Inflation film containing an active agent and method for producing the same

Abstract

An inflation film material is provided herein that includes a base polymer and an activator that acts, interacts, or reacts with a selected material. The activator may be a desiccant capable of absorbing moisture. The use of the resulting inflation film material is useful. Related manufacturing methods are also provided herein.

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims priority under 35 U.S.C.§119(e) from U.S. Provisional Patent Application No. US63 / 505,717, entitled "BLOWN FILMS WITH ACTIVE AGENT AND METHODS OF MAKING THE SAME", filed on June 2, 2023, and U.S. Provisional Patent Application No. US63 / 368,498, entitled "BLOWN FILMS WITH ACTIVE AGENT AND METHODS OF MAKING THE SAME", filed on July 15, 2022, the contents of each of which are hereby incorporated by reference in their entirety.

[0002] The present invention relates to an inflation film containing an active agent including but not limited to a desiccant for moisture absorption and a method for manufacturing the same.

Background Art

[0003] Many articles are preferably stored, shipped, and / or utilized in an environment where it is necessary to control and / or regulate. For example, in the field of moisture control, containers and / or packages having the ability to absorb excess moisture trapped inside are recognized as desirable. Control of moisture, oxygen, ethylene, and other gaseous substances may be desirable for applications such as medical, diagnostic, industrial chemistry, laboratories, electronic devices, food packaging, and the like.

[0004] Conventionally, desiccants, oxygen absorbers, and other activators have been used in their raw form, such as free particles contained in sachets or canisters within a package, to control the internal environment of the package. For many applications, it is not desirable for the active substance to be stored in such a free state. To address this problem, the assignee of the present application provides an active carrier polymer containing an activator, where the polymer can be extruded and / or molded into a desired form, such as a container liner, plug, film sheet, pellet, and other such structures. Such an active carrier polymer may optionally contain a channeling agent, such as polyethylene glycol (PEG), which forms channels between the surface and the interior of the carrier polymer to deliver a selected material (such as moisture) to the entrapped activator (such as a desiccant that absorbs moisture).

[0005] As described above, the carrier polymer may be a two-phase composition (i.e., containing a base polymer and an activator, and not containing a channeling agent), or a three-phase composition (i.e., containing a base polymer, an activator, and a channeling agent). The three-phase carrier polymers and methods for their manufacture are described, for example, in U.S. Patent Nos. 5,911,937, 6,080,350, 6,124,006, 6,130,263, 6,194,079, 6,214,255, 6,486,231, 7,005,459, and U.S. Patent Publication No. 2016 / 0039955, which are hereby incorporated by reference herein as if fully set forth.

[0006] Inflation film technology enables the production of useful products such as sheets, films, cylinders, and tubes. This technology is particularly valuable in the production of bags and packaging for consumer products. Briefly, the method involves softening and melting a polymer resin and then expanding the material, thereby resulting in air bubbles encapsulated in the film of the material. It is important that the film formed in this inflation process is very thin and can typically be on the order of 10 mils or less.

[0007] The concept of this method is simple, but for it to be suitable for use, the polymer material needs to meet certain requirements. In particular, properties such as the melting point and melt index affect the success of the inflation film process in forming a material with appropriate properties.

[0008] There is still a need for the provision of inflation film materials that include a base polymer and an activator, particularly a particulate or mineral-based activator.

Summary of the Invention

[0009] Accordingly, in one aspect, there is provided an inflation film material comprising a base polymer and an activator, preferably a particulate or mineral-based activator.

[0010] In some embodiments, the base polymer is selected from polyolefins and polyesters. In some embodiments, the base polymer includes both polyolefins and polyesters. In some embodiments, the base polymer includes a block copolymer.

[0011] In some embodiments, the activator is a desiccant. In some embodiments, the desiccant is selected from silica gel and molecular sieves.

[0012] In some embodiments, the inflation film material further comprises a channeling agent. In some embodiments, the channeling agent is selected from polyglycol, glycerol polyamine, polyurethane, and polycarboxylic acid, or any combination thereof. In some embodiments, the channeling agent is a water-insoluble polymer. In some embodiments, the channeling agent is a water-insoluble polymer. In some embodiments, the channeling agent is selected from propylene oxide polymers, poly(propylene oxide) monobutyl ether, ethylene vinyl acetate (EVA), nylon, or any combination thereof.

[0013] A method for manufacturing an inflation film material comprising a base polymer and an activator is also provided herein, the method comprising the following steps: Extruding a suitable precursor material (a molten mixture of polymer and activator) through a screw extruder while heating, Passing the heated material through a tubular die, Expanding and stretching the heated material under positive pressure, and Cooling the expanded and stretched material is included.

[0014] A complete understanding of the present invention can be obtained from the following description of the preferred embodiments, read in conjunction with the accompanying drawings.

Brief Description of the Drawings

[0015]

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DETAILED DESCRIPTION OF THE INVENTION

[0016] In one aspect, an inflation film material is provided herein that includes a base polymer and an active agent.

[0017] In some embodiments, the base polymer is selected from polyolefins, polyamides, and polyesters. In some embodiments, the base polymer is selected from polyolefins and polyesters. In some embodiments, the base polymer is selected from polyethylene, polypropylene, polyethylene / polypropylene copolymers, and polylactic acid.

[0018] In some embodiments, the base polymer has the formula (-CHR-X-) n where -X- is selected from -CH2-, -COO-, and -CONH-, and R is selected from H and n-C 1~10 alkyl.

[0019] In some embodiments, the base polymer comprises at least one block copolymer.

