WO2000075228A1 - Melanges en phase inverse de poly(ethylene oxyde) et de polyolefine et procede d'extrusion reactive de production des melanges en phase inverse - Google Patents

Melanges en phase inverse de poly(ethylene oxyde) et de polyolefine et procede d'extrusion reactive de production des melanges en phase inverse Download PDF

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Publication number
WO2000075228A1
WO2000075228A1 PCT/US1999/013366 US9913366W WO0075228A1 WO 2000075228 A1 WO2000075228 A1 WO 2000075228A1 US 9913366 W US9913366 W US 9913366W WO 0075228 A1 WO0075228 A1 WO 0075228A1
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Prior art keywords
poly
ethylene oxide
polyolefin
volume
inverse phase
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PCT/US1999/013366
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English (en)
Inventor
James H. Wang
David M. Schertz
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Kimberly-Clark Worldwide, Inc.
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Priority claimed from US09/327,142 external-priority patent/US6214933B1/en
Application filed by Kimberly-Clark Worldwide, Inc. filed Critical Kimberly-Clark Worldwide, Inc.
Priority to MXPA01012354A priority Critical patent/MXPA01012354A/es
Priority to AU46818/99A priority patent/AU4681899A/en
Publication of WO2000075228A1 publication Critical patent/WO2000075228A1/fr

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/18—Manufacture of films or sheets
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F255/00—Macromolecular compounds obtained by polymerising monomers on to polymers of hydrocarbons as defined in group C08F10/00
    • C08F255/02—Macromolecular compounds obtained by polymerising monomers on to polymers of hydrocarbons as defined in group C08F10/00 on to polymers of olefins having two or three carbon atoms
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F283/00—Macromolecular compounds obtained by polymerising monomers on to polymers provided for in subclass C08G
    • C08F283/06—Macromolecular compounds obtained by polymerising monomers on to polymers provided for in subclass C08G on to polyethers, polyoxymethylenes or polyacetals
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L51/00—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
    • C08L51/06—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers grafted on to homopolymers or copolymers of aliphatic hydrocarbons containing only one carbon-to-carbon double bond
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L51/00—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
    • C08L51/08—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers grafted on to macromolecular compounds obtained otherwise than by reactions only involving unsaturated carbon-to-carbon bonds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L71/00—Compositions of polyethers obtained by reactions forming an ether link in the main chain; Compositions of derivatives of such polymers
    • C08L71/02—Polyalkylene oxides
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment

Definitions

  • the present invention relates to inverse phase blends of polyolefin and poly(ethylene oxide) and methods of making inverse phase blends.
  • the liquid repellent film commonly used includes plastic materials such as polyethylene films and the like. Although such products are relatively inexpensive, sanitary and easy to use, disposal of a product once soiled is not without its problems. An ideal disposal method for such products would be to use municipal sewage treatment and private residential septic systems. Products suited for disposal in sewage systems can be flushed down a convenient toilet and are termed "flushable.” While flushing such articles would be convenient, the liquid repellent material which normally does not disintegrate in water tends to plug toilets and sewer pipes. It therefore becomes necessary, although undesirable, to separate the barrier film material from the absorbent article prior to flushing.
  • Polymer blends of polyolefins and poly(ethylene oxide) are melt processible but exhibit very poor mechanical compatibility. This poor mechanical compatibility is particularly manifested in blends having greater than 50 weight percent of polyolefin.
  • the film is not affected by water since typically the majority phase, i.e. polyolefin, will surround and encapsulate the minority phase, i.e. the poly (ethylene oxide).
  • the encapsulation of the poly(ethylene oxide) effectively prevents any degradability and /or flushability advantage that would be acquired by using poly (ethylene oxide).
  • compositions comprising poly(ethylene oxide) incorporating greater amounts of lower cost polyolefin(s) while maintaining or at least not significantly decreasing the water responsiveness of the composition.
  • such compositions can be used to manufacture flushable films and flushable fibers at lower cost. These films and fibers can be used as components in personal care products that are designed to be flushed down conventional toilets. Additionally, the unique water related properties of the compositions described herein compositions make the compositions desirable for the manufacture of filter membranes.
  • the present invention provides for compositions comprising a volume of poly(ethylene oxide) and a greater volume of polyolefin relative to the volume of poly(ethylene oxide) wherein the compositions exhibit an inverse phase morphology.
  • inverse phase morphology means that the volumetric majority constituent, which normally would be expected to form the continuous phase in the composition, is the dispersed phase and the volumetric minority constituent forms the continuous phase in which the volumetric majority constituent is dispersed.
  • Inverse phase polyolefin and poly(ethylene oxide) compositions are desirable because they have improved water responsiveness and water dispersibility compared to compositions comprising the same relative amounts of the aforementioned polymers that do not have inverse phase morphology described above.
  • compositions of the present invention lose a substantial amount of mass when exposed to water. Consequently, films, fibers and articles manufactured from the compositions of the present invention exhibit a significant decrease in the their mechanical properties when exposed to water compared to the dry mechanical properties prior to exposure to water.
