U.S. patent application number 10/623278 was filed with the patent office on 2005-05-12 for low melt flow composition.
Invention is credited to Spinks, Anne E..
Application Number | 20050100744 10/623278 |
Document ID | / |
Family ID | 27623246 |
Filed Date | 2005-05-12 |
United States Patent
Application |
20050100744 |
Kind Code |
A1 |
Spinks, Anne E. |
May 12, 2005 |
Low melt flow composition
Abstract
A composition that includes a polyalphaolefin polymer and from
about 20% by weight to about 70% by weight adsorbent, the
composition being essentially free of a film forming agent.
Inventors: |
Spinks, Anne E.; (Hugo,
MN) |
Correspondence
Address: |
Kirsten K. Stone, Director of Patents and Technolo
H.B. Fuller Company, Patent Department
1200 Willow Lake Blvd.
P.O. Box 64683
St. Paul
MN
55164-0683
US
|
Family ID: |
27623246 |
Appl. No.: |
10/623278 |
Filed: |
July 18, 2003 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
10623278 |
Jul 18, 2003 |
|
|
|
09410292 |
Sep 30, 1999 |
|
|
|
6602444 |
|
|
|
|
Current U.S.
Class: |
428/428 |
Current CPC
Class: |
E06B 3/66342 20130101;
C08K 3/34 20130101; C08L 23/02 20130101; C08K 3/34 20130101 |
Class at
Publication: |
428/428 |
International
Class: |
B32B 007/06; B32B
017/10 |
Claims
What is claimed is:
1. A composition comprising: a polyalphaolefin polymer; and from
about 20% by weight to about 70% by weight adsorbent, said
composition being essentially free of a film forming agent.
2. The composition of claim 1, wherein said polyalphaolefin polymer
comprises a polymer comprising monomers selected from the group
consisting of ethylene, propylene, butene, pentene, hexene, octene,
decene, isoprene, terpene, vinyl acetate, styrene, butadiene, and
combinations thereof.
3. The composition of claim 1, wherein said composition exhibits a
melt flow time of no greater than 60 seconds at 190.degree. C.
4. The composition of claim 1, wherein said composition exhibits a
melt flow time of no greater than 15 seconds at 190.degree. C.
5. The composition of claim 1, wherein said composition exhibits a
melt flow time of less than 5 seconds at 190.degree. C.
6. The composition of claim 1, wherein said composition comprises
from about 40% by weight to about 70% by weight adsorbent.
7. The composition of claim 1, wherein said adsorbent comprises an
adsorbent capable of adsorbing organic species.
8. The composition of claim 1, wherein said composition, when
applied to a substrate and subjected to 88.degree. C. for one
month, is essentially free from sag.
9. The composition of claim 1, wherein said composition passes the
ASTM E1887 fog test.
10. An insulating glass assembly comprising: a first glass
substrate; a second glass substrate; a separator disposed between
said first glass substrate and said second glass substrate; and the
composition of claim 1 in contact with said separator.
11. The assembly of claim 10, wherein said composition exhibits a
melt flow time of less than 5 seconds at 190.degree. C.
12. A composition consisting essentially of: a polyalphaolefin
polymer; from about 20 to about 70% by weight of an adsorbent
selected from the group consisting of moisture adsorbents, volatile
organic adsorbents, and combinations thereof; from 0 to 10% by
weight tackifying resin; and from 0 to 5% by weight
antioxidant.
13. The composition of claim 12 consisting essentially of said
polyalphaolefin polymer and said adsorbent.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation of U.S. application Ser. No.
09/401,292, filed Sep. 30, 1999, now U.S. Pat. No. _________.
BACKGROUND OF THE INVENTION
[0002] The invention relates to low melt flow compositions.
[0003] Insulating glass units often include two panels of glass
separated by a spacer. The panels of glass are placed parallel to
each other and the spacer is sealed to the glass. Insulating glass
units also have other structures including two spacers and three
glass panels. There are also a variety of spacers available
including hollow metal tubes, nonmetal tubes, preformed roll type
spacers, plastic spacers, metal U-channels, and various organic and
inorganic foams.
