Compostable composition, compostable product, and method for preparing compostable product

Abstract

The application relates to compostable products and compositions comprising at least one biodegradable polymer and a hydrophobic agent. In some embodiments, these compostable products and compositions comprise a second biodegradable polymer different from a first biodegradable polymer. In some embodiments, the first biodegradable polymer is selected from the group consisting of: poly (ethylene succinate) (PES), poly (trimethylene succinate) (PTS), poly (butylene succinate) (PBS), poly (butylene succinate-co-butylene adipate) (PBSA), poly (butylene adipate-co-terephthalate) (PBAT), poly (tetramethylene adipate-co-terephthalate) (PTAT) and thermoplastic starch. In some embodiments, the products currently described include packaging.

Description

Technical Field

[0001] The present disclosure generally relates to compostable compositions, compostable products, and methods of making compostable products. Background Art

[0002] Many limited use or disposable products manufactured today require components formed by extrusion and / or molding (e.g., injection molding, blow molding). So-called limited use or disposable refers to that the product and / or component is only used a small number of times or may only be used once before being discarded. Exemplary disposable products include flexible films made of plastic, which are widely used to package various products. In some cases, such flexible films can form air barriers or liquid barriers to prevent degradation and contamination of food. Requirements for food packaging include ensuring that the packaging remains intact for a long time. Therefore, polymer-based flexible films are generally non-biodegradable and non-recyclable. The disposal of such non-biodegradable and non-recyclable (non-renewable) waste is an urgent environmental challenge.

[0003] Previous attempts to provide biodegradable products have relied on, for example, blending polymers to achieve desired mechanical properties. U.S. Patent 5,910,545 describes a biodegradable thermoplastic blend comprising poly(lactic acid) and polybutylene succinate (PBS), and a wetting agent having a hydrophilic-lipophilic balance ratio between 10 and 40. U.S. Patent 10,081,168 describes a packaging material comprising at least one polymer coating comprising at least 70 weight percent polylactide (PLA), and at least 5 weight percent polybutylene succinate (PBS) or a derivative thereof blended therewith. U.S. Patents US20180229917, US20180086538, US102353458, US9957098, US20190328857, US20200024061 and US20180194534 relate to compostable containers. Summary of the invention

[0004] There remains a need to provide compostable but durable compositions and articles. By "durable" compositions, it is meant compositions that can be formed into different articles, including packaging articles that are resistant to transportation and have an effective shelf life. In one aspect, the inventors have developed compostable compositions and articles that surprisingly exhibit high water repellency. In another aspect, the articles of the present application are weather resistant and suitable for use as packaging.

[0005] The application relates to durable but compostable products, which include a first biodegradable polymer and a hydrophobic agent. In some embodiments, the compostable product also includes a second biodegradable polymer that is different from the first biodegradable polymer. In some embodiments, the hydrophobic agent is a biodegradable hydrophobic agent. In some embodiments, the first biodegradable polymer is selected from the group consisting of: poly (butylene succinate), poly (butylene succinate adipate), poly (ethylene succinate), poly (tetramethylene adipate-to-terephthalate) and thermoplastic starch.

[0006] The compostable compositions of the present disclosure may be made from a formulation comprising at least 40 weight percent ("40 wt %), at least 45 wt %, at least 50 wt %, at least 55 wt %, at least 60 wt %, or at least 65 wt % of a biodegradable polymer. In some embodiments, the compostable compositions of the present disclosure may be made from a formulation comprising greater than 50 wt %, greater than 60 wt %, greater than 70 wt %, greater than 80 wt % (e.g., 90 wt %) of a biodegradable polymer. Such compositions may be prepared, for example, by combining a biodegradable thermoplastic such as a first biodegradable polymer (e.g., polybutylene succinate (PBS)) and a second biodegradable polymer (e.g., polylactic acid (PLA)) with a hydrophobic agent (e.g., hydrogenated castor oil extracted from castor seeds) and an inorganic filler derived from a natural deposit (e.g., calcium carbonate, hydrated magnesium silicate).

[0007] The disclosed compostable compositions can be molded into various shapes, can be composted in consumer and / or industrial composting facilities, and are generally suitable for a variety of applications, including but not limited to those involving food and / or food preparation, shipping, and personal hygiene items. In some embodiments, these compostable articles are used in food packaging and provide a liquid barrier to prevent contamination and premature degradation of the food contained therein.

[0008]

[0026] A further understanding of the features and advantages of the present disclosure will be achieved upon consideration of the detailed description and the appended claims.

[0009] Reference symbols used repeatedly in the specification and drawings are intended to represent the same or similar features or elements of the present disclosure. It should be understood that those skilled in the art can design many other modifications and embodiments that fall within the scope and essence of the principles of the present disclosure. The drawings may not be drawn to scale. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The present disclosure can be more fully understood with reference to the following detailed description of various embodiments of the present disclosure in conjunction with the accompanying drawings, in which:

[0011] Figure 1 is a schematic diagram of an exemplary compostable article.

[0012] Figure 2 is a schematic diagram of another exemplary compostable article.

[0013] Figure 3 is a schematic diagram of yet another exemplary compostable article.

[0014] Figure 4A and Figure 4B are schematic illustrations of exemplary compostable articles having a closure in an open (4A) configuration and a closed (4B) configuration.

[0015] Figure 5 is a schematic diagram of an exemplary compostable article having an adhesive portion.

[0016] Figure 6 is a schematic diagram of an exemplary compostable article having two adhesive portions on a closure.

[0017] Figure 7 is a perspective cross-sectional view of an exemplary compostable article according to the present disclosure.

[0018] Figure 8 is a photograph of an exemplary compostable article comprising a pattern and prepared as described in Example 13A below.

[0019] Fig. 9 is a photograph of an exemplary compostable article comprising a pattern and prepared as described in Example 13B below.

[0020] Fig.10 is a photograph of an exemplary compostable article comprising a pattern and prepared as described in Example 23 below.

[0021] Fig.11 is a cross-sectional view of an exemplary compostable article.

[0022] Figures 12A to 12C is a cross-sectional view of an exemplary compostable article including microstructures.

[0023] Fig.13 is a cross-sectional view of an exemplary compostable article including microstructures.

[0024] Fig.14 is a cross-sectional view of an exemplary compostable article including microstructures. DETAILED DESCRIPTION

[0025] Some terms in this disclosure are defined as follows. Other terms will be familiar to those skilled in the art and should be given the meanings that those of ordinary skill in the art would give them.

[0026] Terms indicating high frequency such as (but not limited to) "common", "typical" and "usually" and "commonly", "typically" and "usually" are used herein to refer to features frequently employed in the present invention, and unless explicitly used against the prior art, are not intended to imply that these features are present in the prior art to a lesser extent than those common, common or typical features in the prior art.

[0027] Throughout this disclosure, singular forms such as "a", "an", and "the" are often used for convenience; however, unless the context clearly requires or clearly indicates only the singular, the singular form is intended to include the plural. When referring to the singular alone, the term "only one" is generally used.

[0028] As used herein, the term "or" is generally used in its ordinary sense, including "and / or," unless the context clearly dictates otherwise. The term "and / or" means one or all of the listed elements, or a combination of any two or more of the listed elements.

[0029] As used herein, a material is "compostable" when it degrades or breaks down due to exposure to environmental influences such as sunlight, heat, water, oxygen, pollutants, microorganisms, enzymes, insects, and / or animals.

[0030] As used herein, a material is "compostable" when it meets the requirements of ASTM D6400-19 or ASTM D6868 or both. It should be noted that these two standards apply to different types of materials, so a material, composition or article only needs to meet one of the standards (usually whichever is most applicable) to be "compostable" as defined herein. In addition to meeting the ASTM D6400 or ASTM D6868 standards, a compostable material, composition or article may optionally meet one or more of the following standards: ASTM D5338, EN 12432, AS 4736, ISO 17088 or ISO 14855. It should be noted that the term "compostable" as used herein is not interchangeable with the term "biodegradable." A "compostable" material must degrade into a material having toxicity (specifically, phytotoxicity) that meets the above one or more standards within the time specified by the above one or more standards. The term "biodegradable" does not specify how long a material must degrade, nor does it specify that the compounds it degrades into must pass any standards for toxicity or environmental safety. For example, a material that meets the ASTM D6400 standard (i.e., compostable material) must pass the test specified in ISO 17088, which addresses the issue of "the presence of high levels of regulated metals and other hazardous components," while a "biodegradable" material can have any level of hazardous components.

[0031] As used herein, the term "package" refers to any item used to transport, store or protect goods. Examples of packages according to the present disclosure include, but are not limited to, wrappers, pouches, bags, envelopes, etc. In some embodiments, the package is used to protect food.

[0032] Components of common household items (e.g., bottles, cups, containers, utensils) can be formed from various grades of polymers derived from petrochemicals (i.e., petrochemical-based polymers such as polystyrene, polypropylene and polycarbonate). In order to reduce the impact on the environment, recycled resin streams can be used to manufacture these components. However, the continued consumption of fossil resources and concerns about global warming associated with the use of petrochemicals continue to drive the development of new biodegradable polymers, because biodegradable polymers generally have a relatively low CO2 footprint and may be advantageously associated with the concept of sustainability. In addition, consumers are interested in and expect compostable options for formed parts that can be used, for example, for household items, packaging, food contact applications, and / or parts that may be difficult to recycle into recycling streams (e.g., meat packaging, medical packaging, dental packaging).

[0033] Packaged products, particularly those designed for shipment, such as mailers, envelopes, bags and pouches, can be made of compostable or recyclable paper. However, paper is durable, that is to say it does not have water resistance or weatherability. Therefore, paper products are unacceptable for many packaging and shipping applications, particularly for the application of the environment (for example, during shipping or conveying) that may be exposed to bad weather for packaging. Possibly weather-resistant (i.e. durable) plastics or plastic-containing packaging and shipping products are non-compostable, and therefore most of them eventually become landfill garbage. Even those plastic packaging and shipping products that can be recycled are often not recycled, and when they are recycled, recovery process may be both expensive and time-consuming.

[0034] Biodegradable food packaging products are known.Previous attempts to produce packaging with less environmental impact rely on naturally occurring polymers (e.g., polysaccharides, such as cellulose-based, starch-based). However, in some cases, these polymers degrade too quickly to be considered durable and can not be effectively used as food packaging. In other cases, these polymers are hydrophilic and can not provide enough air and / or moisture barriers for packaged articles. For example, PCT discloses WO91 / 06601 to describe a biodegradable polymer composition comprising one or more polymers and fillers. The filler comprises a degradation-enhancing material, which comprises a cleavage agent (such as a surfactant) and a biodegradable safety material. PCT discloses WO 93 / 00601 to describe a biodegradable film consisting of starch and water. PCT discloses WO 96 / 03886 to describe a biodegradable molding for packaging food or non-food products. These moldings comprise a self-supporting substrate obtained by baking a suspension based on a starch product, and a waterproof film made of a wax component.

