WO2019094667A1 - Polyolefin elastomer blends for elastomeric films - Google Patents

Polyolefin elastomer blends for elastomeric films Download PDF

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Publication number
WO2019094667A1
WO2019094667A1 PCT/US2018/059938 US2018059938W WO2019094667A1 WO 2019094667 A1 WO2019094667 A1 WO 2019094667A1 US 2018059938 W US2018059938 W US 2018059938W WO 2019094667 A1 WO2019094667 A1 WO 2019094667A1
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Prior art keywords
compound
polyolefin
flow rate
melt flow
polyolefin elastomer
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PCT/US2018/059938
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French (fr)
Inventor
Ketan Shah
Cesar Cruz
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Polyone Corporation
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Publication date
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Priority to CN201880072742.1A priority Critical patent/CN111344347A/en
Priority to US16/762,719 priority patent/US11512191B2/en
Priority to EP18877276.8A priority patent/EP3707207A4/en
Publication of WO2019094667A1 publication Critical patent/WO2019094667A1/en

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    • 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
    • C08L23/04—Homopolymers or copolymers of ethene
    • C08L23/08—Copolymers of ethene
    • C08L23/0807—Copolymers of ethene with unsaturated hydrocarbons only containing more than three carbon atoms
    • C08L23/0815—Copolymers of ethene with aliphatic 1-olefins
    • 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
    • C08L23/14—Copolymers of propene
    • C08L23/142—Copolymers of propene at least partially crystalline copolymers of propene with other olefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/22—Layered products comprising a layer of synthetic resin characterised by the use of special additives using plasticisers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/302—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • 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
    • C08K5/00—Use of organic ingredients
    • C08K5/0008—Organic ingredients according to more than one of the "one dot" groups of C08K5/01 - C08K5/59
    • C08K5/0025—Crosslinking or vulcanising agents; including accelerators
    • 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
    • C08L23/14—Copolymers of propene
    • 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
    • C08L23/16—Elastomeric ethene-propene or ethene-propene-diene copolymers, e.g. EPR and EPDM rubbers
    • 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
    • C08L23/18—Homopolymers or copolymers of hydrocarbons having four or more carbon atoms
    • C08L23/20—Homopolymers or copolymers of hydrocarbons having four or more carbon atoms having four to nine carbon atoms
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L25/00—Compositions of, homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Compositions of derivatives of such polymers
    • C08L25/02—Homopolymers or copolymers of hydrocarbons
    • C08L25/04—Homopolymers or copolymers of styrene
    • C08L25/06—Polystyrene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L25/00—Compositions of, homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Compositions of derivatives of such polymers
    • C08L25/02—Homopolymers or copolymers of hydrocarbons
    • C08L25/04—Homopolymers or copolymers of styrene
    • C08L25/08—Copolymers of styrene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L53/00—Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L53/00—Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
    • C08L53/02—Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers of vinyl-aromatic monomers and conjugated dienes
    • C08L53/025—Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers of vinyl-aromatic monomers and conjugated dienes modified
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2270/00—Resin or rubber layer containing a blend of at least two different polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2274/00—Thermoplastic elastomer material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/536—Hardness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2555/00—Personal care
    • B32B2555/02—Diapers or napkins
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2203/00—Applications
    • C08L2203/02—Applications for biomedical use
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2203/00—Applications
    • C08L2203/16—Applications used for films
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2205/00—Polymer mixtures characterised by other features
    • C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2205/00—Polymer mixtures characterised by other features
    • C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
    • C08L2205/025—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2205/00—Polymer mixtures characterised by other features
    • C08L2205/03—Polymer mixtures characterised by other features containing three or more polymers in a blend
    • C08L2205/035—Polymer mixtures characterised by other features containing three or more polymers in a blend containing four or more polymers in a blend
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2207/00—Properties characterising the ingredient of the composition
    • C08L2207/04—Thermoplastic elastomer

Definitions

  • This invention relates to thermoplastic elastomer compounds including polyolefin elastomer blends. This invention also relates to elastomeric films which are useful for making components of disposable hygiene articles.
  • disposable hygiene articles can include baby care products such as disposable diapers, adult incontinence care products such as disposable undergarments, and feminine care products such as disposable sanitary pads.
  • Disposable hygiene articles typically include one or more components made from elastomeric films.
  • elastomeric films often must meet specific requirements for properties such as good softness, very high elasticity, good tensile strength, low hysteresis, low stress-relaxation, and desirable levels of tension at various levels of extension.
  • elastomeric films typically must be capable of high speed processing to enable efficient manufacturing of disposable hygiene articles.
  • elastomeric films and the materials from which they are made ideally must be very low cost because the hygiene articles are designed to be disposable.
  • elastomeric films formed from materials such as polyisoprene rubber and styrene-isoprene-styrene (SIS) block copolymers.
  • materials such as polyisoprene rubber and styrene-isoprene-styrene (SIS) block copolymers.
  • SIS-based elastomeric films can be susceptible to thermal, oxidative, and/or ultraviolet (UV) degradation, which can limit usefulness of SIS-based elastomeric films during both manufacturing and end- product use.
  • UV ultraviolet
  • SIS-based elastomeric films can have levels of stress-relaxation and hysteresis that are undesirable.
  • thermoplastic elastomer compounds and elastomeric films formed therefrom which are based on elastomers other than styrene-isoprene-styrene (SIS) block copolymers but are compatible with and capable of good high processing using incumbent manufacturing equipment and processes designed or adapted specifically for conventional elastomeric films such SIS-based elastomeric films.
  • SIS styrene-isoprene-styrene
  • thermoplastic elastomer compounds having a Melt Flow Rate (230 °C, 2.16 kg) of no less than about 5 g / 10 min and a Melt Flow Rate (190 °C, 2.16 kg) of no less than about 1 g / 10 min, it is possible to achieve elastomeric films that are capable of good high speed processing on incumbent manufacturing equipment and processes designed or adapted specifically for conventional elastomeric films such as SIS-based elastomeric films.
  • thermoplastic elastomer compounds and elastomeric films formed therefrom possess properties desirable for disposable hygiene articles, such as good softness, very high elasticity, good tensile strength, low hysteresis, low stress-relaxation, and desirable levels of tension at various levels of extension, while also being relatively low cost.
  • the present invention is directed to thermoplastic elastomer compounds that include a polyolefm elastomer blend of at least two different polyolefm elastomers, styrene-ethylene/butylene- styrene block copolymer, and plasticizer.
  • the compounds have a Melt Flow Rate (230 °C, 2.16 kg) of no less than about 5 g / 10 min and a Melt Flow Rate (190 °C, 2.16 kg) of no less than about 1 g / 10 min.
  • the present invention is directed to elastomeric films formed from thermoplastic elastomer compounds as described herein.
  • the present invention is directed to disposable hygiene articles including elastomeric films as described herein.
  • the present invention is directed to thermoplastic elastomer compounds. In other embodiments, the present invention is directed to elastomeric films. In further embodiments, the present invention is directed to disposable hygiene articles. Required and optional features of these and other embodiments of the present invention are described.
  • compound means a composition or mixture resulting from melt mixing, or compounding, a neat polymer and at least one other ingredient including but not limited to one or more additives, or one or more other polymers, or both.