[0020] In some embodiments, the base polymer comprises a block copolymer that includes an ester monomer block. In some further embodiments, the base polymer comprises a block copolymer that includes a poly(alkylene) terephthalate monomer block. In some further embodiments, the alkylene is selected from ethylene, propylene, and butylene.

[0021] In some embodiments, the base polymer comprises a block copolymer that includes a polyether glycol block.

[0022] In some embodiments, the base polymer comprises a block copolymer that includes both an ester monomer block and a polyether glycol block. In some embodiments, the base polymer comprises a HYTREL® block copolymer. In some embodiments, the base polymer comprises HYTREL® 7246.

[0023] In some embodiments, the base polymer comprises an ethylene / α-olefin copolymer. In some further embodiments, the α-olefin is propylene, 1-butene, 1-pentene, 1-pentene having one or more methyl substituents, ethyl substituents, or propyl substituents, 1-hexene, 1-hexene having one or more methyl substituents, ethyl substituents, or propyl substituents, 1-heptene, 1-heptene having one or more methyl substituents, ethyl substituents, or propyl substituents, 1-octene, 1-octene having one or more methyl substituents, ethyl substituents, or propyl substituents, 1-nonene, 1-nonene having one or more methyl substituents, ethyl substituents, or propyl substituents, 1-decene substituted with ethyl, methyl or dimethyl, 1-dodecene, and styrene. In some further embodiments, the α-olefin is selected from propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, and 1-dodecene.

[0024] In some embodiments, the base polymer comprises two block copolymers. In some further embodiments, one of the two block copolymers is the ethylene / α-olefin copolymer disclosed herein. In some further embodiments, the base polymer comprises EXACT™ 3040. In some further embodiments, one of the two block copolymers is a block copolymer containing both an ester monomer block and a polyether glycol block disclosed herein. In some further embodiments, the base polymer comprises HYTREL® 7246. In some further embodiments, the base polymer comprises both EXACT™ 3040 and HYTREL® 7246. In some further embodiments, the base polymer consists of a mixture of EXACT™ 3040 and HYTREL® 7246.

[0025] In some embodiments, the base polymer includes both a polyolefin and a polyester. In some embodiments, the polyolefin ranges from 10 wt% to 40 wt%, optionally from 15 wt% to 30 wt% of the total composition. In some embodiments, the polyester ranges from 20 wt% to 80 wt%, optionally from 25 wt% to 70 wt%, optionally from 30 wt% to 60 wt% of the total composition. In some embodiments, the polyolefin has the formula (-CH2CHR-) n wherein R is selected from H and n-C 1~10 alkyl. In some embodiments, the polyester has the formula ((-CH2) m COO-) n wherein m is selected from 1, 2, 3, 4, and 5. In some embodiments, the polyester has the formula (-CHRCOO-) n wherein R is selected from H and n-C 1~10 alkyl.

[0026] In some embodiments, the activator is a desiccant. In some embodiments, the desiccant is selected from silica gel and molecular sieves. In some embodiments, the desiccant does not contain metal oxides. In some embodiments, the desiccant does not contain metal carbonates. In some embodiments, the desiccant does not contain metal halides.

[0027] In any embodiment, the activator is preferably a particulate, granular and / or mineral-based material and is optionally present in an amount of at least 35 wt% to 70 wt%, optionally 40 wt% to 60 wt%, optionally 45 wt% to 55 wt% based on the total weight of the entrained polymer.

[0028] In some embodiments, the inflation film material further includes a channeling agent. In some embodiments, the channeling agent is selected from polyglycols such as polyethylene glycol (PEG), ethylene-vinyl alcohol (EVOH), polyvinyl alcohol (PVOH), glycerin polyamine, polyurethane, and polycarboxylic acids including polyacrylic acid or polymethacrylic acid.

[0029] In some embodiments, the channeling agent can be a water-insoluble polymer such as poly(propylene oxide) monobutyl ether, for example, Polyglykol B01 / 240 manufactured by CLARIANT. In other embodiments, the channeling agent can be poly(propylene oxide) monobutyl ether such as Polyglykol B01 / 20 manufactured by CLARIANT, a propylene oxide polymer such as Polyglykol D01 / 240 manufactured by CLARIANT, ethylene vinyl acetate (EVA), nylon 6, nylon 66, or any combination of the foregoing.

[0030] In some embodiments, the base polymer has the formula selected from (-CH2CHR-) n and (-CHRCOO-) n wherein R is selected from H and n-C 1~10 alkyl. In some embodiments, R is selected from H and n-C 1~10 alkyl. In some embodiments, R is selected from H, CH3, C2H5, n-C4H9, n-C6H 13 and n-C8H 17 In some embodiments, R is selected from C2H5, n-C4H9, and n-C6H 13

[0031] Also provided herein is a method for manufacturing an inflation film material disclosed herein, the method comprising the following steps: extruding a suitable precursor material through a screw extruder while heating, passing the heated material through a tubular die, expanding and stretching the heated material under positive pressure, and cooling the expanded and stretched material

[0032] ​​In some embodiments, the extrusion is carried out at a temperature between 140°C and 190°C, optionally between 145°C and 175°C, optionally between 150°C and 170°C, optionally between 150°C and 165°C. As used herein, the term "between" includes the endpoints of the recited numerical range.

[0033] In some embodiments, the extrusion is carried out at a rotational speed of 5 rpm or more, optionally 10 rpm or more, optionally 15 rpm or more, optionally 25 rpm or more, optionally 35 rpm or more, optionally 45 rpm or more, optionally 55 rpm or more.