[0035] In one aspect, the present disclosure recognizes the problem of providing a compostable packaging article, such as a shipping article or a food packaging article, that provides a degree of weather resistance, water resistance, or moisture resistance. The present disclosure also recognizes the problem of sealing the edges of a compostable sheet, particularly by the well-known, fast, and inexpensive heat sealing process, to manufacture a compostable article, such as a bag, pouch, or envelope, having an open edge and one or more sealed edges.

[0036] In short, the solution for some or all of these problems and other problems that may or may not be specified in the present disclosure lies in compostable compositions and articles. Compostable compositions and articles of the present disclosure can be made from a preparation comprising at least 40 weight percent ("40 wt %), at least 45 wt %, at least 50 wt %, at least 55 wt %, at least 60 wt % or at least 65 wt % of a first biodegradable polymer and a hydrophobic agent, wherein the first biodegradable polymer is more specifically a first compostable polymer, and the hydrophobic agent is more specifically a first compostable hydrophobic agent. In some embodiments, compostable compositions and articles of the present disclosure can be made from a preparation comprising a first biodegradable polymer (more specifically, a first compostable polymer) greater than 50 wt %, greater than 60 wt %, greater than 70 wt %, greater than 80 wt % (e.g., 90 wt %). In some embodiments, the compostable composition additionally comprises a second biodegradable polymer, which is more specifically a second compostable polymer. For example, a first biodegradable polymer (e.g., polybutylene succinate (PBS)) and a second biodegradable polymer (e.g., polylactic acid (PLA)) are combined with a hydrophobic agent (e.g., hydrogenated castor oil extracted from castor seeds). In some embodiments, an inorganic filler derived from natural deposits (e.g., calcium carbonate, hydrated magnesium silicate) is added.

[0037] The disclosed compositions can be molded into a variety of shapes, can be compostable in consumer and / or industrial composting facilities, and are generally suitable for use in a variety of applications, including but not limited to those involving food and / or food preparation.

[0038] In one aspect, the compostable article according to the present application is a packaging article, which includes a first wall and a second wall, the first wall having a first inner surface and a first outer surface opposite to the first inner surface, and the second wall having a second inner surface and a second outer surface opposite to the second inner surface. The first inner surface and the second inner surface define the interior of the packaging article, and the first outer surface and the second outer surface define the exterior of the packaging article. The packaging article has one or more edges, wherein the first wall is attached to the second wall. Optionally, the article may have at least one opening, wherein the first wall is not attached to the second wall; not all cases require this, because the packaging article can be formed around an object to be placed inside the packaging article, thereby eliminating the need for articles with openings. The first wall or the second wall is composed of a compostable material comprising a first biodegradable polymer and a hydrophobic agent. In some embodiments, the first wall and the second wall are composed of a compostable material. In some embodiments, the packaging article also includes a compostable coating. In some embodiments, the compostable coating includes a heat-sealable compostable coating.

[0039] Biodegradable polymers :

[0040] The compostable compositions and articles of the present disclosure comprise a first biodegradable polymer, and optionally comprise a second biodegradable polymer different from the first biodegradable polymer. In some embodiments, the first biodegradable polymer is an aliphatic polyester. In some embodiments, the aliphatic polyester is prepared by succinic acid or adipic acid. In some embodiments, the first biodegradable polymer is selected from the group consisting of: poly (ethylene succinate) (PES), poly (trimethylene succinate) (PTS), poly (butylene succinate) (PBS), poly (butylene succinate-to-butylene adipate) (PBSA), poly (butylene adipate-to-terephthalate) (PBAT) and poly (tetramethylene adipate-to-terephthalate) (PTAT). In some embodiments, the first biodegradable polymer is poly (butylene succinate). In other embodiments, the first biodegradable polymer is thermoplastic starch. In any of the preceding embodiments, the first biodegradable polymer is specifically compostable, ie it is a first compostable polymer.

[0041] In some embodiments, the second biodegradable polymer is selected from the group consisting of polylactide (PLA), polyglycolide (which is used herein to include both polyglycolide and polyglycolic acid), polycaprolactone, and copolymers of polylactide, polyglycolide and polycaprolactone, or two or more thereof. In some embodiments, the second biodegradable polymer is selected from the group consisting of zein, cellulose esters, polyhydroxyalkanoates, polyhydroxyvalerates, polyhydroxycaproates, poly(ethylene succinate) (PES), poly(trimethylene succinate) (PTS), poly(butylene succinate) (PBS), poly(butylene succinate-co-butylene adipate) (PBSA), poly(butylene adipate-co-terephthalate) (PBAT), poly(tetramethylene adipate-co-terephthalate) (PTAT), thermoplastic starch, and combinations thereof. In some embodiments, the first biodegradable polymer comprises polybutylene succinate, and the second biodegradable polymer comprises polylactide. In other embodiments, the compostable composition consists essentially of polybutylene succinate and a hydrophobic agent. In some embodiments, the hydrophobic agent is a compostable hydrophobic agent.

[0042] The compostable compositions and articles of the present disclosure generally comprise 40% to 75% by weight, optionally 45% to 70% by weight, or optionally 50% to 60% by weight of the total weight of the first biodegradable polymer and the second biodegradable polymer, the first biodegradable polymer and the second biodegradable polymer being specifically the first compostable polymer and the second compostable polymer. In some embodiments, the ratio of the weight percentage of the first biodegradable polymer (specifically, the first compostable polymer) to the weight percentage of the second biodegradable polymer (specifically, the second compostable polymer) in the composition is 0.5:1 to 1.5:1, optionally 0.75:1 to 1.25:1, or optionally 1:1, 0.1:1, 0.2:1, 2:1, 5:1, and 10:1.

[0043] The term "PLA" is intended to include both polylactide and polylactic acid.

[0044] Polybutylene succinate (PBS) is a thermoplastic aliphatic polyester that naturally decomposes into water and carbon dioxide in the presence of microorganisms such as Amycolatopsis sp. HT-6 and Penicillium sp. strain 14-3. Although PBS has uses including packaging, its hydrophilic nature makes it unsuitable as an adequate moisture barrier and is not durable enough for packaging applications.

[0045] Hydrophobic Agent :

[0046] The compostable compositions of the present disclosure advantageously include a hydrophobic agent. While not wishing to be bound by a particular theory, it is believed that the hydrophobic agent can impart useful properties to the disclosed compositions, such as enhanced mold release (when the composition is used in an injection molding process) and hydrophobicity.

[0047] Examples of suitable hydrophobes include both bio-based and petroleum-based hydrophobes. Exemplary hydrophobes include, but are not limited to, vinyl bis (stearamide) (EBS), castor oil, hydrogenated castor oil (castor wax), soybean wax, polyamic acid, linoleic acid, arachidonic acid, palmitoleic acid, butyric acid, stearic acid, triglycerides, paraffin or related petroleum-based hydrogenated hydrocarbons and mixtures thereof. Specifically, any of the above-mentioned hydrophobes can be compostable.

[0048] The compostable composition of the present disclosure comprises 1 wt % to 15 wt %, optionally 2 wt % to 8 wt % or optionally 2.5 wt % to 6 wt % (e.g., 4 wt %) of a suitable hydrophobic agent, specifically one or more hydrophobic agents in the above-mentioned hydrophobic agent. In some embodiments, the composition may comprise at least 1 wt %, at least 2 wt % or at least 2.5 wt % of a suitable hydrophobic agent. In some embodiments, the composition may comprise less than 10 wt %, less than 8 wt % or less than 6 wt % of a suitable hydrophobic agent. In some embodiments, the hydrophobic agent is a biodegradable hydrophobic agent, and more specifically a compostable hydrophobic agent.

[0049] In one aspect, the coating, layer or component of the compostable article described herein is rendered hydrophobic due to the presence of at least one of a biodegradable hydrophobic agent or a compostable hydrophobic agent in an amount of 0.5 to 15 polymer weight. By "hydrophobic" is meant that the compostable article of the present application exhibits an advancing water contact angle of at least 90°.

[0050] filler

[0051] The compostable compositions of the present disclosure typically include at least one filler. When used, the filler is typically selected to impart useful properties to the disclosed compositions, for example, the addition of a filler may allow for changes in the Young's modulus (ksi), elongation %, and stress at break (psi) of the compostable composition.

[0052] Fillers suitable for use with embodiments of the present disclosure are known to those of ordinary skill in the art and may include inorganic materials such as calcium carbonate, talc, kaolin, clay, alumina trihydrate, calcium sulfate, glass bubbles, ground mica, zeolites, calcium phosphates, and combinations thereof.

[0053] Other fillers useful in embodiments of the present disclosure may include biodegradable fibers such as wood fibers, wood pulp, bamboo fibers, and combinations thereof.

[0054] In preferred embodiments, the compostable composition comprises 10% to 60% by weight, optionally 12% to 55% by weight, or optionally 14% to 50% by weight of filler. In some embodiments, the compostable composition comprises at least 10% by weight, at least 12% by weight, or at least 14% by weight of filler. In some embodiments, the compostable composition comprises at most 60% by weight, at most 55% by weight, or at most 50% by weight of filler. The use of filler is optional, because in some embodiments, even without the use of filler, the compostable composition also may have suitable or desired characteristics.

[0055] Useful fillers in embodiments of the compostable compositions of the present disclosure may be present in various shapes (e.g., spherical, rectangular, triangular, cylindrical, tubular, fibrous, plate-like, flaky). Useful fillers in embodiments of the compostable compositions of the present disclosure may also be present in various sizes. For example, the median particle size of a useful filler may be 0.1 μm to 10 μm, optionally 0.25 μm to 8 μm, optionally 0.5 μm to 6 μm, optionally 0.75 μm to 4 μm, or optionally 0.8 μm to 2 μm (e.g., 1.5 μm).

[0056] Other optional components

[0057] The compostable composition optionally comprises additional components to impart properties that may be desired in a particular application. Optional components may include, but are not limited to, other polymers (e.g., polypropylene, polyethylene, ethylene vinyl acetate, polyethylene terephthalate, polymethylpentene, and combinations thereof) (wherein such polymers may include a third biodegradable polymer and / or a petrochemical-based polymer), a release agent, a flame retardant, a conductive agent, an antistatic agent, a pigment, a dye, an antioxidant, an impact modifier, a stabilizer (e.g., a UV absorber), a wetting agent, or any combination thereof.

[0058] Specifically, compostable pigments and dyes can be used. Examples include PLA masterbatch colorants available from Clariant Corp. (Minneapolis, MN, USA) in the OM or OMB product lines, or those available from Techmer PM LLC (Clinton, TN, USA) in Clinton, Tennessee, USA in the PLAM or PPM product lines. Typically, when colorants are used, they are blended with other compostable composition components in an amount of 0.5% to 5% by weight.

