Polymeric material for an insulated container

Patent metadata

Field	Value
Publication number	US-10011696-B2
Application number	US-201314063252-A
Country	US
Kind code	B2
Filing date	Oct 25, 2013
Priority date	Oct 26, 2012
Publication date	Jul 3, 2018
Grant date	Jul 3, 2018

Abstract

A formulation includes a polymeric material, a nucleating agent, a blowing, and a surface active agent. The formulation can be used to form a container.

First claim

The invention claimed is:

1. A polymeric material comprising
a) a high melt strength polypropylene base resin with long chain branching,
b) a second polymer comprising a polypropylene copolymer, polypropylene homopolymer, polyethylene, or mixtures thereof, and
c) at least two nucleating agents,
wherein the polymeric material is cellular and non-aromatic.

2. The polymeric material of claim 1 , wherein the polypropylene base resin has unimodal molecular weight distribution.

3. The polymeric material of claim 1 , wherein the polypropylene base resin material has a melt strength of at least 36 per ISO16790.

4. The polymeric material of claim 1 , wherein the polypropylene base resin material has a melting temperature of at least 163° C.

5. The polymeric material of claim 1 , wherein the polypropylene homopolymer is a crystalline polypropylene homopolymer.

6. The polymeric material of claim 5 , wherein the crystalline polypropylene homopolymer has a crystalline phase exceeding 51% at 10° C./min cooling rate.

7. The polymeric material of claim 1 , wherein the polypropylene copolymer is an impact polypropylene copolymer.

8. The polymeric material of claim 1 , wherein the second polymer comprises polyethylene.

9. The polymeric material of claim 8 , wherein the polyethylene is selected from the group consisting of low density polyethylene, linear low density polyethylene, high density polyethylene, ethylene-vinyl acetate copolymers, ethylene-ethylacrylate copolymers, ethylene-acrylic acid copolymers, polymethylmethacrylate mixtures of at least two of the foregoing, and combinations thereof.

10. The polymeric material of claim 1 , wherein the at least two nucleating agents is selected from the group consisting of a chemical nucleating agent, a physical nucleating agent, and a combination of a chemical nucleating agent and a physical nucleating agent.

11. The polymeric material of claim 10 , wherein the chemical nucleating agent is citric acid or a citric acid-based material.

12. The polymeric material of claim 10 , wherein the physical nucleating agent is selected from the group consisting of talc, CaCO 3 , mica, kaolin clay, chitin, aluminosilicates, graphite, cellulose, and mixtures of at least two of the foregoing.

13. The polymeric material of claim 1 further comprising a blowing agent.

14. The polymeric material of claim 13 , wherein the blowing agent is selected from the group consisting of chemical blowing agents, physical blowing agents, and combinations thereof.

15. The polymeric material of claim 14 , wherein the physical blowing agent is selected from the group consisting of carbon dioxide, nitrogen, helium, argon, air, water vapor, pentane, butane, and mixtures thereof.

16. The polymeric material of claim 14 , wherein the physical blowing agent is selected from the group consisting of a hydrofluorocarbon, hydrofluoroolefin, haloalkane, or haloalkane refrigerant.

17. The polymeric material of claim 16 , wherein the hydrofluorocarbon is 1,1,1,2-tetrafluoroethane.

18. The polymeric material of claim 13 , wherein the blowing agent is a physical blowing agent and further comprises a processing aid that enhances solubility of the physical blowing agent.

19. The polymeric material of claim 14 , wherein the physical blowing agent is at least one gas that is introduced as a liquid under pressure into a molten resin.