[0034] In some embodiments, the extrusion is carried out at a rotational speed of 65 rpm or less, optionally 55 rpm or less, optionally 45 rpm or less, optionally 35 rpm or less, optionally 30 rpm or less, optionally 25 rpm or less, optionally 20 rpm or less.

[0035] In some embodiments, the extrusion is carried out at a rotational speed between 10 rpm and 75 rpm, optionally between 15 rpm and 65 rpm, optionally between 15 rpm and 60 rpm, optionally between 20 rpm and 50 rpm.

[0036] In some embodiments, the extrusion is carried out at a rotational speed between 5 rpm and 35 rpm, optionally between 10 rpm and 30 rpm, optionally between 10 rpm and 25 rpm, optionally between 10 rpm and 20 rpm.

[0037] In some embodiments, the tensile strength of the inflation film material is significantly different from that of the cast extrusion film material being compared. In some embodiments, the tensile strength of the inflation film material is significantly greater than that of the cast extrusion film material being compared.

[0038] In some embodiments, the dirt impact resistance of the inflation film material is significantly different from that of the cast extrusion film material being compared. In some embodiments, the dirt impact resistance of the inflation film material is significantly greater than that of the cast extrusion film material being compared.

[0039] In some embodiments, the transparency of the inflation film material is significantly different from that of the cast extrusion film material being compared. In some embodiments, the transparency of the inflation film material is significantly greater than that of the cast extrusion film material being compared.

[0040] In some embodiments, the haze of the inflation film material is significantly different from that of the cast extrusion film material being compared. In some embodiments, the haze of the inflation film material is significantly greater than that of the cast extrusion film material being compared.

[0041] In some embodiments, the brittleness of the inflation film material is significantly different from that of the cast extrusion film material being compared. In some embodiments, the brittleness of the inflation film material is significantly less than that of the cast extrusion film material being compared.

[0042] In some embodiments, the density of the inflation film material is significantly different from that of the cast extrusion film material being compared. In some embodiments, the density of the inflation film material is significantly greater than that of the cast extrusion film material being compared. In some embodiments, the density of the inflation film material is significantly less than that of the cast extrusion film material being compared.

[0043] In some embodiments, the tensile strength of the inflation film material in the machine and / or direction is significantly different from the tensile strength of the cast extrusion film material being compared. In some embodiments, the tensile strength of the inflation film material in the machine and / or direction is significantly greater than the tensile strength of the cast extrusion film material being compared.

[0044] In some embodiments, the elongation of the inflation film material in the machine and / or direction is significantly different from the elongation of the cast extrusion film material being compared. In some embodiments, the elongation of the inflation film material in the machine and / or direction is significantly greater than the elongation of the cast extrusion film material being compared.

[0045] In some embodiments, the Young's modulus of the inflation film material in the machine and / or direction is significantly different from the Young's modulus of the cast extrusion film material being compared. In some embodiments, the Young's modulus of the inflation film material in the machine and / or direction is significantly greater than the Young's modulus of the cast extrusion film material being compared.

[0046] Also provided herein are inflation film companion polymers disclosed herein and containers including an internal space suitable for storing products. Such products include, for example, food, pharmaceuticals, medical devices, or drug delivery devices. In some embodiments, the container includes at least one molded article including the inflation film companion polymer disclosed herein disposed within the internal space. In some embodiments, placing a product within the container forms a headspace formed by the internal space not occupied by the product. In some embodiments, the container includes a bottom surface, an upper surface opening, and one or more sidewalls extending vertically from the bottom surface to the upper surface opening. In some embodiments, the container further includes a cover for closing and / or sealing the container.

[0047] Definitions As used herein, the term "active" is defined as having the ability to act, interact, or react with a selected material (e.g., moisture or oxygen) according to the present invention. Examples of such action or interaction include absorption, adsorption, or release of the selected material.

[0048] As used herein, the term "activating agent" is defined as a material that (1) is immiscible with the base polymer and does not melt when mixed and heated with the base polymer and the channeling agent, i.e., has a melting point higher than the melting point of either the base polymer or the channeling agent, and (2) acts, interacts, or reacts with a selected material. The term "activating agent" may include, but is not limited to, materials that absorb, adsorb, or release a selected material. The activating agent according to the present invention may be in the form of particles, preferably minerals, but the present invention should generally not be considered limited to particulate activating agents (unless otherwise specified in each claim).

[0049] As used herein, the term "polyolefin" refers to a polymer having the formula (-CH2CHR-) n wherein R is selected from H, alkyl, chloro, aryl, hydroxy, acyloxy, acetoxy, carboxy, and alkoxycarbonyl. In some embodiments, R is selected from H, alkyl, and phenyl. In some embodiments, R is selected from H and C 1~10 alkyl. In some embodiments, R is selected from H and n-C 1~10 alkyl. In some embodiments, R is selected from H and CH3. In some embodiments, the polyolefin is selected from polyethylene, low density polyethylene ("LDPE"), linear low density polyethylene (LLDPE), very low density polyethylene (VLDPE), ultra low density polyethylene (ULDPE), and medium density polyethylene (MDPE).

[0050] As used herein, the term "polyester" refers to a polymer having the formula (-X-COO-) nrefers to a polymer having, where X is a divalent organic moiety. In some embodiments, the polyester has the formula (-CHRCOO-) n wherein R is selected from H and n-C 1~10 alkyl. In some embodiments, the polyester has the formula ((-CH2) m COO-) n wherein m is selected from 1, 2, 3, 4, and 5. In some embodiments, the polyester has the formula (-OOC-Y-COO-Z) n wherein Y and Z are each divalent organic moieties. In some embodiments, Y = 1,4-phenylene. In some embodiments, Z is selected from ethylene, butylene (tetramethylene), hexylene (hexamethylene), and 1,4-cyclohexenedimethylene. In some embodiments, the polyester is polyethylene terephthalate ("PET"). In some embodiments, the polyester is poly-1,4-cyclohexenedimethylene terephthalate ("PCDT").