[0059] Composition preparation

[0060] The compostable compositions of the present disclosure can be prepared by methods well known to those of ordinary skill in the relevant art. For example, a twin-screw extruder (purchased from APV (now part of Baker Perkins, Inc., Grand Rapids, Michigan, USA, under the trade name "MP2030") can be used to compound a first biodegradable polymer (e.g., PBS) with a hydrophobic agent (e.g., hydrogenated castor oil). Other components such as a second biodegradable polymer (e.g., PLA) and an inorganic filler can be added to the extruder feed. Optional components can also be added during the compounding process. After leaving the twin-screw extruder, the compostable composition can be pulled through a water bath via a knurled nip roller, and then the cooled composition is granulated using a rotating cutting blade. The particles can be further processed by known methods, such as, but not limited to, injection molding, blow molding, injection blow molding, or profile extrusion to provide a shaped article.

[0061] Compostable compositions may also be prepared by other methods, such as by mixing liquid solutions or dispersions of the components and subsequently drying (e.g., after casting a film of the composition). Other suitable methods for preparing compostable compositions are also possible. The selected preparation method may depend on the desired use or properties of the compostable composition and is readily determined, for example, by a person skilled in the art of polymer or material science.

[0062] Products

[0063] Any number of articles may be formed from the compositions of the present disclosure. Such formed articles may include items such as: trays and containers useful in food preparation and / or food storage; tape dispensers and tape cores; hooks (such as those commercially available under the trade name COMMAND from 3M Company, St. Paul, MN, USA); flat tubes formed into rolls that can be used in automated systems such as the ROLLBAG 3200 bagging machine (available from PAC Machinery, San Rafael, CA, USA); rigid packaging containers with or without fixed lids, separate lids, or live hinged lids; and packaging materials (e.g., bags, envelopes, pouches, or temporary corrugated boxes and carton closure systems and corner pieces), such as those commercially available under the trade name BOX LATCH from Eco Latch Systems, LLC, Pewaukee, WI, USA.

[0064] In certain forms such as packaging products, examples of products include envelopes, mailers, pouches, tubes, etc., which can be completely closed (e.g., with objects inside) or can have openings. In a specific embodiment, the compostable product of the present disclosure generally has two walls, i.e., a first wall and a second wall, each of which has an inner surface facing the interior of the product and an outer surface facing the exterior of the product. Therefore, the inner surface of the first wall ("first inner surface") faces the inner surface of the second wall ("second inner surface").

[0065] The two walls are usually made of a sheet of material, which can be a single layer material or a multilayer material. Wherein each wall can be made of different sheets, in which case the two walls can be made of the same or different materials. More commonly, the first wall and the second wall are made of the same sheet of material, which is folded to produce these two different walls. In these cases, the first wall and the second wall can be made of the same material. In some embodiments, the first wall or the second wall comprises a sheet prepared by the compostable composition of the application. In some embodiments, the first wall and the second wall are made of a compostable composition.

[0066] The first wall and the second wall are attached along at least one edge of the packaged article. Depending on the configuration and shape of the article, the two walls can be attached along two, three, four or even more edges. The first wall and the second wall can be directly attached (such as sealed together) or they can be indirectly attached through an intermediate structure (such as a fold, a welt or the like). The packaged article also includes an opening to which the first wall and the second wall are not attached.

[0067] The article, in particular the packaging article, may include an opening to which the first wall and the second wall are not attached. However, the opening is not necessary, as the packaging article can also be formed around the object located inside, thereby eliminating the need to manufacture an article with an opening and then close the opening.

[0068] There may be mechanisms or features that facilitate easy opening of the packaged article after sealing. Examples include perforations, scores, plastic seals, or embedded drawstrings or cords. When an opening or closure is present, one or more of these features may be present near the opening or closure to facilitate opening the packaged article near the opening or closure, or they may be present on different portions of the packaged article. While these features, when employed, are most commonly in a straight line parallel to at least one edge of the packaged article, without requiring a specific configuration; other shapes or layouts may be used depending on the intended use of the packaged article.

[0069] The compostable articles formed from the compositions of the present disclosure meet the ASTM D6400 standard. In addition or alternatively, when the sheet products are compostable, they may meet the ASTM D6868 standard. In addition to meeting one or both of the aforementioned standards, the compostable formed articles may also meet at least one of the EN 12432 standard, the AS 4736 standard, or the ISO 17088 standard. Certain compostable formed articles also meet the ISO 14855 standard.

[0070] Fiber layer

[0071] In some embodiments, compostable products include a fiber layer. The fiber layer includes nonwoven materials and cellulosic materials, such as paper and cardboard. In some embodiments, the fiber layer is biodegradable. Exemplary biodegradable fiber layers and fibers include those biodegradable fiber layers and fibers made from the following raw materials: polylactide (PLA), naturally occurring zein, polycaprolactone, cellulose ester, polyhydroxyalkanoate (PHA) (for example, poly-3-hydroxybutyrate (PHB), polyhydroxyvalerate (PHV), polyhydroxycaproate (PHH), poly (ethylene succinate) (PES), poly (trimethylene succinate) (PTS), poly (butylene succinate) (PBS), poly (butylene succinate-to-butylene adipate) (PBSA), poly (butylene adipate-to-terephthalate) (PBAT), poly (tetramethylene adipate-to-terephthalate) (PTAT) and mixtures thereof.

[0072] Suitable nonwoven materials include spunbond fabrics, meltblown fabrics, spunlace materials, airlaid materials, wetlaid materials, carded materials, and combinations thereof. Spunbond fibers are known in the art and refer to fabrics prepared by depositing extruded spun filaments onto a collecting belt in a uniform, random manner and then bonding the fibers. The fibers are separated during the layering process by air jets or electrostatic charges. Layers comprising spunbond fibers may be provided by techniques known in the art (e.g., using generally as described in U.S. Pat. No. 8,802,002 (Berrigan et al.) Figure 1The apparatus shown in FIG. 1 , the disclosure of which is incorporated herein by reference, and is also commercially available, for example, from NatureWorks LLC, Minnetonka, MN, under the trade name "INGEO BIOPOLYMER 6202D" (polylactic acid fibers; spunbond scrim, smoothing calender). Standard meltblown fiber forming processes are disclosed, for example, in U.S. Patent Publication 2006 / 0096911 (Brey et al.), the disclosure of which is incorporated herein by reference in its entirety. Blown microfibers (BMF) are produced by molten polymer entering and flowing through a die, the flow being distributed in a die cavity across the width of the die, and the polymer flowing out of the die through a series of orifices as filaments. In an exemplary embodiment, a heated air stream flows through an air manifold and an air knife assembly adjacent to a series of polymer orifices that constitute the die outlet (die head). The heated air stream can be adjusted in temperature and velocity to attenuate (attenuate) the polymer filaments to a desired fiber diameter. The BMF fibers are conveyed in the turbulent air flow toward the rotating surface, where they collect to form a layer.

[0073] Particular fiber layers that may be used have a sufficient basis weight to allow them to withstand weather conditions such as heat, cold, rain or snow, and other conditions that may be encountered during packaging and shipping processes, and also to allow them to withstand handling that may occur during packaging and shipping, such as being dropped, jostled, struck against other objects, etc. In some embodiments, the basis weight of the fiber layer is 6 g / m 2 Up to 300g / m 2 When nonwoven materials are used, any nonwoven basis weight suitable for the intended use may be used, and a variety of basis weights may be suitable depending on the needs of the user. Most commonly, the basis weight (in g / m 2 Basis weight (also in g / m2) will be no less than 20, optionally no less than 30, optionally no less than 40, optionally no less than 50, optionally no less than 75, optionally no less than 100, optionally no less than 125, optionally no less than 150, optionally no less than 175, optionally no less than 200, optionally no less than 225, or optionally no less than 250. ... 2 The basis weight (also in g / m2) is typically no greater than 250, optionally no greater than 225, optionally no greater than 200, optionally no greater than 175, optionally no greater than 150, optionally no greater than 125, optionally no greater than 100, optionally no greater than 75, optionally no greater than 50, optionally no greater than 40, or optionally no greater than 30. For example, the basis weight (also in g / m2) is typically no greater than 250, optionally no greater than 225, optionally no greater than 200, optionally no greater than 175, optionally no greater than 150, optionally no greater than 125, optionally no greater than 100, optionally no greater than 75, optionally no greater than 50, optionally no greater than 40, or optionally no greater than 30. 2 The basis weight of the nonwoven material used may be 20 to 100, and more specifically, the basis weight of the cellulose-based wall may be 50 to 250.

[0074] An exemplary compostable article comprising a first wall and a second wall (such as any of those described herein) may include a fiber layer. A particularly useful material that can be used in the first wall, the second wall, or both is cellulose. When used, cellulose is typically a component of paper. Any form of paper can be used in the first wall, the second wall, or both, as long as it is compostable. Kraft paper is particularly useful for this purpose, but other compostable papers may also be used.

[0075] The first wall, the second wall, or both may be constructed from a single layer or sheet of material, or may be constructed from multiple sheets. When a single layer or sheet is used, it is typically PLA or paper. However, any of the materials identified herein as the second biodegradable polymer, and mixtures or blends thereof may also be used. A mixture may refer to a construction in which a single fiber has two or more types of second biodegradable polymers, or may refer to the use of two or more types of fibers in a single fiber layer or sheet, each fiber having different components.

[0076] When multiple layers or sheets are used for the first wall, the second wall, or both, they can be the same or different layers or sheets. Two, three, four, or even more layers or sheets can be used. In a configuration where there are two layers or sheets, one of the sheets is an inner layer or sheet disposed on the interior of the applicable wall, and the other layer or sheet is an outer layer sheet disposed on the exterior of the applicable wall. In a configuration where there are three layers or sheets, there is an additional intermediate layer or sheet between the inner and outer layers or sheets.

[0077] These layers or sheet material can be coated with compostable coating, any compostable coating in compostable coating as herein described, and more specifically, those compostable coatings comprising the first biodegradable (particularly, compostable) polymer and hydrophobic agent, and more specifically, the compostable coating comprising PBS and hydrophobic agent.More details about adoptable coating are provided below.At least, at least one of the first inner surface (of the first wall) or the first outer surface or the second inner surface (of the second wall) or the second outer surface is coated with one or more coatings, and these one or more coatings are made up of compostable coating, and more specifically made up of heat-sealable compostable coating.But, in many cases, one, two, three or more layers or one or both sides of sheet material in the layer or sheet constituting the first wall or the second wall are coated with compostable coating.

[0078] These layers or sheets can be bonded together in any suitable manner. Compostable coatings as discussed herein can be heat sealable coatings, in which case these layers or sheets can be bonded together by heat sealing processes (such as induction welding or impulse sealing). The coating on the adjacent sides of these sheets or layers can have an adhesive that can be used for laminating these sheets or layers. Patterned calendering rollers can also be used to bond adjacent layers.