  • the terms “formed from” or “forming” mean, with respect to an article (e.g., a film) and a compound, that the article is molded, extruded, calendered, thermoformed, or otherwise shaped from the compound.
  • the terms “formed from” or “forming” mean, in some embodiments, the article can comprise, consist essentially of, or consist of, the compound.
  • the term "free of a certain component or substance means, in some embodiments, that no amount of that component or substance is intentionally present, and, in other embodiments, that no functionally effective amount of that component or substance is present, and, in further embodiments, that no amount of that component or substance is present.
  • Melt Flow Rate means a melt flow rate according to ASTM D 1238 at specified testing conditions.
  • Melt Flow Rate (190 °C, 2.16 kg) means a Melt Flow Rate at testing conditions of a temperature of 190 °C and a gravimetric weight of 2.16 kg.
  • Melt Flow Rate (230 °C, 2.16 kg) means a Melt Flow Rate at testing conditions of a temperature of 230 °C and a gravimetric weight of 2.16 kg.
  • Thermoplastic elastomer compounds of the present invention include a polyolefin elastomer blend of at least two different polyolefin elastomers, styrene-ethylene/butylene-styrene block copolymer, and plasticizer.
  • the thermoplastic elastomer compounds have a Melt Flow Rate (230 °C, 2.16 kg) of no less than about 5 g / 10 min and a Melt Flow Rate (190 °C, 2.16 kg) of no less than about 1 g / 10 min.
  • the compound has a Melt Flow Rate (230%)
  • the compound has a Melt Flow Rate (230 °C, 2.16 kg) from about 6 to about 15, or from about 7 to about 15, or from about 8 to about 15 g / 10 min.
  • the compound has a Melt Flow Rate (190
  • the compound has a Melt Flow Rate (190 °C, 2.16 kg) from about 1.5 to about 10 g / 10 min. In further embodiments, the compound has a Melt Flow Rate (190 °C, 2.16 kg) from about 2 to about 10 g / 10 min.
  • the compound is free of styrene-isoprene- styrene (SIS) block copolymer given that the thermoplastic elastomer compound of the present invention and elastomeric films formed therefrom can be used instead of SIS-based elastomeric films.
  • SIS styrene-isoprene- styrene
  • Thermoplastic elastomer compounds of the present invention include a polyolefin elastomer blend.
  • the polyolefin elastomer blend includes at least two different types or grades of polyolefin elastomers.
  • the polyolefin elastomer blend includes a first polyolefin elastomer and a second polyolefin elastomer different from the first polyolefin elastomer.
  • the polyolefin elastomer blend includes a first polyolefin elastomer, a second polyolefin elastomer different from the first polyolefin elastomer, and a third polyolefin elastomer different from each of the first polyolefin elastomer and the second polyolefin elastomer.
  • the polyolefin elastomer blend further includes a fourth polyolefin elastomer different from each of the first polyolefin elastomer, the second polyolefin elastomer, and the third polyolefin elastomer.
  • the polyolefin elastomer blend further includes any number of additional polyolefin elastomers each of which are different from each of the other polyolefin elastomers included in the polyolefin elastomer blend, provided that the resulting thermoplastic elastomer compounds have a Melt Flow Rate (230 °C, 2.16 kg) of no less than about 5 g / 10 min and a Melt Flow Rate (190 °C, 2.16 kg) of no less than about 1 g / 10 min..
  • the polyolefin elastomer blend includes no more than four, or, no more than three, or, no more than two, different polyolefin elastomers.
  • thermoplastic elastomer compound in increasingly greater amounts can have the effect of improving high speed processability, but also it can negatively affect desirable end-use properties such good softness, low stress-relaxation, and low hysteresis.
  • SEBS block copolymer and plasticizer in the thermoplastic elastomer compound in increasingly greater amounts can have the effect of improving desirable end-use properties such good softness, low stress-relaxation, and low hysteresis, but also it can negatively affect high speed processability.
  • Polyolefin elastomers suitable for use in the polyolefin elastomer blend of the present invention include conventional or commercially available polyolefin elastomers.
  • Each of the at least two different polyolefin elastomers can be selected such that, when combined as described herein with the at least one other polyolefin elastomer, styrene-ethylene/butylene-styrene block copolymer, and plasticizer, the resulting thermoplastic elastomer compound has a Melt Flow Rate (230 °C, 2.16 kg) of no less than about 5 g / 10 min and a Melt Flow Rate (190 °C, 2.16 kg) of no less than about 1 g / 10 min.
  • suitable polyolefin elastomers can be selected, at least in part, to provide other properties desirable for the end-use application.
  • suitable polyolefin elastomer include propylene-based elastomers, ethylene/a-olefin random copolymers, and combinations thereof.
  • Suitable propylene-based elastomers include those described in International Appl. Pub. No. WO 2005/049670 filed by ExxonMobil Chemical.
  • suitable propylene-based elastomers are comprised of (a) at least about 60 weight percent of propylene- derived units, (b) at least about 6 weight percent of ethylene-derived units, and (c) from about 0.3 to about 10 weight percent of diene-derived units, based on a combined weight of the propylene-derived units, the ethylene-derived units, and the diene-derived units.
  • Non-limiting examples of commercial available propylene- based elastomers include those available under the VISTAMAXX brand from ExxonMobil Chemical, including but not limited to the following grades: 2330; 3000; 3020; 3980; 6102; 6202; and 6502.
  • VISTAMAXX 2330 polypropylene-based elastomers can be further characterized as propylene-based elastomer comprising about 13 weight percent of ethylene-derived units and having a Melt Flow Rate (230 °C, 2.16 kg) of about 290 g / 10 min and a Shore A hardness of about 77 according to ASTM D2240.
  • VISTAMAXX 3000 polypropylene-based elastomers can be further characterized as propylene-based elastomer comprising about 11 weight percent of ethylene-derived units and having a Melt Flow Rate (190 °C, 2.16 kg) of about 3.7 g / 10 min and a Shore D hardness of about 27 according to ASTM D2240.
  • VISTAMAXX 3020 polypropylene-based elastomers can be further characterized as propylene-based elastomer comprising about 11 weight percent of ethylene-derived units and having a Melt Flow Rate (190 °C, 2.16 kg) of about 1.1 g / 10 min and a Shore D hardness of about 34 according to ASTM D2240.
  • VISTAMAXX 3980 polypropylene-based elastomers can be further characterized as propylene-based elastomer comprising about 9 weight percent of ethyl ene-derived units and having a Melt Flow Rate (190 °C, 2.16 kg) of about 3.6 g / 10 min and a Shore D hardness of about 34 according to ASTM D2240.
  • VISTAMAXX 6102 polypropylene-based elastomers can be further characterized as propylene-based elastomers including about 16 weight percent of ethyl ene-derived units and having a Melt Flow Rate (190 °C, 2.16 kg) of about 1.4 g / 10 min and a Shore A hardness of about 66 according to ASTM D2240.
  • VISTAMAXX 6202 polypropylene-based elastomers can be further characterized as propylene-based elastomers including about 15 weight percent of ethyl ene-derived units and having a Melt Flow Rate (190 °C, 2.16 kg) of about 9.1 g / 10 min and a Shore A hardness of about 66 according to ASTM D2240.
