NON-CROSSLINKED FOAM

Abstract: A non-crosslinked foam of a composition compris­ ing (A) 72 to 98% by weight of a 1-butene polymer, and (B) 28 to 2% by weight of a propylene polymer, the percentages being based on the total weight of the 1-butene polymer and the propylene polymer.

Description: This invention relates to a non-crosslinked foam of a composition comprising a major proportion of a 1-butene polymer and a minor proportion of a propylene polymer. More specifically, it relates to a non-crosslinked foam of a composition comprising a 1-butene polymer and a propylene polymer having excellent heat resistance, sealability and heat creep resistance, and to its use as a cap liner. In recent years, cans for holding beverages have been superseded by bottles. Ampoules for holding pharmaceuticals are also desired to be replaced by bottles with screw caps because glass fragments are likely to get into the contents upon opening. The most important property required of caps used in such bottles is sealability, and to secure this property, foams of high-pressure low-density polyethylene have gained widespread use as cap liners of thermoplastic resins. Containers holding pharmaceuticals and drinks are usually subjected to sterilization treatment at high temperatures, or retorting, after filling. The sterilizing temperature has recently tended to become higher for shortening the sterilizing time and increasing productivity, and nowadays, the sterilization treatment is carried out mainly at temperatures as high as at least 100°C. High-pressure low-density polyethylene foams have a low heat-resistant temperatures and cannot be sterilized at high temperatures of at least 100°C and therefore cannot be used for such an application. On the other hand, polypropylene has excellent heat resistance but a uniform foam of polypropylene alone is very difficult to obtain. JP-A-40,167/1981 discloses a foam prepared from a mixture of 90 to 30% by weight of polypropylene and 10 to 70% by weight of polybutene-1. The patent publication states that this foam has excellent heat resistance, high-temperature creep characteristics, mechanical strength and thermal insulating property and is suitable for use as thermally insulating material for high-temperature structures. It also states that when the mixing proportions of polypropylene and polybutene-1 fall outside the above-specified ranges, a good foam cannot be obtained. JP-A-129,025/1983 discloses a polyolefin foam prepared from a mixture of (a) 60 to 98% by weight of a propylene/ethylene block copolymer having a melt index of 0.5 to 2.0 and an ethylene content of 5 to 15%, (b) 1 to 20% by weight of polybutene or a butene copolymer having a melt index of 2 to 10, and (c) 1 to 20% by weight of low-density polyethylene having a melt index of 2 to 10. EP-A-147690 describes foamed articles having good cushioning and heat insulating properties formed from preliminary foamed particles of a non-crosslinked resin based on a mixture of 10 to 95% by weight of an alpha-olefin/propylene random copolymer having a heat of crystallization of note more than 10 Cal/g and 90 to 5% by weight of an ethylene/propylene random copolymer. Chem. Abs. 89/1978-73052 describes foams useful as thermal insulators prepared from blends of 30-90% polypropylene or ethylene-propylene copolymer with 70-10% of poly(1-butene). The invention provides a non-crosslinked foam of a composition comprising (A) 72 to 98% by weight of a 1-butene homopolymer or a copolymer composed of at least 80 mole % of polymerized units of 1-butene and no more than 20 mole % of an alpha-olefin of 2 to 20 carbon atoms other than 1-butene, and (B) 28 to 2% by weight of a propylene polymer, the percentages being based on the total weight of the 1-butene polymer and the propylene polymer. When the 1-butene polymer (A) is a copolymer if preferably contains at least 90 mole%, of polymerized units of 1-butene and not more than 10 mole%, of polymerized units of an alpha-olefin having 2 to 20 carbon atoms other than 1-butene. Examples of the other alpha-olefin having 2 to 20 carbon atoms include ethylene, propylene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene, 1-tetradecene, and 1-octadecene. For easy production of a foam, the 1-butene polymer (A) is preferably a crystalline polymer having a melt flow rate (MFR: ASTM D1238, E) of 0.05 to 50 g/10 min., preferably 0.1 to 20 g/10 min. The melting point of the 1-butene polymer (A) is preferably at least 100°C, more preferably at least 120°C, in order to give a foam having good heat resistance. The propylene polymer (B) used in this invention includes, for example, a homopolymer of propylene and copolymers composed of at least 70 mole%, preferably at least 90 mole%, of polymerized units of propylene and not more than 30 mole%, preferably not more than 10 mole%, of polymerized units of an alpha-olefin having 2 to 10 carbon atoms other than propylene. Examples of the other alpha-olefin