[0051] As used herein, the term "base polymer" optionally refers to a polymer in which the gas transmission rate of the selected material is substantially lower than, lower than, or substantially equivalent to the gas transmission rate of the channeling agent. By way of example, in embodiments where the selected material is moisture and the active ingredient is a moisture-absorbing desiccant, such transmission rate is the water vapor transmission rate. The primary function of the base polymer is to provide the structure of the entrained polymer. Suitable base polymers include thermoplastic polymers such as polyolefins such as polypropylene and polyethylene, polyisoprene, polybutadiene, polybutene, polysiloxane, polycarbonate, polyamide, ethylene-vinyl acetate copolymer, ethylene-methacrylic acid copolymer, poly(vinyl chloride), polystyrene, polyester, polyanhydride, polyacrylonitrile, polysulfone, polyacrylate ester, acrylic acid, polyurethane, and polyacetal, or copolymers or mixtures thereof.

[0052] Referring to such a comparison of the water vapor transmission rate of the base polymer and the water vapor transmission rate of the channeling agent, in one embodiment, the channeling agent has a water vapor transmission rate that is at least 2 times the water vapor transmission rate of the base polymer. In another embodiment, the channeling agent has a water vapor transmission rate that is at least 5 times the water vapor transmission rate of the base polymer. In another embodiment, the channeling agent has a water vapor transmission rate that is at least 10 times the water vapor transmission rate of the base polymer. In yet another embodiment, the channeling agent has a water vapor transmission rate that is at least 20 times the water vapor transmission rate of the base polymer. In yet another embodiment, the channeling agent has a water vapor transmission rate that is at least 50 times the water vapor transmission rate of the base polymer. In yet another embodiment, the channeling agent has a water vapor transmission rate that is at least 100 times the water vapor transmission rate of the base polymer.

[0053] As used herein, the term "channeling agent" or "channeling agents" is defined as a material that is immiscible with the base polymer and has an affinity for transporting gaseous substances at a faster rate than the base polymer. Optionally, the channeling agent can form channels through the host polymer when formed by mixing the base polymer and the channeling agent. Optionally, such channels can deliver a selected material through the host polymer at a faster rate than in the case of the base polymer alone.

[0054] As used herein, the term "channel" or "interconnected channels" is defined as a passage formed of a channeling agent that penetrates the base polymer and can be interconnected with each other.

[0055] As used herein, the term "carrier polymer" is defined as a monolithic material formed from at least a base polymer, an activator, and optionally a channeling agent that is incorporated or distributed throughout. Thus, carrier polymers include two-phase polymers and three-phase polymers. "Mineral-filled polymers" are a type of carrier polymer where the activator is in the form of a mineral, such as mineral particles like molecular sieves or silica gel.

[0056] As used herein, the terms "monolithic", "monolithic structure", or "monolithic composition" are defined as a composition or material that does not contain two or more distinct macroscopic layers or parts. Thus, a "monolithic composition" does not include a multilayer composite (although it may be part of a multilayer composite).

[0057] As used herein, the term "phase" is defined as a part or component of a monolithic structure or monolithic composition that is uniformly distributed throughout the structure or composition to impart its monolithic properties.

[0058] As used herein, the term "selected material" is defined as a material that can be acted upon by an activator, or interact or react with an activator and be delivered through the channels of a carrier polymer. For example, in embodiments where a desiccant is used as the activator, the selected material can be moisture or a gas that can be absorbed by the desiccant.

[0059] As used herein, the term "three-phase" is defined as a monolithic composition or structure that includes three or more phases. An example of a three-phase composition according to the present invention can be a carrier polymer formed from a base polymer, an activator, and a channeling agent. Optionally, a three-phase composition or structure can include additional phases, such as a colorant (thus, "three-phase" indicates at least three phases including a base polymer, an activator, and a channeling agent).

[0060] Suitable channeling agents can include polyglycols such as polyethylene glycol (PEG), ethylene vinyl alcohol (EVOH), polyvinyl alcohol (PVOH), glycerin polyamine, polyurethane, and polycarboxylic acids including polyacrylic acid or polymethacrylic acid. Alternatively, the channeling agent 35 can be a water-insoluble polymer such as poly(propylene oxide) monobutyl ether such as Polyglykol B01 / 240 manufactured by CLARIANT. In other embodiments, the channeling agent can be a poly(propylene oxide) monobutyl ether such as Polyglykol B01 / 20 manufactured by CLARIANT, a propylene oxide polymer such as Polyglykol D01 / 240 manufactured by CLARIANT, ethylene vinyl acetate (EVA), nylon 6, nylon 66, or any combination of the above.

[0061] When the active agent is a desiccant, any desiccant suitable for a given application can be used. Usually, physical absorption desiccants are preferred for many applications. These can include molecular sieves, silica gel, clay, and starch. Alternatively, the desiccant can be a chemical compound that forms crystals containing water, or a compound that reacts with water to form a new compound.

