Sealed Air Corporation

Sealed Air Corporation (US)

Shau-Tarng Lee

Natarajan S Ramesh

Nelson E Malwitz

James J Baker

Maurizio Brandolini

Brent Sholl

Claes Hermansson

Andrew Oiestad

The invention is directed to a composite foam material that is alkaline and heat resistance. The composite foam material comprises a foam layer that having a film layer attached thereto and in which at least one of the film or foam layers includes a carbon free radical scavenger agent that is dispersed therein. The carbon free radical scavengers neutralize free radicals that are generated in the polymeric material (e.g., film or foam layer) and help prevent the degradation of the foam composite material. In particular, foam composite materials in accordance with the present invention can be used in underlayment applications in which exposure to heat can degrade the underlayment. As a result, the durability and useful life of the composite sheet material can be extended. In some embodiments of the present invention provides a floor underlayment material that overcomes many of the problems discussed above.

Alkaline and heat resistant foam composite and floor underlayment

An expanded cellular ethylenic polymer product is provided from an irradiated, noncross-linked linear ethylenic polymer. Linear ethylenic polymers can be irradiated at ambient conditions sufficient to introduce branching in the polymer in the absence of detectable cross-linking as indicated by the absence of gels. The irradiated linear ethylenic polymer is compatible with highly branched low density polyethylene and, when mixed therewith, produces a resin having a single broad based melting temperature range as determined by direct scanning calorimetry, which indicates that the polymers in the mixture have similar crystallization behavior suitable for producing low density foams by extrusion foaming. The linear polymers can be obtained from recycled shrink wrap film. Low densities of from 0.7 to less than 4 pcf can be achieved. The foams typically have improved tear resistance as compared to previous products prepared from low density polyethylene, at comparable low densities.

Compatible linear and branched ethylenic polymers and foams therefrom

An extruded thin sheet foam is disclosed prepared from a polyolefin resin in which the blowing agent comprises a blend of from about 1 to 25% by weight of carbon dioxide and the balance of C3 to C4 VOCs. Thin foam sheets produced with the blowing agent age about twice as fast as foams prepared with VOCs, are remarkably stable, and can be produced at high throughputs.

Expandable composition, blowing agent, and process for extruded thermoplastic foams

A foam and method for making such foam includes a blend of a low density polyethylene and a higher density ethylene polymer. The ethylene polymer has a density ranging from greater than 0.94 to about 0.97 grams/cubic centimeter and a melt flow index of greater than 10 g/10 minutes, and may include at least one member selected from ethylene/alpha-olefin copolymer, ethylene homopolymer, and blends thereof.

Foam comprising polyolefin blend and method for producing same

Compitable linear and branched ethylenic polymers and foams therefrom

A process additive for polyolefin films and foams produces products having reduced aging time and reduced greasiness and reduced grease-like transfer as compared to glycerol monostearate (GMS). Carbon dioxide based blowing agents are suitable. The process additive comprises a fatty acid N-aliphatic alcohol amide of the general formula R&mdash;CON(R&prime;)R&Prime;. R is a fatty hydrocarbon radical having from about 8 to 30 carbons. R&prime; typically is hydrogen. R&prime; can also be an alkyl radical of from about 1 to 6 carbons or an alkyl alcohol radical of from about 1 to 6 carbons. R&Prime; is an alkyl alcohol fragment of from about 1 to 6 carbons. The alkyl alcohol fragments can be monohydric or polyhydric. Secondary fatty monoalkanolamides in which R&prime; is hydrogen are particularly useful, especially stearamide monoethanolamine (MEA). The benefits of the invention can be achieved and enhanced in some examples by mixing the fatty acid N-aliphatic alcohol amide with an ester of a long chain fatty acid with a polyhydric alcohol, including GMS. Examples of fatty acid N-aliphatic alcohol amides include cocamide MEA, lauramide monoisopropylamine (MIPA), oleamide MIPA, and stearamide 2,3-propanediol.

Polyolefin products and process additives therefor having reduced transfer to substrates

A method for accelerating the release of a flammable blowing agent from an expanded foam is disclosed. According to the method, an expanded foam structure is perforated to form a first series of channels extending partially through its thickness from a first surface and a second series of channels extending partially through its thickness from a second surface opposite the first surface. The channels provide paths enabling the blowing agent to escape more rapidly from the interior of the expanded foam structure.

Method of forming a partially perforated foam

Ionomer present in a polyethylene resin from about 1 to 40% by weight of the resin produces superior extruded foam sheet products that approach the pore size and resiliency of foams prepared from chemical blowing agents. The results can be achieved at normal extrusion rates and on standard extrusion foaming equipment. Tear strength is improved so that collapsible foam packaging products can be produced in which the foam body is cut through except for a surface thereof that remains intact to provide a hinge or joint about which the cut foam bodies can be pivoted.

Polyolefin/ionomer blend for improved properties in extruded foam products

Partially perforated foam

A process additive for polyolefin films and foams produces products having reduced aging time and reduced greasiness and reduced grease-like transfer as compared to glycerol monostearate (GMS). Carbon dioxide based blowing agents are suitable. The process additive comprises a fatty acid N-aliphatic alcohol amide of the general formula R-CON(R')R'. R is a fatty hydrocarbon radical having from about 8 to 30 carbons. R' typically is hydrogen. R' can also be an alkyl radical of from about 1 to 6 carbons or an alkyl alcohol radical of from about 1 to 6 carbons. R' is an alkyl alcohol fragment of from about 1 to 6 carbons. The alkyl alcohol fragments can be monohydric or polyhydric. Secondary fatty monoalkanolamides in which R' is hydrogen are particularly useful, especially stearamide monoethanolamine (MEA). The benefits of the invention can be achieved and enhanced in some examples by mixing the fatty acid N-aliphatic alcohol amide with an ester of a long chain fatty acid with a polyhydric alcohol, including GMS. Examples of fatty acid N-aliphatic alcohol amides include cocamide MEA, lauramide monoisopropylamine (MIPA), oleamide MIPA, and stearamide 2,3-propanediol.

Polyolefin products and process additives therefor having reduced

A foam comprising a blend of a low density polyethylene and an ethylene/alpha-olefin copolymer is disclosed. The ethylene/alpha-olefin copolymer is preferably LLDPE and has a density ranging from about 0.86 to about 0.94 grams/cubic centimeter and a melt flow index of greater than 10 g/10 minutes. A method for producing such foam is also disclosed.

Growing community of inventors

Oakland, NJ, United States of America

Shau-Tarng Lee