[0004] Insulating glass units are prone to the accumulation of
chemical "fog" on the interior surface of the glass panels. Fogging
can be caused by off gassing of organic and inorganic materials in
the spacer or from other structures in the interior of the
insulating glass assembly, e.g., painted decorative grids. The
spacers frequently contain a desiccant to adsorb residual moisture
that may enter the airspace during the life of the unit. Desiccants
are available in a variety of forms including compositions that
include organic or inorganic carriers and an adsorbent capable of
adsorbing moisture or volatile organic compounds. When placed in an
insulating glass assembly these compositions reduce fogging.
SUMMARY
[0005] In one aspect, the invention features a composition that
includes a polyalphaolefin polymer, and from about 20% by weight to
about 70% by weight adsorbent, the composition being essentially
free of a film forming agent. In one embodiment, the
polyalphaolefin polymer includes monomers selected from the group
consisting of ethylene, propylene, butene, pentene, hexene, octene,
decene, terpene, isoprene, styrene, butadiene, vinyl acetate and
combinations thereof.
[0006] In other embodiments, the composition includes from about
40% by weight to about 70% by weight adsorbent. In one embodiment,
the adsorbent includes an organic adsorbent. In some embodiments,
the composition further includes no greater than about 10% by
weight organic adsorbent.
[0007] In another embodiment, the composition, when applied to a
substrate and subjected to 88.degree. C. for one month, is free of
visible sag.
[0008] In some embodiments, the composition exhibits a melt flow
time of no greater than 60 seconds, preferably no greater than 15
seconds, more preferably less than 5 seconds.
[0009] In another aspect, the invention features an insulating
glass assembly that includes a first glass substrate, a second
glass substrate, a separator disposed between the first glass
substrate and the second glass substrate, and an above-described
composition in contact with the separator.
[0010] In other aspects, the invention features a composition that
includes a polyalphaolefin polymer and from about 20% by weight to
about 70% by weight adsorbent, the composition exhibiting a melt
flow time of less than 5 seconds at 190.degree. C.
[0011] In some aspects, the invention features a composition that
consists essentially of a polyalphaolefin polymer, from about 20%
by weight to about 70% by weight of an adsorbent selected from the
group consisting of moisture adsorbents, volatile organic
adsorbents, and combinations thereof, from 0 to 10% by weight
tackifying resin, and from 0 to 5% by weight antioxidant. In one
embodiment, the composition consists essentially of polyalphaolefin
polymer and adsorbent.
[0012] A film forming agent is a material other than a
polyalphaolefin polymer that forms a film or assists in forming a
film including, e.g., polyisobutylene and butyl rubber.
[0013] The adsorbent composition adheres to separators (e.g., metal
or plastic channels) used in insulating glass units without sagging
or loss of adhesion during the useful life of the unit in which the
composition is incorporated. The adsorbent composition can adsorb
moisture and volatile organic compounds from its surrounding
atmosphere.
[0014] The adsorbent composition is also pumpable (i.e., has a melt
flow time of no greater than about 60 seconds when tested per ASTM
D-1238, Procedure B using an 1100 gram load and a 6-8 gram sample,
at 190.degree. C. (374.degree. F.)) and exhibits a sufficiently low
melt flow time such that the composition flows easily. The
adsorbent composition is particularly well suited for use in
insulating glass assemblies and in processes for preparing
insulating glass assemblies. Insulating glass assemblies that
include the adsorbent composition can be free from fogging during
the useful life of the glass assembly.
[0015] The adsorbent compositions include large amounts of
adsorbent, yet exhibit melt flow times of less than 5 seconds at
190.degree. C.
[0016] Additional features and advantages of the invention will be
apparent from the description of the preferred embodiment thereof
and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a sectional view of an edge assembly of an
insulating glass unit that includes an adsorbent composition.
[0018] FIG. 2 is a sectional view of a corner of a separator of the
insulating glass unit of FIG. 1.
DETAILED DESCRIPTION
[0019] Referring to FIGS. 1 and 2, an insulating glass unit 10
includes separator 12 positioned between glass sheets 14, 16.
