A BIODEGRADABLE AND FERTILIZABLE, BREATHABLE FILM CONTENT AND ITS PRODUCTION PROCESS.

Abstract

The invention is intended for use in many fields, particularly in the hygiene and medical sectors. a biodegradable and compostable, breathable film content and This relates to the production process of this film. The subject of the invention is a biologically degradable (biodegradable) material. The most important feature of the biodegradable, breathable film is its breathability and its triple polymer structure. The subject of the invention is a biodegradable film. compostable, breathable film; compound extrusion(100), film extrusion(110) and It is obtained as a result of a process that includes stretching (120) steps.

Description

TARIFF A BIODEGRADABLE AND FERTILIZABLE, BREATHABLE FILM CONTENT AND ITS PRODUCTION PROCESS. Subject Matter and Technical Scope of the Invention The invention relates to a biodegradable and compostable, breathable film and its production process, intended for use in numerous fields, primarily the hygiene and medical sectors. The most important characteristic of the biodegradable and compostable, breathable film is its breathability and its triple polymer structure. The biodegradable and compostable, breathable film is obtained through a process involving compound extrusion, film extrusion, and stretching steps. State of the Art Today, with the advancement of technology, societal consumption has increased, and these consumption habits have brought with them various problems. The problems created by consumption habits are a common problem for the whole world. Sustainability, while not being able to completely solve these problems, is a concept that can minimize them. Sustainability aims to transfer natural resources to future generations, and in doing so, it does not disregard human needs. Plastic is the third most widely used petroleum derivative in the world. Over 200 million tons of plastic are consumed annually, and these plastics, such as polystyrene, polypropylene, polyethylene, polymethyl methacrylate, and polyvinyl chloride, are petroleum-based. They take over 500 years to decompose in nature, negatively impacting aquatic life. Furthermore, these types of plastics are ingested by marine and poultry animals, leading to their deaths. On the other hand, the mountains of waste created by these plastics are also an environmental problem. In light of this information, biodegradable solutions and bioplastics are areas with potential for development. There is a great need for plastic materials based on biological raw materials that decompose in nature and can be repeatedly produced from nature, replacing synthetic and non-biodegradable plastics that increase dependence on petroleum and cause environmental pollution. The use of bioplastics is being encouraged as an alternative to petroleum-based plastics. Bioplastics are made from natural polymers such as agricultural waste, cellulose, potato and corn starch. They are 100% biodegradable in nature, as durable and versatile as petroleum-based plastics. They are used in many sectors such as agriculture, textiles, medicine, and packaging. In European and American countries, the popularity of bioplastics is increasing for ecological reasons. Their advantages include reducing carbon footprint, saving energy in production, being renewable, and reducing non-biodegradable waste that pollutes the environment. They also do not contain harmful chemicals such as phthalates and bisphenol A and do not alter the taste or smell of food when used as packaging. It is important to know that not all bioplastics are biodegradable. Only bioplastics derived from renewable biological resources are biodegradable. Biodegradable polymers are polymers that can be dissolved by the action of bacteria, fungi, algae, yeasts, and other microorganisms found in nature. Biodegradable polymers can be produced naturally by living organisms or can be synthetically produced polymers whose biodegradability has been proven. Cellulose, starch, leather, chitin, chitosan, and bacterial polyester are examples of polymers produced by living organisms. Polylactic acid (PLA), polycaprolactone (PCL), polyglycolic acid (PGA), and poly(butylene dipate-coterephthalate) (PBAT) are examples of synthetically produced polymers whose biodegradability has been proven. In addition to the environmental problems caused by plastic waste, hygiene products, and especially diapers, constitute a large share of this waste. Diapers are the third most common type of waste found in landfills and make up 30% of non-biodegradable waste. According to a report by the U.S. Environmental Protection Agency, disposable diapers generate 3.5 million tons of waste nationwide each year. Besides plastic waste, these diapers also harm the environment because they contain pathogenic solid waste. Studies indicate that it takes up to 500 years for diapers to decompose in nature, releasing