U.S. patent application number 12/610710 was filed with the patent office on 2010-07-01 for high-clarity blended ionomer compositions and articles comprising the same.
This patent application is currently assigned to E.I. DU PONT DE NEMOURS AND COMPANY. Invention is credited to Karlheinz Hausmann, Richard Allen Hayes, Steven C. Pesek, W. Alexander Shaffer, Charles Anthony Smith.
Application Number | 20100166991 12/610710 |
Document ID | / |
Family ID | 42285296 |
Filed Date | 2010-07-01 |
United States Patent
Application |
20100166991 |
Kind Code |
A1 |
Hausmann; Karlheinz ; et
al. |
July 1, 2010 |
HIGH-CLARITY BLENDED IONOMER COMPOSITIONS AND ARTICLES COMPRISING
THE SAME
Abstract
An ionomer blend composition comprises a blend of a first
ionomer and a second ionomer that is different from the first
ionomer. The first ionomer is derived from a first precursor acid
copolymer that has a melt flow rate of about 10 to about 4000 g/10
min and that comprises copolymerized units of an .alpha.-olefin and
about 20 to about 30 wt % of copolymerized units of an
.alpha.,.beta.-ethylenically unsaturated carboxylic acid. Moreover,
the first precursor acid can be neutralized to a level of about 40%
to about 90% to form a sodium ionomer that has a MFR of about 0.7
to about 25 g/10 min and a freeze enthalpy that is less than about
3.0 j/g or that is not detectable, when determined by differential
scanning calorimetry (DSC). A variety of articles may comprise or
be produced from the ionomer blend composition, for example by
injection molding.
Inventors: |
Hausmann; Karlheinz;
(Auvernier, CH) ; Hayes; Richard Allen; (Beaumont,
TX) ; Pesek; Steven C.; (Orange, TX) ;
Shaffer; W. Alexander; (Orange, TX) ; Smith; Charles
Anthony; (Vienna, WV) |
Correspondence
Address: |
E I DU PONT DE NEMOURS AND COMPANY;LEGAL PATENT RECORDS CENTER
BARLEY MILL PLAZA 25/1122B, 4417 LANCASTER PIKE
WILMINGTON
DE
19805
US
|
Assignee: |
E.I. DU PONT DE NEMOURS AND
COMPANY
Wilmington
DE
|
Family ID: |
42285296 |
Appl. No.: |
12/610710 |
Filed: |
November 2, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61141504 |
Dec 30, 2008 |
|
|
|
Current U.S.
Class: |
428/35.7 ;
428/220; 428/339; 525/221 |
Current CPC
Class: |
C08L 23/0876 20130101;
Y10T 428/31645 20150401; B32B 17/10045 20130101; B32B 17/10743
20130101; B32B 2367/00 20130101; C09J 123/0876 20130101; F41H
5/0407 20130101; C08L 2205/02 20130101; B32B 17/10761 20130101;
C08L 33/02 20130101; Y10T 428/31855 20150401; Y10T 428/1352
20150115; C08L 23/0876 20130101; C08L 23/0876 20130101; B32B
17/10981 20130101; C08L 33/02 20130101; Y10T 428/269 20150115; C08L
2205/025 20130101; B32B 17/10853 20130101; C08L 2666/04
20130101 |
Class at
Publication: |
428/35.7 ;
525/221; 428/220; 428/339 |
International
Class: |
C08L 33/02 20060101
C08L033/02; B32B 27/32 20060101 B32B027/32; B32B 1/02 20060101
B32B001/02 |
Claims
1. A composition comprising an ionomer blend, said ionomer blend
comprising, based on the total weight of the ionomer blend, about 5
to about 95 wt % of a first ionomer and about 95 to about 5 wt % of
a second ionomer, said ionomer blend having a neutralization level
of 10% to 90%, based on the total number of neutralized and
unneutralized carboxylic acid groups in the ionomer blend, wherein:
(A) said first ionomer is the neutralization product of a first
precursor acid copolymer; and i) the first precursor acid copolymer
comprises copolymerized units of a first .alpha.-olefin having 2 to
10 carbon atoms and further comprises about 20 to about 30 wt %,
based on the total weight of the first precursor acid copolymer, of
copolymerized units of a first .alpha.,.beta.-ethylenically
unsaturated carboxylic acid having 3 to 8 carbon atoms; ii) the
first precursor acid copolymer has a melt flow rate of about 70 to
about 1000 g/10 min; and iii) the first precursor acid copolymer,
when neutralized to a level of about 40% to about 90% and when
comprising counterions that consist essentially of sodium cations,
produces a sodium ionomer; and said sodium ionomer has a melt flow
rate of about 0.7 to about 25 g/10 min and a freeze enthalpy that
is not detectable or that is less than about 3.0 j/g, when
determined by differential scanning calorimetry (DSC) in accordance
with ASTM D3418; (B) said second ionomer is the neutralization
product of a second precursor acid copolymer, wherein i) the second
precursor acid copolymer comprises copolymerized units of a second
.alpha.-olefin having 2 to 10 carbon atoms; and about 18 to about
30 wt %, based on the total weight of the second precursor acid
copolymer, of copolymerized units of a second
.alpha.,.beta.-ethylenically unsaturated carboxylic acid having 3
to 8 carbon atoms; the second .alpha.-olefin may be the same as or
different from the first .alpha.-olefin; the amount of the second
.alpha.-olefin may be the same as or different from the amount of
the first .alpha.-olefin; the second .alpha.,.beta.-ethylenically
unsaturated carboxylic acid may be the same as or different from
the first .alpha.,.beta.-ethylenically unsaturated carboxylic acid;
and the amount of the second .alpha.,.beta.-ethylenically
unsaturated carboxylic acid may be the same as or different from
the amount of the first .alpha.,.beta.-ethylenically unsaturated
carboxylic acid; ii) the second precursor acid copolymer has a melt
flow rate of about 60 g/10 min or less; and iii) the second ionomer
has a melt flow rate of about 10 g/10 min or less at the
neutralization level of the ionomer blend; and the melt flow rate
of the second ionomer at the neutralization level of the ionomer
blend is different from the melt flow rate of the first ionomer at
the same neutralization level; and (C) the melt flow rates are
determined in accordance with ASTM method D1238 at a polymer melt
temperature of 190.degree. C. and under a weight of 2.16 kg.
2. The composition of claim 1, wherein the first precursor acid
copolymer has a melt flow rate of about 150 to about 400 g/10 min
and the second precursor acid copolymer has a melt flow rate of
about 30 g/10 min or less.