Separator 12 is adhered to glass sheets 14, 16 with a moisture
and/or gas impervious adhesive 18. An adsorbent composition 20 is
disposed in channel 22 defined by walls 24, 26, and 28 of separator
12. The adsorbent composition preferably adheres to the channel 22
defined by separator 12. Separator 12 can be made of a variety of
materials including, e.g., polymers and metal. Useful metal
substrates include, e.g., aluminum, steel, stainless steel, nickel,
and tin. Insulating glass assemblies can be constructed in a
variety of forms. Examples of suitable glass assemblies are
described in, e.g., EP 475,213 and incorporated herein.
[0020] The adsorbent composition is formulated to adsorb chemicals
present in the atmosphere to which the adsorbent composition will
be exposed. The adsorbent composition is formulated to be useful as
a desiccating composition. Preferably the adsorbent composition is
formulated to adsorb moisture, organic vapors, and combinations
thereof. The adsorbent composition is formulated such that
insulating glass assemblies that include the adsorbent composition
are free from fog during the useful life of the assembly.
Preferably the adsorbent composition and insulating glass
assemblies that include the adsorbent composition pass the ASTM
E1887 fog test for insulating glass units.
[0021] The adsorbent composition exhibits a melt flow time of no
greater than about 60 seconds, more preferably no greater than
about 15 seconds, most preferably less than 5 seconds, when tested
according to ASTM D-1238, Procedure B, using a 1100 gram load and
an 8 gram sample at 190.degree. C. (374.degree. F.).
[0022] The adsorbent composition is also preferably free from sag
(i.e., visible movement) when applied to the substrate. Preferably
the adsorbent composition is free from sag after being adhered to a
substrate and maintained at a temperature of at least 60.degree. C.
(140.degree. F.) for a period of at least two weeks, preferably for
a period of at least about one month at a temperature of 88.degree.
C. (190.degree. F.).
[0023] The adsorbent composition includes a polyalphaolefin polymer
and an adsorbent. The polyalphaolefin polymer is selected to
exhibit sufficient cohesive strength and heat resistance such that
the polymer can be placed in an open U-channel insulating glass
assembly without impairing the utility of the glass assembly. The
volatile organic content of the polyalphaolefin polymer is
preferably no greater than about 20% by weight, more preferably no
greater than about 5% by weight. The polyalphaolefin polymer is
preferably amorphous, i.e., low degree of crystallinity.
[0024] Useful polyalphaolefin polymers have a number average
molecular weight (Mn) of from about 7,000 to about 14,000, a weight
average molecular weight (Mw) of from about 35,000 to about 90,000;
and a polydispersity (MWD) no greater than 6.2.
[0025] Suitable polyalphaolefin polymers include, e.g.,
homopolymers, copolymers, terpolymers, random polymers, block
polymers, radial polymers, star branched polymers, multicomponent
polymers, and combinations thereof. Useful polymers include
monomers including, e.g., ethylene, propylene, butene, hexene,
octene, decene, terpenes, isoprenes, vinyl acetate, styrene and
butadiene. Examples of useful polymers include propylene-ethylene,
propylene-butene, propylene-ethylene-butene,
styrene-isoprene-styrene, styrene-butadiene-styrene,
styrene-ethylene-butene-styrene, and
styrene-ethylene-propylene-styrene, ethylvinyl acetate, oxides of
ethylvinyl acetate, and combinations thereof.
[0026] Useful commercially available propylene polymers include,
e.g., Eastman E1003 amorphous propylene-ethylene copolymer (Eastman
Chemical), the Rextac series of amorphous polyolefin polymers
including Rextac 2100 series homopolymers, Rextac 2500 series
ethylene-propylene copolymers, and Rextac 2700 series
butene-propylene copolymers and terpolymers. Other useful polymers
include polymers available under the trade designations Eastoflex
(available from Eastman Chemical) including Eastoflex T1035
polypropylene-ethylene-butene terpolymer having a Mn of about 4,000
and a Mw of about 16,000, K-Tac A-100 amorphous polypropylene
(available from Baychem), Insight.TM. polyalphaolefin polymers
commercially available from Dow Chemical (Midland, Mich.) and
Exxact.TM. polyalphaolefin polymers commercially available from
Exxon Chemical (Texas).