  • the compositions of the present invention are substantially water degradable and may be used to produce flushable films, fibers and articles. Significantly, films, fibers and articles can be produced which incorporate greater amounts of essentially water-insoluble polyolefins relative to amount of water-soluble poly(ethylene oxide) while remaining water- degradable and flushable. Thus, flushable articles such as diapers and feminine pads can be manufactured with smaller amounts water-soluble and water-responsive resins, at lower cost.
  • Fig. 1 is a SEM photomicrograph of a back-scattered electron image of a cross-sectional view of a 4 mil (0.004 inch) film from the composition of Comparative Example A, a blend of 60 weight percent LDPE and 40 weight PEO that does not have inverse phase morphology.
  • Fig. 2 is a SEM photomicrograph of a back-scattered electron image of a cross-sectional view of a 4 mil film from the composition of Example 1, an inverse phase blend of 60 weight percent LDPE and
  • Fig. 3 is a SEM photomicrograph of a back-scattered electron image of a cross-sectional view of a 4 mil from the composition of Example 2, an inverse phase blend of 60 weight percent LDPE and 40 weight percent PEO that are grafted with about 5.5 weight percent of
  • Fig. 4 is a SEM photomicrograph of a back-scattered electron image of a cross-sectional view of a 4 mil film from the composition of Example 3, an inverse phase blend of 60 weight percent LDPE and
  • Fig. 5 is a SEM photomicrograph of a secondary electron image of a topological view of a 4 mil film from the composition of Example 11, an inverse phase blend of 60 weight percent LDPE and
  • Fig. 6 is a SEM photomicrograph of a back-scattered electron image of a cross-sectional view of a 4 mil film from the composition of Example 11, an inverse phase blend of 60 weight percent LDPE and 40 weight percent PEO that are grafted with about 5 weight percent of HEMA monomer.
  • Fig. 7 is a SEM photomicrograph of a secondary electron image of a topological view of a 4 mil film from the composition of Example 13, an inverse phase blend of 60 weight percent LDPE and
  • Fig. 8 is a SEM photomicrograph of a back-scattered electron image of a cross-sectional view of a 4 mil film from the composition of Example 13, an inverse phase blend of 60 weight percent LDPE and 40 weight percent PEO that are grafted with about 15 weight percent of HEMA monomer.
  • Fig. 9 is a graph illustrating the wet and dry tensile curves of a film of the non-inverse phase composition of Comparative Example A.
  • Fig. 10 is a graph illustrating the wet and dry tensile curves of a film of the inverse phase composition of Example 10.
  • Fig. 11 is a graph illustrating the wet and dry tensile curves of a film of the inverse phase composition of Example 11.
  • Fig. 12 is a graph illustrating the wet and dry tensile curves of a film of the inverse phase composition of Example 12.
  • Fig. 13 is a graph illustrating the wet and dry tensile curves of a film of the inverse phase composition of Example 13.
  • Fig. 14 is a bar graph comparing the wet and dry mechanical properties of a film of the inverse phase composition of Example 10 versus the wet and dry mechanical properties of a film of the non- inverse phase composition of Comparative Example A.
  • Fig. 15 is a bar graph comparing the wet and dry mechanical properties of a film of the inverse phase composition of Example 10 versus the wet and dry mechanical properties of a film of the non- inverse phase composition of Comparative Example A.
  • Fig. 16 is a bar graph comparing the wet and dry mechanical properties of a film of the inverse phase composition of Example 12 versus the wet and dry mechanical properties of a film of the non- inverse phase composition of Comparative Example A.
  • Fig. 17 is a bar graph comparing the wet and dry mechanical properties of a film of the inverse phase composition of Example 13 versus the wet and dry mechanical properties of a film of the non- inverse phase composition of Comparative Example A.
  • compositions of the present invention comprise a larger volume of a polyolefin and a lesser volume of a poly(ethylene oxide) where the poly(ethylene oxide) comprises the continuous phase and the polyolefin comprises the discontinuous phase.
  • the inverse phase compositions of the present invention comprise a volume majority of a polyolefin. As used herein, "volume majority" means greater amount by volume.
  • the compositions of the Examples are described by reference to weight percentages of the polyolefin component, low density polyethylene, and poly(ethylene oxide) component.
  • the volume percentage of polyolefin incorporated in the compositions of the Examples is greater than the weight percentage, e.g. 55 weight percent of low density polyethylene is equal to about 60 volume percent of low density polyethylene.
  • compositions of the present invention may comprise as little as 51 percent by volume to as much as 99 percent by volume of a polyolefin and any amount of poly(ethylene oxide) as long as there is a sufficient amount of poly(ethylene oxide) to form a continuous phase around the polyolefin.
  • the compositions of the present invention comprise from about 51 volume percent to about 95 weight percent of a polyolefin and from about 49 volume percent to about 5 weight percent of polyethylene oxide) which may be grafted with a vinyl monomer.
  • the compositions of the present invention comprise from about 60 volume percent to about 85 volume percent of a polyolefin and from about 40 volume percent to about 15 volume percent of poly(ethylene oxide) grafted with a polar vinyl monomer.
