Aqueous Dispersions of Polyolefins Breaking the Extrusion Barrier - - PowerPoint PPT Presentation

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Aqueous Dispersions of Polyolefins Breaking the Extrusion Barrier - - PowerPoint PPT Presentation

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Place for, company logo from speaker Aqueous Dispersions of Polyolefins Breaking the Extrusion Barrier Ronald Wevers Session 6.2 , Paper 7633 What comes to mind when you think of polyolefins ? Films Plastic Pellets Molded Articles &

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Aqueous Dispersions of Polyolefins

Breaking the Extrusion Barrier

Ronald Wevers

Session 6.2 , Paper 7633

Place for, company logo from speaker

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DOW CONFIDENTIAL - Do not share without permissionSession 6.2 Paper 7633, Ronald Wevers 2

What comes to mind when you think

  • f polyolefins ?

Films

Molded Articles & Containers

Plastic Pellets

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DOW CONFIDENTIAL - Do not share without permissionSession 6.2 Paper 7633, Ronald Wevers 3

Traditional Polyolefin Converting Processes

Blown / Cast Film Injection, Compression, Blow - Molding Extrusion Coating / Lamination Profile & Sheet Foam Extrusion

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DOW CONFIDENTIAL - Do not share without permissionSession 6.2 Paper 7633, Ronald Wevers 4

Waterborne Polyolefin Dispersions 40-55 % Solids , < 500 cps Viscosity

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DOW CONFIDENTIAL - Do not share without permissionSession 6.2 Paper 7633, Ronald Wevers 5

Converting Options for Polyolefin Dispersions

Printing/Coating Processes (Rotogravure) Spray Application Dipping Frothed Foams

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DOW CONFIDENTIAL - Do not share without permissionSession 6.2 Paper 7633, Ronald Wevers 6

Waterborne Application Vs Extrusion for Coating of Polyolefins

  • Thinner coatings
  • Use existing waterborne application

equipment

  • Higher line speeds
  • Penetrate porous / fibrous webs
  • Coat at low temperature
  • Coat complex geometry
  • Coat in pattern
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DOW CONFIDENTIAL - Do not share without permissionSession 6.2 Paper 7633, Ronald Wevers 7

Polyolefin Dispersion Characteristics

  • Avg. Particle Size ~ 1 µ
  • Solids Content (by wt) 40 to

55% solids

  • pH – 8.0-10.5
  • Viscosity (Brookfield @ 25°

C) < 500 cps

Polyolefin Water Stabilizing Agent

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DOW CONFIDENTIAL - Do not share without permissionSession 6.2 Paper 7633, Ronald Wevers 8

Example Polyolefin Dispersions

  • 25

85 No Propylene Copolymer Dispersion E

  • 55

60 No Ethylene Copolymer Dispersion D

  • 25

85 Yes Propylene Copolymer Dispersion C

  • 55

116 Yes Ethylene Copolymer Dispersion B

  • 55

60 Yes Ethylene Copolymer Dispersion A Polymer Tg (deg C) Polymer Melting Point (deg C) Carboxylic Acid Content Polymer Composition Product Designation

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DOW CONFIDENTIAL - Do not share without permissionSession 6.2 Paper 7633, Ronald Wevers 9

Film Formation – Hot Stage Microscopy

Polyolefin Particles

Homogeneous Film

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DOW CONFIDENTIAL - Do not share without permissionSession 6.2 Paper 7633, Ronald Wevers 10

Mechanical Properties of 250 µ Films Cast from Dispersion D

1 2 3 4 5 6 7 100 200 300 400 500 600 700 Strain % Stress MPa 60° C, 10 mil, 30 min, VAC 70° C,10 mil, 30 min, VAC 80° C,10 mil, 30 min, VAC 1 2 3 4 5 6 7 100 200 300 400 500 600 700 Strain % Stress MPa 60° C, 10 mil, 30 min, VAC 70° C,10 mil, 30 min, VAC 80° C,10 mil, 30 min, VAC