[0062] Suitable absorbent materials can, in any embodiment, also include the following: (1) metals and alloys such as, but not limited to, nickel, copper, aluminum, silicon, solder, silver, and gold; (2) metal-plated particles such as silver-plated copper, silver-plated nickel, and silver-plated glass microspheres; (3) inorganic substances such as BaTiO3, SrTiO3, SiO2, Al2O3, ZnO, TiO2, MnO, CuO, Sb2O3, WC, fused silica, fumed silica, amorphous fused silica, sol-gel silica, sol-gel titanate, mixed titanate, ion exchange resin, lithium-containing ceramics, and hollow glass microspheres; (4) carbon-based materials such as carbon, activated carbon, carbon black, ketjen black, and diamond powder; (5) elastomers such as polybutadiene and polysiloxane, semimetals, ceramics; and (6) other fillers and pigments.

[0063] In another example, the absorbent material may be a carbon dioxide scavenger such as calcium oxide. In the presence of moisture and carbon dioxide, calcium oxide changes to calcium carbonate. Thus, calcium oxide can be used as an absorbent material in applications where carbon dioxide absorption is required. Such applications include the preservation of fresh foods that emit carbon dioxide (e.g., fruits and vegetables).

[0064] Other suitable active agents according to the present invention include release materials. Such materials can include any suitable material that releases a material selected from the release materials. The selected material released from the release material can be in the form of a solid, gel, liquid, or gas. These substances can serve various functions such as supplying biologically active components such as fragrances, flavorants, fragrance sources, insecticides, pest repellents, antibacterial agents, baits, and aromatics, supplying humidifying or drying substances, delivering air-mediated active chemicals such as corrosion inhibitors, ripening agents, odor generators, and the like.

[0065] Suitable biocides for use as release materials in the carrier polymers of the present invention include, but are not limited to, insecticides, herbicides, nematicides, fungicides, rodenticides, and / or mixtures thereof. In addition to biocides, the coatings of the present invention can also release nutrients, plant growth regulators, pheromones, defoliants, and / or mixtures thereof.

[0066] Quaternary ammonium compounds can also be used as release materials according to the present invention. Such compounds not only function as surfactants but also impart sterility to the surface of the carrier polymer or establish conditions that reduce the number of microorganisms that may be partially pathogenic. A number of other antibacterial agents, such as compounds of related species like benzalkonium chloride and hexachlorophene, can also be used as release agents according to the present invention.

[0067] Other potential release substances include fragrances, including natural fragrances, essential oil fragrances, and synthetic fragrances, and blends thereof. Typical fragrance materials that may form part or, in some cases, all of the active ingredient include natural essential oils such as lemon oil, mandarin oil, clove leaf oil, ptycholen oil, cedarwood oil, patchouli oil, ravintsara oil, neroli oil, ylang-ylang oil, rose absolute or jasmine absolute, natural resins such as labdanum resin or olibanum resin, single fragrance chemicals that can be of natural origin or synthetically produced, such as alcohols like geraniol, nerol, citronellol, linalool, tetrahydrogeraniol, betaphenylethyl alcohol, methylphenylcarbinol, dimethylbenzylcarbinol, menthol, or cedrol, aldehydes such as citral, citronellal, hydroxycitronellal, lauric aldehyde, undecylenic aldehyde, cinnamic aldehyde, amylcinnamic aldehyde, vanillin, or heliotropin, acetic esters and other esters derived from such alcohol - aldehydes, acetals derived from such aldehydes, ketones such as methylhexyl ketone, ionone, and methyl ionone, phenolic compounds such as eugenol and isoeugenol, and synthetic musks such as musk xylene, musk ketone, and ethylene brassylate.

[0068] In some embodiments, the base polymer ranges from 10 wt% to 90 wt%, optionally 20 wt% to 80 wt%, optionally 30 wt% to 70 wt%, optionally 40 wt% to 60 wt% of the total composition.

[0069] In some embodiments, the base polymer ranges from 20 wt% to 90 wt%, optionally 30 wt% to 80 wt%, optionally 40 wt% to 70 wt%, optionally 50 wt% to 60 wt% of the total composition.

[0070] In some embodiments, the base polymer ranges from 30 wt% to 90 wt%, optionally 40 wt% to 80 wt%, optionally 50 wt% to 70 wt% of the total composition.

[0071] When using any channeling agent, the channeling agent can be provided in the range of 1% to 15% by weight, optionally 2% to 12% by weight, and optionally about 5% by weight.

[0072] It is considered that the higher the concentration of the active agent in the mixture, the greater (optionally) the absorption capacity, adsorption capacity, and release capacity of the final composition. However, if the concentration of the active agent is too high, the carrier polymer will become more brittle, and any of the thermoforming, extrusion, or good bubble formation of the molten mixture composed of the active agent, base polymer, and channeling agent in the inflation film manufacturing process may become more difficult.

[0073] In some embodiments, the loading amount of the active agent can be in the range of 10% to 80% by weight, optionally 35% to 70% by weight, optionally 40% to 60% by weight, and optionally 45% to 55% by weight based on the total weight of the carrier polymer.

[0074] In some embodiments, the loading amount of the active agent can be in the range of 10% to 70% by weight, optionally 30% to 60% by weight, and optionally 35% to 50% by weight based on the total weight of the carrier polymer.

[0075] In some embodiments, the loading amount of the active agent can be in the range of 10% to 60% by weight, optionally 20% to 50% by weight, and optionally 25% to 45% by weight based on the total weight of the carrier polymer.

[0076] In some embodiments, the loading amount of the active agent can be in the range of 10% to 50% by weight, optionally 15% to 45% by weight, optionally 20% to 40% by weight, and optionally 25% to 35% by weight based on the total weight of the carrier polymer.