  • the polyolefin and the poly(ethylene oxide) are grafted with at least one polar vinyl monomer. It has unexpectedly been discovered that an inverse phase morphology, where the hydrophilic moiety constitutes the continuous phase, can be achieved by a minority component in the film to greatly expand the water sensitivity and degradability of a film.
  • the composition of the present invention comprises a blend of from about 60 volume percent to about 85 volume percent of a polyolefin, such as polyethylene, and from about 40 volume percent to about 15 volume percent of poly(ethylene oxide) with an effective amount of monomer grafted onto the polyolefin and poly(ethylene oxide) to render the phase inversion.
  • Suggested polyolefins useful for the practice of the invention include, but are not limited to, various thermoplastic polyethylenes, polypropylenes, polypropylenes and saturated ethylene polymers.
  • Suggested saturated ethylene polymers useful in the practice of this invention are homopolymers or copolymers of ethylene and are essentially linear in structure.
  • the term "saturated” refers to polymers that are fully saturated, but also includes polymers containing up to about 5 percent unsaturation.
  • Homopolymers of ethylene include, but are not limited to, those prepared under either low pressure, i.e., linear low density or high density polyethylene, or high pressure, i.e., branched or low density polyethylene.
  • High-density polyethylenes are generally characterized by a density that is about equal to or greater than 0.94 grams per cubic centimeter (g/cc). Generally, high-density polyethylenes useful as the base resin in the present invention have a density ranging from about 0.94 g/cc to about 0.97 g/cc.
  • the polyolefin can have a melt index, as measured at 2.16 kg and 190°C, ranging from about 0.005 decigrams per minute (dg/min) to 100 dg/min. Desirably, the polyolefin has a melt index of 0.01 dg/min to about 50 dg/min and more desirably of 0.05 dg/min to about 25 dg/min.
  • mixtures of polyolefins, particularly polyethylenes can be used as the base polyolefin resin in producing the graft copolymer compositions of the present invention, and such mixtures should have a melt index greater than 0.005 dg/min to less than about 100 dg/min.
  • the low density polyethylene used as the polyolefin component in the following examples has a density of less than 0.94 g/cc and are usually in the range of 0.91 g/cc to about 0.93 g/cc.
  • the low-density polyethylene has a melt index ranging from about 0.05 dg/min to about 100 dg/min and desirably from 0.05 dg/min to about 20 dg/min.
  • Ultra low-density polyethylene can be used in accordance with the present invention. Generally, ultra low-density polyethylene has a density of less than 0.90 g/cc.
  • the above polyolefins can also be manufactured by using the well known multiple-site Ziegler-Natta catalysts or the more recent single-site metallocene catalysts.
  • the metallocene catalyzed polyolefins have better controlled polymer microstructures than polyolefins manufactured using Ziegler-Natta catalysts, including narrower molecular weight distribution, well controlled chemical composition distribution, co-monomer sequence length distribution, and stereoregularity.
  • Metallocene catalysts are known to polymerize propylene into atactic, isotactic, syndiotactic, isotactic-atactic stereoblock copolymer.
  • the polyolefin component of the compositions of the present invention is thermoplastic in order to facilitate the production of the compositions of the invention and to facilitate the processing of the compositions into articles, particularly, films.
  • Copolymers of ethylene which can be useful in the present invention may include, but are not limited to, copolymers of ethylene with one or more additional polymerizable, unsaturated monomers.
  • copolymers include, but are not limited to, copolymers of ethylene and alpha olefins (such as propylene, butene, hexene or octene) including linear low density polyethylene, copolymers of ethylene and vinyl esters of linear or branched carboxylic acids having 1-24 carbon atoms such as ethylene-vinyl acetate copolymers, and copolymers of ethylene and acrylic or methacrylic esters of linear, branched or cyclic alkanols having 1-28 carbon atoms.
  • alpha olefins such as propylene, butene, hexene or octene
  • poly(ethylene oxide) polymers suitable for the present invention include homopolymers and copolymers of ethylene oxide that are water soluble.
  • the poly(ethylene oxide) component of the present invention can have molecular weights ranging from about 50,000 to about 8,000,000 grams per mol and, desirably, can range from about 100,000 to about 8,000,000 g/mol. More desirably, the average molecular weight of the poly(ethylene oxide) component of the present invention ranges from about 200,000 to about 6,000,000 g/mol.
  • the poly(ethylene oxide) component of the compositions of the present invention has a average molecular weight of less than 200,000 g/mol, the addition of the monomer and subsequent grafting of the monomer is not needed to get the desired phase inversion.
  • the an inverse phase composition of poly(ethylene oxide) and polyolefin was achieved by melt blending 60 weight percent of a low density polyethylene and a 100,000 g/mol polyethylene oxide).
  • poly(ethylene oxide) is a dry free flowing white powder having a crystalline melting point in the order of about 65°C, above which poly(ethylene oxide) resin becomes thermoplastic and can be formed by molding, extrusion and other methods known in the art.
  • compositions of the present invention have grafted thereto an effective amount of polar vinyl monomer. Grafting unexpectedly produces compositions and films having an inverse phase morphology.
  • a variety of polar vinyl monomers may be useful in the practice of this invention.
