigned to Pactiv LLC reassignment Pactiv LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FORBES, ALAN H., WU, WEN PAO
Priority to TW101114281A priority patent/TW201300229A/zh
Publication of US20120267368A1 publication Critical patent/US20120267368A1/en
Assigned to THE BANK OF NEW YORK MELLON reassignment THE BANK OF NEW YORK MELLON PATENT SECURITY AGREEMENT Assignors: CLOSURE SYSTEMS INTERNATIONAL INC., EVERGREEN PACKAGING INC., GRAHAM PACKAGING COMPANY, L.P., GRAHAM PACKAGING PET TECHNOLOGIES INC., Pactiv LLC, PACTIV PACKAGING INC., Reynolds Consumer Products LLC, Reynolds Presto Products Inc.
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/34—Silicon-containing compounds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D43/00—Lids or covers for rigid or semi-rigid containers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/10—Metal compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
    • C08K3/24—Acids; Salts thereof
    • C08K3/26—Carbonates; Bicarbonates
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/10—Homopolymers or copolymers of propene
    • C08L23/12—Polypropene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
    • C08K3/24—Acids; Salts thereof
    • C08K3/26—Carbonates; Bicarbonates
    • C08K2003/265—Calcium, strontium or barium carbonate

Definitions

  • the present application generally relates to polymer compositions particularly suited for disposable lids and the like. Particularly, the present application relates to a disposable lid comprising a thermoformed sheet having a polymer composite of polyolefin and at least one mineral filler.
  • Hot beverages such as freshly brewed coffee for people on the go, are usually served in heavy paper cups with disposable lids. Coffee is typically brewed at 90-96° C., held at 82-88° C. and served at 70-80° C.
  • a coffee cup lid preferably has a mechanical strength to withstand the force required to push the lid onto the cup and to maintain the dimensional stability at the temperature of the coffee.
  • the mechanical strength of a material within a range of temperatures can be correlated to the material's heat deflection temperature (“HDT”) or deflection temperature under load (“DTUL”).
  • HDT heat deflection temperature
  • DTUL deflection temperature under load
  • Current lidding material for hot beverage cups is primarily made of high impact polystyrene (“HIPS”), which has an ease of processing and a good balance between rigidity and toughness due to its amorphous structure.
  • HIPS high impact polystyrene
  • high impact polystyrene resin can be susceptible to chemical attack and solvent crazing.
  • the presence of residual styrene monomer in the resin can cause an unpleasant odor.
  • high impact polystyrene resin amongst all the commodity resins, has a comparatively high carbon footprint. Therefore, there remains an opportunity for an improved disposable lid.
  • the application includes a disposable lid comprising a thermoformed sheet in the shape of a lid for a hot beverage container.
  • the sheet comprises a polymer composite of a polyolefin and at least one mineral filler.
  • the sheet has a thickness less than about 0.035 inches and a heat deflection temperature at least comparable to that of high impact polystyrene.
  • the heat deflection temperature can be at least about that of high impact polystyrene.
  • the heat deflection temperature according to ASTM D648-06 Standard Test Method for Deflection Temperature of Plastics Under Flexural Load in the Edgewise Position (2006) can be at least about 87° C.
  • the mineral filler can include a high aspect ratio mineral filler, for example, selected from the group consisting of talc, mica, wollastonite, or combinations thereof.
  • the polymer composite can comprise at least about 10% by weight of the high aspect ratio mineral filler.
  • the mineral filler can include a low aspect ratio mineral filler, such as calcium carbonate.
  • the polymer composite can comprise at least about 20% by weight of the low aspect ratio mineral filler.
  • the polyolefin can be selected from the group consisting of polypropylene homopolymer, polypropylene impact copolymer, ethylene-propylene random copolymer, high density polyethylene, or combinations thereof.
  • the polyolefin includes polypropylene, the mineral filler includes a high aspect ratio mineral filler, and the polymer composite comprises at least about 10% by weight of the mineral filler.
  • the polyolefin includes polypropylene, the mineral filler includes a low aspect ratio mineral filler, and the polymer composite comprises at least about 20% by weight of the mineral filler.