  • VISTAMAXX 6502 polypropylene-based elastomers can be further characterized as propylene-based elastomers including about 13 weight percent of ethylene-derived units and having a Melt Flow Rate (190 °C, 2.16 kg) of about 21 g / 10 min and a Shore A hardness of about 71 according to ASTM D2240.
  • Suitable ethyl ene/a-olefin random copolymers include random copolymers formed by polymerizing ethylene with one or more C3-C10 a-olefins such as propylene, 1 -butene, 1-pentene, 1-hexene, 4-methyl-l-pentene, 1- heptene, 1-octene, 1 -nonene, and 1-decene.
  • C3-C10 a-olefins such as propylene, 1 -butene, 1-pentene, 1-hexene, 4-methyl-l-pentene, 1- heptene, 1-octene, 1 -nonene, and 1-decene.
  • suitable ethylene/a-olefin random copolymers include ethylene/propylene copolymers, ethyl ene/butene copolymers, ethyl ene/hexane copolymers, and ethylene/octene copolymers.
  • Non-limiting examples of commercial available ethylene/a- olefin random copolymers include those available under the ENGAGE brand from Dow Chemical; and those available under the EXACT brand from
  • Thermoplastic elastomer compounds of the present invention include styrene-ethylene/butylene-styrene (SEBS) block copolymer.
  • SEBS styrene-ethylene/butylene-styrene
  • SEBS block copolymers suitable for use in the present invention include conventional and commercially available SEBS block copolymers. Suitable SEBS block copolymer can be selected such that, when combined as described herein with the polyolefin elastomer blend and plasticizer, the resulting thermoplastic elastomer compound has a Melt Flow Rate (230 °C, 2.16 kg) of no less than about 5 g / 10 min and a Melt Flow Rate (190 °C, 2.16 kg) of no less than about 1 g / 10 min.
  • suitable SEBS block copolymer is selected from low molecular weight SEBS block copolymer or medium molecular weight SEBS block copolymer, as represented by SEBS block copolymer having a Melt Flow Rate (230 °C, 5 kg) of no greater than about 1 g / 10 min.
  • suitable SEBS block copolymer can have a weight average molecular weight that is, in some embodiments, less than about 500,000, and, in other embodiments, less than about 200,000, and, in further embodiments, less than about 100,000, and, in even further embodiments, less than about 75,000.
  • Non-limiting examples of commercially available SEBS block copolymer include those available under the KRATON brand from Kraton Polymers, such as grades G1641, G1650, G1651, and G1654; those available under the SEPTON brand from Kuraray, such as the 8000 series and including grade 8004; and those available under the GLOBALPRENE brand from LCY Chemical, such a grades 9550 and 9551.
  • Plasticizer [00056] Thermoplastic elastomer compounds of the present invention include plasticizer.
  • Plasticizers suitable for use in the present invention include conventional and commercially available plasticizers. Suitable plasticizers can be selected such that, when combined as described herein with the polyolefin elastomer blend and SEBS block copolymer, the resulting thermoplastic elastomer compound has a Melt Flow Rate (230 °C, 2.16 kg) of no less than about 5 g / 10 min and a Melt Flow Rate (190 °C, 2.16 kg) of no less than about 1 g / 10 min.
  • suitable plasticizers include any conventional oil, such as white mineral oil, vegetable oil, synthetic oil, and the like, which is capable of plasticizing the polyolefin elastomer and/or the SEBS block copolymer.
  • Non-limiting examples of commercially available plasticizer oils include those available under the PURETOL 550 brand from Petro-Canada, and those available under the PRFMOL 382 brand from ExxonMobil.
  • thermoplastic elastomer compounds of the present invention further include one or more optional additives.
  • Suitable optional additives include conventional or commercially available plastics additives. Those skilled in the art of thermoplastics compounding, without undue experimentation, can select suitable additives from available references, for example, E.W. Flick, "Plastics Additives Database,” Plastics Design Library (Elsevier 2004).
  • Optional additives can be used in any amount that is sufficient to obtain a desired processing or performance property for the thermoplastic elastomer compound and/or the elastomeric film formed therefrom. The amount should not be wasteful of the additive nor detrimental to the processing or performance of the thermoplastic elastomer compound and/or the elastomeric film formed therefrom.
  • Non-limiting examples of additives suitable for use in the present invention include one or more selected from antioxidants and stabilizers; bonding agents; colorants such as pigments or dyes; impact modifiers; non-elastomeric thermoplastic polymer; tackifiers; ultraviolet light absorbers; and waxes.
  • non-elastomeric thermoplastic polymer is selected from non-elastomeric polyolefin thermoplastic polymers, non- elastomeric polystyrene-based thermoplastic polymers, and combinations thereof.
  • Non-elastomeric thermoplastic polymer can be included, for example, to adjust processability or other properties in the thermoplastic elastomer compound. Suitable non-elastomeric thermoplastic polymer should be compatible with the polyolefin elastomer blend and the SEBS block copolymer.
  • Suitable non-elastomeric thermoplastic polymers include conventional and commercially available non-elastomeric polyolefin resins, including homopolymers, copolymers, blends of polymers, mixtures of polymers, alloys of polymers, and combinations thereof.
  • Non-limiting examples of non-elastomeric polyolefin polymers include polyethylene (including low-density (LDPE), high-density (HDPE), ultra-high molecular weight (UHDPE), linear-low-density (LLDPE), very-low density (VLDPE), etc.), polypropylene, polybutylene, polyhexalene, and polyoctene.
  • non-elastomeric polyolefin polymers is selected from high density polyethylene (HDPE) and/or polypropylene homopolymer (PP). Such polyolefins are commercially available from a number of sources.
  • Suitable non-elastomeric thermoplastic polymers also include conventional and commercially available non-elastomeric polystyrene resins, including homopolymers, copolymers, blends of polymers, mixtures of polymers, alloys of polymers, and combinations thereof.
  • non-elastomeric polystyrene-based polymers include polystyrene. Such polystyrenes are commercially available from a number of sources.
  • thermoplastic elastomer compound of the present invention is free of non- elastomeric thermoplastic polymer, for example, non-elastomeric polyolefins and non-elastomeric polystyrenes, as an additive ingredient.
  • Table 1 shows ranges of ingredients, in weight percent, which can be acceptable, desirable, and preferable for some embodiments of thermoplastic elastomer (TPE) compounds of the present invention. Weight percent is based on total weight the thermoplastic elastomer compound.
  • Thermoplastic elastomer compounds of the present invention can comprise, consist essentially of, or consist of these ingredients. Any number between the ends of the ranges is also contemplated as an end of a range, such that all possible combinations are contemplated within the possibilities of Table 1 as embodiments of compounds for use in the present invention. Unless expressly stated otherwise herein, any disclosed number is intended to refer to both exactly the disclosed number and "about" the disclosed number, such that either possibility is contemplated within the possibilities of Table 1 as embodiments of compounds for use in the present invention.
  • thermoplastic elastomer compounds of the present invention are uncomplicated once the proper ingredients have been selected.
  • the compound can be made in batch or continuous operations.
  • Mixing in a continuous process typically occurs in an extruder that is elevated to a temperature that is sufficient to melt the polymer matrix with addition of all additives at the feed-throat, or by injection or side-feeders downstream.