  • the term "monomer(s)" as used herein includes the traditional definition of a monomers as well as macromonomers which are oligomers and polymers capable of polymerization. As used herein monomers also include mixtures of monomers, oligomers and /or polymers as described above and any other reactive chemical species, which is capable of covalent bonding with the parent polymer (s).
  • Ethylenically unsaturated monomers containing a polar functional group such as hydroxyl, carboxyl, amino, carbonyl, halo, glycidyl, , cyano, thiol, sulfonic, sulfonate, etc. are appropriate for this invention and are suggested. Desired ethylenically unsaturated monomers include acrylates and methacrylates.
  • Suggested polar vinyl monomers include, but are not limited to, 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, poly(ethylene glycol) acrylates, polyethylene glycol) methacrylates, poly(ethylene glycol) diacrylates, acrylic acid, methacrylic acid, maleic anhydride, itaconic acid, acrylamide, glycidyl methacrylate, 2-bromoethyl acrylate, 2-bromoethyl methacrylate, carboxyethyl acrylate, sodium acrylate, 3-hydroxypropyl methacrylate, 3- hydroxypropyl acrylate, 2-chloroacrylonitrile, 4-chlorophenyl acrylate, 2-cyanoethyl acrylate, glycidyl acrylate, 4-nitrophenyl acrylate, pentabromophenyl acrylate, poly(propylene glycol) acrylates, poly(propylene glycol) methacrylates, 2-propene
  • Suggested derivatives include, but are not limited to, poly(ethylene glycol) ethyl ether acrylates, poly(ethylene glycol) alkyl ether acrylates, poly(ethylene glycol) alkyl ether methacrylates, and poly(ethylene glycol) ethyl ether methacrylates of various molecular weights.
  • Any polar vinyl monomer or a mixture of monomers including a polar vinyl monomer or monomers may be added to the reactive mixture of the component polymers with or separately from, the polymers during the blending process.
  • the addition of a polar vinyl monomer and an initiator to the process is desirable when a poly(ethylene oxide) of molecular weight greater than about 100,000 grams per mol is used as the volume minority component of the inverse phase blend.
  • the polymers and the monomer(s) may be added simultaneously. For example, the polymer, the initiator and the monomer(s) and may be added together into the hopper of the extruder, barrel #1. It is more desirable to add the polymers to the reactive vessel first and to melt the polymers before adding either the initiator or monomer.
  • compositions of the present invention may be by any of several methods.
  • the components, the polyolefin, poly(ethylene oxide), monomer and initiator can be premixed before heating blending to produce an inverse phase composition.
  • the components may be added simultaneously or separately to a reaction vessel for melting and blending.
  • the polyolefin and poly(ethylene oxide) should be melt blended before adding monomer or initiator.
  • the monomer and initiator may be added to the molten polymers separately or combined in a solution comprising the monomer and initiator.
  • compositions comprising two or more dissimilar polymers such as a polyolefin and a water- soluble polymer such a poly(ethylene oxide) to form heterogeneous blends of the dissimilar polymers where the polymer component comprising the volume majority of the blend, greater than 50 volume percent, forms a continuous phase and the polymer component comprising the minority of the blend, less than 50 volume percent, forms the discontinuous or disperse phase of the blend.
  • the discontinuous phase is also referred to as the disperse phase because it is dispersed in the continuous phase formed by the majority component. This is illustrated in Fig. 1. Fig.
  • FIG. 1 is a scanning electron microscopic (SEM) photomicrograph of a back-scattered electron image of a cross-sectional view of a 4 mil (0.004 inch) film of Comparative Example A, a blend of 60 weight percent of ungrafted polyethylene, the darker phase shown in the photomicrograph, and 40 weight percent of an ungrafted poly(ethylene oxide), the lighter phase shown in the photomicrographs. Due to the density difference between polyethylene and poly(ethylene oxide), the volume percentage of polyethylene in the blend of Comparative Example 1 is about 67 percent and the volume percentage of poly(ethylene oxide) is only about 33 percent. In Fig. 1, it is observed that the volume majority component of the blend, the darker polyethylene, forms the continuous phase and the volume minority component of the blend, the lighter poly (ethylene oxide), forms the discontinuous /disperse phase.
  • SEM scanning electron microscopic
  • the volume minority component of the compositions of the present invention forms a continuous phase and the volume majority component forms a discontinuous phase.
  • Figs. 2-8 include scanning electron microscopic photomicrographs of back-scattered electron images of cross-sectional and topographical views by secondary electron images of 4 mil films of Examples 1, 2, 3, 11 and 13.
  • the compositions of the present invention comprise a volume majority of a polyolefin and a volume minority of poly(ethylene oxide) yet exhibit inverse phase morphology.
  • compositions and films of the present invention have a poly(ethylene oxide) as the continuous phase and a polyolefin as the discontinuous phase notwithstanding that there is a significantly greater amount of polyolefin.
  • many of the inverse phase compositions demonstrated herein have a volume ratio of polyolefin to poly(ethylene oxide) of about 2 to 1.