[0079] One or more layers or sheets in these layers or sheets can be planar layers or sheets. It is also possible that one or more layers or sheets in these layers or sheets are embossed. Embossed layers or sheets can provide some buffering for the contents of the packaging product, and therefore can be advantageous for certain uses. Any embossing pattern can be used, but regular patterns or repeating patterns are most often used. Examples of repeating patterns are rhombus, square, circle, triangle, hexagon and mixed patterns with different shapes. When using multiple layers or sheets, any one or all of these layers or sheets can be embossed. Most commonly, when using two layers or sheets, the inner layer or sheet is embossed, and the outer layer or sheet is not embossed. When using three layers or sheets, then usually the middle or inner layer or sheet is embossed, and other layers or sheets are not embossed. However, other configurations can be adopted. For example, in a three-layer construction, it may be useful to emboss both the interior layer or sheet as well as the middle layer or sheet to provide additional cushioning beyond that provided by just one embossed layer or sheet.

[0080] In some embodiments, the fibrous layer comprises a sheet of loop material that can subsequently be cut into sheets to form loop portions for a fastener. The sheet of loop material generally comprises a backing comprising a thermoplastic backing layer having a generally uniform morphology, and longitudinally oriented fibrous sheets having generally undeformed anchor portions and arcuate portions bonded or fused in the thermoplastic backing layer at spaced apart bond locations, and the arcuate portions protruding from the front surface of the backing between the bond locations.

[0081] In some embodiments, the fibers include a core-sheath construction, wherein the core and sheath may be made of the same material or different materials. Fibers made of one material or fibers made of different materials or combinations of materials may be used in the same fiber sheet.

[0082] When a sheet of loop material is used to form the loop portion of a fastener intended for limited use (i.e., for use where the fastener will typically be opened and closed 10 times or less), preferably, the height of the arcuate portion of the fibrous sheet from the backing is less than about 0.64 centimeters (0.250 inches) and preferably less than about 0.38 centimeters (0.15 inches); the width of the bond locations should be between about 0.005 inches and 0.075 inches; and the width of the arcuate portion of the fibrous sheet should be between about 0.06 inches and 0.35 inches. An exemplary method for preparing suitable loop materials is described in U.S. Pat. No. 5,256,231, the disclosure of which is incorporated herein by reference in its entirety.

[0083] Compostable paint

[0084] Compostable articles according to the application may also include compostable coatings, which may also be heat sealable coatings in a specific embodiment. For packaging products including the first wall and the second wall, at least one of the first inner surface (of the first wall), the second inner surface (of the second wall), the first outer surface (of the first wall) and the second outer surface (of the second wall) may be coated with one or more compostable coatings. Compostable coatings include heat sealable compostable coatings. Other layers or sheets may also be coated with any coating in the coating discussed herein, or may be coated with other coatings that do not detract from the compostability of the first wall and the second wall.

[0085] Heat sealable compostable coating is generally compostable composition as described herein.Therefore, it generally comprises one or more of polybutylene succinate, poly (butylene succinate adipate), poly (ethylene succinate), poly (tetramethylene adipate-to-terephthalate), hydrogenated castor oil or thermoplastic starch.Specifically, the heat sealable compostable coating comprises at least one of polybutylene succinate, poly (butylene succinate adipate), poly (ethylene succinate), hydrogenated castor oil or poly (tetramethylene adipate-to-terephthalate).More specifically, the coating comprises polybutylene succinate, castor oil (such as hydrogenated castor oil) or both.The heat sealable compostable coating can be used for several purposes.By allowing wherein the first wall to be attached to one or more edges of the second wall to be heat sealed, the heat sealable compostable coating can be used to form a packaged product. It can also be used to provide weather resistance or water resistance to packaging products.

[0086] Other components may also be included in the coating. Specifically, compostable pigments and dyes may be used. Examples include PLA masterbatch colorants available from Clariant in Minneapolis, Minnesota, USA, under the OM or OMB product lines, or those available from Techmer PM in Clinton, Tennessee, USA, under the PLAM or PPM product lines. Typically, when colorants are used, they are blended with other coating components in an amount of 0.5 to 5 weight percent.

[0087] There are at least two ways to place the coating on a layer or sheet. Both ways are important, and either way can be used with any embodiment of the article as described herein.

[0088] A first specific way to apply the coating to the underlying sheet or layer material after the underlying sheet or layer is formed is to apply it to any fibrous material such as discussed herein. This can be done by any suitable method. Typically, the method used is extrusion.

[0089] A second specific way to apply a coating is to coat individual fibers of a fiber material, sheet or layer with a coating. This results in a core-sheath configuration, where the core acts as the sheet or layer material and the sheath acts as the coating. Various ways of preparing core-sheath fibers are known in the art, and in principle any of these ways can be used depending on the composition of the core and sheath. In principle, additional coatings can be applied to the sheath, and these additional coatings are within the scope of the coatings as described herein.

[0090] In any embodiment of the articles described herein, a combination of the two aforementioned methods may be used. Thus, in certain cases, individual fibers are coated in a core-sheath configuration, and the coating is disposed on one or both sides of a layer or sheet of material made of core-sheath fibers, wherein the coating may be the same or different coating than the sheath.

[0091] In either case, the coating need not be applied to the entire layer or sheet, but may be applied to only a portion of the layer or sheet. More specifically, however, the coating is applied to the entirety of at least one side of the layer or sheet. Even more specifically, the coating (most specifically, a coating comprising polybutylene succinate) is applied to the entirety of both sides of the layer or sheet.

[0092] One particularly useful configuration of one or more layers or sheets of these layers or sheets is a polylactic acid layer or sheet, which is fully coated with polybutylene succinate on both sides, and more specifically coated with a mixture of polybutylene succinate and castor oil, optionally coated with one or more pigments or dyes as additional components of the coating. More specifically, these layers or sheets with polylactic acid layers or sheets fully coated with polybutylene succinate on both sides can be embossed. Another particularly useful configuration of these layers or sheets is a paper layer or sheet fully coated with polybutylene succinate on both sides. More specifically, a paper layer or sheet fully coated with polybutylene succinate on both sides can be embossed. In any layer or sheet completely coated on both sides, and specifically, in the aforementioned polylactic acid or paper layer or sheet completely coated with polybutylene succinate on both sides, the coating may be in the form of a layer arranged on the material layer or material sheet, or may be in the form of a skin arranged on the fibers of the material layer or material sheet.

[0093] The coating thickness (in micrometers) can be any thickness necessary to provide the desired properties, but is typically greater than 10, greater than 15, greater than 20, greater than 25, greater than 30, greater than 35, greater than 40, greater than 45, or even greater than 50. The coating thickness (in micrometers) is typically less than 60, less than 55, less than 50, less than 45, less than 40, less than 35, less than 30, less than 25, or even less than 20. An exemplary range of coating thickness (in micrometers) is 20 to 50. When the coating is a sheath on a core fiber, the "coating thickness" refers to the thickness of the sheath; when the coating is applied as a layer, the "coating thickness" refers to the thickness of the layer.

[0094] Microstructure

[0095] In some embodiments, the compostable article further comprises a microstructure. The compostable article comprising the microstructure unexpectedly shows enhanced water repellency. Without wishing to be bound by theory, it is believed that these microstructures form channels on the surface of the biodegradable polymer layer, thereby hindering the entry of water (i.e., preventing the wetting of the surface). Therefore, a high water contact angle is observed, and the compostable article shows increased hydrophobicity.

[0096] In some embodiments, the microstructures may extend continuously across the entire length or width of the polymer layer, for example in the form of tracks. In other embodiments, the microstructures are discrete features (e.g., in the form of hooks or pillars). Exemplary methods of producing microstructures are described in U.S. Patents 5,053,028; 5,868,987; 6,000,106; 6,132,660; 6,417,294; and 7,168,139. ​​The disclosures of these U.S. Patents are incorporated herein by reference in their entirety.

[0097] In some embodiments, the microstructure includes a column. In other embodiments, the microstructure includes a rod and a cap. In some embodiments, the cap may have a rectangular, elliptical, circular or semicircular cross-section. In some embodiments, the width of the cap is greater than the width of the rod. In some embodiments, the rod and the cap are made of the same material. In other embodiments, the rod and the cap are made of different materials. In some embodiments, the rod and the cap are integrated. In other embodiments, the rod and the cap are separate components.

[0098] In some embodiments, the polymer layer and the microstructure are made of the same material. In other embodiments, the material of the polymer layer is different from the material of the microstructure. As used herein, "different" means at least one of the following: (a) at least 2% difference in at least one infrared peak, (b) at least 2% difference in at least one nuclear magnetic resonance peak, (c) at least 2% difference in number average molecular weight, or (d) at least 5% difference in polydispersity. Examples of differences in polymer materials that can provide differences between polymer materials include composition, microstructure, color, and refractive index. With respect to polymer materials, the term "same" means not different.

[0099] Adhesives

[0100] In some embodiments, one or more adhesive portions can be provided on compostable articles. In some embodiments, as previously mentioned, adhesive portion is provided on the articles comprising the first wall and the second wall. In these articles, adhesive portion is provided on the tops of these walls. These adhesive portions are not considered to be a part for these walls. Usually, when adopting, these adhesive portions are near the opening in the packaged articles, and can be used for closing these articles. If adopting capping, then these one or more adhesive portions are usually on this capping, or on a part of the outer surface, this capping can contact this part when folded into the closed position, so as to allow this capping to adhere to this closed position. In many cases, two adhesive portions are provided.

[0101] The one or more adhesive portions are typically in the form of one or more strips extending generally parallel to the opening of the packaging article, but this is not required.

[0102] The one or more adhesive parts can be any suitable adhesive, depending on the desired use, but are most commonly compostable adhesives. In certain cases, the one or more adhesive parts consist of a compostable adhesive. The one or more adhesive parts can be a water-activated adhesive or a pressure-sensitive adhesive. Most specifically, a compostable pressure-sensitive adhesive is employed. Exemplary compostable adhesives are known, and examples include copolymers of 2-octyl acrylate and acrylic acid; copolymers of sugar-modified acrylates; blends of polylactic acid, polycaprolactone, and resins; blends of poly(hydroxyalkanoates) and resins; protein adhesives; natural rubber adhesives; and polyamides containing dimer acids.

[0103] One or more release liners may be disposed on any or all of the one or more adhesive portions. While it is advantageous for the release liner to be compostable or at least recyclable, this is not required, as the release liner can be disposed of separately from the packaging article after use and need not be placed in a composting environment with the packaging article. Thus, packaging articles as described herein may be "compostable" if they have one or more release liners, even if any or all of the release liners are compostable.

[0104] Phase Change Materials (PCM)

[0105] The compostable compositions and products of the present application may also include phase change materials (PCM). PCM is a substance with high melting heat, which can store and release a large amount of energy (that is, undergo phase change) at a certain temperature when it melts or solidifies. During phase changes such as melting or freezing, the molecules themselves are rearranged and cause entropy changes, thereby causing the absorption or release of latent heat. During the entire phase change process, the temperature of the material itself remains constant. Some exemplary common PCMs include salts, hydrated salts, fatty acids and paraffin. Such PCMs through suitable packaging can be used as thermal devices. However, unlike dry ice or wet ice, most PCMs themselves are not easy to adapt to shipping and transportation applications. They must be paired with appropriate protective covers. PCM and protective covers together form a packaging structure that will be able to protect the products to be transported at the desired temperature.