toxic gases such as methane. Furthermore, estimates suggest that 200,000 trees are destroyed annually in the U.S. to produce disposable diapers. Currently, alternatives to disposable diapers include washable and reusable diapers, as well as biodegradable diapers. Patent US2017224540, “Biodegradable, biobased diaper,” relates to the composition of a bio-based and / or biodegradable disposable diaper. In this study, the diaper components are defined as outer layer, inner layer, absorbent pad, side layer, fastening ends, and elastic waistband. The invention states that the diaper consists of more than 25% bio-based content. The components include aromatic polyester (PBS, polybutylene succinate, PBT, polybutylene interphalt, PBAT, poly(butylene dipteraphthalate) or combinations thereof), cellulosic polymer-based biodegradable polymer, polylactic acid (PLA), bamboo or cotton, modified starch, cellulose, and keratin. This patent does not address the harmonization of the PBAT, PLA, and TPS components. Furthermore, the diaper is not breathable and is only partially biodegradable. Patent US2002098341, “Biodegradable breathable film and laminate,” relates to a film material for use in personal care products and disposable medical devices. The invention is described as a breathable, stretch-thin film containing filler particles and a biodegradable thermoplastic polymer. The film has voids around the filler particles to facilitate the passage of water vapor. The biodegradable thermoplastic polymer can be selected from polyesters of polylactic acid, polycaprolactone, and butenediol, adipic acid, succinic acid, and / or terephthalic acid. The film may also be used as a laminate consisting of multiple layers. Patent US2010 / 0068484, titled “Highly breathable biodegradable films,” relates to a film with highly breathable and biodegradable properties. The invention consists of a biodegradable polymer matrix and primary and secondary filler particles distributed within this matrix. The primary filler is stated to be calcium carbonate, and the secondary filler is titanium dioxide. The biodegradable polymer can be aromatic polyester, aliphatic polyester, aromatic-aliphatic copolyester, or combinations thereof. This work also addresses the production of the film. The article “Characterization of TPS / PLA Blends Obtained by Extrusion and Thermopressing (Carmen MO Müller, Alfredo TN Pires and Fabio Yamashita)” presents test results and water absorption isotherms for the mechanical properties and water vapor permeability of PLA / TPS blends prepared by extrusion and thermopressing. The morphological characteristics of the samples are visualized using SEM, and the thermal properties of pure polymers and blends are determined by DSC. In this study, SEM (scanning electron microscopy) and DSC (differential scanning calorimetry) results show that the TPS / PLA blends do not mix and that two phases exist. Patent WO2005 / 056656, titled “Biodegradable and breathable polymer film,” describes a biodegradable, breathable film composition. The film contains 30-70% biodegradable copolyester and 30-70% filler material by weight. When subjected to uniaxial or biaxial stretching, the voids increase, and water vapor permeability reaches at least 800 g / m² / 24 hours. It is stated that the copolyester can be selected from aliphatic or aromatic acids, and the filler material can preferably be calcium carbonate. The film is applicable to disposable breathable products such as personal care products, absorbent products, healthcare products, and medical fabrics. Patent WO02 / 085421, “Biodegradable films having enhanced ductility and breathability,” relates to personal care products containing biodegradable films. The biodegradable film in question possesses high breathability and ductility (softness, malleability, ductility). It consists of a biodegradable polymer and a water-soluble polymer (preferably polyethylene oxide, polyethylene glycol, or a copolymer). In the current state of the technology, many studies have been conducted on biodegradable films that can be used in the hygiene and medical sectors. Some of these studies have highlighted breathability as a key feature. Breathability is an important characteristic in baby diapers. Microporous, breathable products prevent liquid leakage, while water vapor is wicked away from the skin through selectively permeable layers. These types of breathable diapers reduce pore clogging, maintain normal skin moisture, and eliminate friction. They also prevent fungal infections and provide additional benefits in preventing diaper rash. One observation regarding the current state of the technology is that biodegradable films generally contain single or double polymer structures. There are no studies showing a triple polymer structure. Furthermore, it has not been possible to create a polymer composition using PBAT, PLA, and TPS polymers; these three incompatible polymers, whose