A NON-DUSTING WINDOW ENVELOPE FILM UTILIZING A WAXY ANTI-FLECKING AGENT

Abstract: Disclosed are window envelopes and a method of making wherein the window envelope film from which window patches are made contains an anti-flecking agent in the form of a wax.

Description: The invention relates to a window envelope and to reducing film dust formation during the process of preparing and patching of polystyrene window envelope film. A window envelope is an envelope with one or more openings of any shape, usually rectangular, which allows examination of any information, typically a name and an address, printed on a limited area of matter within. The opening or openings are sealed or closed by a window patch composed of a non-opaque plastic film, usually polystyrene. US-A-3,709,753 refers to a method of applying windows to envelopes where a volatile solvent is applied to the underside of the blank for making an envelope to saturate the blank around the window opening. Then a transparent strip such as polystyrene which is slightly larger than the window opening is pressed onto the blank over the window opening. From DE-A-2 301 496 a rubber modified polystyrene is known comprising an anti-static agent. A useful agent is a long chain aliphatic acid amide or its alkylene oxide derivatives. The preferred agent is lauric diethanol amide. Patching is the process in which window envelope film is cut into patches of a desired length and width, gummed around the edges, and applied to the window envelope. Alternatively, the edges of the window opening or openings may be gummed instead of the edges of the window patch. The patching process requires the use of a vacuum drum to ensure proper positioning of the film. Film dust results from abrasion and scratching of the passing film by the surface of the vacuum drum due to the disparity in the speed of the passing film and the angular velocity of the drum. The abrasions and imperfections on the surface of the vacuum drum fleck away particles from the surface of the passing film resulting in film dust. Film dusting was not a serious problem until recent advances in the operating speed of window envelope film patching units. Older units operated at about 400 envelopes per minute while modern units typically operate at about 800-1000 envelopes per minute. The increased scratching and abrasion of the passing film by the vacuum drum exacerbated the dusting phenomena to the point of becoming a serious problem. The vacuum drum on a typical commercial patcher has a multiplity of minute vacuum holes and grooves on its surface to effect the adherence thereto and guidance thereon of the passing film or film patches. Vacuum holes are recessed in the grooves, which traverse the surface of the vacuum drum in both the machine and cross-machine directions relative to the passing window envelope film. The film dust accumulates in the vacuum holes and grooves and on the raised surfaces of the drum frustrating the adhering effects of the vacuum. Film dust also accumulates at a lesser rate in the internal areas of the vacuum drum and in the apparatus creating the vacuum. Process downtime is required to clean the vacuum drum and associated vacuum implementation equipment. Window envelope films are typically composed primarily of extruded polystyrene, and, optionally, contains a small proportion of a rubber-reinforced polymer to add a cosmetically desirable haze or measure of translucency to the film with the measure of translucency being proportional to the concentration of the rubber-reinforced polymer. Window envelope film may be manufactured in both biaxial and uniaxial orientations. Biaxial orientation is generally preferred because of the superior cuttability of the film in the transverse or cross-machine direction. It is the object of the present invention to provide a window envelope having the window opening covered by a transparent polystyrene film strip having a reduced dusting behavior. This object is attained by a window envelope having one or more window openings, the window openings being entirely closed by a non-opaque plastic window patch being formed of a window envelope film comprising polystyrene, characterized in that the window envelope film comprises a dust-reducing quantity of an anti-flecking agent or a combination of two or more anti-flecking agents comprising a wax having a vapor pressure at 177°C (350°F) of less than about 66.65 mbar (50 mmHg) and a melting point of from 32.2°C to 149°C (90°-300°F). The solution of the object includes also a method for preparing an extruded non-opaque window envelope film comprising polystyrene, characterized by incorporating into the window envelope film composition before extrusion a dust-reducing quantity of an anti-flecking agent or a combination of two or more anti-flecking agents comprising a wax having a vapor pressure at 177°C (350°F) of less than about 66.65 mbar (50 mmHg) and a melting point of from 32.2°C to 149°C (90°-300°F). This window envelope film is used for patching a window envelope according to the present invention. The window patch being formed of a window envelope film having a composition which comprises: polystyrene and a dust-reducing quantity of an anti-flecking agent comprising a wax or combination of waxes of an acid, acid salt, ester, or amide derivative of an saturated aliphatics or alkylaromatics having a carbon chain length of from C10 to C35, an amide derivative of an unsaturated aliphatics and alkylaromatics having a carbon chain length of from C10 to C35, or a polyolefin having a monomer carbon chain length of C2 or C3, and having a vapor pressure of less than 66.65 mbar (50 mm. Hg) at 177°C (350°F) and a melting point of 32°-149°C (90-300°F). The present invention discloses a way to substantially