Polyolefin elastomer blends for elastomeric films

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.

Claims

1. An elastomeric film, the elastomeric film formed from 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 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.

2. The elastomeric film of claim 1, wherein the thermoplastic elastomer compound has a Melt Flow Rate (230° C., 2.16 kg) of no less than about 6 g/10 min.

3. The elastomeric film of claim 1, wherein the thermoplastic elastomer compound has a Melt Flow Rate (190° C., 2.16 kg) of no less than about 1.5 g/10 min.

4. The elastomeric film of claim 1, wherein the thermoplastic elastomer compound has a Melt Flow Rate (230° C., 2.16 kg) from about 6 to about 15 g/10 min.

5. The elastomeric film of claim 1, wherein the thermoplastic elastomer compound has a Melt Flow Rate (190° C., 2.16 kg) from about 1.5 to about 10 g/10 min.

6. The elastomeric film of claim 1, 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 elastomeric film 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 elastomeric film of claim 1, wherein one or more of the polyolefin elastomers of the polyolefin elastomer blend is selected from the group consisting of propylene-based elastomer, ethylene/α-olefin random copolymer, and combinations thereof.

9. The elastomeric film of claim 1, 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 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.

10. The elastomeric film of claim 1, 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) propylene-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 elastomeric film of claim 1, wherein the thermoplastic elastomer 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 elastomeric film 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 elastomeric film of claim 1, wherein the thermoplastic elastomer compound comprises: (a) from about 20 to about 85 weight percent, by weight of the thermoplastic elastomer compound, of the polyolefin elastomer blend; (b) from about 10 to about 50 weight percent, by weight of the thermoplastic elastomer compound, of the styrene-ethyl ene/butylene-styrene block copolymer; (c) from about 5 to about 40 weight percent, by weight of the thermoplastic elastomer compound, of the plasticizer; and (d) from 0 to about 12 weight percent, by weight of the thermoplastic elastomer 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 elastomeric film of claim 1, wherein the thermoplastic elastomer compound is free of styrene-isoprene-styrene block copolymer.

15. A multilayer film or laminate structure comprising at least one film according to claim 1.

16. A disposable hygiene article comprising at least one component comprising an elastomeric film formed from 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 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.

17. The elastomeric film of claim 1, wherein the elastomeric film is a product formed by the extrusion of the thermoplastic elastomer compound.

18. The elastomeric film of claim 13, wherein the thermoplastic elastomer compound comprises: from about 9 to about 16 weight percent, by weight of the thermoplastic elastomer compound, of the plasticizer.

Description

EXAMPLES

(1) Non-limiting examples of thermoplastic elastomer compounds of various embodiments of the present invention are provided.

(2) Table 2 below shows sources of ingredients for the thermoplastic elastomer compounds of the Comparative Examples and the Examples.

(3) TABLE-US-00002 TABLE 2 Ingredient Description Brand Source Polyolefin elastomer VISTAMAXX 3020 ExxonMobil Chemical Polyolefin elastomer VISTAMAXX 6102 ExxonMobil Chemical Polyolefin elastomer VISTAMAXX 6202 ExxonMobil Chemical Polyolefin elastomer VISTAMAXX 6502 ExxonMobil Chemical SEBS block copolymer SEPTON 8004 Kuraray SEBS block copolymer GLOBALPRENE LCY Chemical 9550 SEBS block copolymer GLOBALPRENE LCY Chemical 9551 SEBS block copolymer KRATON G1641 Kraton Polymers SEBS block copolymer KRATON G1650 Kraton Polymers SEBS block copolymer KRATON G1654 Kraton Polymers Polypropylene PRO-FAX 6331 LyondellBasell homopolymer Polypropylene PRO-FAX PD702 LyondellBasell homopolymer White mineral oil 380 USP White Oil (multiple) White mineral oil PURETOL 550 Oil Petro-Canada Antioxidant IRGANOX 1010 BASF Antioxidant IRGAFOS 168 BASF

(4) 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.