[0027] The composition is preferably essentially free of film
forming agents, more preferably free of film forming agents
including e.g., polyisobutylene and butyl rubber.
[0028] The adsorbent of the composition is capable of adsorbing
molecules present in the atmosphere to which the adsorbent is
exposed. The adsorbent is selected based upon the characteristics
of the application in which the adsorbent composition is to be used
and the desired molecules to be adsorbed. The adsorbent can be
selected to adsorb chemicals including, e.g., moisture, organic
species (e.g., hydrocarbons, aromatics, and carbon dioxide), and
combinations thereof. Preferably the adsorbent is an inorganic
particulate material. Examples of useful adsorbents include natural
zeolite (e.g., chabasite, gumerinite, levynite, erinite, mordenite
and analcite), molecular sieves (e.g., alkali metal
alumino-silicates), silica gel, silica-magnesia gel, silica-alumina
gel, activated carbon, activated alumina, calcium oxide and
combinations thereof. Suitable alkali metal alumino-silicate
molecular sieves include, e.g., calcium, potassium, and sodium
alkali metal alumino silicates. Useful molecular sieves are
available under the trade designations Molsiv.RTM. Adsorbent Type
13x, and Molecular Sieve Type 3A, Type 4A and Type 5A, which are
all commercially available from UOP (Illinois) and molecular sieves
available from W.R. Grace (Maryland). Preferably the adsorbent
exhibits a particle size of no greater than about 50 to about 100
mesh.
[0029] Useful adsorbent compositions include an adsorbent capable
of adsorbing moisture in an amount of at least about 20% by weight,
preferably from about 20% by weight to about 70% by weight, more
preferably from about 30% by weight to about 70% by weight, most
preferably from about 40% by weight to about 70% by weight.
Preferably the adsorbent composition also includes an adsorbent
capable of adsorbing organic species in an amount of no greater
than about 20% by weight of, more preferably from about 8% by
weight to about 10% by weight. A particularly useful adsorbent
mixture includes from about 20% by weight to about 60% by weight
adsorbent capable of adsorbing moisture and 8-10% by weight
adsorbent capable of adsorbing organic species.
[0030] The adsorbent composition can optionally include a
tackifying resin. Suitable tackifying resins are compatible with
the polyalphaolefin polymer, exhibit good UV resistance, and
contain no greater than low amounts (preferably are free) of
components capable of volatilizing at temperatures encountered by
insulating glass units. Examples of suitable tackifying resins
include hydrogenated wood rosin, e.g., Foral 105 (commercially
available from Hercules, Del.), hydrocarbon tackifying resins,
e.g., RegalRez 1094 hydrogenated hydrocarbon tackifying resin
(Hercules, Del.) and ECR 165C C.sub.5/C.sub.9 tackifying resin
(available from Exxon Chemical, Tenn.). Preferably the composition
includes no greater than 60% by weight tackifying resin, more
preferably no greater than about 20% by weight, most preferably the
composition is free from tackifying resin.
[0031] The adsorbent composition can also include additives, e.g.,
fillers, pigments, antioxidants, UV and thermal stabilizers,
adhesion promoters and combinations thereof. Examples of useful
fillers include calcium carbonate, e.g., Hubercarb Q-325 calcium
carbonate available from J. M. Huber (Illinois), talc, e.g., Nytal
Talc available from R.T. Vanderbilt Co. (Connecticut), Snobrite
clay available from Albion Kaolin Co. (Georgia), mica, e.g.,
Minerolite Mica available from Mineral Mining Corp. (South
Carolina), and fumed silica available from Cabot Corp. (Illinois).
Treated and coated fillers are also useful.
[0032] The invention will now be further described by way of the
following examples.
EXAMPLES
[0033] Test Procedures
[0034] Test procedures used in the examples include the
following.
