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 & Containers DOW CONFIDENTIAL - Do not share without permissionSession 6.2 2 Paper 7633, Ronald Wevers
Traditional Polyolefin Converting Processes Blown / Cast Film Injection, Compression, Blow - Molding Extrusion Coating / Lamination Profile & Sheet Foam Extrusion DOW CONFIDENTIAL - Do not share without permissionSession 6.2 3 Paper 7633, Ronald Wevers
Waterborne Polyolefin Dispersions 40-55 % Solids , < 500 cps Viscosity DOW CONFIDENTIAL - Do not share without permissionSession 6.2 4 Paper 7633, Ronald Wevers
Converting Options for Polyolefin Dispersions Printing/Coating Processes (Rotogravure) Dipping Frothed Foams Spray Application DOW CONFIDENTIAL - Do not share without permissionSession 6.2 5 Paper 7633, Ronald Wevers
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 DOW CONFIDENTIAL - Do not share without permissionSession 6.2 6 Paper 7633, Ronald Wevers
Polyolefin Dispersion Characteristics Polyolefin Water Stabilizing Agent • Avg. Particle Size ~ 1 µ • Solids Content (by wt) 40 to 55% solids • pH – 8.0-10.5 • Viscosity (Brookfield @ 25° C) < 500 cps DOW CONFIDENTIAL - Do not share without permissionSession 6.2 7 Paper 7633, Ronald Wevers
Example Polyolefin Dispersions Product Polymer Carboxylic Acid Polymer Polymer Tg Designation Composition Content Melting (deg C) Point (deg C) Dispersion A Ethylene Yes 60 -55 Copolymer Dispersion B Ethylene Yes 116 -55 Copolymer Dispersion C Propylene Yes 85 -25 Copolymer Dispersion D Ethylene No 60 -55 Copolymer Dispersion E Propylene No 85 -25 Copolymer DOW CONFIDENTIAL - Do not share without permissionSession 6.2 8 Paper 7633, Ronald Wevers
Film Formation – Hot Stage Microscopy Polyolefin Particles Homogeneous Film DOW CONFIDENTIAL - Do not share without permissionSession 6.2 9 Paper 7633, Ronald Wevers
Mechanical Properties of 250 µ Films Cast from Dispersion D 7 7 60° 60° C, 10 mil, 30 min, VAC C, 10 mil, 30 min, VAC 6 6 70° 70° C,10 mil, 30 min, VAC C,10 mil, 30 min, VAC 80° 80° C,10 mil, 30 min, VAC C,10 mil, 30 min, VAC 5 5 Stress MPa Stress MPa 4 4 3 3 2 2 1 1 0 0 0 0 100 100 200 200 300 300 400 400 500 500 600 600 700 700 Strain % Strain % DOW CONFIDENTIAL - Do not share without permissionSession 6.2 10 Paper 7633, Ronald Wevers
Properties of Polyolefin Dispersions • Water resistance • Oil & grease resistance • Heat sealability • Elasticity /flexibility • Adhesion to polyolefins • Adhesion to polar substrates DOW CONFIDENTIAL - Do not share without permissionSession 6.2 11 Paper 7633, Ronald Wevers
Carpet Backing Benefits • Interlayer adhesion with Polypropylene Tuft & Fabrics • Thermoformability (Automotive) • Moisture resistance • Ability to recycle • Application via conventional latex coating processes DOW CONFIDENTIAL - Do not share without permissionSession 6.2 12 Paper 7633, Ronald Wevers
Frothed Polyolefin Foam Coatings Foam directly onto various substrates Open cell structure High elasticity & soft, luxuriant feel Biocompatibility High filler acceptance Embossable DOW CONFIDENTIAL - Do not share without permissionSession 6.2 13 Paper 7633, Ronald Wevers
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 DOW CONFIDENTIAL - Do not share without permissionSession 6.2 14 Paper 7633, Ronald Wevers
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 DOW CONFIDENTIAL - Do not share without permissionSession 6.2 15 Paper 7633, Ronald Wevers
A New Alternative for Oil & Grease Resistance (OGR) - 24hrs in 60 deg C Oven Corn Sesam Vege- Olive Peanu Canol Oleic e t a Acid table Pass Pass Pass Pass Pass Pass HS Polyolefin Dispersion A HS HS HS HS HS HS HS Styrene/But yl Acrylate Latex HS = Highly Saturated Polyolefin Dispersions provide excellent OGR which is maintained after creasing DOW CONFIDENTIAL - Do not share without permissionSession 6.2 16 Paper 7633, Ronald Wevers
Moisture Resistance of Polyolefin Dispersion Coatings Cobb 120 MVTR Dispersion % Solids Brookfield Visc (cP) pH (g/sqm/120 sec) (g/sqm/24hr) Polyolefin Dispersion E 50% 56 12 1 40 Polyolefin Dispersion B 44% 510 11 7 420 None - - - 28 950 DOW CONFIDENTIAL - Do not share without permissionSession 6.2 17 Paper 7633, Ronald Wevers
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 DOW CONFIDENTIAL - Do not share without permissionSession 6.2 18 Paper 7633, Ronald Wevers
Acknowledgements Brad Moncla Gary Strandburg Talia Collins Miguel Prieto Rob Cotton Mark VanSumeren Charles Diehl Kevin Maak John Homoelle Matt Kalinowski Wenbin Liang Pekka Salminen Mike Levinson Roebi Urscheler DOW CONFIDENTIAL - Do not share without permissionSession 6.2 19 Paper 7633, Ronald Wevers
THANK YOU PRESENTED BY Ronald Wevers Dow Chemical rwevers@dow.com
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