reduce or practically eliminate film-dusting in window envelope film or other similar polystyrene-based films with similar dusting problems. The method comprises the introduction of an anti-flecking agent in the form of a wax or waxes to the predominantly polystyrene film composition. The mode of operation of the wax is not entirely clear, but it is believed to consist of a combination of two different actions. One mode is as a lubricant and the other is in the nature of a plasticizer or softener in that it makes the polystyrene film more deformable than it is without the wax. A lubricant in the film composition lowers the coefficient of friction of the film surface contacting the vacuum drum resulting in reduced film dust formation. A practical limit to the addition of a lubricant to a film is that it must not be so lubricious as to cause adherence and guidance problems between the film and affected process surfaces; i.e., the vacuum drum surfaces. The other mode of operation of the anti-flecking agent and the most important for purposes of the present invention, is in the nature of a plasticizing or softening action. The plasticizing or softening action of the anti-flecking agent makes the film more deformable. Instead of flecking the film surface in contact with the vacuum drum, the imperfections and abrasions on the vacuum drum surface merely groove or plough it. Thus, the film is still scratched and abraded but not flecked. A non-dusting window envelope film is, for the purpose of the present invention, defined as a polystyrene window envelope film with an amount of an anti-flecking agent added sufficient to reduce film dust formation on the surface of the vacuum drum of the patching unit of the type specified in the Comparitive Example to an extent that there is no trace visible to the unaided eye after a 1219 meters (4000 feet) run of such film when conducted at substantially the same processing conditions as in the Comparitive Example. Subsequent references to a dust-reducing quantity of an anti-flecking agent mean an amount or concentration of an anti-flecking agent in the window envelope film sufficient to effectuate the desired dust-reducing characteristic of above said non-dusting window envelope film. A preferred composition of the non-dusting window envelope film useful for the present invention is polystyrene and from 0.1 to 5.0 percent by weight of one or more of the waxes as an anti-flecking agent, and, usually, an amount of a hazing agent sufficient to haze the film. The most preferred film composition is polystyrene, a hazing agent, and from 0.5 to 1.2 percent by weight of a wax or waxes as an anti-flecking agent. Wax concentrations greater than 5 percent by weight in the film may result in undesirable whitening or discoloration of the film due to phase incompatibility between the polystyrene and the wax. Suitable waxes include waxy acid, acid salt, ester, or amide derivatives of saturated aliphatics and alkylaromatics having a chain length of about C10 to C35, and amide derivatives of unsaturated aliphatics or aromatics having a carbon chain length of C10 to C35, and a polyolefin having a monomer carbon chain length of C2 or C3. Examples of suitable waxy acid derivatives include behenic, arachidic, stearic, palmitic, and lauric. Examples of waxy acid salts include the sodium, magnesium, zinc and calcium salts of the aforementioned acids. Examples of waxy ester derivatives include the ethyl, propyl, or butyl esters of the fatty acids such as butyl stearate, ethyl stearate, butyl laurate, and isopropyl palmitate. Other examples of waxy ester derivatives include such derivatives of mineral waxes such as montanic acid tri-ester and montanic acid di-ester. Examples of waxy amide derivatives include bis-stearamide, bis-lauramide, and stearamide. Examples of polyolefinic waxes include polyethylene and polypropylene. Molecular weights of suitable polyolefinic waxes include those in the 5000-10000 range. A suitable wax will have a vapor pressure of less than about 66.65 mbar (50 mm Hg) at 177°C (350°F) and a melting point of from 32.2° to 149°C (90 to 300°F). Vapor pressures above this point may result in flashing of the wax at the lip of the extrusion die, and melting points above or below the indicated parameters may result in wax viscosities inconsistent with that of the polystyrene film. Preferred anti-flecking agents are polyethylene waxes from 5000 to 10000 MW and from 0.90 to 0.98 g/cm³ density. The most preferred anti-flecking agent is polyethylene wax of the non-oxidized hydrocarbon type with a molecular weight of from 8500 to 9500, a melting point of from 138°-143°C (280° to 290°F), and a density of from 0.95 to 0.97 g/cm³, which classifies it as high-density. Other suitable polyethylene waxes include halogenated or oxidized derivatives of the hydrocarbon species. Other waxes suitable as hazing agents include the bis-amide of stearic acid and the tri- and di-esters of montanic acid. Bis-stearamide wax is an off-white amide wax commonly used as a lubricant for plastics. It has a molecular weight of from 475 to 525, a density of from 0.99 to 1.01 g/cm³, and a melting point of from 138°C to 142°C (280 to 288°F). Montanic acid tri- and di-esters are waxy yellowish solids. These waxes have densities of from 1.00 to 1.03 g/cm³, melting points of from 78°-83°C (172 to 182°F), and molecular weights of from 900 to 1400. The hazing agent is a substance, usually a rubber compound, added to the polystyrene to reduce film gloss and add a measure of haze or translucency to the film. This reduced gloss and introduced haze is desirable in window envelope film because the information shown under the film in the window envelope opening is more easily read with than without the haze, and any information