3. The composition of claim 1, wherein the first precursor acid
copolymer comprises about 20 to about 25 wt % of copolymerized
units of the first .alpha.,.beta.-ethylenically unsaturated
carboxylic acid; and wherein the second precursor acid copolymer
comprises about 20 to about 25 wt % of copolymerized units of the
second .alpha.,.beta.-ethylenically unsaturated carboxylic acid;
and wherein the second .alpha.,.beta.-ethylenically unsaturated
carboxylic acid may be the same as or different from the first
.alpha.,.beta.-ethylenically unsaturated carboxylic acid; and the
amount of the second .alpha.,.beta.-ethylenically unsaturated
carboxylic acid may be the same as or different from the amount of
the first .alpha.,.beta.-ethylenically unsaturated carboxylic
acid.
4. The composition of claim 1, wherein the neutralization level of
the ionomer blend is from about 15% to about 70%, wherein the
ionomer blend comprises carboxylate groups and cations, and wherein
the cations consist essentially of sodium cations.
5. The composition of claim 1, wherein, at the neutralization level
of the ionomer blend, the first ionomer has a melt flow rate of
about 0.7 to about 10 g/10 min and the second ionomer has a melt
flow rate of about 5 g/10 min or less.
6. The composition of claim 1, wherein the ionomer blend comprises
about 60 to about 95 wt % of the first ionomer and about 5 to about
40 wt % of the second ionomer.
7. An article comprising or produced from the composition of claim
1.
8. The article of claim 7, which is in the form of a film or a
sheet or a molded article.
9. The article of claim 8, which is a film or sheet prepared by a
process selected from the group consisting of dipcoating, solution
casting, lamination, melt extrusion, blown film, extrusion coating,
and tandem extrusion coating.
10. The article of claim 8, which is a molded article prepared by a
process selected from the group consisting of compression molding,
injection molding, extrusion molding, and blow molding.
11. The article of claim 10, which is an injection molded
article.
12. The article of claim 11, having a minimum thickness of at least
about 3 mm.
13. The article of claim 11, wherein the injection molded article
has a multi-layer structure having at least one layer that consists
essentially of the composition recited in claim 1, said at least
one layer having a minimum thickness of at least about 3 mm.
14. The article of claim 13 that is a container.
15. The article of claim 11 that is a sheet, a container, a cap or
stopper, a tray, a medical device or instrument, a handle, a knob,
a push button, a decorative article, a panel, a console box, or a
footwear component.
16. The article of claim 15 that is a container.
17. The article of claim 11, which is produced by a process
selected from the group consisting of co-injection molding;
over-molding; injection blow molding; injection stretch blow
molding and extrusion blow molding.
18. An article prepared by injection molding, said article
consisting essentially of the composition of claim 1 and having a
thickness of about 1 to about 100 mm.
19. An ionomer blend composition that is produced by the process
of: a. providing a first ionomer, said first ionomer being the
neutralization product of a first precursor acid copolymer; wherein
i) the first precursor acid copolymer comprises copolymerized units
of a first .alpha.-olefin having 2 to 10 carbon atoms and further
comprises about 20 to about 30 wt %, based on the total weight of
the first precursor acid copolymer, of copolymerized units of a
first .alpha.,.beta.-ethylenically unsaturated carboxylic acid
having 3 to 8 carbon atoms; ii) the first ionomer has a
neutralization level of 40% to 90% and a melt flow rate of about
0.7 to about 25 g/10 min; iii) the first precursor acid copolymer
has a melt flow rate of about 70 to about 1000 g/10 min; and iv)
the first precursor acid copolymer, when neutralized to a level of
about 40% to about 90% and when comprising counterions that consist
essentially of sodium cations, produces a sodium ionomer; and said
sodium ionomer has a melt flow rate of about 0.7 to about 25 g/10
min and a freeze enthalpy that is not detectable or that is less
than about 3.0 j/g, when determined by differential scanning
calorimetry (DSC) in accordance with ASTM D3418; b. providing a
second ionomer, said second ionomer being the neutralization
product of a second precursor acid copolymer, wherein i) the second
precursor acid copolymer comprises copolymerized units of a second
.alpha.-olefin having 2 to 10 carbon atoms; and about 18 to about
30 wt %, based on the total weight of the second precursor acid
copolymer, of copolymerized units of a second
.alpha.,.beta.-ethylenically unsaturated carboxylic acid having 3
to 8 carbon atoms; the second .alpha.-olefin may be the same as or
different from the first .alpha.-olefin; the amount of the second
.alpha.-olefin may be the same as or different from the amount of
the first .alpha.-olefin; the second .alpha.,.beta.-ethylenically
unsaturated carboxylic acid may be the same as or different from
the first .alpha.,.beta.-ethylenically unsaturated carboxylic acid;
and the amount of the second .alpha.,.beta.-ethylenically
unsaturated carboxylic acid may be the same as or different from
the amount of the first .alpha.,.beta.-ethylenically unsaturated
carboxylic acid; ii) the second precursor acid copolymer has a melt
flow rate of about 60 g/10 min or less; and iii) the second ionomer
has a neutralization level of 10% to 35% and a melt flow rate of
about 10 g/10 min or less; and iv) the melt flow rate of the second
ionomer at the neutralization level of the ionomer blend is
different from the melt flow rate of the first ionomer at the same
neutralization level; and c. blending the first ionomer and the
second ionomer; wherein the melt flow rates are determined in
accordance with ASTM method D1238 at a polymer melt temperature of
190.degree. C. and under a weight of 2.16 kg.
20. An article comprising or produced from the ionomer blend
composition of claim 19.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority under 35 U.S.C. .sctn.120
to U.S. Provisional Appln. No. 61/141,504, filed on Dec. 30, 2008,
which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to ionomer compositions and to
articles, for example injection molded articles, made from the
ionomer compositions.
BACKGROUND OF THE INVENTION
[0003] Several patents and publications are cited in this
description in order to more fully describe the state of the art to
which this invention pertains. The entire disclosure of each of
these patents and publications is incorporated by reference
herein.
[0004] Ionomers are copolymers produced by partially or fully
neutralizing the carboxylic acid groups of precursor or parent
polymers that are acid copolymers comprising copolymerized residues
of .alpha.-olefins and .alpha.,.beta.-ethylenically unsaturated
carboxylic acids. A variety of articles made from ionomers by
injection molding processes have been used in our daily life.
[0005] For example, golf balls with ionomer covers have been
produced by injection molding. See, e.g.; U.S. Pat. Nos. 4,714,253;
5,439,227; 5,452,898; 5,553,852; 5,752,889; 5,782,703; 5,782,707;
5,803,833; 5,807,192; 6,179,732; 6,699,027; 7,005,098; 7,128,864;
7,201,672; and U.S. Patent Appln. Publn. Nos. 2006/0043632;
2006/0273485; and 2007/0282069.
[0006] Ionomers have also been used to produce injection molded
hollow articles, such as containers. See, e.g. U.S. Pat. Nos.