molecular structures are given below, have not been harmonized to achieve high efficiency. In this sense, there is a need for a breathable film with a triple polymer structure that is more environmentally friendly, biodegradable and compostable in a shorter time, and possesses superior properties, suitable for use in many fields, especially the hygiene and medical sectors, compared to the current state of the technology. Technical Problems That the Invention Aims to Solve The invention aims to create a biodegradable and compostable, breathable film with a triple polymer structure that possesses superior properties compared to the current state of the art, and which can be used in many fields, primarily in the hygiene and medical sectors. The most important feature of the invention, a biodegradable and compostable, breathable film, is its environmentally friendly nature due to its biodegradable and compostable structure. Thanks to this feature, it will significantly reduce plastic waste, especially from disposable diapers and similar products. The reduction in plastic waste will also prevent the problems of plastics not decomposing or breaking down in nature for many years, which are present in the current state of the art. The invention concerns a biodegradable and compostable, breathable film, one advantage of which is its breathability. Particularly in products such as diapers, adult diapers, etc., a microporous and breathable film is expected to protect skin health. Another advantage of the biodegradable and compostable, breathable film that is the subject of this invention is that it contains polylactic acid (PLA). Polylactic acid is a thermoplastic aliphatic polyester with a molecular structure as follows. It has a melting point above 150°C. Its high melting point facilitates processing without thermal degradation of the melt. Polylactic acid also has a stiff, rigid structure. It is both bio-based and a polymer that is both biodegradable and compostable. Another advantage of the biodegradable and compostable, breathable film that is the subject of this invention is that it contains poly(butylenedipatoterephthalate) (PBAT). Unlike PLA, PBAT is a polymer with a low melting point (120°C). Therefore, it is difficult to process on its own. However, with its flexible and elastic structure, it is a polymer that improves the mechanical properties of the film and facilitates the stretching stage of the process. PBAT has the following molecular structure and is a synthetic polymer. It is biodegradable and compostable. Another advantage of the biodegradable and compostable, breathable film in question is that it contains thermoplastic starch (TPS). TPS is a polymer that is quite difficult to process due to its high moisture retention capacity. However, its high moisture absorption accelerates the decomposition of the biodegradable product. In other words, moisture (water) is a catalyst that accelerates decomposition in nature. Its molecular structure is as follows, making it both bio-based and a biodegradable and compostable polymer. -OH T °\ ΌΗ OH Another advantage of the biodegradable and compostable, breathable film that is the subject of this invention is its inclusion of calcite (CaCCh). Calcite, aided by the stretching method, creates micropores within the triple polymer matrix, thus giving the film its breathable properties. Another advantage of the biodegradable and compostable, breathable film, which is the subject of the invention, is that it is obtained by harmonizing incompatible TPS, PLA, and PBAT polymers to form a ternary polymer structure. The film obtained in this way is less harmful than the known state of the art. This means that it can biodegrade and compost in nature in a shorter time, and constitutes another advantage of the invention. To better understand the subject of the invention, which is a biodegradable and compostable, breathable film, and its production process, the following figures will be used. Explaining the Figures Figure 1 is a flowchart illustrating the process steps for producing the biodegradable and compostable, breathable film that is the subject of the invention. Figure 2 shows a representative image of the apparatus in which compound extrusion takes place in the production process of the biodegradable and compostable, breathable film that is the subject of the invention. Figure 3 shows a representative image of the blowing apparatus where film extrusion takes place in the production process of the biodegradable and compostable, breathable film that is the subject of the invention. Figure 4 shows a representative image of the apparatus in which the stretching process takes place in the production process of the biodegradable and compostable, breathable film that is the subject of the invention. Figure 5 shows a representative image of calcite particles on a biodegradable and compostable, breathable film before the stretching process. Figure 