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Cross-linked foam structures of essentially linear polyolefines and process for manufacture

Assignee: Sentinel Products Corp
•
Filing: 1995-09-19
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Granted: —
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Expires: 2015-09-19
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Abstract

Abstract New cross-linked polymeric foam compositions, and methods for making the same, are provided. The new compositions utilize novel cross-linked polyolefin copolymers and show improvements in strength, toughness, flexibility, heat resistance and heat-sealing temperature ranges as compared to conventional low density polyethylene compositions. The new compositions also show processing improvements over linear low density polyethylene. The novel polyolefins, which are essentially linear, comprise ethylene polymerized with at least one alpha-unsaturated C3 to C20 olefinic comonomer, and optionally at least one C3 to C20 polyene, and exhibit, in an uncross-linked sense, a resin density in the range of about 0.86 g/cm3 to about 0.96 g/cm3, a melt index in the range of about 0.5 dg/min to about 100 dg/min, a molecular weight distribution in the range of from about 1.5 to about 3.5, and a composition distribution breadth index greater than about 45 percent.

Inventors

  • 👤 Robert F. Hurley
  • 👤 Matthew L. Kozma
  • 👤 Kurt A. Feichtinger

Bibliographic Details

Application Number —
Jurisdiction EP
Data Source google_patents
Last Synchronized 2026-11-04 21:01
CPC Classifications
C; C08; C08J; C08J9/00; C08J9/04; C08J9/06; C08F; C08F10/00; C08F255/00; C08F255/02; C08F8/00; C08J9/0061; C08J9/10; C08J9/102; C08J9/103; C08L; C08L23/00; C08L23/02; C08L23/04; C08L23/06; C08L23/08; C08L23/0807; C08L23/0815; C08L23/0846; C08L23/0853; C08L23/10; C08L51/00; C08L51/06; C08L51/08; C08L51/085; C08J2201/00; C08J2201/02; C08J2201/03; C08J2323/00; C08J2323/02; C08J2323/16; C08J2423/00; C08J2425/00; C08L2205/00; C08L2205/02; C08L2205/03; C08L2205/035; C08L23/0869; C08L23/16; C08L2312/00; C08L2314/00; C08L2314/06; C08L83/00; C08L83/04; C08L91/00

Claims Analysis

Total Claims: 22
Claim 1
Independent Claim 93 words
A method of making a foamed material, comprising the steps of: polymerizing ethylene with a C3 to C20 alpha-unsaturated ethylenic monomer to give a copolymer characterized by (i) a resin density in the range of about 0.86 g/cm3 to about 0.96 g/cm3, (ii) a melt index in the range of about 0.5 dg/min to about 100 dg/min, (iii) a molecular weight distribution in the range of from about 1.5 to about 3.5, and (iv) a composition distribution breadth index greater than about 45 percent; inducing cross-linking in the composition; and expanding the composition.
Claim 2
Dependent Claim 19 words
The method of claim 1, wherein the copolymer is also polymerized with at least one C3 to C20 polyene.
Claim 3
Dependent Claim 14 words
The method of claim 1, wherein the copolymer is substantially free of long-chain branching.
Claim 4
Dependent Claim 20 words
The method of claim 3, wherein the copolymer is substantially free of branch lengths having more than 20 carbon atoms.
Claim 5
Dependent Claim 27 words
A method of claim 1, wherein the composition comprises a blend of polymers containing at least about 5% and up to about 100% of said polyolefin copolymer.
Claim 6
Dependent Claim 15 words
The method of claim 1, wherein the composition further comprises a chemically decomposable foaming agent.
Claim 7
Dependent Claim 16 words
The method of claim 6, wherein the foaming agent is added prior to effecting the cross-linking.
Claim 8
Dependent Claim 16 words
The method of claim 6, wherein the foaming agent is added subsequent to effecting the cross-linking.
Claim 9
Dependent Claim 16 words
The method of method of claim 1, wherein the composition further comprises a physical foaming agent.
Claim 10
Dependent Claim 16 words
The method of claim 9, wherein the foaming agent is added prior to effecting the cross-linking.
Claim 11
Dependent Claim 16 words
The method of claim 9, wherein the foaming agent is added subsequent to effecting the cross-linking.
Claim 12
Dependent Claim 20 words
The method of claim 1, wherein the cross-linking is effected by reacting the polymeric composition with a silane cross-linking agent.
Claim 13
Dependent Claim 14 words
The method of claim 1, wherein the cross-linking is effected by free-radical generating initiators.
Claim 14
Dependent Claim 12 words
The method of claim 1, wherein the cross-linking is effected by irradiation.
Claim 15
Dependent Claim 14 words
The method of claim 1, wherein additional reactive monomers are included as cross-linking agents.
Claim 16
Dependent Claim 23 words
The method of claim 11, wherein additional polymeric resins are added to the composition subsequent to grafting but prior to induction of cross-linking.
Claim 17
Dependent Claim 21 words
The method of claim 1, wherein the density of the material is less than 22 pcf but greater than 0.7 pcf.
Claim 18
Dependent Claim 17 words
The method of claim 1, wherein at least 70% of the cells in the material are closed.
Claim 19
Dependent Claim 22 words
The method of claim 1, wherein the composition comprises greater than about 5% but less than about 40% of the polyolefin copolymer.
Claim 20
Dependent Claim 16 words
The method of claim 1, wherein the composition comprises greater than 70% of the polyolefin copolymer.
Claim 21
Dependent Claim 11 words
The method of claim 1, wherein the material is a bead.
Claim 22
Dependent Claim 7 words
The material produced according to claim 1.

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