4,857,258; 4,937,035; 4,944,906; 5,094,921; 5,788,890; 6,207,761;
and 6,866,158, U.S. Patent Publication Nos. 20020180083;
20020175136; and 20050129888, European Patent Nos. EP1816147 and
EP0855155, and PCT Patent Publn. Nos. WO2004062881; WO2008010597;
and WO2003045186.
[0007] Containers produced by injection molding often have thick
wall structures. When ionomers are used in forming such injection
molded containers, the optical properties may suffer due to the
thickness of the wall. There is a need, especially in the cosmetics
industry, to develop containers that are made of ionomer
compositions and that have improved optical properties.
SUMMARY OF THE INVENTION
[0008] Accordingly, provided herein is a composition comprising an
ionomer blend. The ionomer blend comprises about 5 to about 95 wt %
of a first ionomer and about 95 to about 5 wt % of a second
ionomer, based on the total weight of the ionomer blend. In
addition, the ionomer blend has a neutralization level of 10% to
90%, based on the total number of neutralized and unneutralized
carboxylic acid groups in the ionomer blend.
[0009] The first ionomer is the neutralization product of a first
precursor acid copolymer that comprises copolymerized units of a
first .alpha.-olefin having 2 to 10 carbon atoms and about 20 to
about 30 wt %, based on the total weight of the first precursor
acid copolymer, of copolymerized units of a first
.alpha.,.beta.-ethylenically unsaturated carboxylic acid having 3
to 8 carbon atoms. The first precursor acid copolymer also has a
melt flow rate of about 70 to about 1000 g/10 min. When neutralized
to a level of about 40% to about 90% and when comprising cations
that consist essentially of sodium cations, the first precursor
acid copolymer produces a sodium ionomer. The sodium ionomer has a
melt flow rate (MFR) of about 0.7 to about 25 g/10 min and a freeze
enthalpy that is not detectable or that is less than about 3.0 j/g,
when determined by differential scanning calorimetry (DSC) in
accordance with ASTM D3418.
[0010] The second ionomer is the neutralization product of a second
precursor acid copolymer that is different from the first precursor
acid copolymer. The second precursor acid copolymer comprises
copolymerized units of a second .alpha.-olefin having 2 to 10
carbon atoms and about 18 to about 30 wt %, based on the total
weight of the second precursor acid copolymer, of copolymerized
units of a second .alpha.,.beta.-ethylenically unsaturated
carboxylic acid having 3 to 8 carbon atoms. The second
.alpha.-olefin may be the same as or different from the first
.alpha.-olefin, and the second .alpha.,.beta.-ethylenically
unsaturated carboxylic acid may be the same as or different from
the first .alpha.,.beta.-ethylenically unsaturated carboxylic acid.
Likewise, the amount of the second .alpha.-olefin or the second
.alpha.,.beta.-ethylenically unsaturated carboxylic acid may be the
same as or different from the amounts of the first .alpha.-olefin
or the first .alpha.,.beta.-ethylenically unsaturated carboxylic
acid. The second precursor acid copolymer has a melt flow rate of
about 60 g/10 min or less, and the second ionomer has a melt flow
rate of about 10 g/10 min or less at the neutralization level of
the ionomer blend. The second ionomer has a melt flow rate at the
neutralization level of the ionomer blend that is different from
the melt flow rate of the first ionomer at the same neutralization
level.
[0011] Further provided are articles, such as injection-molded
articles, comprising or produced from the composition.
DETAILED DESCRIPTION OF THE INVENTION
[0012] The following definitions apply to the terms as used
throughout this specification, unless otherwise limited in specific
instances.
[0013] The technical and scientific terms used herein have the
meanings that are commonly understood by one of ordinary skill in
the art to which this invention belongs. In case of conflict, the
present specification, including the definitions herein, will
control.
[0014] As used herein, the terms "comprises," "comprising,"
"includes," "including," "containing," "characterized by," "has,"
"having" or any other variation thereof, are intended to cover a
non-exclusive inclusion. For example, a process, method, article,
or apparatus that comprises a list of elements is not necessarily
limited to only those elements but may include other elements not
expressly listed or inherent to such process, method, article, or
apparatus.
[0015] The transitional phrase "consisting of" excludes any
element, step, or ingredient not specified in the claim, closing
the claim to the inclusion of materials other than those recited
except for impurities ordinarily associated therewith. When the
phrase "consists of" appears in a clause of the body of a claim,
rather than immediately following the preamble, it limits only the
element set forth in that clause; other elements are not excluded
from the claim as a whole.
[0016] The transitional phrase "consisting essentially of" limits
the scope of a claim to the specified materials or steps and those
that do not materially affect the basic and novel characteristic(s)
of the claimed invention. A `consisting essentially of` claim
occupies a middle ground between closed claims that are written in
a `consisting of` format and fully open claims that are drafted in
a `comprising` format. Optional additives as defined herein, at a
level that is appropriate for such additives, and minor impurities
are not excluded from a composition by the term "consisting
essentially of".
[0017] When a composition, a process, a structure, or a portion of
a composition, a process, or a structure, is described herein using
an open-ended term such as "comprising," unless otherwise stated
the description also includes an embodiment that "consists
essentially of" or "consists of" the elements of the composition,
the process, the structure, or the portion of the composition, the
process, or the structure.
[0018] The articles "a" and "an" may be employed in connection with
various elements and components of compositions, processes or
structures described herein. This is merely for convenience and to
give a general sense of the compositions, processes or structures.
Such a description includes "one or at least one" of the elements
or components. Moreover, as used herein, the singular articles also
include a description of a plurality of elements or components,
unless it is apparent from a specific context that the plural is
excluded.
[0019] The term "about" means that amounts, sizes, formulations,
parameters, and other quantities and characteristics are not and
need not be exact, but may be approximate and/or larger or smaller,
as desired, reflecting tolerances, conversion factors, rounding
off, measurement error and the like, and other factors known to
those of skill in the art. In general, an amount, size,
formulation, parameter or other quantity or characteristic is
"about" or "approximate" whether or not expressly stated to be
such.
[0020] The term "or", as used herein, is inclusive; that is, the
phrase "A or B" means "A, B, or both A and B". More specifically, a
condition "A or B" is satisfied by any one of the following: A is
true (or present) and B is false (or not present); A is false (or
not present) and B is true (or present); or both A and B are true
(or present). Exclusive "or" is designated herein by terms such as
"either A or B" and "one of A or B", for example.
[0021] In addition, the ranges set forth herein include their
endpoints unless expressly stated otherwise. Further, when an
amount, concentration, or other value or parameter is given as a
range, one or more preferred ranges or a list of upper preferable
values and lower preferable values, this is to be understood as
specifically disclosing all ranges formed from any pair of any
upper range limit or preferred value and any lower range limit or
preferred value, regardless of whether such pairs are separately
disclosed. The scope of the invention is not limited to the
specific values recited when defining a range.