6 is a representative image of calcite particles and micropores on a breathable film that is biodegradable and compostable after stretching. Section, Part, and Flow Reference Numbers That Help Describe the Invention 1- Compound extrusion machine 1a - First feed hopper 1b- Second feeding hopper 1c - Power supply input 1d - Hive 1e- Vacuum 1f - Cutting unit 2- Blown film extrusion apparatus 2a - Feeding hopper 2b - Extruder 2c - Mold 2d - Cooling chamber 2e- Nip rolls 2f - Other rolls 2g - Film roll 3- Stretching device 3a- Sarici 3b- Calcite 3c - Space Process Flowchart to Help Explain the Invention 100 - Compound Extrusion Stage 110 - Film Extrusion Stage 120 - Stretching Phase Detailed Description of the Invention The invention concerns a biodegradable and compostable, breathable film; an alternative to plastics currently in use, it is environmentally friendly, can decompose quickly in nature, and can be used in various fields. It also has breathable properties due to its microporous structure. The subject of the invention is a biodegradable and compostable, breathable film, most generally composed of a triple structure of thermoplastic starch (TPS), poly(butylenenadipate-co-terafthalate) (PBAT), and polylactic acid (PLA). It should be noted that these three materials are polymers that are difficult to harmonize. The components of the film in question, and their percentages by weight, are as follows: Component by Weight Percentage: Polylactic Acid (PLA) 10-50%, Poly(butylenenadipate-co-terafthalate) (PBAT) 10-70%, Thermoplastic Starch (TPS) 1-30%, Calcite 10-50%, Compatibilizer 0.1-10%. Table 1: Components and Weight Percentages of the Film Subject to the Invention As given in Table T, the subject of the invention is a biodegradable and compostable, breathable film containing 10-50% PLA, 10-70% PBAT, 1-30% TPS, 10-50% calcite, and 0.1-10% compatibilizer by weight. Technically, the calcite should have a particle size of 0.5-3.0 pm d50 and a moisture content less than 0.20%. Calcite is used as a filler material and also provides breathability to the film. The subject of the invention is a biodegradable and compostable, breathable film containing 0.1-10% by weight of compatibilizer. Maleic anhydride graft polymer is preferably used as the compatibilizer, acting as a binder for three incompatible polymers: PLA, PBAT, and TPS. PLA has a weight percentage ranging from 10% to 50%. The PLA to be used should preferably have a moisture content of 0.15-0.25%, a fluidity index of 3-15 g / 10 min, and a density of 1.15-1.35 g / cm³. PBAT is a biodegradable polyester. The subject of this invention is a biodegradable and compostable, breathable film containing PLA at a weight percentage ranging from 10% to 70%. Technically, a moisture content of 0.15-0.25%, a fluidity index of 2-6 g / 10 min, and a density of 1.15-1.35 g / cm³ are preferred. The thermoplastic starch content in the film should preferably be in the range of 0-30% by weight. The fluidity index should preferably be between 1-10 g / min, and the density should be in the range of 1.30-1.50 g / cm3. The biodegradable and compostable, breathable film obtained from the materials mentioned above is expected to have the following technical specifications: Weight (g / m2) 10-30 Breathability, WVTR (Mocon) (g / m2-day) 500-10000 Maximum Tensile Strength in Machine Direction (Longitudinal, MD) (N) 15-30 Elongation at Break in Machine Direction (Longitudinal, MD) (%) 5-200 Maximum Tensile Strength in Counter-Machine Direction (Transverse, CD) (N) 2.5-15 Elongation at Break in Counter-Machine Direction (Transverse, CD) (%) 30-400 Table 2: Technical Specifications of the Film Subject to the Invention According to the data in Table 2, the grammage of the biodegradable and compostable, breathable film, which is the subject of the invention, varies between 10-30 g / m2. Grammage represents the mass per unit area, and lower grammage is more advantageous in terms of decomposition time in nature. It also affects breathability. It can be said that lower grammage films have higher permeability. In terms of breathability, the film in question is expected to have a permeability in the range of 500-10000 (g / (m2-day)). High permeability is the goal here. The maximum tensile force in the direction of the machine (longitudinal) is expected to be in the range of 15-30 N, and the maximum tensile force in the opposite direction of the machine (transverse) is expected to be in the range of 2.5-15 N. The elongation at break in the direction of the machine (longitudinal) is in the range of 5-200%, while the elongation at break in the opposite direction of the machine (transverse) is in the range of 30-400%. The production process of the biodegradable and compostable, breathable film that is the subject of this invention generally involves obtaining a semi-finished compound from raw materials through extrusion, subjecting this semi-finished compound to