  • the amount of polar vinyl monomer grafted onto the polyolefin and poly(ethylene oxide) can vary and may range from a total of from about 0.1 weight percent to about 30 weight percent, based on the sum of the weight of the polyolefin and the poly (ethylene oxide). Desirably, the polyolefin and poly (ethylene oxide) have a total of from about 1 weight percent to about 20 weight percent of monomer grafted thereto. More desirably, the polyolefin and poly(ethylene oxide) have a total of from about 1 weight percent to about 10 weight percent of monomer grafted thereto. It is believed that the polar groups of the grafted polar vinyl monomer reduce the interfacial tension between the poly(ethylene oxide) phase and the polyolefin phase. The reduction in interfacial tension is believed to stabilize the polyolefin phase and allow the polyolefin to exist as the dispersed phase in the blend with poly (ethylene oxide).
  • compositions of the present invention a polyolefin and a poly(ethylene oxide) are reacted with a monomer in the presence of a free radical initiator.
  • the initiator serves to initiate free radical grafting of the monomer onto the polyolefin and poly (ethylene oxide).
  • One method of grafting the polymer blends includes melt blending the desired volume or weight ratio of a mixture of the polyolefin and a poly(ethylene oxide) and adding a monomer and a free radical initiator in an extruder and at a reaction temperature where the polyolefin and poly(ethylene oxide) are converted to a molten state.
  • a preferred method includes adding the polyolefin, poly(ethylene oxide), monomer and free radical initiator simultaneously to the extruder before the polymer constituents, i.e., the polyolefin and poly(ethylene oxide) have been melted.
  • the melt extruder used for melt blending can introduce various constituents into the blend at different locations along the screw length.
  • a polar vinyl monomer and initiator can be injected into the blend before or after one or more of the polymer constituents is melted or thoroughly mixed.
  • a polyolefin and poly (ethylene oxide) are added at the beginning of the extruder and polar vinyl monomer is added to melted polymers further down the extruder barrel, a free radical initiator is also fed to the melt blend.
  • polar vinyl monomer is added to melted polymers further down the extruder barrel
  • free radical initiator is also fed to the melt blend.
  • the method of making the compositions is achieved by reactive blending, desirably by a reactive extrusion process.
  • the compositions of the present invention may be made by a batch blending process or a continuous process.
  • desired amounts of polyolefin, poly(ethylene oxide), monomer and initiator may be combined in a vessel and heated and mixed to graft monomer onto the polyolefin and poly(ethylene oxide) and form an inverse phase composition.
  • Another method of making the compositions of the present invention includes melt blending desired amounts of polyolefin and poly (ethylene oxide) in an extruder.
  • monomer and initiator may be added to the polyolefin and poly(ethylene oxide) contemporaneously with the polymers as they are fed into the extruder, after the polymers are fed into the extruder and even between the separate feeding of the polymers into the extruder.
  • the inverse phase compositions are pelletized.
  • the extruded pellets have the desired inverse phase morphology and can be processed into various articles, including but not limited to films having inverse phase morphology.
  • compositions of the present invention can be used to manufacture films and other articles that may be flushable, water sensitive, water responsive, water dispersible or water soluble, depending of the needs of the manufacturer.
  • flushability, water sensitivity, water responsiveness, water dispersablity and water solubility of compositions, films and articles can be increased by increasing the ratio of water-soluble component, poly(ethylene oxide).
  • the compositions of the present invention are amenable to melt processing and conventional thermoplastic processing techniques. Films can be made from compositions using casting, blowing, and compression molding processes.
  • a film of an inverse phase blend is extruded and exposed to water. The water washes away and removes most of the water- soluble poly(ethylene oxide) leaving a non-woven web of polyolefin.
  • the non-woven web of polyolefin may be a HEMA-grafted- polyolefin or PEGMA-grafted-polyolefin web.
  • the non-woven web has been observed to be soft, very drapeable and "silk" like in texture.
  • the non-woven fabric is also wettable and has desirable wicking and water spreading properties that are desirable for many personal care applications.
  • the non-woven fabric may be used as a liner material in diapers, feminine pads and pantiliners.
  • a variety of vessels may be used in the practice of this invention.
  • the inverse phase modification of the polymers can be performed in any vessel as long as the necessary mixing of the polymers, monomer and initiator is achieved and enough thermal energy is provided to effect grafting.
  • such vessels include any suitable mixing device, such as Bradender Plasticorders, Haake extruders, single or multiple screw extruders, or any other mechanical mixing devices which can be used to mix, compound, process or fabricate polymers.
  • the reaction device is a counter-rotating twin-screw extruder, such as a Haake extruder available from Haake, 53 West Century Road, Paramus, NJ 07652 or a co-rotating, twin-screw extruder, such as a ZSK-30 twin- screw, compounding extruder manufactured by Werner & Pfleiderer
  • Free radical initiators which can be used to graft the monomer onto the polyolefin include, but are not limited to, acyl peroxides such as benzoyl peroxide; dialkyl; diaryl; or aralkyl peroxides such as di-t-butyl peroxide; dicumyl peroxide; cumyl butyl peroxide; 1,1- di-t-butyl peroxy-3,5,5-trimethylcyclohexane; 2,5-dimethyl-2,5-di(t- butylperoxy) hexane; 2,5-dimethyl-2,5-bis(t-butylperoxy) hexyne-3 and bis(a-t-butyl peroxyisopropylbenzene); peroxyesters such as t- butyl peroxypivalate
  • the amount of free radical initiator added to the polyolefin and poly(ethylene oxide) should be an amount sufficient to graft from about 1 percent to 100 percent of the polar vinyl monomer onto the polyolefin and poly (ethylene oxide).