[0022] When materials, methods, or machinery are described herein
with the term "known to those of skill in the art", "conventional"
or a synonymous word or phrase, the term signifies that materials,
methods, and machinery that are conventional at the time of filing
the present application are encompassed by this description. Also
encompassed are materials, methods, and machinery that are not
presently conventional, but that will have become recognized in the
art as suitable for a similar purpose.
[0023] Unless stated otherwise, all percentages, parts, ratios, and
like amounts, are defined by weight.
[0024] Unless otherwise specified under limited circumstances, all
melt flow rates are measured according to ASTM method D1238 at a
polymer melt temperature of 190.degree. C. and under a weight of
2.16 kg. Moreover, the terms melt flow rate (MFR), melt flow index
(MFI) and melt index (MI) are synonymous and used interchangeably
herein.
[0025] As used herein, the term "copolymer" refers to polymers
comprising copolymerized units resulting from copolymerization of
two or more comonomers. In this connection, a copolymer may be
described herein with reference to its constituent comonomers or to
the amounts of its constituent comonomers, for example "a copolymer
comprising ethylene and 15 weight % of acrylic acid", or a similar
description. Such a description may be considered informal in that
it does not refer to the comonomers as copolymerized units; in that
it does not include a conventional nomenclature for the copolymer,
for example International Union of Pure and Applied Chemistry
(IUPAC) nomenclature; in that it does not use product-by-process
terminology; or for another reason. As used herein, however, a
description of a copolymer with reference to its constituent
comonomers or to the amounts of its constituent comonomers means
that the copolymer contains copolymerized units (in the specified
amounts when specified) of the specified comonomers. It follows as
a corollary that a copolymer is not the product of a reaction
mixture containing given comonomers in given amounts, unless
expressly stated in limited circumstances to be such.
[0026] The term "dipolymer" refers to polymers consisting
essentially of two monomers, and the term "terpolymer" refers to
polymers consisting essentially of three monomers.
[0027] The term "acid copolymer" as used herein refers to a polymer
comprising copolymerized units of an .alpha.-olefin, an
.alpha.,.beta.-ethylenically unsaturated carboxylic acid, and
optionally other suitable comonomer(s) such as, an
.alpha.,.beta.-ethylenically unsaturated carboxylic acid ester.
[0028] The term "(meth)acrylic", as used herein, alone or in
combined form, such as "(meth)acrylate", refers to acrylic or
methacrylic, for example, "acrylic acid or methacrylic acid", or
"alkyl acrylate or alkyl methacrylate".
[0029] The term "blend", as used herein, is synonymous with the
term "combination". Specifically, unless otherwise specified in
particular circumstances, the term "blend" carries no implications
with respect to the morphology of the compositions to which it
refers.
[0030] Finally, the term "ionomer" as used herein refers to a
polymer that comprises ionic groups that are carboxylate salts, for
example, ammonium carboxylates, alkali metal carboxylates, alkaline
earth carboxylates, transition metal carboxylates and/or
combinations of such carboxylates. Such polymers are generally
produced by partially or fully neutralizing the carboxylic acid
groups of precursor or parent polymers that are acid copolymers, as
defined herein, for example by reaction with a base. An example of
an alkali metal ionomer as used herein is a zinc/sodium mixed
ionomer (or zinc/sodium neutralized mixed ionomer), for example a
copolymer of ethylene and methacrylic acid wherein all or a portion
of the carboxylic acid groups of the copolymerized methacrylic acid
units are in the form of zinc carboxylates and sodium
carboxylates.
[0031] Provided herein is a composition that comprises or is made
from an ionomer blend. The ionomer blend comprises a first ionomer
and a second ionomer. The ionomer blend may comprise about 5 to
about 95 wt % of the first ionomer and about 5 to about 95 wt % of
the second ionomer, or about 60 to about 95 wt % of the first
ionomer and about 5 to about 40 wt % of the second ionomer, or
about 70 to about 90 wt % of the first ionomer and about 10 to
about 30 wt % of the second ionomer, or about 70 to about 80 wt %
of the first ionomer and about 20 to about 30 wt % of the second
ionomer, based on the total weight of the ionomer blend.
[0032] The first ionomer is an ionic, neutralized derivative of a
first precursor acid copolymer comprising copolymerized units of an
.alpha.-olefin having 2 to 10 carbon atoms and copolymerized units
of an .alpha.,.beta.-ethylenically unsaturated carboxylic acid
having 3 to 8 carbon atoms. Preferably, the precursor acid
copolymer comprises about 20 to about 30 wt %, or about 20 to about
25 wt %, based on the total weight of the precursor acid copolymer,
of the copolymerized carboxylic acid. The amount of copolymerized
.alpha.-olefin is complementary to the amount of copolymerized
carboxylic acid and other comonomers, if present, so that the sum
of the weight percentages of the comonomers in the precursor acid
copolymer is 100 wt %.
[0033] The first precursor acid copolymer may have a melt flow rate
(MFR) of about 70 to about 1000 g/10 min, or about 100 to about 500
g/10 min, or about 150 to about 400 g/10 min, or about 200 to about
350 g/10 min, as determined in accordance with ASTM method D1238 at
a polymer melt temperature of 190.degree. C. and under a weight of
2.16 kg.
[0034] Further, when the carboxylate groups of the first precursor
acid copolymer have been neutralized to a level of about 40% to
about 90% and its counterions consist essentially of sodium
cations, a sodium ionomer is produced. This sodium ionomer has a
freeze enthalpy that is not detectable or that is less than about 3
j/g, or less than about 2 j/g, as determined by differential
scanning calorimetry (DSC) in accordance with ASTM method D3418
when using a DSC apparatus manufactured by Mettler or by TA (for
example the Universal V3.9A model). The term "not detectable", as
used in this context, refers to a freeze enthalpy that produces no
observable inflection in the DSC curve. Alternatively, the peak
height may be very small and the peak width at half height may be
relatively great, so that a broad peak having a small integral area
may not be detectable or discernable when a baseline is subtracted
from the DSC trace. In general, when ASTM D3418 is followed, a
freeze enthalpy that falls below 0.2 j/g is not detectable.