[0106] The PCM used in the configuration of the present disclosure maintains the desired temperature of the article to be transported during shipment. Thus, the one or more PCMs may have one or more of the following qualities: good adjustability over a wide range of physical properties; adaptability to temperature and jostling during shipment; freezing without too much supercooling; ability to melt consistently; compatibility with a variety of conventional materials; chemical stability; non-corrosive; non-flammable; and non-toxic. In some embodiments, the PCM is compostable and / or biodegradable. The PCM may take the form of a liquid, gel, hydrocolloid, or a three-dimensional shape (e.g., rectangular, square, or brick-shaped).

[0107] Some exemplary PCMs are as follows. Suitable PCMs can be organic or inorganic materials, including salts, hydrated salts, fatty acids, paraffins, and / or mixtures thereof. Because different phase change material tools for changing phases undergo phase changes (or melts) at various temperatures, the specific material selected for the device may depend on the temperature at which the desired packaging is maintained, which may include a range between about -135°C and about 40°C. The desired range within this range may depend on the intended use of the packaging. For example, food cold chain packaging is typically between about -36°C and about 25°C. Biological or pharmaceutical cold chain packaging is typically between about -135°C and about 40°C.

[0108] In some embodiments for cold chain, a salt solution containing sodium chloride and water of about 20 weight percent to 23 weight percent can be provided as a phase change material. This particular phase change material is characterized by a melting phase transition temperature of about -19°C to about -21°C. Such a temperature range is applicable to the packaging and shipment of many pharmaceutical products, such as drugs, vaccines and other active biological preparations.

[0109] Other exemplary phase change materials or tools for changing phases that can be used for cold chain packaging, devices and articles disclosed herein may include compositions produced according to processes as described in U.S. Patent No. 6,574,971, which have desired phase change temperatures and other characteristics as described above. The materials of U.S. Patent No. 6,574,971 include fatty acids and fatty acid derivatives made by heating and catalytic reaction, cooling, separation and recycling. The reactant material includes fatty acid glycerides, which are selected from the group consisting of: oil or fat extracted from soybeans, palms, coconuts, sunflower seeds, rapeseed, cottonseed, linseed, castor, peanuts, olives, safflower, evening primrose, borage, rice beans, animal tallow and fat, animal fats and mixtures thereof. According to the method of U.S. Patent No. 6,574,971, the reaction mixture is a mixture of fatty acid glycerides with different melting points and the reaction is an ester exchange reaction, or the reaction mixture includes hydrogen and the reaction is a hydrogenation reaction, or the reaction mixture is a mixture of fatty acid glycerides and simple alcohols and the reaction is an alcoholysis reaction.

[0110] Additional exemplary PCMs include those listed in U.S. Patents 9,850,415; 9,914,865; 10,119,057; and 10,745,604, each of which is incorporated herein by reference in its entirety.

[0111] Description of the drawings

[0112] Figure 1An exemplary compostable article configuration 100 is shown in which two edges (111, 112) of a first wall 130 and a second wall 140 are attached. Figure 1 1, the article 100 is configured as a bag. The first edge 111 and the second edge 112 are directly attached, connecting the first wall 130 with the second wall 140. In this figure, only the outer surface 131 of the first wall 130 and the inner surface 142 of the second wall 140 are visible. There is an opening 150 where the first wall 130 and the second wall 140 are not attached. In this case, the bottom 120 is defined by a folded portion in the sheet material that constitutes the article 100.

[0113] Figure 2 Another configuration is shown in which only one edge 211 of the first wall 230 and the second wall 240 is attached. In this figure, the exemplary article 200 is also configured as a bag. The single edge 211 attaches most of the first wall 230 and the second wall 240, while leaving them unattached at the opening 250.

[0114] Figure 3 The configuration of an exemplary packaging article 300 is shown wherein edges 311 and 312 are in the form of hems that attach a first wall 330 and a second wall 340 while leaving an opening 350 where the first wall 330 and the second wall 340 are not attached.

[0115] Figure 4A and Figure 4B Another exemplary configuration of a packaging article 400 is shown, which includes a cover 460 that can be placed in a container such as a container. Figure 4A The open position shown is similar to Figure 4B In the open position, the opening 450 is not covered, but in the closed position, the opening 450 is covered by the cover 460.

[0116] exist Figure 5 An exemplary packaging article 500 with an adhesive portion 501 is shown in FIG. In this example, the packaging article 500 is formed as a bag, and the adhesive portion 501 is arranged near the top of the opening 550 to close the opening 550 when necessary.

[0117] exist Figure 6 An exemplary packaging article 600 with two adhesive portions 601 and 602 is shown in FIG. In this example, the packaging article 600 is formed as a pouch, and the adhesive portions 601 and 602 are arranged on a cover 660 to close an opening 650.

[0118] Figure 7An exemplary layered compostable article 700 according to the present application is shown, which has a first surface 700a and a second surface 700b. Compostable article 700 includes a first compostable polymer layer 710, a second compostable polymer layer 720 and a third compostable polymer layer 730. In the example shown, the first compostable polymer layer 710 and the third compostable polymer layer 730 have the same composition. In some embodiments, the two compostable polymer layers include PBS and a hydrophobic agent. In some embodiments, the first compostable polymer layer and the third compostable polymer layer are prepared by applying a compostable composition to the second compostable polymer layer. In some embodiments, the second compostable polymer layer 720 has a composition different from the first compostable polymer layer 710 and / or the third compostable polymer layer 730 and / or a different presentation form. In some embodiments, the second compostable polymer layer 720 includes PLA. In some embodiments, PLA is spunbonded. In other embodiments, the second compostable polymer layer 720 comprises a nonwoven web comprising PBS. The adhesive layer 740 is disposed on the first surface 700a of the compostable article 700. In some embodiments, the release layer 750 is disposed on the adhesive layer 740. In some embodiments, the release liner 750 comprises a silicone-coated polyester film.

[0119] Fig.11 is a cross-sectional view of an exemplary compostable article according to the present application. The compostable article 1100 includes a biodegradable polymer layer 1110 having a first surface 1120 and an opposite second surface 1130. In one embodiment, the biodegradable polymer layer 1110 comprises a first compostable polymer and a hydrophobic agent. In some embodiments, the first compostable polymer is polybutylene succinate (PBS) and the hydrophobic agent is a compostable hydrophobic agent. In some embodiments, the biodegradable polymer layer 1110 comprises a first biodegradable polymer and a second biodegradable polymer, wherein the first biodegradable polymer is different from the second biodegradable polymer. Figure 1 In the illustrated embodiment, the compostable article 1100 includes a fiber layer 1150 secured to a biodegradable polymer layer 1110 by an adhesive 1140. Other embodiments do not include an adhesive. In some embodiments, the biodegradable polymer layer 1110 is extruded directly onto the fiber layer 1150. In other embodiments, the biodegradable polymer layer 1110 and the fiber layer 1150 are heat laminated.

[0120] FIG. 12A to FIG. 12C is a cross-sectional view of an exemplary compostable article according to the present application. Fig. 12AThe compostable article 1200 includes a biodegradable polymer layer 1210 having a first surface 1220. The microstructure 1260 is arranged on the first surface 1220 of the compostable article 1200. Fig. 12B In the compostable article 1201 of the embodiment of the present invention, the microstructure 1261 protrudes from the first surface 1221 and is integral with the biodegradable polymer layer 1211. The microstructure 1262 of the compostable article 1202 includes a rod 1263 and a cap 1264. The rod 1263 is integral with the cap 1264. In other embodiments (not shown), the rod is not integral with the cap.

[0121] Fig.13 The illustrated compostable article 1300 includes a biodegradable polymer layer 1310 having microstructures 1360 extending from a first surface 1320 of the polymer layer 1310. A nonwoven layer 1350 is secured to a second surface of the biodegradable polymer layer 1310 by an adhesive 1340.

[0122] exist Fig.14 In the illustrated compostable article 1400, a nonwoven layer 1450 is adjacent to microstructures 1460 extending from a biodegradable polymer layer 1410. In this embodiment, the nonwoven layer 1450 and the microstructures 1460 form an attachment system. Fig.14 Exemplary uses of the attachment system shown include personal hygiene articles (e.g., feminine hygiene products, incontinence products, and diapers). Diapers generally include a top sheet, a back sheet, and an absorbent core. The diaper also includes a rear waistband portion, a front waistband portion, and a middle crotch portion, to which a fastening assembly is applied laterally. In use, the fastening tabs extend to and engage corresponding opposing landing areas of the diaper to secure the diaper to the wearer. U.S. Pat. No. 10,413,457 Figure 8 An exemplary diaper construction is shown in , the disclosure of which is incorporated herein by reference in its entirety. In some embodiments, the articles of the present disclosure can be used as packaging for feminine hygiene products. In some embodiments, these packages are release liners that enclose and protect feminine hygiene products before use. In other embodiments, the attachment system of the present application can be used to secure the release liner to the feminine hygiene product.

[0123] In order for materials to be considered hydrophobic and effective liquid barriers, they need to be hydrophobic as indicated by an advancing water contact angle measurement of at least 90°. In one aspect, the currently described compostable articles and compositions exhibit an advancing water contact angle measurement of at least 95°. In some embodiments, the compostable compositions of the present disclosure exhibit water contact angle measurements of 120°, 125°, and 135°. Another measure of a material's liquid barrier properties is its water vapor transmission rate (WVTR), as measured in ASTM F1249-13: "Standard Test Method for Water Vapor Transmission Rate Through Plastic Film and Sheeting Using a Modulated Infrared Sensor."

[0124] Example

[0125] The following examples further illustrate the advantages and embodiments of the present invention, but the specific materials and amounts thereof and other conditions and details mentioned in these examples should not be construed as undue limitations of the present invention. Without departing from the scope and spirit of the present invention, the foreseeable variations and modifications of the present disclosure will be apparent to those skilled in the art. Unless otherwise indicated, all parts and percentages are by weight.

[0126] Unless otherwise indicated, all parts, percentages, ratios, etc. in the examples and the remainder of the specification are by weight. The following abbreviations may be used: m = meter; cm = centimeter; mm = millimeter; um = micrometer; ft = foot; in = inch; RPM = revolutions per minute; g = gram; mg = milligram; kg = kilogram; oz = ounce; lb = pound; mL = milliliter; L = liter; Pa = Pascal; kPa = kilopascal; sec = second; min = minute; hr = hour; psi = pounds per square inch; °C = degrees Celsius; °F = degrees Fahrenheit; and phr = parts per hundred parts of resin (by weight). The terms "weight %", "% weight" and "wt %" are used interchangeably.