  • the amount of initiator can vary and should range from about 0.05 weight percent to about 1 weight percent, desirably, from about 0.1 weight percent to about 0.75 weight percent and, more desirably, from about 0.1 weight percent to about 0.5 weight percent.
  • the above weight ranges are based on the weight of initiator added to the total combined weight of polyolefin and poly(ethylene oxide) used to produce the composition.
  • a film when viewed using a scanning electron microscope and using back-scattered electron detector images shows that the poly(ethylene oxide) forms the continuous phase wherein the polyolefin is in a discontinuous phase, that is, dispersed throughout the poly(ethylene oxide) phase.
  • Back- scattered electron detector imaging produces an image wherein the higher average atomic number constituent produces a higher intensity of back-scattered electrons that appear brighter in the photographic image.
  • a constituent having a lower atomic number produces a lower intensity of back-scattered electrons that appear as darker images in the photograph.
  • Back-scattered electron microscope imaging is described in greater detail in Linda C. Sawyer and David T. Grubb, Polymer Microscopy, Chapman & Hall, London,
  • the polyolefin portions of the thermoplastic film have an average cross-sectional diameter ranging from about 0.1 microns to about 50 microns, preferably from about 0.5 microns to about 30 microns and more preferably from about 0.5 microns to about 25 microns.
  • Such "polyolefin portions" can be solidified pockets of polyolefin, fibers or combinations thereof.
  • a 60/40 weight percent resin mixture of low-density polyethylene and poly(ethylene oxide) (hereinafter abbreviated as PEO) was melt blended using an extruder.
  • the low-density polyethylene had a melt index of 1.9 decigrams per minute (dg/min) and a density of 0.917 grams per cubic centimeter (g/cc) (Dow 5031; available from Dow Chemical Company, Midland, MI).
  • the PEO had a molecular weight of 200,000 g/mol (POLYOX® WSRN-80; available from Union Carbide Corp.).
  • the extruder used for making the blend was a Werner & Pfleiderer ZSK-30 extruder (available from Werner & Pfleiderer Corporation, Ramsey, New Jersey).
  • the resin blend was fed to the extruder at a rate of 34 pounds per hour.
  • the extruder had a pair of co-rotating screws arranged in parallel.
  • the center distance between the two shafts was 26.2 mm.
  • the nominal screw diameter was 30 mm.
  • the actual outer screw diameter was 30 mm.
  • the inner screw diameter was 21.3 mm.
  • the thread depth was
  • the extruder had 14 processing barrels, with 13 heated barrels divided into 7 heating zones. The overall processing length was 1340 mm. The seven heating zones were all set at 180 degrees Centigrade (°C). The screw speed was set at 300 rpm. All films of the melt blends in this Comparative Example and
  • Examples 1-9 were made using a Haake counter-rotating twin screw extruder (available from Haake, 53 West Century Road, Paramus, NJ, 07652) equipped with a four inch slit die.
  • the extruder had a length of 300 millimeters.
  • the conical screws had 30 millimeters diameter at the feed port and a diameter of 20 millimeters at the die.
  • the extruder had four heating zones set at 170, 180, 180 and 190°C.
  • the screw speed was 30 rpm.
  • a chilled wind-up roll was used to collect the film.
  • the chilled roll was operated at a speed sufficient to form a film having a thickness of about 4 mils (about 0.004 of an inch) and was maintained at a temperature of 15-20°C.
  • the polyethylene formed the continuous phase and the poly(ethylene oxide) formed the discontinuous phase.
  • Example 1 the PEG-MA feed rate was 1.0 lb/hr and the initiator rate was 0.068 lb/hr.
  • Example 2 the PEG-MA feed rate was 1.9 lb/hr and the initiator rate was 0.068 lb/hr.
  • Example 3 the PEG-MA feed rate was 3.1 lb/hr and the initiator rate was 0.17 lb/hr.
  • the thermoplastic film of the invention exhibited inverse phase morphology.
  • the inverse phase compositions and films of Examples 1-3 comprise a minor amount /volume of poly (ethylene oxide) as the continuous phase and a major/volume amount polyolefin as the disperse phase.
  • Examples 1-3 are believed to comprise a continuous phase of PEGMA-g-PEO and a discontinuous phase of PEGMA-g- LDPE.
  • a 60/40 weight percent resin blend of low density polyethylene (Dow 5031) and poly(ethylene oxide) having a molecular weight of 100,000 g/mol (POLYOX® WSRN-10) was fed to the ZSK-30 extruder at a rate of 35 lb/hr.
  • the seven heating zones were all set at 180°C.
  • the screw speed was 300 rpm.
  • a film of the melt blended resin exhibited an inverse phase morphology having the poly(ethylene oxide) as the continuous phase and the polyethylene as the discontinuous phase.