[0035] The second ionomer in the blend composition is an ionic,
neutralized derivative of a second precursor acid copolymer
comprising copolymerized units of an .alpha.-olefin having 2 to 10
carbon atoms and about 18 to about 30 wt %, or about 20 to about 25
wt %, or about 21 to about 24 wt % of copolymerized units of an
.alpha.,.beta.-ethylenically unsaturated carboxylic acid having 3
to 8 carbon atoms. The .alpha.-olefin or the
.alpha.,.beta.-ethylenically unsaturated carboxylic acid of the
second precursor acid copolymer may, independently, be the same as
or different from the .alpha.-olefin or the
.alpha.,.beta.-ethylenically unsaturated carboxylic acid of the
first precursor acid copolymer. Likewise, the amount of
copolymerized units of the .alpha.-olefin or of the
.alpha.,.beta.-ethylenically unsaturated carboxylic acid of the
second precursor acid copolymer may, independently, be the same as
or different from the amount of copolymerized units of the
.alpha.-olefin or of the .alpha.,.beta.-ethylenically unsaturated
carboxylic acid of the first precursor acid copolymer. In addition,
the second precursor acid copolymer has a melt flow rate (MFR) that
that may be in the range of about 60 g/10 min or less, or about 45
g/10 min or less, or about 30 g/10 min or less, or about 25 g/10
min or less, as determined in accordance with ASTM method D1238 at
190.degree. C. and 2.16 kg.
[0036] To obtain the second ionomer used in the blend composition,
the second precursor acid copolymer may be neutralized with one or
more cation-containing bases to provide an ionomer wherein about
10% to about 35%, or about 15% to about 30% of the hydrogen atoms
of carboxylic acid groups of the second precursor acid copolymer
are replaced by cations, preferably metal cations. That is, the
acid groups are neutralized to a level of about 10% to about 35%,
or about 15% to about 30%, based on the total carboxylic acid
content of the second precursor acid copolymer as calculated or as
measured for the non-neutralized second precursor acid copolymer.
The thus-obtained second ionomer has a MFR of about 10 g/10 min or
less, or about 5 g/10 min or less, or about 3 g/10 min or less, as
determined in accordance with ASTM method D1238 at 190.degree. C.
and 2.16 kg. Those of skill in the art are aware, however, that the
neutralization levels of two ionomers in a blend will equilibrate
over time to a shared neutralization level that is determined by
the total number of acid and base equivalents in the ionomer blend.
The second ionomer has a MFR, at the neutralization level of the
ionomer blend, that is different from the MFR of the first ionomer
at the same neutralization level.
[0037] Suitable .alpha.-olefin comonomers comprised in the first
and second precursor acid copolymers include, but are not limited
to, ethylene, propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene,
3 methyl-1-butene, 4-methyl-1-pentene, and the like and
combinations of two or more thereof. Preferably, the .alpha.-olefin
is ethylene.
[0038] Suitable .alpha.,.beta.-ethylenically unsaturated carboxylic
acid comonomers for use in the first and second precursor acid
copolymers include, but are not limited to, acrylic acids,
methacrylic acids, itaconic acids, maleic acids, maleic anhydride,
fumaric acids, monomethyl maleic acids, and combinations of two or
more thereof. Preferably, the .alpha.,.beta.-ethylenically
unsaturated carboxylic acid is selected from acrylic acids,
methacrylic acids, and combinations of two or more thereof.
[0039] Each of the first and second precursor acid copolymers may
independently further comprise copolymerized units of other
comonomer(s), such as unsaturated carboxylic acids having 2 to 10
carbon atoms or 3 to 8 carbon atoms, or derivatives thereof. Again,
the presence or absence of other comonomers, the identity of the
other comonomers, and the amounts of the other comonomers may be
the same or different and are independently selected for the first
and second precursor acid copolymers. Suitable acid derivatives
include acid anhydrides, amides, and esters. Some suitable
precursor acid copolymers further comprise an ester of the
unsaturated carboxylic acid. Examples of suitable esters of
unsaturated carboxylic acids include, but are not limited to, those
that are set forth in U.S. Provisional Appln. Nos. 61/110,302,
filed on Oct. 31, 2008, and 61/117,645, filed on Nov. 25, 2008
(Attorney Docket No. PP0019). Examples of preferred comonomers
include, but are not limited to, methyl(meth)acrylates, butyl
(meth)acrylates, glycidyl methacrylates, vinyl acetates, and
combinations of two or more thereof. In one preferred ionomer
blend, the first or second precursor acid copolymer does not
incorporate other comonomers.
[0040] To obtain the ionomers useful in the ionomer compositions
described herein, the precursor acid copolymers are neutralized
with a base so that the carboxylic acid groups in the precursor
acid copolymer react to form carboxylate groups. Preferably, the
precursor acid copolymers are neutralized to a level of about 20 to
about 90%, or about 30% to about 90%, or about 35% to about 90%, or
about 40% to about 90%, or about 40% to about 70%, or about 43% to
about 60%, based on the total carboxylic acid content of the
precursor acid copolymers as calculated or as measured for the
non-neutralized precursor acid copolymers.
[0041] Any stable cation and any combination of two or more stable
cations are believed to be suitable as counterions to the
carboxylate groups in the first and second ionomers. For example,
divalent and monovalent cations, such as cations of alkali metals,
alkaline earth metals, and some transition metals, may be used. In
one preferred ionomer blend, divalent ions such as zinc cations,
are used. In another preferred ionomer blend, monovalent cations,
such as sodium cations, are used. In yet another preferred ionomer
blend, the ion-containing base used to obtain the first or second
ionomer is a sodium ion-containing base.
[0042] The first and second precursor acid copolymers may be
synthesized by methods that are described in detail in U.S.
Provisional Appln. Nos. 61/110,302 and 61/117,645, cited above. In
general, to obtain the first and second ionomers described herein,
during the polymerization reaction, the reactor contents should be
maintained under conditions such that a single phase is present
substantially throughout the reactor. This can be accomplished by
adjusting reactor temperature, by adjusting reactor pressure, by
addition of co-solvents, or by any combination of these techniques,
as described in U.S. Pat. No. 5,028,674. Preferred examples for the
first precursor acid copolymer are synthesized under conditions
that are well within the single-phase region. Conventional means
may be used to determine whether a single phase is maintained
substantially throughout the reactor. For example, Hasch et al., in
"High-Pressure Phase Behavior of Mixtures of
Poly(Ethylene-co-Methyl Acrylate) with Low-Molecular Weight
Hydrocarbons", Journal of Polymer Science: Part B: Polymer Physics,
Vol. 30, 1365-1373 (1992), describe a cloud-point measurement that
can be used in determining the boundary between single-phase and
multiphase conditions.
[0043] To obtain the first and second ionomers used in the blend
composition, each of the first and second precursor acid copolymers
may be neutralized by any conventional procedure, such as those
described in U.S. Pat. Nos. 3,404,134 and 6,518,365. The ionomer
blend may be obtained by combining or blending the first and second
ionomers. Other methods of obtaining the ionomer blend will be
apparent to those of ordinary skill in the art. For example, the
first and second precursor acid copolymers may be blended prior to
neutralization to the desired level. In an alternative example,
other ionomers derived from the first and second precursor acid
copolymers may be blended, or one ionomer and one precursor acid
copolymer may be blended, and the neutralization level of this
intermediate blend may be adjusted upwards or downwards to the
desired level for the ionomer blend.
