Environmentally friendly polylactide-based composite formulations

• US 20030216496A1
• Filed: 11/26/2002
• Published: 11/20/2003
• Est. Priority Date: 05/10/2002
• Status: Active Grant

• Current Assignee: AFI Licensing LLC (Armstrong World Industries Incorporated)
• Original Assignee: AWI Licensing Company (Armstrong World Industries Incorporated)
• Inventors: Drzal, Lawrence T., Rook, Brian P., Misra, Manjusri, Mohanty, Amar Kumar
• Granted Patent: US 6,869,985 B2
• Time in Patent Office: Days
• US Class Current: 524/284
• CPC Class Codes: B29C 67/24 characterised by the choice of material
• CPC Class Codes: B29K 2067/043 PGA, i.e. polyglycolic acid or polyglycolide
• CPC Class Codes: B29K 2067/046 PLA, i.e. polylactic acid or polylactide
• CPC Class Codes: B29L 2031/732 Floor coverings piles carpets B29L2031/7652; for vehicles B29L2031/3017
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: C08J 2367/04 Polyesters derived from hydroxy carboxylic acids, e.g. lactones C08J2367/06 takes precedence
• CPC Class Codes: C08J 5/18 Manufacture of films or sheets
• CPC Class Codes: C08L 101/00 Compositions of unspecified macromolecular compounds
• CPC Class Codes: C08L 2666/02 Organic macromolecular compounds, natural resins, waxes or and bituminous materials
• CPC Class Codes: C08L 67/04 Polyesters derived from hydroxycarboxylic acids, e.g. lactones C08L67/06 takes precedence
• CPC Class Codes: E04F 15/10 of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard , or with a top layer of other materials
• CPC Class Codes: E04F 15/22 Resiliently-mounted floors, e.g. sprung floors laid as webs E04F15/16

Abstract

Polymeric materials and products, including sheet flooring materials prepared from the polymeric materials, and processes for preparing the polymeric materials, are disclosed. The polymeric materials include a polylactic acid-based polymer in combination with plasticizer and a compatibilizer, and optionally include a filler. The polymeric material can include between about 30 to about 50 percent by weight polyvinyl chloride, polyethylene glycol, polyglycolide, ethylene vinyl acetate, polycarbonate, polycaprolactone, polyhydroxyalkanoates, or polyolefins modified with polar groups, for example, ionomers. The plasticizer is typically an epoxidized vegetable oil or esterified and epoxidized vegetable oil and is typically present in an amount of between about 10 and about 50% by weight. In some embodiments, the compatibilizer is a polyolefin modified with one or more polar functional groups, and is typically present in an amount of between about 5 and about 10% by weight. The material can be used in decorative surface coverings, such as a floor coverings, particularly when it is in the form of a polymeric sheet. The polymeric material can be present in at least one layer of a floor covering, which floor covering can also include one or more additional layers such as wear layers, foamed or foamable layers, top coat layers and design layers. The additional layers can also include the polymeric material.

Claims

1. A process for preparing a polymeric material comprising the steps of

a) preparing a mixture comprising a polylactic acid-based polymeric material, a plasticizer and a compatibilizer,

b) heating the mixture,

c) forming the heated mixture into a desired shape, and

d) solidifying the formed, heated mixture by cooling.

2. The process of claim 1, wherein the components of the mixture are mixed in an extruder.

3. The process of claim 1, wherein the mixture is heated above the melting point of the polylactic acid-based polymeric material.

4. The process of claim 1 wherein the polylactic acid-based polymeric material comprises predominantly poly-L-lactide.

5. The process of claim 1, wherein the polylactic acid-based polymeric material comprises between about 30 to about 50 percent by weight of a polymer selected from the group consisting of polyvinyl chloride, polyethylene glycol, polyglycolide, ethylene vinyl acetate, polycarbonate, polycaprolactone, a polyhydroxyalkanoate, a polyolefin modified with at least one polar group other than the compatibilizer, and combinations thereof.

6. The process of claim 5, wherein the polyolefin modified with at least one polar functional group is an ionomer.

7. The process of claim 1, wherein the plasticizer is selected from the group consisting of an adipate, a phthalate, a citrate, an epoxidized vegetable oil, an esterified and epoxidized vegetable oil, and combinations thereof.

8. The process of claim 1, wherein the compatibilizer comprises a polyolefin modified with at least one polar functional group.