[0127] Material

[0128] Table 1. Materials

[0129]

[0130]

[0131] Test Method

[0132] Percent Elongation, Break Stress, and Young's Modulus :Use Engel 100TL Ton press to injection mold the exemplary and comparative compostable compositions prepared as described below to prepare "dog bone" samples, and these compositions are tested. The thickness of the thin part of the sample is measured to be 0.125 inches (3.1mm), the length is 2.50 inches (12.7mm), and the width is 0.50 inches (12.7mm). Before testing, the test sample is weathered for two weeks at 120℉ (49℃) and 65% relative humidity, and is balanced at 73.1℉ (22.8℃) and 50% relative humidity for at least 12 hours. Use electromechanical universal test system (purchased from MTS Systems Corporation (MTS Systems Corporation, Eden Prairie, MN, USA) in Eden Prairie, Minnesota, USA with trade name "MTS CRITERION MODEL 43") to measure the tensile properties of the sample under constant tensile rate. The load frame was equipped with a 10 kN load cell and a mechanical wedge clamp (purchased from MTS Systems, Inc., Eden Prairie, Minnesota, USA, under the trade name "MTS ADVANTAGE" and part number 056-079-501) was used to secure the sample. The gap between the clamps was adjusted to 2.5 inches (63.5 mm) and the test rate was 0.2 inches / minute. Before each reading, the load sensor was zeroed without a test sample in the clamp. Once the sample broke in the test area, the load sensor stopped vertical movement. Before testing, a thickness gauge was used to record the actual thickness of the center of the sample. The temperature of the room where the test was performed was controlled at 73.1°F ± 2°F and the relative humidity was controlled at 50% ± 2%. For each test, the following reports are available: elongation %, stress at break ("psi") and Young's modulus ("ksi"). Young's modulus is calculated as the ratio of stress to strain in the initial linear region of the stress-strain curve.

[0133] Other testing methods Additional test methods used to characterize exemplary articles are summarized in Table 2 below. For coefficient of friction testing, the side of the sample forming the outside of the pouch as described in the preparation process was tested against a steel surface. For tensile properties, the sample width was 0.5 in (1.2 cm) for the unlined material and 1 in (2.5 cm) for the padded material. The samples were conditioned overnight in a temperature and humidity controlled room, and a tensile speed of 10 in / min (25 cm / min) was used. The samples were tested in the machine direction (MD) and the cross-web (cross-web) direction (CD). Slip was determined as the average force reading during uniform sliding of the surface, and the dynamic coefficient of friction was calculated as slip divided by the sled weight (200 g).

[0134] Table 2. Test methods

[0135]

[0136]

[0137] Compostable Film and Pouch Examples

[0138] The following describes the methods for preparing the compostable films and pouches of Examples 1 to 26.

[0139] PLA web production

[0140] According to the following process, a nonwoven fiber layer is made from INGEO Biopolymer 6202D: the multilayer composite materials in all embodiments are prepared according to the general method disclosed in U.S. Patent No. 3,802,817, the disclosure of which is incorporated herein by reference in its entirety. Specifically, the equipment for forming a spunbond web includes a first station and a second station, wherein the first station is used to make a first nonwoven layer, and the second station is used to make a second nonwoven layer. Each station includes at least an extrusion head, a beam reduction device, and a quenching flow, wherein the two stations share a collector surface. The first station is positioned upstream of the second station, causing the precursor produced at the first station to first arrive at the collector surface and form a first fiber mass on the collector surface. The precursor from the second station is therefore deposited on the surface of the first fiber mass and forms a second fiber mass thereon.

[0141] The fiber-forming material is melted in the extruder and pumped into the extrusion heads, which include a plurality of orifices arranged in a regular pattern (e.g., a straight row). The filaments of the fiber-forming liquid are extruded from the extrusion head and may be delivered to the attenuator through an air-filled space. The filaments are intentionally depicted as a core / skin configuration. Even though the core and skin are made of the same material, this configuration still exists because there is an interface between the two layers of material (core and skin). An air quenching stream is directed toward the extruded filaments; the air may reduce the temperature of the extruded filaments or partially solidify them.

[0142] The filaments pass through the attenuator and are subsequently deposited onto a generally flat collector surface where they are collected as a first fiber mass. The filaments passing through the attenuator are deposited onto the surface of a first fiber mass or web.

[0143] The collector is typically porous and a gas extraction (vacuum) device may be positioned beneath the collector to assist in depositing the fibers onto the collector (the porosity of the collector (e.g., relatively small-scale porosity) does not change the fact that the collector is generally flat as defined above).

[0144] With respect to the above-mentioned apparatus, the fiber layer was prepared as follows. In step 1, PLA / PLA (all PLA used was purchased under the trade name INGEO Biopolymer 6202D) sheath / core precursor was extruded at a temperature of 200°C to 230°C (sheath) and 230°C (core), and then quenched at 10°C by quenching air at 23 m / s. 3 The flow rate in area 1 and at 23m / min 3 The PLA / PLA spunbond first composite layer was formed by pulling in zone 2 at a flow rate of 1 / min. The PLA single component filaments were extruded at 230°C and then passed through quenching air at 15°C at a speed of 12 m / min. 3 / min flow rate to be pulled to lay on the first composite layer to form a double-layer web. Then, the double-layer web passes through a through-air bonding station (i.e., autogenous bonding), where hot air at 100°C to 125°C and then to 130°C is blown onto the double-layer web to thermally bond the double-layer web. The web speed is adjusted as needed to obtain the desired basis weight. In the case of a faster web speed, a lower basis weight is obtained; in the case of a higher web speed, a higher basis weight is obtained.

[0145] PLA webs having the following basis weights were produced using the equipment and process described above:

[0146] Preparation Example 1a: Basis weight 25 g / m 2

[0147] Preparation Example 1b: Basis weight 45 g / m 2

[0148] Preparation Example 1c: Basis weight 80 g / m 2

[0149] Preparation Example 1d: Basis weight 30 g / m 2

[0150] Web coating processes

[0151] The webs were coated by melt extrusion of the coating material using a 58 mm twin screw extruder (available from Davis-Standard, Pawcatuck, CT, USA, under the trade designation "DTEX58") operating at an extrusion temperature of 260°C, with a heated hose (260°C) leading to a 760 mm drop die (available from Cloeren, Orange, TX, USA, with a 686 mm flash, 0 mm to 1 mm adjustable die lip, single layer feed block system). The solid coating material was fed into the twin screw system at a rate of 50 lbs / hour (22.7 kg / hr) under the above conditions. The resulting molten resin formed a thin sheet upon exiting the die and was cast onto the web. The surface roughness was set to an average roughness of 75 by using a sleeve (available from American Roller, Union Grove, WI) against the cast film side and a silicone rubber nip roll (80-85 durometer; available from American Roller) against the spunbond side. The layered composite was pressed between the two nip rolls with a nip force of approximately 70 kPa and a line speed adjusted to provide the desired coating thickness.

[0152] Preparation of Examples 2 to 25

[0153] Example 2

[0154] BIOPBS FD72 was coated on the bottom of a 900 m long web from Preparation Example 1a with a coating thickness of 25 μm. The web was cut in half; one half (450 m long) was used as the product of this example and the other half was used for Example 5.

[0155] Example 3

[0156] BIOPBS FD72 was coated on the bottom of a 900 m long web from Preparation Example 1b with a coating thickness of 25 μm. The web was cut in half; one half (450 m long) was used as the product of this example and the other half was used for Example 6.

[0157] Example 4

[0158] BIOPBS FD72 was coated on the bottom of a 900 m long web from Preparation Example 1c. The web was cut in half; one half (450 m long) was used as the product of this example and the other half was used for Example 7.

[0159] Example 5

[0160] The web from Example 2 was cut into two halves (two 450 m lengths). On top of one of the halves 99.5% BIOPBS FZ71 and 0.5% PLAM 69962 were coated using a nip roll for matte finishing. The coating thickness was 25 μm.

[0161] Example 6

[0162] The web from Example 3 was cut into two halves (two 450 m lengths). BIOPBS FZ71 and 0.5% PLAM 69962 were coated on top of one of the halves using a nip roll for matte finishing. The coating thickness was 25 μm.

[0163] Example 7

[0164] The web from Example 4 was cut into two halves (two 450 m lengths). BIOPBS FZ71 and 0.5% PLAM 69962 were coated on top of one of the halves using a nip roll for matte finishing. The coating thickness was 25 μm.

[0165] Example 8

[0166] The top of the web prepared according to Preparative Example 1b was coated with a composition of 80% BIOPBS FZ71, 0.5% PLAM 69962, and 19.5% of a mixture of 95% BIOPBS FZ71 and 5% CASTORWAX.

[0167] Example 9

[0168] The top of the web prepared according to Example 2 was coated with a composition of 80% BIOPBS FZ71, 0.5% PLAM 69962, and 19.5% of a mixture of 95% BIOPBS FZ71 and 5% CASTORWAX.

[0169] Example 10

[0170] A conventional extrusion coating line was used to produce 40# kraft paper (purchased from Wulin Company) coated with PBS on both sides. The top coating had a composition of 80% BIOPBS FZ71, 0.5% PLAM 69962 and 19.5% of a mixture of 95% BIOPBS FZ71 and 5% CASTORWAX. The bottom coating had BIOPBS FD72 with a coating thickness of 25 μm.

[0171] Embodiment 11

[0172] The web of Preparative Example 1d was coated on both sides by melt extrusion of the coating material using the web coating procedure described above, except that the solid coating material was fed into the twin screw system at a rate of 200 lb / hr (90.7 kg / hr) under the conditions provided.

[0173] The coating on the top side was a composition of 99% BIOPBS FZ71 and 1% PLAM 69962, applied at a thickness of 75 micrometers (μm); and the coating on the bottom side was a composition of 95% PBS FD72, 4% OM0364246, and 1% OM9364251, applied at a thickness of 75 μm.

[0174] The web was made into pouches using an automatic pouch making machine, Model M2106WASP-25 (available from Hudson-Sharp, Green Bay, WI, USA). The machine folded the web so that the two bottom coating layers faced each other, so that the two bottom coating layers became the inside of the pouch. The web was folded approximately 15.2 cm (6 inches) from the centerline, leaving a flap of approximately 15.2 cm (6 inches).

[0175] Two strips (approximately 19.05 mm or 0.75 inches) of hot melt pressure sensitive adhesive HM6422PI are extruded onto the lidding, and a PP701.2 metallized release liner is secured on top of one strip of hot melt PSA, and a PET release liner is secured on top of the other strip of hot melt PSA. Individual pouches are then formed by using a hot knife cutting operation to cut and seal the side edges.

[0176] Example 12

[0177] Example 12 is the same as Example 11, but with the following differences:

[0178] During the web coating process, solid coating material was fed into the twin screw system at a rate of 50 lbs / hr (22.7 kg / hr).

[0179] The thickness of both the top and bottom coatings was 37 μm. The composition of both coatings was the same as the corresponding coatings used in Example 11.

[0180] Examples 13A and 13B

[0181] The first PLA web was prepared and coated as in Example 12. The second PLA web was prepared as follows. A masterbatch of 95% BIOPBS FZ71 and 5% CASTORWAX was used as a molten polymer flowing through a plurality of orifices. According to the method described in WO1999051799, short fibers were produced using 95% BIOPBS FZ91 with 5% hydrogenated castor oil as the sheath and LUMINY L130 as the core (3 denier, 31 mm). The fibers were oriented at a perpendicular angle to the molten filament (fiber) flow and collected as a nonwoven fiber layer.