[0044] The ionomer blend may be neutralized to any level between
0.01% and 100.00% that does not result in an intractable product,
that is, one that is not processable in the melt. Preferably, the
ionomer blend is neutralized to a level of 10% to 90%, 15% to 90%,
10% to 70%, 15% to 70%, 10% to 60%, or 15% to 60%. The melt flow
rate of the ionomer blend is expected to be within the range
defined by the melt flow rates of the first and second ionomer at
the neutralization level of the blend.
[0045] The ionomer blend composition described herein may further
contain any suitable additive known in the art. Such additives
include, but are not limited to, plasticizers, processing aides,
flow enhancing additives, flow reducing additives (e.g., organic
peroxides), lubricants, pigments, dyes, optical brighteners, flame
retardants, impact modifiers, nucleating agents, antiblocking
agents (e.g., silica), thermal stabilizers, hindered amine light
stabilizers (HALS), UV absorbers, UV stabilizers, dispersants,
surfactants, chelating agents, coupling agents, adhesives, primers,
reinforcement additives (e.g., glass fiber), fillers, and the like,
and mixtures or combinations of two or more conventional additives.
These additives are described in the Kirk Othmer Encyclopedia of
Chemical Technology, 5.sup.th Edition, John Wiley & Sons (New
Jersey, 2004), for example.
[0046] These conventional ingredients may be present in the
compositions in quantities that are generally from 0.01 to 15
weight %, preferably from 0.01 to 10 weight %, so long as they do
not detract from the basic and novel characteristics of the
composition and do not significantly adversely affect the
performance of the composition or of the articles prepared from the
composition. In this connection, the weight percentages of such
additives are not included in the total weight percentages of the
thermoplastic compositions defined herein. Typically, many such
additives may be present in from 0.01 to 5 weight %, based on the
total weight of the ionomer composition.
[0047] The optional incorporation of such conventional ingredients
into the compositions can be carried out by any known process. This
incorporation can be carried out, for example, by dry blending, by
extruding a mixture of the various constituents, by a masterbatch
technique, or the like. See, again, the Kirk-Othmer Encyclopedia.
Three notable additives are thermal stabilizers, UV absorbers, and
hindered amine light stabilizers. These additives are described in
detail in U.S. Provisional Appln. No. 61/141,940, filed on Dec. 31,
2008 (Attorney Docket No. PP0055).
[0048] Further provided are articles comprising the ionomer blend
composition described herein. The first ionomer used in the blend
composition, as described in U.S. Provisional Patent Appln. Nos.
61/110,302 and 61/117,645, cited above, can be used to form an
article, such as a film or sheet or a molded article, with improved
optical properties. It was surprisingly found that the improved
optical properties are not affected by the cooling rate under which
the article was obtained. As the first precursor acid copolymer has
a relatively high MFR (about 70 to about 1000 g/10 min), however,
the toughness of the first ionomer may be insufficient for some end
uses. By blending the first ionomer with the second ionomer, which
is derived from a second precursor acid copolymer having a
relatively lower MFR (about 60 g/10 min or lower), the ionomer
blend composition has an improved level of toughness compared to
the first ionomer.
[0049] In addition, the haze level of a polymer blend is often
higher than that of any of the polymer components in the blend. It
is therefore expected that the ionomer blend composition described
herein will have a haze level that is higher than those of the
first and second ionomers. Also surprisingly, however, the ionomer
blend described herein has a haze level that is lower than that of
the second ionomer. Moreover, the ionomer blend may exhibit a haze
level that is lower than that of either the first or the second
ionomer.
[0050] Returning now to the description of the article provided
herein, this article may be in any shape or form, such as a film or
sheet or a molded article.
[0051] The article may be a film or sheet, which may be prepared by
any conventional process, such as, dipcoating, solution casting,
lamination, melt extrusion, blown film, extrusion coating, tandem
extrusion coating, or by any other procedures that are known to
those of skill in the art. The films or sheets are preferably
formed by melt extrusion, melt coextrusion, melt extrusion coating,
blown film, or by a tandem melt extrusion coating process.
[0052] Alternatively, the articles comprising the ionomer blend
compositions described herein are molded articles, which may be
prepared by any conventional molding process, such as, compression
molding, injection molding, extrusion molding, blow molding,
injection blow molding, injection stretch blow molding, extrusion
blow molding and the like. Articles may also be formed by
combinations of two or more of these processes, such as for example
when a core formed by compression molding is overmolded by
injection molding.
[0053] Information about these fabrication methods may be found in
reference texts such as, for example, the Kirk Othmer Encyclopedia,
the Modern Plastics Encyclopedia, McGraw-Hill (New York, 1995) or
the Wiley Encyclopedia of Packaging Technology, 2d edition, A. L.
Brody and K. S. Marsh, Eds., Wiley-Interscience (Hoboken,
1997).
[0054] In another alternative, the article comprising the ionomer
blend composition described herein is an injection molded article
having a minimum thickness (i.e., the thickness at the smallest
dimension of the article) of at least about 1 mm. Preferably, the
injection molded article may have a thickness of about 1 mm to 100
mm, or 2 mm to 100 mm, or 3 to about 100 mm, or about 3 to about 50
mm, or about 5 to about 35 mm.
[0055] In yet another alternative, the article is an injection
molded article in the form of a multi-layer structure (such as an
over-molded article), wherein at least one layer of the multi-layer
structure comprises or consists essentially of the ionomer
composition described above and that layer has a minimum thickness
of at least about 1 mm. Preferably, the at least one layer of the
multi-layer article has a thickness of about 1 mm to 100 mm, or 2
mm to 100 mm, or 3 to about 100 mm, or about 3 to about 50 mm, or
about 5 to about 35 mm.
[0056] In yet another alternative, the article is an injection
molded article in the form of a sheet, a container (e.g., a bottle
or a bowl), a cap or stopper (e.g. for a container), a tray, a
medical device or instrument (e.g., an automated or portable
defibrillator unit), a handle, a knob, a push button, a decorative
article, a panel, a console box, or a footwear component (e.g., a
heel counter, a toe puff, or a sole).
[0057] In yet another alternative, the article is an injection
molded intermediate article for use in further shaping processes.
For example, the article may be a pre-form or a parison suitable
for use in a blow molding process to form a container (e.g., a
cosmetic container). The injection molded intermediate article may
be in the form of a multi-layer structure such as the one described
above, and it may therefore produce a container having a
multi-layer wall structure.
[0058] Injection molding is a well-known molding process. When the
article described herein is in the form of an injection molded
article, it may be produced by any suitable injection molding
process. Suitable injection molding processes include, for example,
co-injection molding and over-molding. These processes are
sometimes also referred to as two-shot or multi-shot molding
processes.