(5) Table 3 below shows the formulations and certain properties of Comparative Examples A to C.

(6) TABLE-US-00003 TABLE 3 Example A B C Wt. Wt. Wt. Wt. Wt. Wt. Ingredient Parts % Parts % Parts % SEPTON 8004 43.50 43.50 — — — — GLOBALPRENE 9550 — — — — 10.00 10.00 GLOBALPRENE 9551 — — 36.00 36.00 26.00 26.00 380 USP White Oil 31.50 31.50 20.00 20.00 20.00 20.00 VISTAMAXX 6102 19.00 19.00 5.60 5.60 5.60 5.60 VISTAMAXX 3020 5.60 5.60 10.00 10.00 10.00 10.00 VISTAMAXX 6502 — — 28.00 28.00 28.00 28.00 IRGANOX 1010 0.20 0.20 0.20 0.20 0.20 0.20 IRGAFOS 168 0.20 0.20 0.20 0.20 0.20 0.20 TOTAL 100.00 100.00 100.00 100.00 100.00 100.00 Properties Good High Speed No No No Processing Melt Flow Rate 4.50 4.20 3.50 (230° C., 2.16 kg) (g/10 min) (ASTM D1238) Melt Flow Rate 0.75 2.00 1.73 (190° C., 2.16 kg) (g/10 min) (ASTM D1238) Hardness (Shore A) 41.9 48.0 51.5 (ASTM D2240) Tensile Strength (psi) 841.6 1016.4 1058.8 (ASTM D638) Tensile Elongation (%) 794.7 745.4 749.9 (ASTM D638)

(7) Table 4 below shows the formulations and certain properties of Comparative Examples D to G.

(8) TABLE-US-00004 TABLE 4 Example D E F Wt. Wt. Wt. Wt. Wt. Wt. Ingredient Parts % Parts % Parts % GLOBALPRENE 9550 27.00 27.00 32.00  32.00  20.00  20.00  GLOBALPRENE 9551 — — 9.00 9.00 — — PROFAX 6331 — — — — 12.00  12.00  PROFAX PD702 — — — — — — 380 USP White Oil 36.00 36.00 36.00  36.00  36.00  36.00  VISTAMAXX 6102 6.00 6.00 6.00 6.00 5.00 5.00 VISTAMAXX 3020 7.00 7.00 7.00 7.00 — — VISTAMAXX 6502 9.60 9.60 9.60 9.60 5.60 5.60 KRATON 1654 12.00 12.00 — — 15.00  15.00  KRATON 1641 2.00 2.00 — — 6.00 6.00 IRGANOX 1010 0.20 0.20 0.20 0.20 0.20 0.20 IRGAFOS 168 0.20 0.20 0.20 0.20 0.20 0.20 TOTAL 100.00 100.00 100.00  100.00  100.00  100.00  Properties Good High Speed No No No Processing Melt Flow Rate 2.80 4.5  1.5  (230° C., 2.16 kg) (g/10 min) (ASTM D1238) Melt Flow Rate 0.60 0.97 0.37 (190° C., 2.16 kg) (g/10 min) (ASTM D1238) Hardness (Shore A) (not reported) (not reported) (not reported) (ASTM D2240) Tensile Strength (psi) (not reported) (not reported) (not reported) (ASTM D638) Tensile Elongation (%) (not reported) (not reported) (not reported) (ASTM D638) Example G Wt. Wt. Ingredient Parts % GLOBALPRENE 9550 15.00 15.00 GLOBALPRENE 9551 — — PROFAX 6331 — — PROFAX PD702 12.00 12.00 380 USP White Oil 36.00 36.00 VISTAMAXX 6102 10.60 10.60 VISTAMAXX 3020 — — VISTAMAXX 6502 5.00 5.00 KRATON 1654 15.00 15.00 KRATON 1641 6.00 6.00 IRGANOX 1010 0.20 0.20 IRGAFOS 168 0.20 0.20 TOTAL 100.00 100.00 Properties Good High Speed No Processing Melt Flow Rate 2.47 (230° C., 2.16 kg) (g/10 min) (ASTM D1238) Melt Flow Rate 0.82 (190° C., 2.16 kg) (g/10 min) (ASTM D1238) Hardness (Shore A) (not reported) (ASTM D2240) Tensile Strength (psi) (not reported) (ASTM D638) Tensile Elongation (%) (not reported) (ASTM D638)

(9) Table 5 below shows the formulations and certain properties of Examples 1 to 3.