  • the polyolefin includes high density polyethylene, the mineral filler includes a high aspect ratio mineral filler, and the polymer composite comprises at least about 20% by weight of the mineral filler.
  • the polyolefin includes high density polyethylene, the mineral filler includes a low aspect ratio mineral filler, and the polymer composite comprises at least about 40% by weight of the mineral filler.
  • the polyolefin can include polypropylene
  • the mineral filler can include a high aspect ratio mineral filler
  • the polymer composite can have a shrinkage comparable to that of high impact polystyrene.
  • the polymer composite can have a shrinkage of about 0.5% to about 1.0% when measured according to the ASTM D955 standard (1996). In this manner, the polymer composite comprises about 20% to about 40% by weight of the mineral filler.
  • the polyolefin can include polyethylene
  • the mineral filler can include a high aspect ratio mineral filler
  • the polymer composite can have a shrinkage comparable to that of polypropylene.
  • the polymer composite can have a shrinkage of about 1.25% to about 1.75% when measured according to the ASTM D955 standard (1996).
  • the polymer composite comprises about 30% to about 50% by weight of the mineral filler.
  • the polymer composite consists essentially of the polyolefin and the at least one mineral filler.
  • the polymer composite can further comprise additives selected from the group consisting of colorants, processing aids, and combinations thereof.
  • the hot beverage container can be a coffee cup, although a lid for other suitable containers is contemplated.
  • the polymer composite can have a carbon footprint lower than high impact polystyrene.
  • the polymer composite can have a greenhouse gas emission lower than high impact polystyrene.
  • FIG. 1 is a graph of the heat deflection temperature of neat high impact polystyrene, neat polypropylene, neat high density polyethylene, and certain mineral filled polymer composites, respectively, in accordance with the disclosed subject matter.
  • FIG. 2 is a graph of the shrinkage characteristics of neat high impact polystyrene, neat polypropylene, neat high density polyethylene, and certain mineral filled polymer composites, respectively, in accordance with the disclosed subject matter.
  • the disposable lids presented herein generally are intended for use with cups or other containers for holding high temperature beverages, such as coffee. Although reference will be made herein to lids for hot beverage cups, other similar or suitable uses are contemplated.
  • polyolefins typically have a heat deflection temperature lower than high impact polystyrene (“HIPS”) and thus are not suitable for use alone (i.e., neat) as a lidding material for hot beverage cups.
  • HIPS high impact polystyrene
  • the heat deflection temperature of the polyolefin can be improved by adding at least one mineral filler to form a polymer composite.
  • the resulting polymer composite can have a heat deflection temperature at least about that of high impact polystyrene and thus be suitable for use as a lidding material for hot beverage cups or the like.
  • Disposable lids in accordance with the disclosed subject matter include a thermoformed sheet in the shape of a lid for a hot beverage container.
  • the sheet comprises a polymer composite of a polyolefin and at least one mineral filler.
  • the sheet has a thickness less than about 0.035 inches and a heat deflection temperature at least comparable to that of high impact polystyrene.
  • the mineral filler can include any suitable mineral filler for increasing the heat deflection temperature of the polyolefin.
  • the mineral filler can include a high aspect ratio filler, a low aspect ratio filler, or a blend of both.
  • the term “aspect ratio” of a particle is defined herein for purpose of understanding as a ratio of a largest dimension of the particle divided by a smallest dimension of the particle. The aspect ratios are determined by scanning under an electron microscope (2,000 times magnified) and visually viewing the outside surfaces of the particles to determine the lengths and thicknesses of the particles.
  • a high aspect ratio filler is defined herein as a filler having an aspect ratio of at least about 5:1.
  • the high aspect ratio fillers of the present disclosed subject matter generally have an aspect of from about 5:1 to about 40:1, and preferably from about 10:1 to about 20:1.
  • the high aspect filler can include talc, mica, wollastonite, or combinations thereof.
  • Commercially available talc materials include, but are not limited to, JETFIL® 575, available from Luzenac America of Englewood, Colo.