  • a resin blend having a 60/40 weight ratio of low density polyethylene (Dow 5031) and poly(ethylene oxide) (POLYOX® WSRN-80) was fed to a Haake extruder at 5.0 lb/hr.
  • the Haake extruder was similar to that described above in the Comparative Example except the extruder included a two-hole strand die instead of the four inch slit die.
  • specified amounts of the monomer, PEG-MA, and free radical initiator (Lupersol 101) were added at the feed throat.
  • the extruder had four heating zones set at 170, 180, 180, and 190°C.
  • the screw speed of the extruder was 150 rpm.
  • the strands were cooled in air and pelletized.
  • the blend was 60/40 PE/PEO, the PEG-MA feed rate was 0.50 lb/hr and the initiator rate was 0.025 lb/hr.
  • Example 6 the blend was 65/35 PE/PEO, the PEG-MA feed rate was 0.50 lb/hr and the initiator rate was 0.025 lb/hr.
  • Example 7 the blend was 70/30 PE/PEO, the PEG-MA feed rate was 0.50 lb/hr and the initiator rate was 0.025 lb/hr.
  • Example 8 the blend was 75/25 PE/PEO, the PEG-MA feed rate was 0.50 lb/hr and the initiator rate was 0.025 lb/hr.
  • Example 9 the blend was 80/20 PE/PEO, the PEG-MA feed rate was 0.50 lb/hr and the initiator rate was 0.025 lb/hr.
  • the films and compositions of Examples 5-9 exhibit inverse phase morphology having a polar vinyl monomer grafted poly(ethylene oxide) as the continuous phase and a polar vinyl monomer grafted polyolefin as the discontinuous phase.
  • the amount of monomer grafted onto the poly(ethylene oxide) was determined, by proton NMR spectroscopy in deuterated water, to be 9.52 weight percent based on the amount of poly(ethylene oxide) in the blend.
  • the amount of unreacted monomer was determined, by proton nuclear magnetic resonance (NMR) spectroscopy in deuterated water, to be 2.02 weight percent based on the amount of polyethylene and poly(ethylene oxide) in the blend.
  • the amount of monomer grafted onto the polyethylene was determined to be 0.51 weight percent by Fourier-Transform Infrared (FT-IR) and oxygen content analysis as described in copending U. S. patent application 08/733,410 filed October 18, 1996 the entire disclosure of which is incorporated herein by reference.
  • FT-IR Fourier-Transform Infrared
  • the seven heating zones were all set at 180°C.
  • the screw speed was 300 rpm.
  • a monomer, 2-hydroxyethyl methacrylate abbreviated as HEMA; commercially available from Aldrich Chemical Company of
  • Example 10 the HEMA feed rate was 0.75 lb/hr and the initiator rate was 0.068 lb/hr.
  • Example 11 the HEMA feed rate was 1.5 lb/hr and the initiator rate was 0.068 lb/hr.
  • Example 12 the HEMA feed rate was 3 lb/hr and the initiator rate was 0.068 lb/hr.
  • Example 13 the HEMA feed rate was 4.5 lb/hr and the initiator rate was 0.17 lb/hr.
  • LDPE /PEO exhibited inverse phase morphology having HEMA-g- PEO as the continuous phase and HEMA-g-LDPE as the discontinuous phase.
  • the dry and wet mechanical properties of films from the four 60/40 PE/PEO of Examples 10-13 and Comparative Example A were determined and are presented in Table 1 below.
  • the thickness of the tested films were measure and reported in thousandths of an inch.
  • the elongation-at-break or strain-at-break of the tested films were measured and are reported as a percentage.
  • the peak stress or tensile strength of the tested films was measured and is reported in units of MPa.
  • the energy-to-break or toughness of the tested films was measure and is reported in units of MJ/m 3 .
  • the modulus or rigidity of the tested films was measured and is reported in units of MPa.
  • Films comprising compositions of the present invention are wettable and lose a significant portion of their water-soluble component, poly(ethylene oxide), with exposure to water or aqueous solutions. Consequently, such films lose most of their mechanical properties when exposed to water and possess only a small fraction of their dry mechanical properties.
  • the decrease in mechanical properties of wet films of the present invention, Examples 10-13, versus dry films is illustrated in Table 1 above. Films of the present invention have dry properties comparable to non-inverse phase films of the same polyolefin and poly(ethylene oxide) content but have wet properties significantly less than films of non-inverse phase morphology.
  • Figure 10 shows the wet and dry tensile curves of a film of Example 10. It was determined that the film lost most of its tensile strength after 30 seconds of exposure to water. Other mechanical properties of the films were measured before exposure to water (dry) and after exposure to water (wet). From dry to wet, the percentages in loss of mechanical properties for the film of Example 10 in strain (elongation-at-break), strength (peak stress), toughness (energy-to-break), and rigidity (modulus) are 86 %, 75 %, 97 % and 64 %, respectively.
  • the bar chart of Figure 14 gives illustrates a comparison of the mechanical properties of dry and wet films of Example 10 versus Comparative Example A. Such decreases in mechanical properties after exposure to water are desirable in many flushable applications. Additionally, the film of Example 10 was observed to wettable by water and the surface of the film became slimy when submerged in water.