  • Extruder speeds can range from about 200 to about 700 revolutions per minute (rpm), and preferably from about 300 rpm to about 500 rpm.
  • the output from the extruder is pelletized for later forming, extrusion, molding, thermoforming, foaming, calendering, and/or other processing into plastic articles.
  • thermoplastic elastomer compounds of the present invention are formed by extrusion processes, including co-extrusion processes, into elastomeric films.
  • Thermoplastic elastomer compounds of the present invention and elastomeric films formed therefrom can be useful for making any elastomeric film component of disposable hygiene articles.
  • Non-limiting examples of disposable hygiene articles include baby care products such as disposable diapers, adult incontinence care products such as disposable undergarments, and feminine care products such as disposable sanitary pads.
  • Non-limiting examples of elastomeric film components of disposable hygiene articles include pull tabs, side tabs, side panels, waistbands, laminate layers, chassis elements, and the like.
  • thermoplastic elastomer compounds of the present invention and elastomeric films formed therefrom which are based on a polyolefin elastomer blend rather than styrene-isoprene-styrene (SIS) block copolymers, it is possible to provide a "drop-in" solution that is capable of good high speed processing using incumbent manufacturing equipment and processes designed or adapted specifically for using SIS-based elastomeric films to make disposable hygiene articles.
  • SIS styrene-isoprene-styrene
  • thermoplastic elastomer compounds of the present invention and elastomeric films made therefrom possess properties, such as good softness, very high elasticity, good tensile strength, low hysteresis, low stress-relaxation, and desirable levels of tension at various levels of extension, which are desirable for various components of disposable hygiene articles.
  • thermoplastic elastomer compounds of the present invention and elastomeric films made therefrom can be at least cost-competitive with conventional elastomeric films such as SIS-based elastomeric films.
  • Some aspects of the present invention are directed to elastomeric films formed from thermoplastic elastomer compounds as described herein.
  • elastomeric films are monolayer films formed from thermoplastic elastomer compounds as described herein. In other embodiments, elastomeric films are incorporated into laminate structures or formed into multilayer films, such as coextruded films, including at least one layer formed from thermoplastic elastomer compounds as described herein and at least one other layer formed from a different material, for example, a polyolefin-based material. [00086] Other aspects of the present invention are directed to disposable hygiene articles including elastomeric films formed from thermoplastic elastomer compounds as described herein.
  • disposable hygiene articles are selected from baby care products such as disposable diapers, adult incontinence care products such as disposable undergarments, and feminine care products such as disposable sanitary pads.
  • thermoplastic elastomer compounds of various embodiments of the present invention are provided.
  • Table 2 below shows sources of ingredients for the thermoplastic elastomer compounds of the Comparative Examples and the Examples.
  • thermoplastic elastomer compound examples were compounded and extruded as pellets on a twin screw extruder at typical mixing and extruding conditions. Subsequently, the extruded pellets were formed into plaques or films and then evaluated for the reported properties. [00091] Table 3 below shows the formulations and certain properties of Comparative Examples A to C.
  • Table 7 below shows the formulations and certain properties of Examples 10 to 14.
  • thermoplastic elastomer compounds and make elastomeric films which are based on polyolefin elastomer blends rather than styrene-isoprene-styrene (SIS) block copolymers but which are compatible with manufacturing equipment and processes designed or adapted specifically for SIS-based elastomeric films, while possessing properties desirable for making disposable hygiene articles and while also being relatively low cost.
  • SIS styrene-isoprene-styrene

Abstract

A thermoplastic elastomer compound includes a polyolefin elastomer blend of at least two different polyolefin elastomers, styrene-ethylene/butylene- styrene block copolymer, and plasticizer. The compound has a Melt Flow Rate (230 °C, 2.16 kg) of no less than about 5 g / 10 min and a Melt Flow Rate (190 °C, 2.16 kg) of no less than about 1 g / 10 min. Elastomeric films formed from the compound can be used in place of elastomeric films based on styrene- isoprene- styrene (SIS) block copolymers to make components of disposable hygiene articles.

Description

POLYOLEFIN ELASTOMER BLENDS
FOR ELASTOMERIC FILMS
CLAIM OF PRIORITY
[0001] This application claims the benefit of U.S. Provisional Patent
Application Serial No. 62/584,705 bearing Attorney Docket Number 12017026 and filed on November 10, 2017, which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates to thermoplastic elastomer compounds including polyolefin elastomer blends. This invention also relates to elastomeric films which are useful for making components of disposable hygiene articles.
BACKGROUND OF THE INVENTION
[0003] Demand exists for disposable hygiene articles and related personal care products. Generally, disposable hygiene articles can include baby care products such as disposable diapers, adult incontinence care products such as disposable undergarments, and feminine care products such as disposable sanitary pads.
[0004] Disposable hygiene articles typically include one or more components made from elastomeric films. To be useful as a component of disposable hygiene articles, elastomeric films often must meet specific requirements for properties such as good softness, very high elasticity, good tensile strength, low hysteresis, low stress-relaxation, and desirable levels of tension at various levels of extension. Further, elastomeric films typically must be capable of high speed processing to enable efficient manufacturing of disposable hygiene articles. Lastly, elastomeric films and the materials from which they are made ideally must be very low cost because the hygiene articles are designed to be disposable. [0005] Conventionally, disposable hygiene articles are made using elastomeric films formed from materials such as polyisoprene rubber and styrene-isoprene-styrene (SIS) block copolymers. However, these materials have drawbacks. For example, SIS-based elastomeric films can be susceptible to thermal, oxidative, and/or ultraviolet (UV) degradation, which can limit usefulness of SIS-based elastomeric films during both manufacturing and end- product use. Additionally, in some instances, SIS-based elastomeric films can have levels of stress-relaxation and hysteresis that are undesirable.
[0006] Notwithstanding the drawbacks of conventional elastomeric films such as SIS-based elastomeric films, there are barriers to adoption of elastomeric films formed from materials other than SIS for use in making disposable hygiene articles. For example, changes to a material for purposes of improving performance properties of the elastomeric film formed from the material can negatively affect the high speed processability of the elastomeric film. Likewise, changes to a material for purposes of improving high speed processability of the elastomeric film formed from the material can negatively affect the performance properties of the elastomeric film.
[0007] Moreover, commercial manufacturing of disposable hygiene articles and their elastomeric film components can involve relatively costly equipment and relatively complex processes. In many instances, at least some manufacturing equipment or processes are designed or adapted specifically for use of conventional elastomeric films such as SIS-based elastomeric films. Disadvantageously, use of materials other than SIS could require prohibitively costly changes to the incumbent manufacturing equipment or the processes.
SUMMARY OF THE INVENTION
[0008] Consequently, a need exists for thermoplastic elastomer compounds and elastomeric films formed therefrom which are based on elastomers other than styrene-isoprene-styrene (SIS) block copolymers but are compatible with and capable of good high processing using incumbent manufacturing equipment and processes designed or adapted specifically for conventional elastomeric films such SIS-based elastomeric films. Moreover, a need exists for such thermoplastic elastomer compounds and elastomeric films formed therefrom which are not only capable of good high speed processing, but which also possess properties desirable for disposable hygiene articles and are relatively low cost.