[0182] The first PLA web is stacked on top of the second PLA web, with the bottom side of the first PLA web contacting the second PLA web. The two webs are then sealed together by ultrasonic welding using a Branson AED machine equipped with an 11.4 cm × 15.2 cm (4.5 "× 6") aluminum block horn and a 1:1.5 amplifier. The welding method is energy welding. The welding value for a 7.62 cm (3 inch) circle is 700 J at a pressure of 552 kPa (80 psi). The amplitude is set to 100%, the trigger is 45.4 kg (100 lbs), and the holding time is 1 second.

[0183] In Example 13A, the anvil includes six cavities with a 38 mm (1.5 inch) circular dot pattern, each circle having 36 points (each point is 1.5 mm (0.061 inches)). In Example 13B, the anvil is a nested hexagonal pattern. These hexagons are nested hexagonal patterns, with a distance of 20 mm from one corner to the opposite corner, with a 1 mm thick wall, and each spaced 5 mm apart. The pouches of Examples 13A and 13B are formed by using a H-458 manual impulse sealer (purchased from Wulin Company). The web is folded away from the center line to leave a cover, wherein the second PLA web faces the inside. The edges are heat sealed by the impulse sealer heat, and the edges are cut to produce the final pouch.

[0184] Figure 8 This is a photograph of Example 13A (circular dot pattern). Fig. 9 This is a photograph of Example 13B (hexagonal pattern).

[0185] Examples 14A and 14B

[0186] Examples 14A and 14B were similar to Examples 13A and 13B, respectively, except that a third spunbond PLA web (Preparation Example 1d) was placed between the first and second PLA webs of Examples 13A and 13B prior to the ultrasonic welding step.

[0187] Embodiment 15

[0188] A PLA web was prepared as described for the second PLA web in Examples 13A and 13B. Two sheets of 30# kraft paper were heat laminated on one side to a 20 μm thick coating of BIOPBS FD92. The PLA web was placed between the two sheets of kraft paper so that the coating on the kraft paper faced the PLA web.

[0189] The pouches were made by the ultrasonic welding and impulse sealing process of Example 13A.

[0190] Example 16

[0191] Using the web coating process provided above, a mixture of 99% BIOPBS FZ71 and 1% PLAM69962 was coated on the top side of the spunbonded first PLA web (Preparation Example 1a) (coating thickness of 37 μm), and BIOPBS FZ71 was coated on its bottom side (coating thickness of 37 μm). The coated PLA web was then embossed using the method described in US5256231, where a 35.6 (14 inch) wide web was fed into a diamond patterning tool to form a 3D structure.

[0192] A second smooth PLA web was then heat laminated to the embossed and coated web to form a two-layer web, wherein the second smooth PLA web was identical to the embossed first PLA web layer except that it was not embossed. The webs were laminated such that the top side of the embossed PLA web was laminated to the bottom side of the smooth PLA web.

[0193] The two-layer web was converted into a pouch using the impulse seal process described in Example 13A with the embossed PLA web on the inside of the mailer and the smooth PLA web on the outside of the mailer.

[0194] Embodiment 17

[0195] An embossed PLA web was prepared as described in Example 16. The embossed PLA web was heat laminated to a layer of 30# Kraft paper (Style S-3575) so that the top side of the PLA web was in contact with the Kraft paper. The resulting material was formed into a pouch by the impulse sealing process described for Examples 13A and 13B, with the embossed PLA web on the inside of the pouch and the Kraft paper on the outside of the pouch.

[0196] Embodiment 18

[0197] 30# Kraft paper was coated with BIOPBS FZ71 in one size with a coating thickness of 25 μm. The coated Kraft paper was embossed according to the process described in Example 16. The coated Kraft paper was then heat laminated to another uncoated 30# Kraft paper so that the coating layer of the coated Kraft paper contacted the uncoated Kraft paper to form a double layer material. The double layer material was formed into a small bag using the impulse sealing method described in Example 13A.

[0198] Embodiment 19

[0199] Using the web coating process provided above, a composition of 98% BIOPBS FZ71, 0.7% OMB8264260, and 1.3% OM0364246 was coated on the top of the spunbond PLA fiber layer (Preparation Example 1a) at a coating thickness of 25 μm, and 98% BIOPBS FZ71, 1% OM0364246, and 1% OM9364251 were coated on the bottom thereof at a coating thickness of 25 μm. The web was converted to a pouch using the process described in Example 11, including placement of the PSA and release liner on the lid.

[0200] Embodiment 20

[0201] A spunbond PLA fiber layer (Preparation Example 1b) was coated and converted into a pouch by the method described in Example 19.

[0202] Embodiment 21

[0203] According to the method of Example 19, a 45 g / m 2 The web was coated and converted into a pouch by the method described in Example 19.

[0204] Embodiment 22

[0205] The first PLA web of Preparative Example 1a was coated using the web coating procedure described above: the top side was coated with a mixture of 90% BIOPBS FZ71 and 10% PLAM 69962 at a coating thickness of 37 μm, and the bottom side was coated with a mixture of 90% BIOPBS FZ71, 5% OM0364246, and 5% OM9364251 at a coating thickness of 37 μm.

[0206] The first coated PLA web was then embossed using the method described in US5256231, where a 35.6 (14 inch) wide web was fed into a diamond patterned tool to form a 3D structure.

[0207] A second PLA web is then heat laminated to the embossed and coated web to form a two-layer web, wherein the second PLA web is identical to the embossed first PLA layer except that it is not embossed. The webs are laminated such that the top side of the embossed PLA web is laminated to the bottom side of the smooth PLA web.

[0208] The two-layer web was converted into a pouch using the impulse seal process described in Example 13A with the embossed PLA web on the inside of the mailer and the smooth PLA web on the outside of the mailer.

[0209] Embodiment 23

[0210] An embossed PLA web was made according to Example 22 and then heat laminated to a layer of 30# Kraft paper (Style S-3575) so that the top side of the PLA web was in contact with the Kraft paper. The resulting material was made into a pouch by the impulse sealing process described in Example 13A with the embossed PLA web on the inside of the pouch and the Kraft paper on the outside of the pouch.

[0211] Fig.10 This is a photograph of the pouch of this example.

[0212] Embodiment 24

[0213] For Example 24A, using the web coating process described above, a composition of 98% BIOPBS FZ71, 0.7% OMB8264260, and 1.3% OM0364246 was coated on the top of the spunbond PLA fiber layer (Preparation Example 1a) at a coating thickness of 25 μm, and 98% BIOPBS FZ71, 1% OM0364246, and 1% OM9364251 was coated on the bottom thereof at a coating thickness of 25 μm. The material was folded and the edges were continuously sealed using a SEAMMASTER LM920 ultrasonic welder (available from SONOBOND, West Chester, PA, US) using a 2 inch (5.0 cm) horn, 1:1.5 amplifier, 50% amplitude, 3-row stitch pattern, 50 psi (345 kPa), 0.75 inch (1.9 cm) diameter cylinder, and a speed of 15 ft / min (4.6 m / min) to form a flat tube. For Example 24B, an embossed PLA web was prepared as described for Example 22, and the tube was prepared using the same continuous ultrasonic process used for Example 24A.

[0214] The rolled tubes of Examples 24A and 24B were fed into a ROLLBAG 3200 bagging machine (available from PAC Machinery, San Rafael, CA, USA) to produce flat (24A) and cushioned (24B) packaging products.

[0215] Embodiment 25

[0216] For Example 25A, a composition of 98% BIOPBS FZ71, 0.7% OMB8264260, and 1.3% OM0364246 was coated on the top of the spunbond PLA fiber layer (Preparation Example 1b) at a coating thickness of 25 μm, and 98% BIOPBS FZ71, 1% OM0364246, and 1% OM9364251 were coated on the bottom thereof at a coating thickness of 25 μm using the web coating procedure described above. For Example 25B, an embossed PLA web was prepared as described for Example 22.

[0217] Individual flat (Example 25A) and padded (Example 25B) packaging pouches were made by folding each material and sealing the side edges using a Branson AED ultrasonic welder (available from Emerson Automation Solutions, St. Louis, MN, US) with a 14" x 0.25" (36 cm x 0.64 cm) aluminum horn, a 1:1.5 amplifier, 75% amplitude, anvil with a 14" x 0.25" (36 cm x 0.64 cm) knurl pattern, a 250 lb (113 kg) trigger, a pressure of 60 psi (414 kPa) on a 3 inch (7.6 cm) diameter cylinder, and a hold time of 0.30 seconds.

[0218] Embodiment 26

[0219] Flat and padded pouches were prepared as described for Examples 25A and 25B. A strip of hot melt pressure sensitive adhesive (approximately 19.05 mm or 0.75 inches) was prepared. The adhesive was extruded onto a silicone coated paper release liner which was then cut to make the adhesive strip. The strip was secured to the top of the flap of the flat mailer and to the lip of the padded mailer.

[0220] The packaging articles prepared as described in Examples 1 to 26 were tested using the test methods listed above. The results are reported in Table 3 below.

[0221] Table 3. Results

[0222]

[0223] Comparative Composition and Compostable Composition Examples

[0224] The compostable compositions of Examples I to XIII and Comparative Compositions CI to CIII were prepared as described below.

[0225] Prior to processing, polybutylene succinate ("PBS") and polylactic acid ("PLA") resins were dried at 170°F (77°C) for a minimum of 4 hours and a maximum of 12 hours in a mobile desiccant drying system (available under the trade designation "Model MDCW015" from Conair Group, Inc., Abbotsford, Canada) to remove residual moisture. The materials were metered at the weight percent ("wt %) ratios for each example shown in Table 4. The materials were compounded as follows using a 30 mm twin screw extruder ("TSE") with a L / D ratio of 30 (available under the trade designation "MP2030" from APV (now part of Baker Perkins, Grand Rapids, Michigan, USA). The desired ratios were compounded using a weigh screw feeder (available under the trade designation "K-TRON PBS and PLA were metered into the feed throat of the TSE ("K-TRON T20" purchased from Coperion, GmbH, Stuttgart, Germany). In zone 6 of the TSE, a side filler feeder (purchased under the trade designation "K-TRON T20" from Coperion, GmbH, Stuttgart, Germany) was used at an L / D of approximately 18, wherein hydrophobic agents (e.g., CASTORWAX, EBS) and / or fillers (i.e., talc, CaCO3) were introduced when used. When hydrophobic agents and inorganic fillers were used, they were premixed in the desired ratio prior to addition to the polymer feed. A weigh screw feeder (purchased under the trade designation "K-TRON T20" purchased from Coperion, Stuttgart, Germany) metered these material blends. At the discharge end of the TSE, a single-hole strand die was used to extrude the output melt. The processing steel temperature was ambient temperature (e.g., 20°C to 25°C) in zone 1, 300°F (149°C) in zone 2, and 350°F (177°C) from zone 3 to the die. At a screw speed of 250RPM, the total throughput was 15lbs / hr (6.8kg / hr). The extrudate from the TSE was pulled through a 6-foot (1.8m) water bath cooled to 55°F (13°C) via a knurled nip roll and pelletized using a rotating cutting blade.