  • Commercially available mica materials include SUZOREX® 325-PP, available from Zemex Industrial Minerals, Inc.
  • Commercially available wollastonite includes, but is not limited to, the NYGLOS® series of wollastonite, available from NYCO Minerals Inc. of Calgary, Alberta, Canada.
  • a low aspect ratio filler of the disclosed subject matter generally has an aspect ratio of from 1:1 to about 3:1, preferably from 1:1 to about 2:1.
  • the low aspect ratio filler can include calcium carbonate, barium sulfate, or the combination thereof.
  • Commercially available calcium carbonate includes, but is not limited to, OMYACARB FT®, available from OMYA Inc. of Cincinnati, Ohio, or Supercoat®, from Imerys Performance Minerals Inc. of Alpharetta, Ga.
  • One example of commercially available barium sulfate is BARITE 2075®, available from Polar Minerals in Mentor, Ohio.
  • the filler mixture can include any suitable weight percentage of the high and low aspect ratio fillers.
  • the filler mixture can comprise at least 50 wt. % high aspect ratio filler.
  • the filler mixture can be from about 50 to about 80 wt. % high aspect ratio filler and from about 20 to about 50 wt. % low aspect ratio filler.
  • the polyolefin can be any suitable polyolefin.
  • the polyolefin can be selected from the group consisting of polypropylene homopolymer, polypropylene impact copolymer, ethylene-propylene random copolymer, high density polyethylene, or combinations thereof.
  • the polyolefin can be a blend of homopolymer polypropylene and impact copolymer polypropylene, in any desired weight percent, such as a 60/40 blend, or a blend ratio sufficient o achieve a desirable impact property of the composite.
  • the polymer composite can consist essentially of the polyolefin and the at least one mineral filler.
  • the polymer composite can further comprise any additives known to one of ordinary skill in the art.
  • the additive can include colorants, processing aids such as those commonly used for processing composites, or combination thereof.
  • the disposable lid can be formed using a variety of conventional manufacturing and forming processes, including thermoforming or injecting molding processes, although a thermoforming process is employed herein.
  • a thermoforming process is employed herein.
  • pellets of a polyolefin resin are melted in a twin screw extruder.
  • Powders of the at least one mineral filler are mixed with and/or added into the polyolefin melt to form a blend.
  • the blend is extruded through a die to form an extruded sheet.
  • the extruded sheet is then thermoformed to a desired shape of the disposable lid.
  • a mineral-filled compound of high filler content in pellet form can be produced from a typical compounding process, and the pellets further diluted to a desirable filler content in the sheet extrusion process.
  • the thickness of the lid can be selected as desired, but is typically less than about 0.15 inches, preferably less than about 0.035 inches. Preferably, the lid can be about 0.01 to about 0.025 inches thick.
  • the lid can be the natural color of the polyolefin/filler mixture, or a variety of colors or color combinations.
  • the height, weight, shape, and design of the lid can be selected as desired to fit a suitable hot beverage container, such as a coffee cup, as is well known in the art. For example, the lid can weigh about 3 to about 4 grams. Exemplary lid designs include, but are not limited to, those described and shown in U.S. Pat. Nos.
  • the heat deflection temperature (“HDT”) also known as the deflection temperature under load (“DTUL”) can be determined according to ASTM D648-06, Standard Test method for Deflection Temperature of Plastics Under Flexural Load in the Edgewise Position (2006).
  • Table 1 includes the heat deflection temperature measured according to the ASTM D648-06 standard (2006) for neat high impact polystyrene, neat polypropylene (“PP”), neat high density polyethylene (“HDPE”), and various mineral filled polymer composites in accordance with the disclosed subject matter.
  • the data provided in Table 1 is based on nominally 12.7 mm wide by 3.17 mm thick injection molded bars with a span of 101.6 mm.
  • FIG. 1 provides a graphical representation of the heat deflection temperature data provided in Table 1. Particularly, FIG. 1 shows the increase of heat deflection temperature as a function of mineral filler content for four different combinations of polypropylene or high density polyethylene with talc or calcium carbonate, respectively, as compared with neat HIPS as a control.