[0009] The aforementioned needs are met by one or more aspects of the present invention.
[00010] It has been found that, by combining a blend of at least two different polyolefm elastomers with styrene-ethylene/butylene-styrene block copolymer and plasticizer to provide thermoplastic elastomer compounds having a Melt Flow Rate (230 °C, 2.16 kg) of no less than about 5 g / 10 min and a Melt Flow Rate (190 °C, 2.16 kg) of no less than about 1 g / 10 min, it is possible to achieve elastomeric films that are capable of good high speed processing on incumbent manufacturing equipment and processes designed or adapted specifically for conventional elastomeric films such as SIS-based elastomeric films. Advantageously, in addition to being capable of such good high speed processing, such thermoplastic elastomer compounds and elastomeric films formed therefrom possess properties desirable for disposable hygiene articles, such as good softness, very high elasticity, good tensile strength, low hysteresis, low stress-relaxation, and desirable levels of tension at various levels of extension, while also being relatively low cost.
[00011] In some aspects, the present invention is directed to thermoplastic elastomer compounds that include a polyolefm elastomer blend of at least two different polyolefm elastomers, styrene-ethylene/butylene- styrene block copolymer, and plasticizer. The compounds have a Melt Flow Rate (230 °C, 2.16 kg) of no less than about 5 g / 10 min and a Melt Flow Rate (190 °C, 2.16 kg) of no less than about 1 g / 10 min.
[00012] In other aspects, the present invention is directed to elastomeric films formed from thermoplastic elastomer compounds as described herein. [00013] In further aspects, the present invention is directed to disposable hygiene articles including elastomeric films as described herein.
[00014] Features of the invention will become apparent with reference to the following embodiments. There exist various refinements of the features noted in relation to the above-mentioned aspects of the present invention. Additional features may also be incorporated in the above-mentioned aspects of the present invention. These refinements and additional features may exist individually or in any combination. For instance, various features discussed below in relation to any of the described aspects of the present invention may be incorporated into any of the described aspects of the present invention alone or in any combination.
EMBODFMENTS OF THE INVENTION
[00015] In some embodiments, the present invention is directed to thermoplastic elastomer compounds. In other embodiments, the present invention is directed to elastomeric films. In further embodiments, the present invention is directed to disposable hygiene articles. Required and optional features of these and other embodiments of the present invention are described.
[00016] As used herein, the term "compound" means a composition or mixture resulting from melt mixing, or compounding, a neat polymer and at least one other ingredient including but not limited to one or more additives, or one or more other polymers, or both.
[00017] As used herein, the terms "formed from" or "forming" mean, with respect to an article (e.g., a film) and a compound, that the article is molded, extruded, calendered, thermoformed, or otherwise shaped from the compound. As such, the terms "formed from" or "forming" mean, in some embodiments, the article can comprise, consist essentially of, or consist of, the compound.
[00018] As used herein, the term "free of a certain component or substance means, in some embodiments, that no amount of that component or substance is intentionally present, and, in other embodiments, that no functionally effective amount of that component or substance is present, and, in further embodiments, that no amount of that component or substance is present.
[00019] As used herein, the term "Melt Flow Rate" means a melt flow rate according to ASTM D 1238 at specified testing conditions.
[00020] As used herein, the term "Melt Flow Rate (190 °C, 2.16 kg)" means a Melt Flow Rate at testing conditions of a temperature of 190 °C and a gravimetric weight of 2.16 kg.
[00021] As used herein, the term "Melt Flow Rate (230 °C, 2.16 kg)" means a Melt Flow Rate at testing conditions of a temperature of 230 °C and a gravimetric weight of 2.16 kg.
[00022] Thermoplastic Elastomer Compound
[00023] Thermoplastic elastomer compounds of the present invention include a polyolefin elastomer blend of at least two different polyolefin elastomers, styrene-ethylene/butylene-styrene block copolymer, and plasticizer.
[00024] According to the present invention, the thermoplastic elastomer compounds have a Melt Flow Rate (230 °C, 2.16 kg) of no less than about 5 g / 10 min and a Melt Flow Rate (190 °C, 2.16 kg) of no less than about 1 g / 10 min.
[00025] In some embodiments, the compound has a Melt Flow Rate (230
°C, 2.16 kg) of no less than about 6 g / 10 min. In other embodiments, the compound has a Melt Flow Rate (230 °C, 2.16 kg) from about 6 to about 15, or from about 7 to about 15, or from about 8 to about 15 g / 10 min.
[00026] In some embodiments, the compound has a Melt Flow Rate (190
°C, 2.16 kg) of no less than about 1.5 g / 10 min. In other embodiments, the compound has a Melt Flow Rate (190 °C, 2.16 kg) from about 1.5 to about 10 g / 10 min. In further embodiments, the compound has a Melt Flow Rate (190 °C, 2.16 kg) from about 2 to about 10 g / 10 min.
[00027] While not intending to be bound by theory, it is believed that compounds having both a Melt Flow Rate (230 °C, 2.16 kg) of no less than about 5 g / 10 min and a Melt Flow Rate (190 °C, 2.16 kg) of no less than about 1 g / 10 min generally can be expected to be capable of good high speed processing on incumbent manufacturing equipment and processes designed or adapted specifically for conventional elastomeric films such as SIS-based elastomeric films for use in making disposable hygiene articles.
[00028] In some embodiments, the compound is free of styrene-isoprene- styrene (SIS) block copolymer given that the thermoplastic elastomer compound of the present invention and elastomeric films formed therefrom can be used instead of SIS-based elastomeric films.
[00029] Polyolefin Elastomer Blend
[00030] Thermoplastic elastomer compounds of the present invention include a polyolefin elastomer blend.
[00031] According to the present invention, the polyolefin elastomer blend includes at least two different types or grades of polyolefin elastomers.
[00032] For example, in some embodiments, the polyolefin elastomer blend includes a first polyolefin elastomer and a second polyolefin elastomer different from the first polyolefin elastomer. In other embodiments, the polyolefin elastomer blend includes a first polyolefin elastomer, a second polyolefin elastomer different from the first polyolefin elastomer, and a third polyolefin elastomer different from each of the first polyolefin elastomer and the second polyolefin elastomer. In further embodiments, the polyolefin elastomer blend further includes a fourth polyolefin elastomer different from each of the first polyolefin elastomer, the second polyolefin elastomer, and the third polyolefin elastomer. Likewise, in even further embodiments, the polyolefin elastomer blend further includes any number of additional polyolefin elastomers each of which are different from each of the other polyolefin elastomers included in the polyolefin elastomer blend, provided that the resulting thermoplastic elastomer compounds have a Melt Flow Rate (230 °C, 2.16 kg) of no less than about 5 g / 10 min and a Melt Flow Rate (190 °C, 2.16 kg) of no less than about 1 g / 10 min.. However, in some embodiments, the polyolefin elastomer blend includes no more than four, or, no more than three, or, no more than two, different polyolefin elastomers.