20. The polymeric material of claim 14 , wherein the chemical blowing agent is selected from the group consisting of azodicarbonamide; azodiisobutyro-nitrile; benzenesulfonhydrazide; 4,4-oxybenzene sulfonylsemicarbazide; p-toluene sulfonyl semi-carbazide; barium azodicarboxylate; N,N′-dimethyl-N,N′-dinitrosoterephthalamide; trihydrazino triazine; methane; ethane; propane; n-butane; isobutane; n-pentane; isopentane; neopentane; methyl fluoride; perfluoromethane; ethyl fluoride; 1,1-difluoroethane; 1,1,1-trifluoroethane; 1,1,1,2-tetrafluoro-ethane; pentafluoroethane; perfluoroethane; 2,2-difluoropropane; 1,1,1-trifluoropropane; perfluoropropane; perfluorobutane; perfluorocyclobutane; methyl chloride; methylene chloride; ethyl chloride; 1,1,1-trichloroethane; 1,1-dichloro-1-fluoroethane; 1-chloro-1,1-difluoroethane; 1,1-dichloro-2,2,2-trifluoroethane; 1-chloro-1,2,2,2-tetrafluoroethane; trichloromonofluoromethane; dichlorodifluoromethane; trichlorotrifluoroethane; dichlorotetrafluoroethane; chloroheptafluoropropane; dichlorohexafluoropropane; methanol; ethanol; n-propanol; isopropanol; sodium bicarbonate; sodium carbonate; ammonium bicarbonate; ammonium carbonate; ammonium nitrite; N,N′-dimethyl-N,N′-dinitrosoterephthalamide; N,N′-dinitrosopentamethylene tetramine; azodicarbonamide; azobisisobutylonitrile; azocyclohexylnitrile; azodiaminobenzene; bariumazodicarboxylate; benzene sulfonyl hydrazide; toluene sulfonyl hydrazide; p,p′-oxybis(benzene sulfonyl hydrazide); diphenyl sulfone-3,3′-disulfonyl hydrazide; calcium azide; 4,4′-diphenyl disulfonyl azide; and p-toluene sulfonyl azide.

21. The polymeric material of claim 1 , further comprising a slip agent.

22. The polymeric material of claim 21 , wherein the slip agent is an amide of fat or fatty acid, a low molecular weight amide, or fluoroelastomer.

23. The polymeric material of claim 22 , wherein the fatty acid amide is a single unsaturated C 18 to C 22 amide.

24. The polymeric material of claim 22 , wherein the fatty acid amide is erucamide or oleamide.

25. The polymeric material of claim 1 , further comprising at least one of an impact modifier, colorant, or compound regrind.

26. The polymeric material of claim 25 , wherein the colorant is titanium dioxide.

27. The polymeric material of claim 1 , wherein the polymeric material has an average aspect ratio of cells of about 1.0 to about 3.0.

28. The polymeric material of claim 27 , wherein the average aspect ratio of cells is about 1.0 to about 2.0.

29. The polymeric material of claim 1 , wherein the polymeric material has a density of about 0.01 g/cm 3 to about 0.19 g/cm 3 .

30. The polymeric material of claim 29 , wherein the polymeric material has a density of about 0.05 g/cm 3 to about 0.19 g/cm 3 .

31. The polymeric material of claim 1 , wherein the polymeric material has a density of about 0.1 g/cm 3 to about 0.185 g/cm 3 .

32. The polymeric material of claim 1 , wherein the polymeric material has a tear resistance in the machine direction of at least about 282 grams-force according to ASTM D1922-93.

33. The polymeric material of claim 1 , wherein the polymeric material requires at least about 282 grams-force to tear the material in the machine direction according to Elmendorf test method ASTM D1922-93.

34. The polymeric material of claim 1 , wherein the polymeric material structure requires at least about 212 grams-force to tear the material in the transverse direction according to Elmendorf test method as described in ASTM D1922-93.

35. The polymeric material of claim 1 , wherein the polymeric material requires a force in a range of about 213 grams-force to about 351 grams-force to tear the material in the machine direction according to Elmendorf test method ASTM D1922-93.

36. The polymeric material of claim 1 , wherein the polymeric material requires a force in a range of about 143 grams

Assignees

• Berry Plastics Corp

Inventors

• Leser Chris K
• Driskill Philip A
• Wallace Charles T
• Euler John B
• Paladino Jason J
• Maravich Milan C
• Davis Daniel O
• Mann Jeffrey A
• Bowlds Randy A
• Contrada Svetlana I
• Sun David Dezhou

Classifications

• C08J9/0061 Primary

  characterized by the use of several polymeric components · CPC title

• Y10T428/1397

  Single layer [continuous layer] · CPC title

• B32B3/26

  characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids {(foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205); characterised by an apertured layer} · CPC title

• C08J9/04 Primary

  using blowing gases generated by a previously added blowing agent · CPC title

• B32B27/18

  characterised by the use of special additives · CPC title