[0077] Optionally, the channeling agent can be provided in the range of 1 wt% to 15 wt%, optionally 2 to 12 wt%, optionally 5 wt% to 12 wt%, optionally about 10 wt%, optionally about 9 wt%, optionally about 8 wt%, optionally about 7 wt%, optionally about 6 wt%, optionally about 5 wt%, optionally about 4 wt%, optionally about 3 wt%, optionally about 2 wt%. Optionally, the base polymer can be in the range of 10 wt% to 65 wt% of the total composition, optionally 20 wt% to 45 wt%, optionally 25 wt% to 35 wt%. Optionally, a colorant is added, for example, in the range of about 0.5 wt% to 2 wt% of the total composition, or about 1 wt%. Regarding the base polymer, the activating agent, the channeling agent, and the colorant, any combination of the above ranges is conceivable.

[0078] Figures 1 - 6 show the carrier polymer 20 and various packaging assemblies formed from the carrier polymer according to certain embodiments of the present disclosure. The carrier polymer 20 includes a base polymer 25, optionally a channeling agent 35, and an activating agent 30, respectively. As shown, the channeling agent 35 forms interconnecting channels 45 through the carrier polymer 20. At least a portion of the activating agent 30 is contained within these channels 45, whereby the channels 45 communicate between the activating agent 30 and the exterior of the carrier polymer 20 through channel openings 48 formed in the outer surface of the base polymer 25. The activating agent 30 can be, for example, any one of various release materials described in further detail below. Although a channeling agent (e.g., 35) is preferred, the present disclosure broadly includes carrier polymers that optionally do not contain a channeling agent.

[0079] Figure 1 shows a plug 55 composed of a carrier polymer 20 according to a particular embodiment of the present invention. The plug 55 may be placed within a container. As described above, the carrier polymer 20 includes a base polymer 25, a channeling agent 35, and an activating agent 30.

[0080] FIG. 2 is a cross-sectional view of the plug 55 shown in FIG. 1. Also, FIG. 2 shows that the channelling agent 35 forms the interconnecting channels 45 and solidifies to establish a passage through the entire plug 55 in which the entrained polymer 20 solidifies. At least a portion of the activator 30 is contained within the channels 45 such that the channels 45 communicate between the activator 30 and the exterior of the entrained polymer 20 via the channel openings 48 formed in the outer surface of the entrained polymer 25.

[0081] FIG. 3 shows an embodiment of the plug 55 having a structure and configuration similar to that of the plug 55 of FIG. 2, where the interconnecting channels 45 are finer compared to those shown in FIG. 2. This can occur by using a dimerizing agent (i.e., a plasticizer) together with the channelling agent 35. The dimerizing agent can enhance the compatibility between the base polymer 25 and the channelling agent 35. This enhanced compatibility is promoted by the lower viscosity of the blend, which can facilitate a more complete mixing of the base polymer 25 and the channelling agent 35 that might otherwise resist mixing into a homogeneous solution under normal conditions. When the entrained polymer 20 with the added dimerizing agent solidifies, the interconnecting channels 45 formed therethrough are more widely dispersed and have a smaller porosity, thereby establishing a higher density of interconnecting channels throughout the plug 55.

[0082] The interconnecting channels 45 as disclosed herein facilitate the permeation of desired materials such as moisture, gas, or odour through the base polymer 25 which generally acts as a barrier to the permeation of these materials. For this reason, the base polymer 25 itself acts as a barrier substance in which the activator 30 can be entrained. The interconnecting channels 45 formed from the channelling agent 35 provide a pathway for the desired materials to move through the entrained polymer 10. In the absence of these interconnecting channels 45, a relatively small amount of the desired material is thought to be delivered to or from the activator 30 through the base polymer 25. Also, when the desired material is delivered from the activator 30, for example, in embodiments where the activator 30 is a releasing material such as an antibacterial agent gas releasing material, the desired material may be released from the activator 30.

[0083] Figure 4 shows one embodiment of the companion polymer 10 according to the present disclosure. The arrows indicate the path of a selected material, such as moisture, from the outside of the companion polymer 10 through the channel 45 to the particles of the activator 30.

[0084] Figure 5 shows an active sheet or film 75 formed from a companion polymer 20 that is used in combination with a barrier sheet 80 to form a composite material according to an aspect of the present invention. The properties of the active sheet or film 75 are similar to those described with respect to the plug 55. The barrier sheet 80 can be a substrate such as a foil and / or polymer having low water permeability or oxygen permeability. The barrier sheet 80 has compatibility with the companion polymer structure 75 and is thus configured to thermally bond to the active sheet or film 75 when the active sheet or film 75 solidifies after dispensing.

[0085] Figure 6 shows an embodiment in which the active sheet or film 75 and the barrier sheet 80 are combined to form a packaging wrap having active properties on the inner surface formed by the companion polymer 20 within the active sheet or film 75 and moisture vapor resistance properties on the outer surface formed by the barrier sheet 80. In this embodiment, the active sheet or film 75 occupies a portion of the barrier sheet 80. The method of manufacturing the active sheet or film 75 according to the present invention and adhering it to the barrier sheet 80 is not particularly limited.

[0086] In one embodiment, as shown in FIG. 6, the sheets of FIG. 5 are joined together to form an active package 85. As shown, two laminates or composites are provided, each formed from an active sheet 75 joined to a barrier sheet 80. The sheet laminates are laminated with the active sheets or films 75 facing each other so as to be disposed inside the package and are joined at a seal area 90 formed on the outer periphery of the sealed area inside the package.