[00033] While not intending to be limited by theory, it is generally believed that including polyolefin elastomer in the thermoplastic elastomer compound in increasingly greater amounts can have the effect of improving high speed processability, but also it can negatively affect desirable end-use properties such good softness, low stress-relaxation, and low hysteresis. Conversely, it is generally believed that including SEBS block copolymer and plasticizer in the thermoplastic elastomer compound in increasingly greater amounts can have the effect of improving desirable end-use properties such good softness, low stress-relaxation, and low hysteresis, but also it can negatively affect high speed processability. It is further generally believed that by using a blend of at least two different types or grades of polyolefin elastomers, as opposed to using only one type or grade of polyolefin elastomer, it is possible to achieve good high speed processing at a relatively lower total amount of polyolefin elastomer(s) included in the compound, which, in turn, can minimize any negative effect on desirable end-use properties such good softness, low stress-relaxation, and low hysteresis.
[00034] Polyolefin elastomers suitable for use in the polyolefin elastomer blend of the present invention include conventional or commercially available polyolefin elastomers. Each of the at least two different polyolefin elastomers can be selected such that, when combined as described herein with the at least one other polyolefin elastomer, styrene-ethylene/butylene-styrene block copolymer, and plasticizer, the resulting thermoplastic elastomer compound has a Melt Flow Rate (230 °C, 2.16 kg) of no less than about 5 g / 10 min and a Melt Flow Rate (190 °C, 2.16 kg) of no less than about 1 g / 10 min. Additionally, suitable polyolefin elastomers can be selected, at least in part, to provide other properties desirable for the end-use application. [00035] Non-limiting examples of suitable polyolefin elastomer include propylene-based elastomers, ethylene/a-olefin random copolymers, and combinations thereof.
[00036] Suitable propylene-based elastomers include those described in International Appl. Pub. No. WO 2005/049670 filed by ExxonMobil Chemical.
[00037] For example, in some embodiments, suitable propylene-based elastomers are comprised of (a) at least about 60 weight percent of propylene- derived units, (b) at least about 6 weight percent of ethylene-derived units, and (c) from about 0.3 to about 10 weight percent of diene-derived units, based on a combined weight of the propylene-derived units, the ethylene-derived units, and the diene-derived units.
[00038] Non-limiting examples of commercial available propylene- based elastomers include those available under the VISTAMAXX brand from ExxonMobil Chemical, including but not limited to the following grades: 2330; 3000; 3020; 3980; 6102; 6202; and 6502.
[00039] VISTAMAXX 2330 polypropylene-based elastomers can be further characterized as propylene-based elastomer comprising about 13 weight percent of ethylene-derived units and having a Melt Flow Rate (230 °C, 2.16 kg) of about 290 g / 10 min and a Shore A hardness of about 77 according to ASTM D2240.
[00040] VISTAMAXX 3000 polypropylene-based elastomers can be further characterized as propylene-based elastomer comprising about 11 weight percent of ethylene-derived units and having a Melt Flow Rate (190 °C, 2.16 kg) of about 3.7 g / 10 min and a Shore D hardness of about 27 according to ASTM D2240.
[00041] VISTAMAXX 3020 polypropylene-based elastomers can be further characterized as propylene-based elastomer comprising about 11 weight percent of ethylene-derived units and having a Melt Flow Rate (190 °C, 2.16 kg) of about 1.1 g / 10 min and a Shore D hardness of about 34 according to ASTM D2240. [00042] VISTAMAXX 3980 polypropylene-based elastomers can be further characterized as propylene-based elastomer comprising about 9 weight percent of ethyl ene-derived units and having a Melt Flow Rate (190 °C, 2.16 kg) of about 3.6 g / 10 min and a Shore D hardness of about 34 according to ASTM D2240.
[00043] VISTAMAXX 6102 polypropylene-based elastomers can be further characterized as propylene-based elastomers including about 16 weight percent of ethyl ene-derived units and having a Melt Flow Rate (190 °C, 2.16 kg) of about 1.4 g / 10 min and a Shore A hardness of about 66 according to ASTM D2240.
[00044] VISTAMAXX 6202 polypropylene-based elastomers can be further characterized as propylene-based elastomers including about 15 weight percent of ethyl ene-derived units and having a Melt Flow Rate (190 °C, 2.16 kg) of about 9.1 g / 10 min and a Shore A hardness of about 66 according to ASTM D2240.
[00045] VISTAMAXX 6502 polypropylene-based elastomers can be further characterized as propylene-based elastomers including about 13 weight percent of ethylene-derived units and having a Melt Flow Rate (190 °C, 2.16 kg) of about 21 g / 10 min and a Shore A hardness of about 71 according to ASTM D2240.
[00046] Suitable ethyl ene/a-olefin random copolymers include random copolymers formed by polymerizing ethylene with one or more C3-C10 a-olefins such as propylene, 1 -butene, 1-pentene, 1-hexene, 4-methyl-l-pentene, 1- heptene, 1-octene, 1 -nonene, and 1-decene.
[00047] For example, in some embodiments, suitable ethylene/a-olefin random copolymers include ethylene/propylene copolymers, ethyl ene/butene copolymers, ethyl ene/hexane copolymers, and ethylene/octene copolymers.
[00048] Non-limiting examples of commercial available ethylene/a- olefin random copolymers include those available under the ENGAGE brand from Dow Chemical; and those available under the EXACT brand from
ExxonMobil Chemical.
[00049] SEBS Block Copolymer
[00050] Thermoplastic elastomer compounds of the present invention include styrene-ethylene/butylene-styrene (SEBS) block copolymer.
[00051] SEBS block copolymers suitable for use in the present invention include conventional and commercially available SEBS block copolymers. Suitable SEBS block copolymer can be selected such that, when combined as described herein with the polyolefin elastomer blend and plasticizer, the resulting thermoplastic elastomer compound has a Melt Flow Rate (230 °C, 2.16 kg) of no less than about 5 g / 10 min and a Melt Flow Rate (190 °C, 2.16 kg) of no less than about 1 g / 10 min.
[00052] In some embodiments, suitable SEBS block copolymer is selected from low molecular weight SEBS block copolymer or medium molecular weight SEBS block copolymer, as represented by SEBS block copolymer having a Melt Flow Rate (230 °C, 5 kg) of no greater than about 1 g / 10 min.
[00053] For example, suitable SEBS block copolymer can have a weight average molecular weight that is, in some embodiments, less than about 500,000, and, in other embodiments, less than about 200,000, and, in further embodiments, less than about 100,000, and, in even further embodiments, less than about 75,000.
[00054] Non-limiting examples of commercially available SEBS block copolymer include those available under the KRATON brand from Kraton Polymers, such as grades G1641, G1650, G1651, and G1654; those available under the SEPTON brand from Kuraray, such as the 8000 series and including grade 8004; and those available under the GLOBALPRENE brand from LCY Chemical, such a grades 9550 and 9551.
[00055] Plasticizer [00056] Thermoplastic elastomer compounds of the present invention include plasticizer.
[00057] Plasticizers suitable for use in the present invention include conventional and commercially available plasticizers. Suitable plasticizers can be selected such that, when combined as described herein with the polyolefin elastomer blend and SEBS block copolymer, the resulting thermoplastic elastomer compound has a Melt Flow Rate (230 °C, 2.16 kg) of no less than about 5 g / 10 min and a Melt Flow Rate (190 °C, 2.16 kg) of no less than about 1 g / 10 min.