having 2 to 10 carbon atoms other than propylene include ethylene, 1-butene, 4-methyl-1-pentene, 1-hexene, 1-octene and 1-decene. For easy production of a foam, the propylene polymer (B) is preferably a crystalline polymer having a melt flow rate (MFR: ASTM D1238, L) of 0.1 to 50 g/10 min., more preferably 0.5 to 20 g/10 min. The non-crosslinked foam of this invention is composed of 72 to 98% by weight, preferably 75 to 95% by weight, of the 1-butene polymer (A) and 28 to 2% by weight, preferably 25 to 5% by weight, of the propylene polymer (B) because with such a composition, the foam can be easily produced and has flexibility. The non-crosslinked foam of this invention preferably has an expansion ratio of 1.5 to 8, especially 1.7 to 4. It has good flexibility and contains a small proportion of open cells. When it is applied as a cap liner, it has excellent sealability. The expansion ratio denotes the ratio of the true density (d o ) of the unfoamed composition from which the foam is prepared to the apparent density (d) of the resulting foam, (d o /d). One preferred method of producing the non-crosslinked foam of this invention is a so-called extrusion foaming method which comprises extruding a composition comprising the 1-butene polymer (A), the propylene polymer (B), and a blowing agent in the molten or softened state from a die to release the extrudate into an atmosphere under normal atmospheric pressure from a high pressure state, thereby expanding the gas generated from the blowing agent in the composition. The blowing agent in such an extrusion foaming method is used generally in an amount of 0.2 to 5 parts by weight, preferaly 0.4 to 2 parts by weight, per 100 parts by weight of the 1-butene polymer (A) and the propylene polymer (B) combined. If the amount of the blowing agent is less than 0.2 part by weight, the expansion ratio is low and a good foam may not be obtained. If it exceeds 5 parts by weight, the expansion ratio becomes too high, and the proportion of open cells tends to become larger. Hence, the sealability of the resulting form as a cap liner is reduced. Specific examples of the blowing agent are evaporable blowing agents, for example fluorinated aliphatic hydrocarbons such as trichloromonofluoromethane and dichlorotetrafluoroethane, and aliphatic hydrocarbons such as propane, methyl chloride, isobutane, pentane and hexane; and decomposable blowing agents such as sodium bicarbonate, ammonium carbonate, azodicarbonamide, barium azodicarboxylate, N,N′-dinitrosopentamethylenetetramine, 4,4-hydroxybis(benzenesulfonyl hydrazide), diphenylsulfone-3,3-disulfonyl hydrazide, p-tolueenesulfonyl semicarbazide, trihydrazinotriazine and biurea. The evaporable blowing agents which completely volatilize leaving no residue and therefore are free from a hygienic problem, and azodicarbonamide and sodium bicarbonate as the decomposable blowing agent are preferred among them. The composition used in this invention may contain additives normally used in polyolefins, such as heat stabilizers, slip agents and antistatic agents, in addition to the blowing agent. The amounts of these additives are such as not to impair the objects of the present invention. The non-crosslinked foam of this invention may be in various forms such as sheets, pipes, rods and tubes by properly changing the die of the extruder. A packing material such as a bottle closure may be produced using the non-crosslinked foam of this invention by, for example, punching out (cutting out) a cap liner of a predetermined shape from the foam in a sheet or rod shape, and as required, fitting it into a metallic outer shell of a crown cap, for example, or bonding it to the shell by an adhesive or otherwise. Since the non-crosslinked foam of this invention has excellent flexibility, sealability, heat resistance, heat creep resistance and hygienic property, they can be used as a lining material for bottle closures such as various types of crown caps, pilfer-proof caps, and side seal caps. Such caps can be used for holding pharmaceuticals and beverages and can be subjected to sterilizing treatment at high temperatures. The following Examples illustrate the present invention in greater detail. It should be understood however that the present invention is not limited in any way to these examples unless it departs from its spirit and scope. EXAMPLE 1 Production of a non-crosslinked foamed sheet:- One hundred parts by weight of a resin mixture (PB-I + PP-I) composed of 95% by weight of a 1-butene homopolymer (PB-I; MFR=0.4 g/10 min.; [η]: 2.6 dl/g; melting point: 125°C) and 5% by weight of a propylene homopolymer (PP-I; MFR=0.5 g/10 min.) were mixed by a tumbler with 0.2 part by weight of azodicarbonamide (ADCA: Vinfor AC#3, a tradename for a product of Eiwa Chemical Industry Co., Ltd.) and 0.3 part by weight of sodium bicarbonate. The mixture was melt-kneaded in a single-screw extruder (screw diameter 40 mm; set temperature 210°C) and