[0035] Melt Flow Time Test Procedure
[0036] Melt flow time is measured according to ASTM Test Method
D-1238 Procedure B using a 1100 gram weight and a 6-8 gram sample
at a temperature of 190.degree. C. The amount of time it takes for
the sample to flow out of the orifice of a Kayness D7031 Melt Flow
Apparatus (Kayness Inc., Pennsylvania) is recorded as the melt flow
time.
[0037] Sag Test Procedure
[0038] A 0.5".times.3".times.0.06" film is aligned on a 1".times.4"
tin plated steel substrate, heated in an oven to adhere the film to
the substrate, and then cooled. The sample is then hung vertically
in an oven at 190.degree. F. (88.degree. C.). The sample is
observed for visible signs of film movement.
[0039] Fog Test Procedure
[0040] The sample is tested for fog according to ASTME E1887 for
insulating glass units. The sample is recorded as a pass or a
fail.
[0041] Sample Preparation
Example 1
[0042] 600 g Eastoflex E1003 amorphous propylene-ethylene copolymer
(Eastman Chemical, Tennessee) and 150 g Type 3A molecular sieve
(UOP, Illinois) were combined and mixed for one hour at
approximately 150.degree. C.
[0043] The melt flow time of the composition of Example 1 was
measured. The composition ran through the orifice of the test
apparatus prior to applying a weight to the sample. Accordingly,
the composition was determined to have a melt flow time of less
than 5 seconds at 190.degree. C.
Example 2
[0044] 480 g Eastoflex E1003 amorphous propylene/ethylene
copolymer, 120 g Type 3A molecular sieve (UOP) and 360 g Type 3A
molecular sieve (UOP) were combined and mixed for one hour at
approximately 150.degree. C.
[0045] The melt flow time of the composition of Example 2 was
measured. The composition ran through the orifice of the test
apparatus prior to applying a weight to the sample. Accordingly,
the composition was determined to have a melt flow of less than 5
seconds at 190.degree. C.
Example 3
[0046] 150 g Eastoflex E1003 amorphous propylene-ethylene copolymer
and 150 g Type 3A molecular sieve (UOP) were combined and mixed for
one hour at approximately 150.degree. C.
[0047] The melt flow time of the composition of Example 3 was
measured. The composition ran through the orifice of the test
apparatus prior to applying a weight to the sample. Accordingly,
the composition was determined to have a melt flow time of less
than 5 seconds at 190.degree. C.
Example 4
[0048] 120 g Eastoflex E1003 amorphous propylene-ethylene copolymer
and 180 g Type 3A molecular sieve (UOP) were combined and mixed for
one hour at 150.degree. C.
[0049] The melt flow time of the composition of Example 4 was
measured. The composition ran through the orifice of the test
apparatus prior to applying a weight to the sample. Accordingly,
the composition was determined to have a melt flow time of less
than 5 seconds at 190.degree. C.
Example 5
[0050] 90 g Eastoflex E1003 amorphous propylene-ethylene copolymer
and 210 g Type 3A molecular sieve (UOP) were combined and mixed for
one hour at 180.degree. C.
[0051] The melt flow time of the composition of Example 5 was
measured according to the Melt Flow Time Test Procedure and was
determined to have a melt flow time of 37 seconds at 190.degree.
C.
Example 6
[0052] 66.4 g Hubercarb Q325 calcium carbonate (J. M. Huber), 513.4
g Eastman D178 amorphous propylene/ethylene copolymer (Eastman
Chemical), 0.2 Monarch 120 carbon black (Cabot Corp,
Massachusetts), 6.1 g Irganox 1076 antioxidant, 21.8 Kronos 2020
titanium dioxide (Kronos Inc., Texas), 53.7 Indopol H100 polybutene
(Amoco Corp, Illinois), 138.4 g Type 3A molecular sieve (UOP),
293.6 g Type 3A molecular sieve (W. R. Grace), and 108 g Type 13x
molecular sieve (W. R. Grace) were combined and mixed together for
one hour at 150.degree. C.
[0053] The composition was tested according to the Melt Flow Time
Test Procedure. The composition ran through the orifice of the test
apparatus prior to applying a weight to the sample. Accordingly,
the composition was determined to have a melt flow time of less
than 5 seconds at 190.degree. C.