[00058] In some embodiments, suitable plasticizers include any conventional oil, such as white mineral oil, vegetable oil, synthetic oil, and the like, which is capable of plasticizing the polyolefin elastomer and/or the SEBS block copolymer.
[00059] Non-limiting examples of commercially available plasticizer oils include those available under the PURETOL 550 brand from Petro-Canada, and those available under the PRFMOL 382 brand from ExxonMobil.
[00060] Optional Additives
[00061] In some embodiments, thermoplastic elastomer compounds of the present invention further include one or more optional additives.
[00062] Suitable optional additives include conventional or commercially available plastics additives. Those skilled in the art of thermoplastics compounding, without undue experimentation, can select suitable additives from available references, for example, E.W. Flick, "Plastics Additives Database," Plastics Design Library (Elsevier 2004).
[00063] Optional additives can be used in any amount that is sufficient to obtain a desired processing or performance property for the thermoplastic elastomer compound and/or the elastomeric film formed therefrom. The amount should not be wasteful of the additive nor detrimental to the processing or performance of the thermoplastic elastomer compound and/or the elastomeric film formed therefrom. [00064] Non-limiting examples of additives suitable for use in the present invention include one or more selected from antioxidants and stabilizers; bonding agents; colorants such as pigments or dyes; impact modifiers; non-elastomeric thermoplastic polymer; tackifiers; ultraviolet light absorbers; and waxes.
[00065] In some embodiments, non-elastomeric thermoplastic polymer is selected from non-elastomeric polyolefin thermoplastic polymers, non- elastomeric polystyrene-based thermoplastic polymers, and combinations thereof.
[00066] Non-elastomeric thermoplastic polymer can be included, for example, to adjust processability or other properties in the thermoplastic elastomer compound. Suitable non-elastomeric thermoplastic polymer should be compatible with the polyolefin elastomer blend and the SEBS block copolymer.
[00067] Suitable non-elastomeric thermoplastic polymers include conventional and commercially available non-elastomeric polyolefin resins, including homopolymers, copolymers, blends of polymers, mixtures of polymers, alloys of polymers, and combinations thereof. Non-limiting examples of non-elastomeric polyolefin polymers include polyethylene (including low-density (LDPE), high-density (HDPE), ultra-high molecular weight (UHDPE), linear-low-density (LLDPE), very-low density (VLDPE), etc.), polypropylene, polybutylene, polyhexalene, and polyoctene. In some embodiments, non-elastomeric polyolefin polymers is selected from high density polyethylene (HDPE) and/or polypropylene homopolymer (PP). Such polyolefins are commercially available from a number of sources.
[00068] Suitable non-elastomeric thermoplastic polymers also include conventional and commercially available non-elastomeric polystyrene resins, including homopolymers, copolymers, blends of polymers, mixtures of polymers, alloys of polymers, and combinations thereof. Non-limiting examples of non-elastomeric polystyrene-based polymers include polystyrene. Such polystyrenes are commercially available from a number of sources.
[00069] Notwithstanding the above, in some embodiments, the thermoplastic elastomer compound of the present invention is free of non- elastomeric thermoplastic polymer, for example, non-elastomeric polyolefins and non-elastomeric polystyrenes, as an additive ingredient.
[00070] Ranges of Ingredients in the TPE Compounds
[00071] Table 1 below shows ranges of ingredients, in weight percent, which can be acceptable, desirable, and preferable for some embodiments of thermoplastic elastomer (TPE) compounds of the present invention. Weight percent is based on total weight the thermoplastic elastomer compound.
[00072] Thermoplastic elastomer compounds of the present invention, in some embodiments, can comprise, consist essentially of, or consist of these ingredients. Any number between the ends of the ranges is also contemplated as an end of a range, such that all possible combinations are contemplated within the possibilities of Table 1 as embodiments of compounds for use in the present invention. Unless expressly stated otherwise herein, any disclosed number is intended to refer to both exactly the disclosed number and "about" the disclosed number, such that either possibility is contemplated within the possibilities of Table 1 as embodiments of compounds for use in the present invention.
Figure imgf000014_0001
[00073] Processing
[00074] The preparation of thermoplastic elastomer compounds of the present invention is uncomplicated once the proper ingredients have been selected. The compound can be made in batch or continuous operations.
[00075] Mixing in a continuous process typically occurs in an extruder that is elevated to a temperature that is sufficient to melt the polymer matrix with addition of all additives at the feed-throat, or by injection or side-feeders downstream. Extruder speeds can range from about 200 to about 700 revolutions per minute (rpm), and preferably from about 300 rpm to about 500 rpm. Typically, the output from the extruder is pelletized for later forming, extrusion, molding, thermoforming, foaming, calendering, and/or other processing into plastic articles.
[00076] Subsequent forming such as extrusion, molding, thermoforming, calendering, and/or other processing techniques are well known to those skilled in the art of thermoplastics polymer engineering. Without undue experimentation but with reference to publications such as "Extrusion, The Definitive Processing Guide and Handbook", "Handbook of Molded Part Shrinkage and Warpage", "Specialized Molding Techniques", "Rotational Molding Technology", and "Handbook of Mold, Tool and Die Repair Welding", all part of the Plastics Design Library series published by Elsevier, one can make articles of any conceivable shape and appearance using compounds of the present invention.
[00077] In some embodiments, thermoplastic elastomer compounds of the present invention are formed by extrusion processes, including co-extrusion processes, into elastomeric films.
USEFULNESS OF THE INVENTION
[00078] Thermoplastic elastomer compounds of the present invention and elastomeric films formed therefrom can be useful for making any elastomeric film component of disposable hygiene articles.
[00079] Non-limiting examples of disposable hygiene articles include baby care products such as disposable diapers, adult incontinence care products such as disposable undergarments, and feminine care products such as disposable sanitary pads.
[00080] Non-limiting examples of elastomeric film components of disposable hygiene articles include pull tabs, side tabs, side panels, waistbands, laminate layers, chassis elements, and the like.
[00081] Using thermoplastic elastomer compounds of the present invention and elastomeric films formed therefrom, which are based on a polyolefin elastomer blend rather than styrene-isoprene-styrene (SIS) block copolymers, it is possible to provide a "drop-in" solution that is capable of good high speed processing using incumbent manufacturing equipment and processes designed or adapted specifically for using SIS-based elastomeric films to make disposable hygiene articles.
[00082] Furthermore, thermoplastic elastomer compounds of the present invention and elastomeric films made therefrom possess properties, such as good softness, very high elasticity, good tensile strength, low hysteresis, low stress-relaxation, and desirable levels of tension at various levels of extension, which are desirable for various components of disposable hygiene articles.
[00083] Additionally, thermoplastic elastomer compounds of the present invention and elastomeric films made therefrom can be at least cost-competitive with conventional elastomeric films such as SIS-based elastomeric films.
[00084] Some aspects of the present invention are directed to elastomeric films formed from thermoplastic elastomer compounds as described herein.
[00085] In some embodiments, elastomeric films are monolayer films formed from thermoplastic elastomer compounds as described herein. In other embodiments, elastomeric films are incorporated into laminate structures or formed into multilayer films, such as coextruded films, including at least one layer formed from thermoplastic elastomer compounds as described herein and at least one other layer formed from a different material, for example, a polyolefin-based material. [00086] Other aspects of the present invention are directed to disposable hygiene articles including elastomeric films formed from thermoplastic elastomer compounds as described herein.