9. The process of claim 1, wherein the mixture further comprises a filler.

10. The process of claim 1, wherein the compatibilizer is present in an amount between about 5 and about 10% by weight based on the polylactic acid-based polymeric material.

11. The process of claim 1, wherein the plasticizer is present in an amount between about and about 50% by weight based on the polylactic acid-based polymeric material.

12. The process of claim 1, wherein the plasticizer is present in an amount between about and about 35% by weight based on the polylactic acid-based polymeric material.

13. A decorative surface covering comprising the polymeric material prepared in accordance with the process of claim 1.

14. The decorative surface covering of claim 13, wherein the decorative surface covering is a floor covering.

15. A process for preparing a polymeric sheet comprising the steps of

a) preparing a mixture comprising a polylactic acid-based polymeric material, a plasticizer and a compatibilizer,

b) heating the mixture,

c) forming the heated mixture into a sheet, and

d) solidifying the sheet by cooling.

16. The process of claim 15, wherein the components of the mixture are mixed in an extruder.

17. The process of claim 15, wherein the mixture is heated above the melting point of the polylactic acid-based polymeric material.

18. The process of claim 15 wherein the polylactic acid-based polymeric material comprises predominantly poly-L-lactide.

19. The process of claim 15, wherein the polylactic acid-based polymeric material comprises between about 30 and about 50 percent by weight of a polymer selected from the group consisting of polyvinyl chloride, polyethylene glycol, polyglycolide, ethylene vinyl acetate, polycarbonate, polycaprolactone, a polyhydroxyalkanoate, a polyolefin modified with at least one polar group other than the compatibilizer, and combinations thereof.

20. The process of claim 19, wherein the polyolefin modified with at least one polar functional group is an ionomer.

21. The process of claim 15, wherein the plasticizer is selected from the group consisting of an adipate, a phthalate, a citrate, an epoxidized vegetable oil, an esterified and epoxidized vegetable oil, and combinations thereof.

22. The process of claim 15, wherein the compatibilizer comprises a polyolefin modified with at least one polar functional group.

23. The process of claim 15, wherein the mixture further comprises a filler.

24. The process of claim 15, wherein the compatibilizer is present in an amount between about 5 and about 10% by weight based on the polylactic acid-based polymeric material.

25. The process of claim 15, wherein the plasticizer is present in an amount between about 10 and about 50% by weight based on the polylactic acid-based polymeric material.

26. The process of claim 15, wherein the plasticizer is present in an amount between about 25 and about 35% by weight based on the polylactic acid-based polymeric material.

27. A polymeric composition comprising a polylactic acid-based polymeric material, a plasticizer and a compatibilizer.

28. The polymeric composition of claim 27 wherein the polylactic acid-based polymeric material comprises predominantly poly-L-lactide.

29. The polymeric composition of claim 27, wherein the polylactic acid-based polymeric material comprises between about 30 and about 50 percent by weight of a polymer selected from the group consisting of polyvinyl chloride, polyethylene glycol, polyglycolide, ethylene vinyl acetate, polycarbonate, polycaprolactone, a polyhydroxyalkanoate, a polyolefin modified with at least one polar group other than the compatibilizer, and combinations thereof.

30. The polymeric composition of claim 29, wherein the polyolefin modified with at least one polar functional group is an ionomer.

31. The polymeric composition of claim 27, wherein the plasticizer is selected from the group consisting of an adipate, a phthalate, a citrate, an epoxidized vegetable oil, an esterified and epoxidized vegetable oil, and combinations thereof.

32. The polymeric composition of claim 27, wherein the compatibilizer comprises a polyolefin modified with at least one polar functional group.

33. The polymeric composition of claim 27, wherein the material further comprises a filler.

34. The polymeric composition of claim 27, wherein the compatibilizer is present in an amount between about 5 and about 10% by weight based on the polylactic acid-based polymeric material.

35. The polymeric composition of claim 27, wherein the plasticizer is present in an amount between about 10 and about 50% by weight based on the polylactic acid-based polymeric material.

36. The polymeric composition of claim 27, wherein the plasticizer is present in an amount between about 25 and about 35% by weight based on the polylactic acid-based polymeric material.