extruded from a pipe-forming die (set temperature 120°C) to give a pipe-like foam. The pipe-like foam was cut open to give a sheet-like foam having a thickness of 2 mm. The resulting foam was closed-cellular and showed a good foamed condition. It had an apparent density of 0.53 g/cm³ and a surface hardness, determined in accordance with JIS K-6301, of 82. Evaluation of the properties of the foam as a cap liner:- A packing material, 27.5 mm in diameter, punched out from the resulting sheet-like foam was pushed and fitted into the inner surface of an aluminum cap having a diameter of 28 mm. Hot water at 80°C was poured in an amount of 110 ml into a glass bottle having a capacity of 120 ml and a mouth diameter of 25 mm, and immediately then, the glass bottle was sealed up with the resulting cap by using a capping machine (made by Shibasaki Seisakusho). The glass bottle was then left to stand in a retorting kettle at 121°C for 30 minutes and taken out. It was laid down and allowed to cool at room temperature for 24 hours. Then, the bottle was checked for leakage of the water it held. Thereafter, the airtightness value and the opening torque value of the glass bottle were measured by the following methods. Continued pressure reduction resistance value (airtightness value) (mmHg) A pressure gauge was thrusted into the cap of the glass bottle, and the pressure of the inside of the bottle was measured. If the bottle is completely sealed up, the pressure of the inside of the bottle ought to be 334 mmHg as a difference between the vapor pressure (355 mmHg) at 80°C of water and the vapor pressure (21 mmHg) of water at room temperature (23°C). The sealability of the glass bottle is better as the airtightness value is nearer to 334 mmHg. When there is leakage, the pressure is 0 mmHg. Opening torque value (kg-cm) The torque of the cap at the time of opening the bottle was measured by using a torque meter and used as a measure of the ease of bottle opening. To secure good sealability with a screw cap, it is generally sufficient to close it tightly. If, however, it is closed too tightly, it cannot be easily opened by a human power. The torque value which permits easy opening by aged people, women and children is considered to be not more than 10 kg-cm. The results are shown in Table 1. EXAMPLES 2-3 Example 1 was repeated except that a propylene/ethylene random copolymer (PEC-I; MFR: 0.5 g/10 min.; ethylene content: 3 mole%) in the amounts indicated in Table 1 was used instead of PP-I used in Example 1. The results were good as shown in Table 1. COMPARATIVE EXAMPLE 1 Example 1 was repeated except that PEC-I used in Example 2 was used in the amount indicated in Table 1 instead of PP-I used in Example 1. Probably because the cap liner composed of the resulting foam had too high a hardness, its adhesion to the bottle mouth was poor, and as shown in Table 1 leakage occurred. The airtightness value was as low as 20 mmHg. The opening torque value was also low. COMPARATIVE EXAMPLE 2 Example 1 was repeated except that PEC-I used in Example 1 was used in the amount indicated in Table 1 instead of PP-I used in Example 1. The foamed state of the resulting foam was bad, and the expansion ratio was not so high. The foam was not closed-cellular, but open-cellular. The properties of the foam as a cap liner were also poor. The results are shown in Table 1.

Claims: A non-crosslinked foam of a composition comprising (A) 72 to 98% by weight of a 1-butene homopolymer or a copolymer composed of at least 80 mole % of polymerized units of 1-butene and not more than 20 mole % of an alpha-olefin having 2 to 20 carbon atoms other than 1-butene and (B) 28 to 2% by weight of a propylene polymer, the percentages being based on the total weight of (A) and (B). A foam according to claim 1 wherein (A) has a melt flow rate of 0.05 to 50 g/10 min. A foam according to claim 1 or 2 wherein (B) is a propylene homopolymer. A foam according to claim 1 or 2 wherein (B) is a copolymer composed of at least 70 mole % of polymerized units of propylene and not more than 30 mole % of polymerized units of an alpha-olefin having 2 to 10 carbon atoms other than propylene. A foam according to any one of the preceding claims wherein (B) has a melt flow rate of 0.1 to 50 g/10 min. A foam according to any one of the preceding claims which comprises 75 to 95% by weight of (A) and 25 to 5% by weight of (B). A foam according to any one of the preceding claims which has an expansion ratio of from 1.5 to 8. A foam according to claim 7 which has an expansion ratio of from 1.7 to 4. A cap liner composed of a non-crosslinked foam as claimed in any one of claims 1 to 8. Filled containers sealed with a cap comprising a cap liner as claimed in claim 9.

Inventors: KAGAWA, FUKASHI, NAKASHIMA, KOGI, TANAKA, HARUHIKO
Applicants: MITSUI PETROCHEMICAL INDUSTRIES, LTD., SHELL OIL COMPANY
Application year: 1987
Main classification: C08L23
IPC codes: C08J9, C08L23, B65D53