further extrusion to form the film, and finally, stretching the film to its final form. The film extrusion process can be either blown or cast extrusion. A flowchart of these process steps is given in Figure T, and the process steps will be examined in detail under the following headings. Compound Extrusion Stage (100) Film Extrusion Stage (110) Stretching Phase (120) Compound Extrusion Stage (100) Compound is a well-known concept in the industry, referring to new raw materials created with desired properties by enriching polymers with various organic and / or inorganic additives. The first stage of the production process for the biodegradable and compostable, breathable film that is the subject of this invention will be compound extrusion. This stage takes place via a representative setup schematically shown in Figure 2. Accordingly, PLA, PBAT, TPS polymers and compatibilizer are fed into the system together, while calcite is fed separately. According to the diagram in Figure 2, the polymers and compatibilizer are fed into the system from the first feed hopper (1a), and calcite from the second feed hopper (1b). The materials reaching the barrels (1d) from the feed inlets (1c) are heated, melted, and mixed in a twin-screw system, where the extrusion process takes place. Afterwards, they arrive at the cutting unit (1f), where they are cut into granules, thus completing this stage.In the underwater cutting system, round granules are preferred because flat granules will absorb moisture. Cutting water and barrel temperatures are important parameters at this stage. Cutting water should preferably be in the range of 40-80 C°. Barrel temperature values, which can also be called extruder temperature, should preferably be between 120-180 C°. Moisture and oligomers are removed with the help of vacuum (1e). Film Extrusion Stage (110) At this stage, the compound granules undergo a second extrusion process to form a film. Figure 3 schematically illustrates a representative setup for film extrusion. According to this schematic, granules fed into the system from the feeder hopper (2a) are melted in the extruder (2b) at a temperature preferably between 150-200 C° and sent to the die (2c). The die temperature should also preferably be between 150-200 C°. The melt passing through the die (2c) is cooled with air in the cooling chamber (2d). After the cooling process, the product, which has become a film, exits through the nib rollers (2e). The resulting film is wound onto other rollers (2f) to form a film roll (2g), and the film extrusion stage is completed. Stretching Phase (120) The subject of this invention is the stretching of the final stage in the production process of a biodegradable and compostable, breathable film. Figure 4 shows a schematic view of the film before stretching and the calcite particles on it. This film is stretched using clamps (3a) on a representative apparatus shown in Figure 3 to obtain a film as shown in Figure 5. Accordingly, voids (3c) are created around the calcite (3b) embedded in the polymer matrix, and the film gains a breathable structure with these micropores. Stretching is preferably done in the machine direction with ratios between 2:1 and 4:1. The stretching temperature is preferably in the range of 50-90 C°. The production process of the biodegradable and compostable, breathable film, which is the subject of this invention, is obtained through the process steps described above. It should be noted that the diagrams of the setup for the production process of the biodegradable and compostable, breathable film, which is the subject of this invention, are representative and the tools and equipment shown herein are not binding. The process can be carried out with different equipment that performs the same function. During compound extrusion (100), polymers and compatibilizer can be fed together or separately. However, in all cases, calcite must be fed separately. Although the cutting is preferably done using an underwater cutting system, different alternative systems such as pool cutting or dry conveyor cutting systems are also possible. Although the number of barrels is shown as 13 in the diagram, this is not binding. Although the film extrusion stage (110) is described based on blown extrusion, it is also possible to produce film with cast film extrusion. The film can be single-layer or multi-layer. The film extrusion (110) and stretching (120) stages can be carried out as a continuous process or in batches. In any case, compound extrusion (100) will be carried out as a separate process. Industrial Application of the Invention The invention, a biodegradable and compostable, breathable film, can be used in many areas, primarily in the hygiene and medical sectors. Some of the application areas include diapers, adult diapers, feminine hygiene products, medical pads, sanitary pads, bladder pads, breast pads, personal safety products, and protective clothing.