(10) TABLE-US-00005 TABLE 5 Example 1 2 3 Wt. Wt. Wt. Wt. Wt. Wt. Ingredient Parts % Parts % Parts % GLOBALPRENE 9550 32.00 32.00 32.00 32.00 30.00 30.00 GLOBALPRENE 9551 7.00 7.00 9.00 9.00 10.00 10.00 380 USP White Oil 36.00 36.00 — — 37.60 37.60 PURETOL 550 Oil — — 36.00 36.00 — — VISTAMAXX 6102 15.00 15.00 6.00 6.00 5.00 5.00 VISTAMAXX 3020 5.00 5.00 7.00 7.00 8.00 8.00 VISTAMAXX 6502 4.60 4.60 9.60 9.60 9.00 9.00 IRGANOX 1010 0.20 0.20 0.20 0.20 0.20 0.20 IRGAFOS 168 0.20 0.20 0.20 0.20 0.20 0.20 TOTAL 100.00 100.00 100.00 100.00 100.00 100.00 Properties Good High Speed Yes Yes Yes Processing Melt Flow Rate 7.20 6.00 6.70 (230° C., 2.16 kg) (g/10 min) (ASTM D1238) Melt Flow Rate 1.50 1.15 1.63 (190° C., 2.16 kg) (g/10 min) (ASTM D1238) Hardness (Shore A) 35.1 37.3 36.2 (ASTM D2240) Tensile Strength (psi) 653 755 727 (ASTM D638) Tensile Elongation (%) 839 796 782 (ASTM D638)

(11) Table 6 below shows the formulations and certain properties of Examples 4 to 9.

(12) TABLE-US-00006 TABLE 6 Example 4 5 6 Wt. Wt. Wt. Wt. Wt. Wt. Ingredient Parts % Parts % Parts % GLOBALPRENE 9550 13.05 13.01 17.40 17.36 13.05 13.01 380 USP White Oil 9.45 9.42 12.60 12.57 9.45 9.42 VISTAMAXX 6202 35.70 35.59 — — 16.70 16.65 VISTAMAXX 6102 35.80 35.69 43.60 43.50 40.00 39.88 VISTAMAXX 6502 4.20 4.19 24.00 23.94 19.00 18.94 VISTAMAXX 3020 1.70 1.69 2.24 2.23 1.70 1.69 IRGANOX 1010 0.20 0.20 0.20 0.20 0.20 0.20 IRGAFOS 168 0.20 0.20 0.20 0.20 0.20 0.20 TOTAL 100.30 100.00 100.24 100.00 100.30 100.00 Properties Good High Speed Yes Yes Yes Processing Melt Flow Rate 6.3 5 6.5 (230° C., 2.16 kg) (g/10 min) (ASTM D1238) Melt Flow Rate 2.9 2.5 3.4 (190° C., 2.16 kg) (g/10 min) (ASTM D1238) Hardness (Shore A) (not reported) (not reported) (not reported) (ASTM D2240) Tensile Strength (psi) (not reported) (not reported) (not reported) (ASTM D638) Tensile Elongation (%) (not reported) (not reported) (not reported) (ASTM D638) Example 7 8 9 Wt. Wt. Wt. Wt. Wt. Wt. Ingredient Parts % Parts % Parts % GLOBALPRENE 9550 13.05 13.01 13.05 13.01 13.05 13.02 380 USP White Oil 9.45 9.42 9.45 9.42 9.45 9.43 VISTAMAXX 6202 16.70 16.65 21.00 20.94 — — VISTAMAXX 6102 40.00 39.88 40.70 40.58 23.20 23.14 VISTAMAXX 6502 19.00 18.94 14.00 13.96 35.00 34.91 VISTAMAXX 3020 1.70 1.69 1.70 1.69 19.15 19.10 IRGANOX 1010 0.20 0.20 0.20 0.20 0.20 0.20 IRGAFOS 168 0.20 0.20 0.20 0.20 0.20 0.20 TOTAL 100.30 100.00 100.30 100.00 100.25 100.00 Properties Good High Speed Yes Yes Yes Processing Melt Flow Rate 6.6 6.6  7.6 (230° C., 2.16 kg) (g/10 min) (ASTM D1238) Melt Flow Rate 3.1 2.87 3.6 (190° C., 2.16 kg) (g/10 min) (ASTM D1238) Hardness (Shore A) (not reported) (not reported) (not reported) (ASTM D2240) Tensile Strength (psi) (not reported) (not reported) (not reported) (ASTM D638) Tensile Elongation (%) (not reported) (not reported) (not reported) (ASTM D638)