[0087] In some embodiments, the entrained polymer is positioned within the container such that substantially all of the portion facing the inside of the container is composed of the entrained polymer. In some embodiments, the container is manufactured such that the entrained polymer is positioned below the height of the liquid medium contained within the package, whereby the active agent and the liquid medium are in direct contact.

[0088] A representative inflation film material forming process is shown in FIG. 7. Pelletized precursor resin is supplied to hopper 105, screw 110 rotates, advancing the material while applying heat and gradually forming a melt. Thereafter, the molten material 115 flows through die 120, resulting in a hollow tube of material. Bubbles 125 are formed within the material by introducing air through a hole at the center of the die. The material advances upward around the bubbles, is cooled, and is finally folded by the action of folding frame 130. Throughout this process, nip roll 135 pulls the material upward and maintains an appropriate tension. The folded material passes through a series of rollers including edge trim 140 and is finally wound onto winder 145.

[0089] Due to the nature of the inflation film manufacturing process, the specific physical properties of the resulting film material may be significantly different from those of other techniques, such as films produced by cast film extrusion. For example, the cast film manufacturing process can produce films with low polymer strand orientation within the material and / or non-uniform polymer strand orientation. In contrast, inflation film materials may be highly oriented, and the orientation is uniform throughout the cylindrical bubble.

[0090] Subsequently, the orientation of the polymer strands within the material can affect the degree of crystallinity and can influence properties such as transparency / haze, tear strength and elongation, puncture resistance, and toughness.

[0091] The mechanical properties of an inflation film can be significantly different from those of a cast film. During the inflation film manufacturing process, the material is stretched in both the transverse and machine directions. In contrast, tenter films may have non-uniform strength in these two directions.

[0092] For an inflation film and a cast film for comparison, other mechanical parameters that may differ in either or both the machine direction and the transverse direction, when applicable, are Young's modulus, dart impact resistance, transparency, brittleness, and density.

[0093] The strength of an inflation film can be different from that of a cast film for comparison. Generally, the tensile strength of an inflation film is similar in the machine direction and the transverse direction of the film. The elongation of an inflation film is similar in the machine direction and the transverse direction of the film.

[0094] Another important feature of the inflation film manufacturing process is that the cooling rate of the film can be adjusted. In this way, the transparency of the film can be regulated.

[0095] Optionally, in any embodiment, the aforementioned extrusion process includes co-extrusion of two or more layers, where at least one of such layers is an active layer (a mixture of a polymer and an active agent), and at least one other of such layers is a polymer material in which the active agent is not incorporated. In such an embodiment, a multilayer composite in which at least one layer is an active companion polymer layer can be formed.

[0096] Although various aspects of the present invention will be described in more detail with reference to the following examples, it should be understood that the present invention is not limited thereto.

Examples

[0097] Example 1. Formulation: Polyolefin The following polyolefin (CH2CHR) nSYLOSIV® K360, 3 Å molecular sieve powder, and in some formulations (as noted), EVA2528 as a channeling agent were combined and used in the tests as desiccants.

Table 1

[0098] Other formulations are contemplated by the present disclosure. Specific formulations contemplated use EVA concentrations between 1% and 15%, such as 2%, 3%, 4%, 5%, 6%, 8%, 10%, 12%, and 15%. Other channeling agents contemplated include polyglycols such as polyethylene glycol (PEG), ethylene-vinyl alcohol (EVOH), and polyvinyl alcohol (PVOH), polyamides such as nylon, and poly(propylene oxide) monobutyl ether.

[0099] Example 2. Extrusion Conditions Extrusion experiments were conducted under the following conditions.

[0100] Samples were processed using an inflation film forming machine (LabTech). A first sample labeled M0033 was processed at a screw temperature of 350°F (177°C) and a die temperature of 350°F (177°C). The material was able to flow around the die and form bubbles. Various screw revolutions per minute (rpm) up to 65 were tried. At low screw speeds, the material did not flow fast enough to reach the nip rolls before becoming hard and brittle, making it difficult to pass through the nip rolls. At 65 rpm, the material still had sufficient ductility to reach the nip rolls. However, upon cooling, the material became hard and brittle, making it difficult to form an inflation film. The nip roll speed was set at 0.5 ft / min. To avoid rapid cooling, the outside air was set lower than 500 rpm.

[0101] The blow molding of a polyethylene sample was attempted at a screw temperature and die temperature of 360°F (182°C). The material flowed around the die and formed bubbles. However, the rotation of the screw stopped during the process. This could be because the size of the raw material in pelletized / chopped form hindered the intake by the screw and periodically inhibited the rotational movement of the screw.

[0102] For each extrusion experiment, the difficulty level of the extrusion process was ranked as "M" (processable) and "D" (difficult). Characteristics of a difficult extrusion experiment include slow formation of the required bubbles and breakage or rupture of the material during processing. [Table 2] [Table 3]

[0103] Under these conditions, no bubbles were formed using any of polyethylene, polypropylene, or polylactic acid at a rotational speed of 15 rpm or 30 rpm and any temperature of 150°C, 165°C, or 180°C. For these materials, the formation of bubbles at 65 rpm and 180°C was accompanied by difficulty.

[0104] Furthermore, compared with the formula where R = H or CH3, a higher filling amount could be achieved using the formula where R = C2H5, n-C4H9, or n-C6H 13 and.

[0105] Further specific conditions are considered for extrusion molding. An extrusion speed between 5 rpm and 30 rpm is assumed. In particular, extrusion speeds selected from 5, 10, 15, 20, and 25 rpm are assumed.