Example 7
[0054] 512.8 g Eastman D-178 polymer, 65.9 g Hubercarb Q325 calcium
carbonate, 0.20 carbon black, 21.6 g Kronos 2020 titanium dioxide,
6.0 Irganox 1076 antioxidant, 53.9 Indopol H1500 polybutene, 432.4
Type 3A molecular sieve (W. R. Grace and UOP), and 108.0 g Type 13x
molecular sieve (W. R. Grace) were combined and mixed together for
one hour at 150.degree. C.
[0055] The composition was tested according to the Melt Flow Time
Test Procedure. The composition ran through the orifice of the test
apparatus prior to applying a weight to the sample. Accordingly,
the composition was determined to have a melt flow time of less
than 5 seconds at 190.degree. C.
Example 8
[0056] 512.8 g Eastman D-178 polyalphaolefin polymer, 77.9 g
Hubercarb Q325 calcium carbonate, 0.10 Monarch 120 carbon black,
21.6 g Kronos 2020 titanium dioxide, 52.0 Indopol H1500 polybutene,
432.1 Type 3A molecular sieve (UOP), and 108.0 g Type 13x molecular
sieve (UOP) were combined and mixed together for one hour at
150.degree. C.
[0057] The composition was tested according to the Melt Flow Time
Test Procedure. The composition ran through the orifice of the test
apparatus prior to applying a weight to the sample. Accordingly,
the composition was determined to have a melt flow time of less
than 5 seconds at 190.degree. C.
Example 9
[0058] 452.9 g Eastman D-178 polyalphaolefin polymer, 72.0 g
Hubercarb Q325 calcium carbonate, 0.2 Monarch 120 carbon black,
21.6 g Kronos 2020 titanium dioxide, 53.5 g Indopol H1500
polybutene, 493.0 g Type 3A molecular sieve, and 109.8 g Type 13x
molecular sieve (W. R. Grace) were combined and mixed together for
one hour at 150.degree. C.
[0059] The composition was tested according to the Melt Flow Time
Test Procedure. The composition ran through the orifice of the test
apparatus prior to applying a weight to the sample. Accordingly,
the composition was determined to have a melt flow time of less
than 5 seconds at 190.degree. C.
Example 10
[0060] 514.1 g Eastman D-178 polyalphaolefin polymer, 72.0 g
Hubercarb Q325 calcium carbonate, 0.2 Monarch 120 carbon black,
22.1 g Kronos 2020 titanium dioxide, 53.2 indopol H1500 polybutene,
432.5 Type 3A molecular sieve (UOP), and 108.1 g Typel3x molecular
sieve (W. R. Grace) were combined and mixed together for one hour
at 150.degree. C.
[0061] The composition was tested according to the Melt Flow Time
Test Procedure. After the 1100 gram weight was applied to the
piston, the composition immediately ran through the orifice of the
test apparatus. Accordingly, the composition was determined to have
a melt flow time of less than 5 seconds at 190.degree. C.
[0062] The melt flow time and sag of the compositions of Examples
1-10 were determined. The results are reported in Table 1.
1TABLE 1 Poly- Filler mer Adsor- Anti- and Ex- (% bent oxidant
Pigment Melt Flow am- by (% by (% by (% by Time ple wt) wt) wt) wt)
(Seconds) Sag Sag 1 80 20 0 0 <5 NT NT 2 50 50 0 0 <5 NT NT 3
50 50 0 0 <5 No No visible visible move- move- ment ment or or
sag sag after 24 after 43 hours. hours. 4 40 60 0 0 <5 NT NT 5
30 70 0 0 <5 NT NT 6 47.2 45 0.5 7.3 <5 NT NT 7 47.2 45 0.5
7.3 <5 NT NT 8 47.2 45 0 7.8 <5 NT NT 9 42.2 50 0 7.8 <5
NT NT 10 47.2 45 0 7.8 <5 NT NT NT = not tested
[0063] Other embodiments are within the claims.
* * * * *