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Abstract

L'invention concerne des compositions en phase inverse contenant une polyoléfine, telle qu'un polyéthylène et un poly(éthylène oxyde) et des procédés de production de compositions en phase inverse. Les compositions en phase inverse présentent une phase inverse dans laquelle le constituant minoritaire en volume, le poly(éthylène oxyde), forme une phase continue et le constituant majoritaire en volume, la polyoléfine, forme une phase dispersée ou discontinue dans la phase de poly(éthylène oxyde) continue. Les compositions en phase inverse présentent des propriétés avantageuses de dégradation dans l'eau et peuvent être utilisées dans la production d'articles d'hygiène personnelle jetables. Dans au moins un mode de réalisation avantageux, la polyoléfine et le poly(éthylène oxyde) sont greffés à un monomère vinylique polaire dans un processus d'extrusion réactive.
PCT/US1999/013366 1999-06-07 1999-06-15 Melanges en phase inverse de poly(ethylene oxyde) et de polyolefine et procede d'extrusion reactive de production des melanges en phase inverse WO2000075228A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
MXPA01012354A MXPA01012354A (es) 1999-06-07 1999-06-15 Mezclas de fase inversa de poli(oxido de etileno) y poliolefina y metodo de extruccion reactiva para hacer mezclas de fase inversa.
AU46818/99A AU4681899A (en) 1999-06-07 1999-06-15 Inverse phase blends of poly(ethylene oxide) and polyolefin and reactive extrusion method of making inverse phase blends

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US09/327,142 US6214933B1 (en) 1996-12-31 1999-06-07 Inverse phase blends and films of poly(ethylene oxide) and polyolefin
US09/327,142 1999-06-07
US09/330,583 1999-06-11
US09/330,583 US6225406B1 (en) 1996-12-31 1999-06-11 Reactive extrusion method of making inverse phase blends of poly(ethylene oxide) and polyolefin

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WO2016124617A1 (fr) * 2015-02-04 2016-08-11 Borealis Ag Procédé de production d'un polymère d'oléfine modifiée dans une extrudeuse

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US5700872A (en) * 1996-12-31 1997-12-23 Kimberly Clark Worlwide, Inc. Process for making blends of polyolefin and poly(ethylene oxide)
WO1998029502A1 (fr) * 1996-12-31 1998-07-09 Kimberly-Clark Worldwide, Inc. Pellicule en polyolefine modifiable dans l'eau et jetable dans les toilettes
WO1998029508A1 (fr) * 1996-12-31 1998-07-09 Kimberly-Clark Worldwide, Inc. Melanges de polyethylene et de poly(ethylene oxyde) dotes d'une morphologie en phase inversee et procede de realisation desdits melanges
WO1999034050A1 (fr) * 1997-12-31 1999-07-08 Kimberly-Clark Worldwide, Inc. Tissu poreux non tisse produit a partir de materiaux composites polymeres
WO1999034049A1 (fr) * 1997-12-31 1999-07-08 Kimberly-Clark Worldwide, Inc. Procede de fabrication d'un tissu poreux, non tisse a partir de matieres composites polymeres

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Publication number Priority date Publication date Assignee Title
US5700872A (en) * 1996-12-31 1997-12-23 Kimberly Clark Worlwide, Inc. Process for making blends of polyolefin and poly(ethylene oxide)
WO1998029502A1 (fr) * 1996-12-31 1998-07-09 Kimberly-Clark Worldwide, Inc. Pellicule en polyolefine modifiable dans l'eau et jetable dans les toilettes
WO1998029508A1 (fr) * 1996-12-31 1998-07-09 Kimberly-Clark Worldwide, Inc. Melanges de polyethylene et de poly(ethylene oxyde) dotes d'une morphologie en phase inversee et procede de realisation desdits melanges
US5807930A (en) * 1996-12-31 1998-09-15 Kimberly-Clark Worldwide, Inc. Process for making blends of polyolefin and poly(ethylene oxide)
WO1999034050A1 (fr) * 1997-12-31 1999-07-08 Kimberly-Clark Worldwide, Inc. Tissu poreux non tisse produit a partir de materiaux composites polymeres
WO1999034049A1 (fr) * 1997-12-31 1999-07-08 Kimberly-Clark Worldwide, Inc. Procede de fabrication d'un tissu poreux, non tisse a partir de matieres composites polymeres

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Publication number Priority date Publication date Assignee Title
WO2016124617A1 (fr) * 2015-02-04 2016-08-11 Borealis Ag Procédé de production d'un polymère d'oléfine modifiée dans une extrudeuse
JP2018504486A (ja) * 2015-02-04 2018-02-15 ボレアリス エージー 押出し機において修飾オレフィンポリマーを生成するためのプロセス
TWI616463B (zh) * 2015-02-04 2018-03-01 柏列利斯股份公司 於擠壓機中製備經改質烯烴聚合物之方法
US10105908B2 (en) 2015-02-04 2018-10-23 Borealis Ag Process for producing modified olefin polymer in an extruder

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