  • neat high impact polystyrene with a heat deflection temperature of 87° C., falls in between the range of temperature where coffee is brewed and served.
  • the heat deflection temperature for neat high density polyethylene at about 69° C., however, is shown to be outside the range of temperature where a lid made from neat high density polyethylene would perform satisfactorily.
  • Examples 1-20 in accordance with the disclosed subject matter of Table 1 show the heat deflection temperatures of various polyolefin and mineral filler combinations at different levels of mineral filler.
  • the calcium carbonate filled polyolefins have a gradual increase in heat deflection temperature relative a respective non-filled (i.e. neat) polyolefin as the mineral content is increased.
  • the talc filled polyolefins have a much higher increase in heat deflection temperature as the mineral filler content is increased.
  • the talc filled polypropylene has a more significant increase in heat deflection temperature, even with the talc content as low as about 10%.
  • a polymer composite in accordance with the disclosed subject matter therefore can be provided with a heat deflection temperature comparable to, equal to, or greater than high impact polystyrene.
  • the mineral filler includes a high aspect ratio mineral (e.g. talc)
  • the polymer composite can comprise as little as about 10% by weight of the mineral filler (see Example 12). Indeed, as shown in FIG. 1 , when polypropylene is used, even less than 10% by weight of talc is needed to achieve the same heat deflection temperature as high impact polystyrene.
  • the polymer composite can comprise at least about 20% by weight of the mineral filler (see Example 17) to achieve the equal or greater heat deflection temperature than high impact polystyrene.
  • a low aspect mineral filler e.g. calcium carbonate
  • the polymer composite can comprise at least about 20% by weight of the mineral filler (see Example 17) to achieve the equal or greater heat deflection temperature than high impact polystyrene.
  • Example 2 when the polyolefin includes high density polyethylene, the mineral filler includes a high aspect ratio mineral filler (e.g. talc), and the polymer composite comprises at least about 20% by weight of the mineral filler, the heat deflection temperature will be greater than that of high impact polystyrene.
  • the mineral filler when the polyolefin includes high density polyethylene, the mineral filler includes a low aspect ratio mineral filler (e.g. calcium carbonate), and the polymer composite comprises at least about 50% by weight of the mineral filler, the heat deflection temperature will be greater than that of high impact polystyrene.
  • the mineral filler when the polyolefin includes high density polyethylene, the mineral filler includes a low aspect ratio mineral filler (e.g. calcium carbonate), and the polymer composite comprises at least about 50% by weight of the mineral filler, the heat deflection temperature will be greater than that of high impact polystyrene.
  • Example 12 when the polyolefin includes polypropylene, the mineral filler includes a high aspect ratio mineral filler (e.g. talc), and the polymer composite comprises at least about 10% by weight of the mineral filler, the heat deflection temperature will be greater than that of high impact polystyrene.
  • the mineral filler when the polyolefin includes polypropylene, the mineral filler includes a low aspect ratio mineral filler (e.g. calcium carbonate), and the polymer composite comprises at least about 20% by weight of the mineral filler, the heat deflection temperature will be greater than that of high impact polystyrene.
  • the mineral filler when the polyolefin includes polypropylene, the mineral filler includes a low aspect ratio mineral filler (e.g. calcium carbonate), and the polymer composite comprises at least about 20% by weight of the mineral filler, the heat deflection temperature will be greater than that of high impact polystyrene.
  • Table 1 and FIG. 2 shows the shrinkage characteristics of polypropylene, high density polyethylene, high impact polystyrene and mineral filled polypropylene and mineral filled high density polyethylene.
  • the shrinkage can be measured in accordance with the ASTM D955 (1996) standard using injection molded bars of the dimensions 12.7 min ⁇ 3.2 mm ⁇ 127 mm in accordance with the standard and as well known in the art.
  • Mineral filled polypropylene can overcome disadvantages of polypropylene (neat) in the mismatch in shrinkage as compared to high impact polystyrene, therefore allowing the use of existing high impact polystyrene tooling for making a part with similar shrinkage of between about 0.5% and about 1.0%. For example, as shown in FIG.