Claims

1 REQUESTS 1. The invention is characterized by the content of a biodegradable and compostable, breathable film. Its defining characteristic is that it is a biodegradable and compostable, breathable film made of polylactic acid. At least three components: poly(butylene dipate-co-terephthalate) and thermoplastic starch. Having a polymer structure, the film in question contains 10-50% polylactic acid, 5 10-70% poly(butylenadipate-co-terephthalate), 1-30% thermoplastic It contains starch, calcite in the range of 10-50%, and compatibilizer in the range of 0.1-10%. biodegradable / compostable in nature and it should be breathable.

2. Biodegradable and compostable, breathable film conforming to Claim 1. Its content and defining characteristic is that the aforementioned harmonizer is maleic anhydride. The graft is made of polymer.

3. Biodegradable and compostable, breathable film conforming to Claim 1. 15 Its defining characteristic is its biodegradable and compostable, breathable composition. The film must be breathable and have a water vapor permeability (WVTR) value of 500- It should be in the range of 10000 (g / m²-day).

4. Biodegradable and compostable, breathable film conforming to Claim 1. 20 Its defining characteristic is its biodegradable and compostable, breathable composition. The film's grammage should be in the range of 10-30 (g / m2).

5. The content of the biodegradable and compostable, breathable film conforming to Claim 1. Its characteristic feature is; biodegradable and compostable, breathable film 25 The poly(butylene dipate-co-terephthalate) used has a moisture content of 0.15-0.25%. It should have a fluidity index in the range of 2-6 g / 10 min and a humidity level of 1.15-1.35 It has a density in the range of g / cm3.

6. The content of the biodegradable and compostable, breathable film conforming to Claim 1 is 30 Its characteristic feature is that it is biodegradable and compostable, and made from a breathable film. The polylactic acid used has a moisture content of 0.15-0.25% and good fluidity. Its index is in the range of 3-15 g / 10 min and its density is 1.15-1.35 g / cm3. 35 2 7. The content of the biodegradable and compostable, breathable film conforming to Claim 1. Its characteristic feature is that it is biodegradable and compostable, and made from a breathable film. The calcite used has a d50 particle size in the range of 0.50-3.0 μm and moisture content. its value is less than 0.20%. 5 8. The content of the biodegradable and compostable, breathable film conforming to Claim 1. Its characteristic feature is that it is biodegradable and compostable, and made from a breathable film. The fluidity index of the thermoplastic starch used is in the range of 1-10 g / 10 min. Its density is 1.30-1.50 g / cm3. 10 9. The content of the biodegradable and compostable, breathable film conforming to Claim 1. Its characteristic feature is its biodegradable and compostable, breathable film. It can be used in the hygiene and medical sectors.

10. The content of the biodegradable and compostable, breathable film conforming to Claim 1. Its characteristic feature is its biodegradable and compostable, breathable film. diapers, adult diapers, feminine hygiene products, medical pads, sanitary ware sanitary pads, bladder pads, breast pads, personal safety products and protective clothing It is usable. 20 11. Invention for a biodegradable and compostable, breathable film. Compound Extrusion Stage (100) Film Extrusion Stage (110) 25 Stretching Phase (120) It is a production process that includes several stages and its characteristic feature is; Compound extrusion stage (100) PLA, PBAT, TPS and maleic The anhydride graft polymer is fed into the system either together or separately, and the calcite is fed separately. 30 The feeding of the system as a result of the materials fed into the system are in the hives (1d) with twin screws. in the system, it is melted, heated, mixed, subjected to extrusion, and more. then obtaining round granules by underwater cutting process in the cutting unit (1f). It includes the processes involved. 35 3 12. A production process conforming to Claim 11, characterized by its compounding properties. During the (compound) extrusion stage (100), the cutting water temperature should preferably be 40-80 Within the CO2 range, the ideal temperature for the hive should be between 120-180 CO2.

13. The production process conforming to claim 11 is characterized by its film extrusion process. 5 second extrusion of compound granules to form a film of stage (110) For this purpose, the granules are first fed from the feed hopper (2a) and subjected to the process. feeding the granules in the extruder (2b) preferably at a temperature between 150-200 C0. melting and sending into the mold (2c) at a temperature of 150-200 C0 and then cooling Cooling with air in the chamber (2d) and making it into a film 10 It includes.

14. The production process conforming to Claim 11 is characterized by its stretching feature. During the stage (120), the stretching should preferably take place in the direction of the machine, stretching The ratio should be between 2:1 and 4:1, and the stretching temperature should preferably be 50-90°C. It is within the range.

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