37. A decorative surface covering comprising the polymeric composition of claim 27.

38. The polymeric composition of claim 27, further comprising a nanocomposite material.

39. The polymeric composition of claim 38, wherein the nanocomposite comprises an organoclay.

40. A sheet material comprising a polylactic acid-based polymeric material, a plasticizer and a compatibilizer.

41. The sheet material of claim 40 wherein the polylactic acid-based polymeric material comprises predominantly poly-L-lactide.

42. The sheet material of claim 40, wherein the polylactic acid-based polymeric material comprises between about 30 and about 50 percent by weight of a polymer selected from the group consisting of polyvinyl chloride, polyethylene glycol, polyglycolide, ethylene vinyl acetate, polycarbonate, polycaprolactone, a polyhydroxyalkanoate, a polyolefin modified with at least one polar group other than the compatibilizer, and combinations thereof.

43. The sheet material of claim 42, wherein the polyolefin modified with at least one polar functional group is an ionomer.

44. The sheet material of claim 40, wherein the plasticizer is selected from the group consisting of an adipate, a phthalate, a citrate, an epoxidized vegetable oil, an esterified and epoxidized vegetable oil, and combinations thereof.

45. The sheet material of claim 40, wherein the compatibilizer comprises a polyolefin modified with at least one polar functional group.

46. The sheet material of claim 40, wherein the material further comprises a filler.

47. The sheet material of claim 40, wherein the compatibilizer is present in an amount between about 5 and about 10% by weight based on the polylactic acid-based polymeric material.

48. The sheet material of claim 40, wherein the plasticizer is present in an amount between about 10 and about 50% by weight based on the polylactic acid-based polymeric material.

49. The sheet material of claim 40, wherein the plasticizer is present in an amount between about 25 and about 35% by weight based on the polylactic acid-based polymeric material.

50. A decorative surface covering comprising the sheet material of claim 40.

51. The decorative surface covering of claim 50, wherein the decorative surface covering is a floor covering.

52. A floor covering comprising at least one layer comprising a polylactic acid-based polymeric material, a plasticizer and a compatibilizer.

53. The floor covering of claim 52 wherein the polylactic acid-based polymeric material comprises predominantly poly-L-lactide.

54. The floor covering of claim 52, wherein the polylactic acid-based polymeric material comprises between about 30 and about 50 percent by weight of a polar polymer selected from the group consisting of polyvinyl chloride, polyethylene glycol, polyglycolide, ethylene vinyl acetate, polycarbonate, polycaprolactone, a polyhydroxyalkanoate, a polyolefin modified with at least one polar group other than the compatibilizer, and combinations thereof.

55. The floor covering of claim 54, wherein the polyolefin modified with at least one polar functional group is an ionomer.

56. The floor covering of claim 52, wherein the plasticizer is selected from the group consisting of an adipate, a phthalate, a citrate, an epoxidized vegetable oil, an esterified and epoxidized vegetable oil, and combinations thereof.

57. The floor covering of claim 52, wherein the compatibilizer is a polyolefin modified with at least one polar functional group.

58. The floor covering of claim 52, wherein the at least one layer further comprises a filler.

59. The floor covering of claim 52, wherein the compatibilizer is present in an amount between about 5 and about 10% by weight based on the polylactic acid-based polymeric material.

60. The floor covering of claim 52, wherein the plasticizer is present in an amount between about 25 and about 35% by weight based on the polylactic acid-based polymeric material.

61. The floor covering of claim 52, further comprising at least one additional layer selected from the group consisting of a wear layer, a foamed layer, a foamable layer, a top coat layer, and a design layer.

62. The floor covering of claim 52, wherein the floor covering is a tile having a notched Izod impact strength of at least about 10 J/m.

63. The floor covering of claim 52, wherein the floor covering is a tile having an apparent bending modulus between about 70 and about 100 kpsi.

64. The floor covering of claim 52, wherein the floor covering is a tile having an indentation between about 90 and 100%.

65. The floor covering of claim 52, wherein the floor covering is a tile having a residual indent between 0 and about 5%.

66. The floor covering of claim 52, wherein the floor covering is a resilient sheet flooring having a notched Izod impact strength between about 80 and about 500 J/m.

67. The floor covering of claim 52, wherein the floor covering is a resilient sheet flooring having an apparent bending modulus between about 10 and about 50 kpsi.

68. The floor covering of claim 52, wherein the floor covering is a resilient sheet flooring having an indentation between about 85 and 100%.

69. The floor covering of claim 52, wherein the floor covering is a resilient sheet flooring having a residual indent between 0 and about 5%.