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DOW CONFIDENTIAL - Do not share without permissionSession 6.2 Paper 7633, Ronald Wevers 11

Properties of Polyolefin Dispersions

  • Water resistance
  • Oil & grease

resistance

  • Heat sealability
  • Elasticity /flexibility
  • Adhesion to polyolefins
  • Adhesion to polar

substrates

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DOW CONFIDENTIAL - Do not share without permissionSession 6.2 Paper 7633, Ronald Wevers 12

Carpet Backing

Benefits

  • Interlayer adhesion with Polypropylene Tuft & Fabrics
  • Thermoformability (Automotive)
  • Moisture resistance
  • Ability to recycle
  • Application via conventional latex coating processes
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DOW CONFIDENTIAL - Do not share without permissionSession 6.2 Paper 7633, Ronald Wevers 13

Frothed Polyolefin Foam Coatings

Foam directly onto various substrates Open cell structure High elasticity & soft, luxuriant feel Biocompatibility High filler acceptance Embossable

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DOW CONFIDENTIAL - Do not share without permissionSession 6.2 Paper 7633, Ronald Wevers 14

PO Dispersions as Paper Coatings

  • Polyolefins have been widely used to modify

paper

  • Limitations exist for extruded polyolefins
  • Thickness (> 10 microns)
  • Adhesion to paper
  • Beneficial properties provided to paper and

board

  • Oil and grease barrier
  • Moisture resistance
  • COF modification
  • Adhesion promoter / tie layer
  • Heat sealability
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DOW CONFIDENTIAL - Do not share without permissionSession 6.2 Paper 7633, Ronald Wevers 15

PODs in Flexible Packaging

Tie Layer / Laminating Adhesive

– Alternative to extrusion lamination

  • Adhesion to polyolefins
  • Adhesion to polar substrates (paper, glass, foil,

polar polymers)

Heat Sealable Layer

  • Apply at low temperatures and high

speeds

  • Low HSIT (<70°

C)

  • Use existing printing equipment
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DOW CONFIDENTIAL - Do not share without permissionSession 6.2 Paper 7633, Ronald Wevers 16

A New Alternative for Oil & Grease Resistance (OGR) -

24hrs in 60 deg C Oven

HS HS HS HS HS HS HS Styrene/But yl Acrylate Latex HS Pass Pass Pass Pass Pass Pass Polyolefin Dispersion A Oleic Acid Canol a Peanu t Olive Vege- table Sesam e Corn

Polyolefin Dispersions provide excellent OGR which is maintained after creasing

HS = Highly Saturated

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DOW CONFIDENTIAL - Do not share without permissionSession 6.2 Paper 7633, Ronald Wevers 17

Moisture Resistance of Polyolefin Dispersion Coatings

950 28

  • None

420 7 11 510 44% Polyolefin Dispersion B 40 1 12 56 50% Polyolefin Dispersion E

MVTR (g/sqm/24hr) Cobb 120 (g/sqm/120 sec) pH Brookfield Visc (cP) % Solids Dispersion

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DOW CONFIDENTIAL - Do not share without permissionSession 6.2 Paper 7633, Ronald Wevers 18

Summary

  • Attributes of polyolefins are available in a water-borne

dispersion

  • PODs provide unique properties
  • Adhesion to polyolefins
  • Heat sealability
  • Barrier properties
  • PODs create opportunities for innovations in building

existing and novel structures

  • Paper and Board
  • Films
  • Foams
  • Textiles
  • Many Others
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DOW CONFIDENTIAL - Do not share without permissionSession 6.2 Paper 7633, Ronald Wevers 19

Acknowledgements

Brad Moncla Talia Collins Rob Cotton Charles Diehl John Homoelle Wenbin Liang Mike Levinson Gary Strandburg Miguel Prieto Mark VanSumeren Kevin Maak Matt Kalinowski Pekka Salminen Roebi Urscheler

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THANK YOU

PRESENTED BY Ronald Wevers Dow Chemical rwevers@dow.com