Annealed porous polyolefin material

Patent metadata

Field	Value
Publication number	US-10640898-B2
Application number	US-201515521064-A
Country	US
Kind code	B2
Filing date	Nov 17, 2015
Priority date	Nov 26, 2014
Publication date	May 5, 2020
Grant date	May 5, 2020

Abstract

A polyolefin material that comprises a thermoplastic composition that is annealed and thereafter drawn in a solid state is provided. The composition contains a continuous phase that includes a polyolefin matrix polymer and a nanoinclusion additive dispersed within the continuous phase in the form of discrete domains. A porous network is defined within the thermoplastic composition that includes a plurality of nanopores, wherein the thermoplastic composition has a glass transition temperature of from about −20° C. to about 50° C. as determined in accordance with ASTM E1640-13.

First claim

What is claimed is:

1. A polyolefin material that comprises a thermoplastic composition that is annealed and thereafter drawn in a solid state, the composition containing a continuous phase that includes a polyolefin matrix polymer and a nanoinclusion additive dispersed within the continuous phase in the form of discrete domains, wherein the nanoinclusion additive includes a polar component and a nonpolar component, wherein a porous network is defined within the thermoplastic composition that includes a plurality of nanopores, wherein the thermoplastic composition has a glass transition temperature of from −20° C. to 50° C. as determined in accordance with ASTM E1640-13.

2. The polyolefin material of claim 1 , wherein the nanopores have an average cross-sectional dimension of 800 nanometers or less.

3. The polyolefin material of claim 1 , wherein the composition has a density of 0.90 g/cm 3 or less.

4. The polyolefin material of claim 1 , wherein nanopores have an average axial dimension of from 100 to 5000 nanometers.

5. The polyolefin material of claim 1 , wherein the polyolefin matrix polymer has a melt flow rate of from 0.5 to 80 grams per 10 minutes as determined at a load of 2160 grams and at 230° C. in accordance with ASTM D1238.

6. The polyolefin material of claim 1 , wherein the polyolefin matrix polymer is a substantially isotactic polypropylene homopolymer or a copolymer containing at least 90% by weight propylene.

7. The polyolefin material of claim 1 , wherein the continuous phase constitutes from 60 wt. % to 99 wt. % of the thermoplastic composition.

8. The polyolefin material of claim 1 , wherein the nanoinclusion additive includes a functionalized polyolefin.

9. The polyolefin material of claim 8 , wherein the functionalized polyolefin is a polyepoxide.

10. The polyolefin material of claim 1 , wherein the nanoinclusion additive includes a polymer having a melt flow rate of from 0.1 to 100 grams per 10 minutes as determined at a load of 2160 grams and at a temperature at least 40° C. above the melting temperature in accordance with ASTM D1238.

11. The polyolefin material of claim 10 , wherein the ratio of the melt flow rate of the polyolefin to the melt flow rate of the nanoinclusion additive is from 0.2 to 8.

12. The polyolefin material of claim 1 , wherein the nanoinclusion additive is in the form of nano-scale domains, wherein the nano-scale domains have an average cross-sectional dimension of from 1 nanometer to 1000 nanometers.

13. The polyolefin material of claim 1 , where in the nanoinclusion additive constitutes from 0.05 wt. % to 20 wt. % of the composition, based on the weight of the continuous phase.

14. The polyolefin material of claim 1 , wherein the composition further comprises a microinclusion additive dispersed within the continuous phase in the form of discrete domains.

15. The polyolefin material of claim 1 , wherein the thermoplastic composition further comprises an interphase modifier.

16. The polyolefin material of claim 1 , wherein the porous network further includes micropores.

17. The polyolefin material of claim 1 , wherein the total pore volume of the polyolefin material is from 15% to 80% per cubic centimeter.

18. The polyolefin material of claim 1 , wherein nanopores constitute 20 vol. % or more of the total pore volume of the polyolefin material.

19. A fiber comprising the polyolefin material of claim 1 .

20. A nonwoven web comprising the fiber of claim 19 .

21. An absorbent article that includes a substantially liquid-impermeable layer, liquid-permeable layer, and an absorbent core, wherein the substantially liquid-impermeable layer, the liquid-permeable layer, or both include the polyolefin material of claim 1 .

22. A method for forming a polyolefin material, the method comprising:
forming a thermoplastic composition that contains a continuous phase that includes a polyolefin matrix polymer and a nanoinclusion additive dispersed within the continuous phase in the form of discrete domains, wherein the nanoinclusion additive includes a polar component and a nonpolar component;
annealing the thermoplastic composition; and
solid state drawing the annealed thermoplastic composition to form a porous network therein, the porous network including a plurality of nanopores;
wherein the thermoplastic composition has a glass transition temperature of from −20° C. to 50° C. as determined in accordance with ASTM E1640-13.

23. The method of claim 22 , wherein annealing occurs at a temperature of from 50° C. to 160° C.

24. The method of claim 22 , wherein annealing occurs for a time of from 5 to 200 minutes.

25. The method of claim 22 , wherein the thermoplastic composition is drawn to a stretch ratio of from 1.1 to 25.

26. The method of claim 22 , wherein the thermoplastic composition is drawn at a temperature of from −50° C. to 150° C.

Assignees

• Kimberly Clark Co

Inventors

• Topolkaraev Vasily A
• Mceneany Ryan J
• Scholl Neil T
• Carrillo Antonio J
• Mleziva Mark M
• Hristov Hristo A
• Galabura Yuriy

Classifications

• B01J20/264

  derived from different types of monomers, e.g. linear or branched copolymers, block copolymers, graft copolymers · CPC title

• D01D5/247

  Discontinuous hollow structure or microporous structure · CPC title

• D04H1/4291 Primary

  Olefin series · CPC title

• C08L23/00 Primary

  Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers · CPC title

• D01F6/04

  from polyolefins · CPC title