[0059] When the injection molded article is produced by an
over-molding process, the ionomer composition may be used as the
substrate material, the over-mold material or both. In certain
articles, when an over-molding process is used, the ionomer
composition described herein may be over-molded on a glass, plastic
or metal container. Alternatively, the ionomer compositions may be
over-molded on any other articles (such as household items, medical
devices or instruments, electronic devices, automobile parts,
architectural structures, sporting goods, etc.) to form a soft
touch and/or protective overcoating. When the over-mold material
comprises the ionomer composition described herein, the melt index
of the ionomer is preferably from 0.75 up to about 35 g/10 min, as
determined in accordance with ASTM D1238 at 190.degree. C. and 2.16
kg.
[0060] In fabrication processes that incorporate a form of blow
molding, such as, for example, injection blow molding, injection
stretch blow molding and extrusion blow molding, and in substrates
or monolayer articles that comprise the ionomer composition, the
ionomer composition preferably comprises an ionomer having zinc
cations. When the overmolding material comprises the ionomer
composition, however, the ionomer may comprise any suitable cation.
Also preferably, the precursor acid copolymer preferably has a melt
index of 200 to 500 g/10 min, as determined in accordance with ASTM
D1238 at 190.degree. C. and 2.16 kg. In addition, the ionomer
preferably has a melt index of from about 0.1 to about 2.0 g/10 min
or from about 0.1 to about 35 g/10 min, as determined in accordance
with ASTM D1238 at 190.degree. C. and 2.16 kg. More specifically,
when the substrate comprises the ionomer, the ionomer preferably
has a melt index of about 0.5 to about 4 g/10 min. When the
overmolding material comprises the ionomer, however, the ionomer
preferably has a melt index of from 0.1 g/10 min or 0.75 g/10 min
or 4.0 g/10 min or 5 g/10 min up to about 35 g/10 min.
[0061] The ionomer blend composition may be molded at a melt
temperature of about 120.degree. C. to about 250.degree. C., or
about 130.degree. C. to about 210.degree. C. In general, slow to
moderate fill rates with pressures of about 69 to about 110 MPa may
be used. The mold temperatures may be in the range of about
5.degree. C. to about 50.degree. C., preferably 5.degree. C. to
20.degree. C., and more preferably 5.degree. C. to 15.degree. C.
Based on the ionomer blend composition and the process type that is
to be used, one skilled in the art would be able to determine the
proper molding conditions required to produce a particular type of
article.
[0062] The following examples are provided to describe the
invention in further detail. These examples, which set forth a
preferred mode presently contemplated for carrying out the
invention, are intended to illustrate and not to limit the
invention.
EXAMPLES
Examples E1 to E3 and Comparative Examples CE1 and CE2
[0063] In the following examples, two ionomer resins (ION A and ION
B) and blends thereof were formed into polymer sheets, which were
in turn used in forming laminates.
[0064] Specifically, ION A was a copolymer of ethylene and
methacrylic acid containing 21.7 wt % of copolymerized units of
methacrylic acid that was 26% neutralized with a sodium
ion-containing base and had a MFR of 1.8 g/10 min (as determined in
accordance with ASTM D1238 at 190.degree. C. and 2.16 kg). The MFR
of the precursor ethylene methacrylic acid copolymer of ION A,
prior to neutralization, was 23 g/10 min (190.degree. C. and 2.16
kg). ION B was a copolymer of ethylene and methacrylic acid
containing 21.7 wt % of copolymerized units of methacrylic acid
that was 53% neutralized with a sodium ion-containing base and had
a MFR of 2.5 g/10 min (190.degree. C. and 2.16 kg). The MFR of the
precursor ethylene methacrylic acid copolymer of ION B, prior to
neutralization, was 350 g/10 min (190.degree. C. and 2.16 kg).
[0065] In preparing each of the two ionomer resins, ION A and ION
B, the precursor acid copolymer was produced by free radical
polymerization in an adiabatic continuously stirred autoclave,
substantially according to the procedure described in Example 1 of
U.S. Pat. No. 5,028,674 with the following exceptions: (1) by
controlling the ratio of ethylene to methacrylic acid and the flow
rate of the initiator, the reactor conditions were maintained at a
temperature of about 200.degree. C. to about 260.degree. C. and at
a pressure of between 170 and 240 MPa; (2) no propane telogen was
fed in the reactor; (3) the total concentration of methanol in the
reactor was maintained at about 2 to 5 mol %, based on the total
feed of ethylene, methacrylic acid, methanol and initiator
solution; and (4) the system was maintained at a steady state with
the residence time of the material flowing through the reactor
being about 5 seconds to 2 minutes. In addition, depending on the
particular acid copolymer to be synthesized, one of two different
free-radical initiators were used, tert-butyl peracetate or
tert-butyl peroctoate. When tert-butyl peracetate was the initiator
(as in preparing the precursor acid copolymer for ION B), it was
utilized as a solution in odorless mineral spirits at 50%
concentration. When tert-butyl peroctoate was the initiator (as in
preparing the precursor acid copolymer for ION A), it was utilized
as a mixture at 90% concentration in odorless mineral spirits. The
ionomers were obtained by partially neutralizing the precursor
copolymers of ethylene and methacrylic acid with sodium hydroxide
solution either in a single screw extruder under high shear melt
mixing conditions with the melt temperature set at 200.degree. C.
to 270.degree. C., or using the general method described in Example
1 of U.S. Pat. No. 6,518,365.
[0066] Further, each of the ionomers or blends of ionomers was fed
into 25 mm diameter Killion extruders under the temperature profile
set forth in Table 1, then cast by extrusion into polymer sheets.
The polymer throughput was controlled by adjusting the screw speed
to maximum throughput, a 150 mm slot die with a nominal gap of 2 mm
was fed by the extruder, and the cast sheet was fed onto a 200 mm
diameter polished chrome chill roll held at a temperature of
between 10.degree. C. and 15.degree. C. and rotating at 1 to 2 rpm.
The nominally 0.76 mm (30 mil) thick sheets were then removed and
cut into 300.times.300 mm squares.
[0067] These ionomer sheets were used as interlayer sheets to form
glass laminates. Annealed glass sheets (100.times.100.times.3 mm)
were washed with a solution of trisodium phosphate (5 g/l) in
de-ionized water at 50.degree. C. for 5 min, then rinsed thoroughly
with de-ionized water and dried. Three sheets of each ionomer
(about 0.76 mm thick) were stacked together and placed between the
two glass sheets to form a pre-lamination assembly having an
interlayer with a total thickness of about 180 mils (2.28 mm). The
moisture level of the ionomer sheets was kept below 0.06 wt % by
minimizing their exposure to ambient conditions (approximately 35%
RH). The pre-lamination assembly was stabilized by the application
of polyester tape in several locations to maintain relative
positioning of each layer with the glass sheets. A nylon fabric
strip was placed around the periphery of the assembly to facilitate
air removal from within the layers.