[0106] Example 3. EXACT (trademark) formulation Using the following materials, the following test formulations were prepared.

[0107] Base resin = EXACT (trademark) 3040

[0108] Complex #1 = 60% K360 SYLOSIV / 40% Resin 3040

[0109] Regarding the base resin and the mixture of Complex #1, the composition of the EXACT™ 3040 formulation is shown in Table 4.

Table 4

[0110] Regarding the base resin and the desiccant SYLOSIV® K360, the composition of the EXACT™ formulation is shown in Table 5.

Table 5

[0111] For each extrusion sample, the quality of the product was scored on a three - point scale of "G" (good), "F" (fair), and "P" (poor). Desirable quality includes a thin wall and no surface features such as wrinkles or bulges. Examples of products with good, fair, and poor quality are shown in Figures 8, 9, and 10, respectively.

[0112] Table 6 and Table 7 report the ease of bubble formation and the quality of the resulting film.

Table 6

Table 7

[0113] Example 4. EXACT™ 3040 / HYTREL® 7246 Polyester Formulation Using the following materials, the following test formulations were prepared.

[0114] The composition of EXACT™ 3040 and the polyester formulation is shown in Table 8.

Table 8

Table 9

[0115] Table 10 and Table 11 report the ease of bubble formation and the quality of the resulting film.

Table 10

Table 11

[0116] Example 5. Moisture Absorption Rate Five films (three of each) of the EXACT™ 3040 formulation of Example 3 and eleven films (three of each) of the EXACT™ 3040 / HYTREL® formulation of Example 4 were selected, cut into 1-inch squares, and placed in a humidity chamber (80%). The weight of the film pieces was measured twice daily for two weeks.

[0117] Figure 11 is a graph showing the moisture absorption of an inflation film containing EXACT™ 3040 in g / day (vertical axis). The graph is defined by extrusion temperature: (a) 150°C, (b) 165°C, (c) 180°C. Formulations: (i) #1 (60% formulation #1) (ii) #2 (40% formulation #1), (iii) #3 (25% formulation #1).

[0118] Figure 12 is a graph showing the moisture absorption of an inflation film containing a mixture of EXACT™ 3040 and HYTREL® 7246 in g / day. The graph is defined by extrusion temperature: (a) 150°C, (b) 165°C, (c) 180°C, (d) 190°C. Formulations: (a) #4 (40% formulation #1) (b) #4 (30% formulation #1), (c) #4 (25% formulation #1).

[0119] Although the disclosed concepts have been described in detail with reference to specific examples thereof, it will be apparent to those skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.

Claims

1. A base polymer comprising an ethylene / α-olefin block copolymer, and It contains 10% to 50% by weight of an activator, An inflation film material wherein the activator is a granular, particulate, and / or mineral-based material.

2. The aforementioned base polymer is of formula (-CH 2 CHR-) n A polyolefin having the formula, where R is H and n-C 1～10 An inflation film material according to claim 1, selected from alkyl groups.

3. R is C 2 H 5 , n-C 4 H 9 , and n-C 6 H 13 The inflation film material according to claim 2, selected from

4. The inflation film material according to claim 1, wherein the α-olefin is selected from propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, and 1-dodecene.

5. The inflation film material according to claim 1, wherein the block copolymer further comprises a poly(butylene) terephthalate monomer block.

6. The inflation film material according to claim 1, wherein the block copolymer further comprises a polyether glycol block.

7. The inflation film material according to claim 1, wherein the material comprises 5% to 30% of the ethylene / α-olefin block copolymer.

8. The inflation film material according to claim 1, wherein the material comprises a block copolymer containing 50% to 85% poly(alkylene) terephthalate monomer blocks.

9. The inflation film material according to claim 1, wherein the activator is a desiccant.

10. The inflation film material according to claim 9, wherein the desiccant is contained in an amount of 20% to 40% by weight relative to the total weight of the inflation film material.

11. The inflation film material according to claim 1, further comprising a channeling agent, wherein the channeling agent is selected from polyglycol, glycerin polyamine, polyurethane, and polycarboxylic acid, or any combination thereof, or the channeling agent is selected from propylene oxide polymer, poly(propylene oxide) monobutyl ether, ethylene vinyl acetate (EVA), nylon, or any combination thereof, and the channeling agent is provided in an amount ranging from 1% to 15% by weight, optionally 2% to 12% by weight, optionally about 5% by weight.

12. The following steps: The base polymer and the activator are combined to form a precursor material. The aforementioned precursor material is extruded using a screw extruder while being heated to form a heated material. Passing the heated material through a tubular die, The heated material is expanded and stretched under positive pressure, and Cooling the expanded and stretched material. Includes, A method for producing an inflation film material according to claim 1, wherein the extrusion is performed at a rotational speed of 10 rpm to 75 rpm and at a temperature of 140°C to 180°C.

13. The method according to claim 12, wherein the rotational speed is 20 rpm to 50 rpm.

14. The method according to claim 12, wherein the temperature is 150°C to 165°C.

15. The method according to claim 12, wherein the method comprises co-extrusion of at least two layers for forming the expanded and stretched material, wherein at least one layer comprises a polymer material that is not mixed with an activator.

16. A method for protecting a product from moisture, A step of providing a container comprising the inflation film material described in claim 1, wherein the container is Interior space, and A cover or sealing area for closing the aforementioned container. Processes including, The process of placing the product in the internal space of the container, A step of enclosing the product in the internal space of the container Includes, The aforementioned product is selected from food, pharmaceuticals, medical devices, or drug delivery devices. A method wherein the method protects the product from moisture.

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