(13) Table 7 below shows the formulations and certain properties of Examples 10 to 14.

(14) TABLE-US-00007 TABLE 7 Example 10 11 12 Wt. Wt. Wt. Wt. Wt. Wt. Ingredient Parts % Parts % Parts % KRATONG1650 13.05 13.01 13.05 13.01 26.10 26.06 380 USP White Oil 9.45 9.42 9.45 9.42 18.90 18.87 VISTAMAXX 6202 17.00 16.95 28.70 28.61 — — VISTAMAXX 6102 35.70 35.60 34.80 34.70 51.40 51.32 VISTAMAXX 6502 23.00 22.93 1220 12.16 — — VISTAMAXX 3020 1.70 1.69 1.70 1.69 3.36 3.35 IRGANOX 1010 0.20 0.20 0.20 0.20 0.20 0.20 IRGAFOS 168 0.20 0.20 0.20 0.20 0.20 0.20 TOTAL 100.30 100.00 100.30 100.00 100.16 100.00 Properties Good High Speed Yes Yes Yes Processing Melt Flow Rate 9.8 9.59 5.62 (230° C., 2.16 kg) (g/10 min) (ASTM D1238) Melt Flow Rate 4.25 4.10 1.65 (190° C., 2.16 kg) (g/10 min) (ASTM D1238) Hardness (Shore A) 59.0 (not reported) 50.4 (ASTM D2240) Tensile Strength (psi) 1180 (not reported) 994 (ASTM D638) Tensile Elongation (%) 950 (not reported) 926 (ASTM D638) Example 13 14 Wt. Wt. Wt. Wt. Ingredient Parts % Parts % KRATON G1650 21.75 21.71 17.40 17.36 380 USP White Oil 15.75 15.72 12.60 12.57 VISTAMAXX 6202 — — — — VISTAMAXX 6102 59.50 59.38 67.60 67.44 VISTAMAXX 6502 — — — — VISTAMAXX 3020  2.80  2.79  2.24  2.23 MB3150 — — — — SCLAIR 2908 — — — — IRGANOX 1010  0.20  0.20  0.20  0.20 IRGAFOS 168  0.20  0.20  0.20  0.20 TOTAL 100.20  100.00  100.24  100.00  Properties Good High Speed Yes Yes Processing Melt Flow Rate 5.38 5.66 (230° C., 2.16 kg) (g/10 min) (ASTM D1238) Melt Flow Rate 1.77 2.19 (190° C., 2.16 kg) (g/10 min) (ASTM D1238) Hardness (Shore A) 52.2 (not reported) (ASTM D2240) Tensile Strength (psi) 1139 (not reported) (ASTM D638) Tensile Elongation (%) 925 (not reported) (ASTM D638)

(15) 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.

(16) 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.

(17) 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.