[0068] The pre-lamination assembly was placed inside a nylon vacuum
bag and sealed. A connection was made to a vacuum pump, and the air
within the bagged assembly was substantially removed by reducing
the air pressure inside the bag was reduced to below 50 millibar
absolute. The bagged assembly was then heated in a convection air
oven to 120.degree. C. and maintained at these conditions for 30
min. A cooling fan was used to cool the assembly to near ambient
temperature, after which the vacuum source was disconnected and the
bag was removed, yielding a fully pre-pressed assembly of glass and
interlayer. Although hermetically sealed around the periphery,
several areas of the assembly were not fully bonded as indicated by
the presence of bubbles in these areas.
[0069] The pre-pressed assembly was placed into an air autoclave
and the temperature and pressure were increased from ambient to
135.degree. C. and 13.8 bar over 15 min. The assembly was
maintained at these conditions for 30 min, after which the
resulting laminate was rapidly cooled (i.e., at Cooling Rate A of
2.5.degree. C./min) to room temperature at ambient pressure. The
thus-obtained laminate was tested for haze in accordance with ASTM
D1003 using a Haze-gard Plus hazemeter (BYK-Gardner, Columbia,
Md.). After this measurement, the same laminate was heated to
120.degree. C. in an oven and maintained at such temperature for 2
to 3 hours before it was slowly cooled (i.e., at Cooling Rate B of
0.1.degree. C./min) to room temperature and then tested for haze
again. The haze results are reported in Table 2, below.
TABLE-US-00001 TABLE 1 Extruder Zone Temperature (.degree. C.) Feed
Ambient Zone 1 100-170 Zone 2 150-210 Zone 3 170-230 Adapter
170-230 Die 170-230
TABLE-US-00002 TABLE 2 Ionomer Component Neutralization MFR Haze
(%) Sample ION A ION B Level (g/ Cooling Cooling No. (wt %) (wt %)
(%) 10 min) Rate A Rate B CE1 100 0 26 1.8 1.05 6.64 E1 80 20 31
2.2* 0.83 5.9 E2 45 55 41 2.3* 0.67 0.88 E3 25 75 46 2.4* 0.62 0.49
CE2 0 100 53 2.5 0.58 0.57 *The MFR of the blends was calculated as
a weighted ratio of the MFR of ION A and of ION B.
Examples E4 to E7 and Comparative Example CE3
[0070] In each of Examples E4 to E7 and Comparative Example CE3, a
ballistic resistant laminate having the dimensions of 500.times.500
mm was prepared with the component laminate layers listed in Table
3. First, the component layers of each laminate were stacked to
form a pre-lamination assembly. The pre-lamination assembly also
included a glass cover sheet placed over the PET film layer in each
of Examples E4 to E7 or the polycarbonate sheet layer in
Comparative Example CE3. The pre-lamination assembly was then
placed in a vacuum bag, which was sealed. A vacuum was applied to
remove the air from the vacuum bag and to remove any air contained
between the assembly layers. The assembly was then subjected to
autoclaving at 135.degree. C. for 60 min under a pressure of 200
psig (14.3 bar) in an air autoclave. The air inside the autoclave
was cooled without admitting any additional air into the autoclave.
After 20 min of cooling (or when the air temperature was less than
about 50.degree. C.), the excess pressure was vented and the vacuum
bag containing the laminated assembly was removed from the
autoclave. The vacuum was then released from the vacuum bag. The
resulting laminate was removed from the vacuum bag, and the glass
cover sheet was removed from the final laminate.
[0071] The laminates were subjected to ballistic testing according
to European Standard EN 1063, Level BR4, the conditions of which
are listed below: [0072] Type of Weapon: hand gun; [0073] Calibre:
0.44 Remington Magnum; [0074] Type of Bullet: full copper alloy
jacket, flat nose, soft core (lead); [0075] Mass of Bullet:
15.6+0.1 g; [0076] Test Range: 5.00+0.5 m; [0077] Bullet Velocity:
440+10 m/s; [0078] Number of Strikes: 3; and [0079] Striking
Distance: 120+10 mm.
[0080] The results of the ballistic tests are set forth in Table
3.
TABLE-US-00003 TABLE 3 Total Areal Ballistic Thickness Density Test
Sample Layer 1 Layer 2 Layer 3 Layer 4 Layer 5 Layer 6 Layer 7 (mm)
(kg/m.sup.2) Result CE3 Glass.sup.1 PVB.sup.2 Glass.sup.1
Polyurethane Polycarbonate 20 43.3 Fail (8 mm) (0.76 mm) (8 mm)
(1.9 mm) (2.5 mm) E4 Glass.sup.1 Ionomer.sup.3 Glass.sup.1
Ionomer.sup.3 Glass.sup.1 PVB.sup.2 PET.sup.4 23.3 43.5 Pass (6 mm)
(1.5 mm) (6 mm) (6 mm) (2.5 mm) (1.52 mm) (0.18 mm) E5 Glass.sup.1
Ionomer.sup.3 Glass.sup.1 Ionomer.sup.3 Glass.sup.1 PVB.sup.2
PET.sup.4 21.6 42 Fail (6 mm) (1.5 mm) (6 mm) (4.5 mm) (2.5 mm)
(1.52 mm) (0.18 mm) E6 Glass.sup.1 Ionomer.sup.3 Glass.sup.1
Ionomer.sup.3 Glass.sup.1 PVB.sup.2 PET.sup.4 20.9 41.1 Pass (6 mm)
(1 mm) (6 mm) (5 mm) (2.5 mm) (1.52 mm) (0.18 mm) E7 Glass.sup.1
Ionomer.sup.3 Glass.sup.1 Ionomer.sup.3 Glass.sup.1 PVB.sup.2
PET.sup.4 21.8 42.1 Pass (6 mm) (1 mm) (6 mm) (6 mm) (2.5 mm) (1.52
mm) (0.18 mm) Notes for Table 3: .sup.1Annealed glass; .sup.2A
Butacite .RTM. poly(vinyl butyral) sheet commercially available
from E.I. du Pont de Nemours and Company of Wilmington, Delaware;
.sup.3Ionomer resin used in Example E3; .sup.4A Melinex .RTM. film
(0.18 mm thick), commercially available from DuPont Teijin Films,
which was primed on one side with a poly(allyl amine) based primer
as described in U.S. at. No. 7,189,457 and on the other side coated
with an abrasion resistant hardcoat as described in European Patent
No. 157030.
[0081] While certain of the preferred embodiments of this invention
have been described and specifically exemplified above, it is not
intended that the invention be limited to such embodiments. Various
modifications may be made without departing from the scope and
spirit of the invention, as set forth in the following claims.
* * * * *