  • talc filled polypropylene at 20-40% talc is suitable for replacing high impact polystyrene from shrinkage perspective.
  • mineral filled high density polyethylene can overcome the disadvantage of high density polyethylene in the mismatch in shrinkage as compared to polypropylene, therefore allowing the use of existing polypropylene tooling for making a mineral filled high density polyethylene part with similar shrinkage to polypropylene of about 1.25% to about 1.75%.
  • talc filled high density polyethylene at 30-50% talc is suitable for replacing neat polypropylene from shrinkage perspective.
  • the polymer composite can have a carbon footprint lower than high impact polystyrene.
  • the polymer composite can have a greenhouse gas emission lower than high impact polystyrene.
  • Table 2 shows cradle-to-grave greenhouse gases emissions of lids in accordance with the disclosed subject matter as compared to lids of high impact polystyrene. The two lids have similar rigidity and perform similarly as a hot beverage cup lid.
  • the comparative example was made from high impact polystyrene sheet of about 0.0214 inches thick and weighed about 3.83 grams.
  • the example in accordance with the disclosed subject matter include 40% talc-filled polypropylene and was made from a 0.0167 inches thick sheet and weighed about 3.32 grams. A base unit of 10,000 pieces was used to calculate the greenhouse gases emissions. Several factors contributed to the much lower greenhouse gases emission of the example in accordance with the disclosed subject matter. These factors include polymer density, GHG emission of base polymers and minerals, and the amount of minerals incorporated in the composite. As can be seen in FIG. 2 , the talc filled polypropylene lid has a nearly 50% reduction in greenhouse gases emission as compared to a similarly performing lid made of high impact polystyrene.

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  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
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  • Table Devices Or Equipment (AREA)
US13/449,632 2011-04-21 2012-04-18 Disposable lid having polymer composite of polyolefin and mineral filler Abandoned US20120267368A1 (en)

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US13/449,632 US20120267368A1 (en) 2011-04-21 2012-04-18 Disposable lid having polymer composite of polyolefin and mineral filler
TW101114281A TW201300229A (zh) 2011-04-21 2012-04-20 具有聚烯烴及礦物填充物之聚合物合成物之免洗蓋

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US201161477886P 2011-04-21 2011-04-21
US13/449,632 US20120267368A1 (en) 2011-04-21 2012-04-18 Disposable lid having polymer composite of polyolefin and mineral filler

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US (1) US20120267368A1 (ja)
EP (1) EP2699630A1 (ja)
JP (1) JP2014512444A (ja)
CN (2) CN103597018A (ja)
CA (1) CA2832644A1 (ja)
MX (1) MX2013012104A (ja)
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US8883280B2 (en) 2011-08-31 2014-11-11 Berry Plastics Corporation Polymeric material for an insulated container
US9102461B2 (en) 2011-06-17 2015-08-11 Berry Plastics Corporation Insulated sleeve for a cup
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US9562140B2 (en) 2013-08-16 2017-02-07 Berry Plastics Corporation Polymeric material for an insulated container
US9688456B2 (en) 2012-12-14 2017-06-27 Berry Plastics Corporation Brim of an insulated container
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US10513589B2 (en) 2015-01-23 2019-12-24 Berry Plastics Corporation Polymeric material for an insulated container
US11091311B2 (en) 2017-08-08 2021-08-17 Berry Global, Inc. Insulated container and method of making the same
US11242180B2 (en) 2018-05-25 2022-02-08 Dart Container Corporation Drink lid for a cup
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US11331887B2 (en) 2018-03-05 2022-05-17 Dart Container Corporation Polyolefin-based composition for a lid and methods of making and using
US11584838B2 (en) 2017-10-10 2023-02-21 Dart Container Corporation Polyolefin-based composition for a lid and methods of making and using
US12011856B2 (en) * 2017-11-13 2024-06-18 Pactiv LLC Mineral-filled polymer articles and methods of forming same
US12024608B2 (en) 2023-01-06 2024-07-02 Dart Container Corporation Polyolefin-based composition for a lid and methods of making and using

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