[0226] Table 4. Compositions of Examples I to XIII and Comparative Compositions CI to CIII

[0227]

[0228] As described above, the mechanical properties of compostable compositions Examples I to XIII and comparative compositions CI to CIII were tested. The results are reported in Table 5 below.

[0229] Table 5. Mechanical test results

[0230]

[0231] Compostable Product Examples

[0232] Comparative Example A (CE A) :

[0233] Comparative Example A was prepared using a 58 millimeter (mm) twin screw extruder (available from Davis-Standard, Pawcatuck, Connecticut, under the trade designation "DTEX58") operating at an extrusion temperature of 260°C with a heated hose (260°C) leading to a 760 mm drop die (available from Cloren, Orange, Texas, with a 686 mm flash, 0 mm to 1 mm adjustable die lip, single layer feed block system). Under the above conditions, polybutylene succinate (BioPBS FZ71) resin was fed into the twin screw system at a rate of 50 lb / hr (22.7 kg / hr). The resulting molten resin formed a thin sheet as it left the die and was cast into a nip assembly consisting of a plasma-coated casting roll (average roughness of 75; purchased from Roller USA, Union Grove, Wisconsin) and a silicone rubber nip roll (80-85 durometer; purchased from Roller USA). The cast film was pressed between the two nip rolls with a nip force of about 70 kilopascals (kPa) at a line speed of 23 meters per minute and was finally wound on a 3-inch cardboard core. The film of Comparative Example A had a thickness of 50 to 75 microns.

[0234] Comparative Example B (CE B) :

[0235] Comparative Example B was prepared by applying microstructures with stems and caps to the film of Comparative Example A. A thin sheet of molten PBS was cast onto a rotating mold with a cavity, as generally described in the examples of U.S. Patent 5,679,302, the disclosure of which is incorporated herein by reference in its entirety. The density of these microstructures was 2200 microstructures / inch 2 (341 microstructures / cm 2 ). The height of each microstructure is 10 mils (0.25 mm), and the web backing thickness is 3.2 mils (80 microns). These covers are generally circular and have a diameter of about 0.27 mm. The microstructured film is cured and peeled off the mold to form a web with an array of upstanding microstructures according to the cavity size.

[0236] Comparative Example C (CE C) :

[0237] Food storage bags available under the trade name "ZIPLOC" were cut into 3 inch x 3 inch materials with the outward side of the film used for testing. This material is hereinafter referred to as Comparative Example C.

[0238] Comparative Example D (CE D) :

[0239] White Teflon tape was purchased from Grainger, Lake Forest, IL. under the trade designation “ITEM #21TF19” and described as “1 / 2” W PTFE THREAD SAMPLE TAPE, WHITE, 260” LENGTH.” This material is hereinafter referred to as Comparative Example D.

[0240] Example (EX1) :

[0241] Example E was prepared as described in Comparative Example A, except that 1 wt % of CASTORWAX was mixed with BioPBS FZ71 resin prior to extrusion.

[0242] Example (EX2) :

[0243] Example F was prepared as described in Example E, except that a microstructure was additionally applied to the film as described in Comparative Example B.

[0244] The advancing water contact angle measurements and water vapor transmission rate values ​​were obtained according to the test methods described above. The results are reported in Table 6 below.

[0245] Table 6. Advancing water contact angle measurement results and water vapor transmission rate values

[0246]

[0247] The embodiments according to the present disclosure exhibit surprisingly high advancing water contact angles, which make them effective liquid barriers, or moisture and weather resistance. Therefore, the compostable compositions according to the present disclosure can be used in applications such as packaging and personal hygiene items.

[0248] Although the terms and expressions employed are used as terms of description rather than limitation, and it is not intended that the use of such terms and expressions exclude any equivalents of the features shown and described or portions thereof, it is recognized that various modifications within the scope of the disclosed embodiments are possible. Therefore, it should be understood that although the present disclosure has been specifically disclosed through specific embodiments and optional features, modifications and variations of the concepts disclosed herein may be deduced by those of ordinary skill in the art, and such modifications and variations are considered to be within the scope of the embodiments of the present invention.

Claims

1. A compostable product, comprising: A biodegradable polymer layer, the biodegradable polymer layer comprising: A compostable composition comprising: a first biodegradable polymer selected from the group consisting of poly(ethylene succinate), poly(trimethylene succinate), poly(butylene succinate), poly(butylene succinate-co-butylene adipate), poly(butylene adipate-co-terephthalate), poly(tetramethylene adipate-co-terephthalate), and thermoplastic starch; a second biodegradable polymer different from the first biodegradable polymer, the second biodegradable polymer selected from the group consisting of polylactide, polyglycolide, polycaprolactone, and copolymers thereof; a filler selected from the group consisting of calcium carbonate, talc, kaolin, clay, alumina trihydrate, calcium sulfate, glass bubbles, ground mica, zeolite, and combinations thereof; as well as a hydrophobic agent selected from the group consisting of vinyl bis(stearamide), hydrogenated castor oil, castor oil, palmitic acid, linoleic acid, arachidonic acid, palmitoleic acid, butyric acid, stearic acid, triglycerides, and combinations thereof; and Fiber layer, wherein the surface of the biodegradable polymer layer comprises microstructures and wherein the fiber layer is engaged with the microstructures to form an attachment system, wherein the ratio of the weight percentage of the first biodegradable polymer to the weight percentage of the second biodegradable polymer in the compostable composition is 0.5:1 to 1.5:1, and wherein the compostable composition comprises 1 wt % to 4 wt % of the hydrophobic agent, and up to 50 wt % of the filler, and The compostable article exhibits a higher water contact angle than a corresponding article without the microstructure.

2. The compostable article of claim 1, wherein the fiber layer comprises polylactic acid, and wherein the fiber layer is coated with the compostable composition.

3. The compostable article of claim 1, wherein the compostable composition further comprises a biodegradable polymer selected from the group consisting of zein, cellulose esters, polyhydroxyalkanoates, polyhydroxyvalerates, polyhydroxyhexanoates, and combinations thereof.

4. The compostable article of claim 1 or 2, wherein the ratio of the weight percent of the first biodegradable polymer to the weight percent of the second biodegradable polymer in the compostable composition is 0.75:1 to 1.25:

1.

5. The compostable article according to claim 1 or 2, wherein the ratio of the weight percentage of the first biodegradable polymer to the weight percentage of the second biodegradable polymer in the compostable composition is 1:

1.

6. The compostable article according to any one of claims 1 to 3, wherein the microstructure is one of continuous or discrete.

7. The compostable article according to any one of claims 1 to 3, wherein the microstructures are selected from the group consisting of hooks, rails and pillars.

8. The compostable article according to any one of claims 1 to 3, wherein the microstructure comprises a stem and a cap.

9. A packaging product comprising: a first wall having a first inner surface and a first outer surface opposite the first inner surface; a second wall having a second inner surface and a second outer surface opposite the second inner surface, the first inner surface and the second inner surface defining an interior of the packaged article, and the first outer surface and the second outer surface defining an exterior of the packaged article; and one or more edges wherein the first wall is attached to the second wall; wherein the first wall or the second wall comprises a compostable composition, the compostable composition comprising: a first biodegradable polymer, the first biodegradable polymer being selected from the group consisting of poly(ethylene succinate), poly(trimethylene succinate), poly(butylene succinate), poly(butylene succinate-co-butylene adipate), poly(butylene adipate-co-terephthalate), poly(tetramethylene adipate-co-terephthalate) and thermoplastic starch; a filler, the filler being selected from the group consisting of The invention relates to a biodegradable polymer selected from the group consisting of: calcium carbonate, talc, kaolin, clay, alumina trihydrate, calcium sulfate, glass bubbles, ground mica, zeolite, and combinations thereof; and a hydrophobic agent selected from the group consisting of: vinyl bis(stearamide), hydrogenated castor oil, castor oil, palmitic acid, linoleic acid, arachidonic acid, palmitoleic acid, butyric acid, stearic acid, triglycerides, and combinations thereof; and a second biodegradable polymer selected from the group consisting of: polylactide, polyglycolide, polycaprolactone, and copolymers thereof; wherein at least one adhesive portion is disposed on the second outer surface and disposed over any coating on the second outer surface, and wherein one or more of the adhesive portions consist of a compostable adhesive, wherein the ratio of the weight percentage of the first biodegradable polymer to the weight percentage of the second biodegradable polymer in the compostable composition is 0.5:1 to 1.5:1, and wherein the compostable composition comprises 1 wt % to 4 wt % of the hydrophobic agent, and up to 50 wt % of the filler, and The surface of the first wall or the second wall comprising the compostable composition comprises a microstructure, wherein the packaging article exhibits a higher water contact angle than a corresponding article without the microstructure.

10. The packaging article of claim 9, wherein the first wall or the second wall further comprises a fiber layer comprising polylactic acid, and wherein the fiber layer is coated with the compostable composition.

11. The packaging article of claim 9, wherein the compostable composition further comprises a biodegradable polymer selected from the group consisting of zein, cellulose esters, polyhydroxyalkanoates, polyhydroxyvalerates, polyhydroxyhexanoates, and combinations thereof.

12. The packaged article of claim 9, wherein the compostable composition is a heat sealable compostable coating.

13. The packaged article of claim 12, wherein the heat-sealable, compostable coating comprises one or more of polybutylene succinate, poly(butylene succinate adipate), poly(ethylene succinate), poly(tetramethylene adipate-co-terephthalate), or thermoplastic starch.

14. The packaging article of any one of claims 9 to 13, wherein at least one of the first wall and the second wall comprises one of a nonwoven material or cellulose.

15. A packaged article according to any one of claims 9 to 13, wherein the first wall and the second wall comprise: an inner layer having a first major surface and an opposing second major surface; and an outer layer having a third major surface and an opposite fourth major surface; wherein the first major surface of the inner layer is the first inner surface, the second inner surface, or both, and the fourth major surface of the outer layer is the first outer surface, the second outer surface, or both.

16. The packaging article of claim 15, further comprising an intermediate layer between the inner layer and the outer layer.

17. A packaging product according to any one of claims 9 to 13, wherein the first wall further comprises a cover, the cover being adapted to be folded between an open configuration and a closed configuration, and the cover extending beyond the opening of the packaging product when in the open configuration and covering the opening in the packaging product when in the closed configuration.

18. An assembly comprising a packaging article according to any one of claims 9 to 13 and an object located within the interior of the packaging article.

19. A method for preparing a packaging product according to any one of claims 9 to 13, the method comprising: folding a first compostable sheet having a heat sealable compostable coating to form a folded sheet, wherein a portion of the folded sheet on one side of the folded portion constitutes the first wall, the first wall having one edge defined by the folded portion; as well as At least one additional edge is sealed to form the packaged article.

20. The method of claim 19, wherein sealing comprises ultrasonic welding.

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