[00087] In some embodiments, disposable hygiene articles are selected from baby care products such as disposable diapers, adult incontinence care products such as disposable undergarments, and feminine care products such as disposable sanitary pads.
EXAMPLES
[00088] Non-limiting examples of thermoplastic elastomer compounds of various embodiments of the present invention are provided.
[00089] Table 2 below shows sources of ingredients for the thermoplastic elastomer compounds of the Comparative Examples and the Examples.
Figure imgf000018_0001
[00090] Examples of the thermoplastic elastomer compound were compounded and extruded as pellets on a twin screw extruder at typical mixing and extruding conditions. Subsequently, the extruded pellets were formed into plaques or films and then evaluated for the reported properties. [00091] Table 3 below shows the formulations and certain properties of Comparative Examples A to C.
Figure imgf000019_0001
[00092] Table 4 below shows the formulations and certain properties of Comparative Examples D to G.
Figure imgf000020_0001
Figure imgf000021_0001
Table 5 below shows the formulations and certain properties of 3.
Figure imgf000022_0001
Table 6 below shows the formulations and certain properties of 9.
Figure imgf000023_0001
Figure imgf000024_0001
[00095] Table 7 below shows the formulations and certain properties of Examples 10 to 14.
Figure imgf000025_0001
Figure imgf000026_0001
[00096] Without undue experimentation, those having ordinary skill in the art can utilize the written description of the present invention, including the Examples, to formulate thermoplastic elastomer compounds and make elastomeric films which are based on polyolefin elastomer blends rather than styrene-isoprene-styrene (SIS) block copolymers but which are compatible with manufacturing equipment and processes designed or adapted specifically for SIS-based elastomeric films, while possessing properties desirable for making disposable hygiene articles and while also being relatively low cost.
[00097] All documents cited in the Embodiments of the Invention are incorporated herein by reference in their entirety unless otherwise specified. The citation of any document is not to be construed as an admission that it is prior art with respect to the present invention.
[00098] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of the present invention.

Claims

WHAT IS CLAIMED IS:
1. A thermoplastic elastomer compound comprising:
(a) a polyolefin elastomer blend comprising:
(i) a first polyolefin elastomer; and
(ii) a second polyolefin elastomer different from the first polyolefin elastomer;
(b) styrene-ethylene/butylene-styrene block copolymer; and
(c) plasticizer;
wherein the compound has a Melt Flow Rate (230 °C, 2.16 kg) of no less than about 5 g / 10 min and a Melt Flow Rate (190 °C, 2.16 kg) of no less than about 1 g / 10 min.
2. The compound of Claim 1 , wherein the compound has a Melt Flow Rate (230 °C, 2.16 kg) of no less than about 6 g / 10 min.
3. The compound of Claim 1 or Claim 2, wherein the compound has a Melt Flow Rate (190 °C, 2.16 kg) of no less than about 1.5 g / 10 min.
4. The compound of any one of Claims 1 to 3, wherein the compound has a Melt Flow Rate (230 °C, 2.16 kg) from about 6 to about 15 g / 10 min.
5. The compound of any one of Claims 1 to 4, wherein the compound has a Melt Flow Rate (190 °C, 2.16 kg) from about 1.5 to about 10 g / 10 min.
6. The compound of any one of Claims 1 to 5, wherein the polyolefin elastomer blend further comprises a third polyolefin elastomer different from each of the first polyolefin elastomer and the second polyolefin elastomer.
7. The compound of Claim 6, wherein the polyolefin elastomer blend further comprises a fourth polyolefin elastomer different from each of the first polyolefin elastomer, the second polyolefin elastomer, and the third polyolefin polymer.
8. The compound of any one of Claims 1 to 7, wherein one or more of the polyolefin elastomers of the polyolefin elastomer blend is selected from the group consisting of propylene-based elastomer, ethyl ene/a-olefin random copolymer, and combinations thereof.
9. The compound of any one of Claims 1 to 8, wherein one or more of the polyolefin elastomers of the polyolefin elastomer blend is selected from propylene-based elastomer comprising (a) at least about 60 weight percent of propylene-derived units, (b) at least about 6 weight percent of ethyl ene-derived units, and (c) from about 0.3 to about 10 weight percent of diene-derived units, based on a combined weight of the propylene-derived units, the ethylene- derived units, and the diene-derived units.
10. The compound of any one of Claims 1 to 9, wherein one or more of the polyolefin elastomers of the polyolefin elastomer blend is selected from the group consisting of:
(a) propylene-based elastomer comprising about 13 weight percent of ethylene-derived units and having a Melt Flow Rate (190 °C, 2.16 kg) of about 21 g / 10 min and a Shore A hardness of about 71 according to ASTM D2240;
(b) propylene-based elastomer comprising about 15 weight percent of ethylene-derived units and having a Melt Flow Rate (190 °C, 2.16 kg) of about 9.1 g / 10 min and a Shore A hardness of about 66 according to ASTM D2240; (c) propyl ene-based elastomer comprising about 16 weight percent of ethylene-derived units and having a Melt Flow Rate (190 °C, 2.16 kg) of about 1.4 g / 10 min and a Shore A hardness of about 66 according to ASTM D2240; and
(d) propylene-based elastomer comprising about 11 weight percent of ethylene-derived units and having a Melt Flow Rate (190 °C, 2.16 kg) of about 1.1 g / 10 min and a Shore D hardness of about 34 according to ASTM D2240.
11. The compound of any one of Claims 1 to 10, wherein the compound further comprises one or more additives selected from the group consisting of antioxidants and stabilizers; bonding agents; colorants; impact modifiers; non- elastomeric thermoplastic polymers; tackifiers; ultraviolet light absorbers; waxes; and combinations thereof.
12. The compound of Claim 11, wherein the non-elastomeric thermoplastic polymer is selected from non-elastomeric polyolefin polymers, non-elastomeric polystyrene polymers, and combinations thereof.
13. The compound of any one of Claims 1 to 12, wherein the compound comprises:
(a) from about 20 to about 85 weight percent, by weight of the compound, of the polyolefin elastomer blend;
(b) from about 10 to about 50 weight percent, by weight of the compound, of the styrene-ethylene/butylene-styrene block copolymer;
(c) from about 5 to about 40 weight percent, by weight of the compound, of the plasticizer; and
(d) from 0 to about 12 weight percent, by weight of the compound, of one or more additives selected from the group consisting of antioxidants and stabilizers, bonding agents, colorants, impact modifiers, non-elastomeric thermoplastic polymers, tackifiers, ultraviolet light absorbers, waxes, and combinations thereof.
14. The compound of any one of Claims 1 to 13, wherein the compound is free of styrene-isoprene-styrene block copolymer.
15. An elastomeric film formed from the compound of any one of Claims 1 to 14.
16. A multilayer film or laminate structure comprising at least one layer formed the compound of any one of Claims 1 to 14.
17. A disposable hygiene article comprising at least one component comprising an elastomeric film formed from the compound of any one of Claims 1 to 14.
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