outside the window opening is made more difficult to read. Examples of suitable hazing agents include homopolymers or copolymers of conjugated dienes, especially butadiene, and copolymer thereof, either block, random, or grafted, with up to about 40 percent of a comonomer such as styrene, EPDM rubbers, acrylate rubbers, chlorinated polyethylene, etc. The hazing agents may be added directly to the polymer melt employed to the prepare window film or compounded first with a polystyrene resin and then incorporated into the polymer melt. Desirably, the rubber particles should be of sufficient size to result in haze formation. Preferred are rubber particles of from 0.5 to 5 µm number average particle size and more preferably from 1.0 to 3.0 µm Preferred film compositions contain from 0.1 to 1.0 percent by weight rubber as a hazing agent. A most preferred rubber compound is the rubbery component of high-impact polystyrene (HIPS), especially such compositions of polybutadiene and polystyrene prepared by mass or solution polymerization containing from 5 to 10 percent by weight rubber. Polybutadiene or rubber particles of from 0.5 to 8.0 µm in diameter are interspersed in the polystyrene matrix of the high-impact polystyrene. A preferred film composition contains from 0.1 to 10.0 percent by weight HIPS as a hazing agent. A most preferred film composition contains from 5.0 to 10.0 percent by weight HIPS as a hazing agent. The following examples are provided as further illustrative of the present invention and are not to be construed as limiting. Unless stated to the contrary, all parts and percentages are based on weight. EXAMPLES The test films were manufactured in a blown tubular extrusion process, though manufacture by other processes such as cast film extrusion may be used. The film constituents, polystyrene, high-impact polystyrene, and, in the case of the treated films, polyethylene wax or bis-stearamide wax, were blended at a temperature between 204°-260°C (400-500°F) with the preferred blending temperature being 238°C (460°F). The operating temperature at the extrusion die is between 149°-232°C (300-450°F) with the preferred temperature being 204°C (400°F). Comparative Example The control test film comprised 10 percent by weight HIPS and the balance polystyrene of about 300,000 molecular weight. The HIPS component in the cases of both the control films and the treated films comprised 7.0 percent by weight rubber particles and 93 percent by weight polystyrene, corresponding to about 0.7 percent by weight rubber particles in the entire film. The rubber particles had an average diameter of about 3 micron number average particle size. The control runs determined the extent of dust formation on the vacuum drum for a comparative polystyrene window envelope film lacking an anti-flecking agent. Five runs of film of 30 µm gauge, 11.43 cm (4.5 in.) width, 7.98 cm (3.14 in.) patch length, and 1219 meters (4000 feet) in length were processed on the HSP Patcher for the F. L. Smithe RA 800 Series Envelope Machine. The HSP Patcher has 0.16 cm (1/16 in.) diameter holes recessed in grooves in both the machine and non-machine directions along the vacuum drum surface. The vacuum drum operated at 800 RPM and (7 in. Hg) 23.7 kilopascals vacuum. After each run, ethylacetate, a solvent for polystyrene, was used to remove and collect the film dust from the surface of the vacuum roll. The solvent was then evaporated and the residue weighed. The average weight of flecked film deposited on the drum surface was 5.4 mg. While this amount may seem small, this was the amount flecked after only about thirty-three minutes of production. Active commercial patching units must be cleaned as often as once a week. Examples 1-2 The tests involving the films treated with the polyethylene wax and the bis-stearamide wax were conducted on the same machine at substantially the same conditions and film dimension specifications as the control film. The film contained 1 percent by weight polyethylene wax, 10 percent by weight HIPS, and the balance polystyrene of about 300,000 molecular weight. The polyethylene wax was unoxidized with an average density of about 0.96 g/cm³ and an average molecular weight of about 9000. The bis-stearamide treated film contained 0.5 percent by weight bis-stearamide wax, 1 percent% by weight HIPS, and the balance polystyrene of about 300,000 molecular weight. The bis-stearamide wax had a density of about 1.0 g/cm³ and a molecular weight of about 500. The vacuum drum was visually inspected after each of two test runs for both the polyethylene wax and the bis-stearamide wax. Examination of the surface of the vacuum drum after the processing of the film treated with polyethylene wax on the patcher revealed no traces of film dust buildup. Examination of the surface of the vacuum drum after processing of the film with the bis-stearamide wax on the patcher revealed a slight but greatly reduced extent of film dusting. Visual inspection of the vacuum drum surface after runs of (4000 feet) 1219 meters of film is an acceptable means of identifying dusting since trace amounts of dust are easily observable. Dusting on the order of 5.4 mg. as in the control tests is readily visible. Example 3 A test run of 13,716 meters (45,000 feet) of polystyrene window envelope film with a 10 percent by weight HIPS concentration by weight and a 1 percent by weight polyethylene wax concentration by weight was performed on the commercial patcher described above to compare with the 1219 meters (4000 feet) run of the same film. Subsequent visual examination of the surface of the vacuum drum after the 13,716 meters (45,000 feet) run revealed no substantial degree of dusting. Electron microscopy of the surface of the polyethylene-treated film and the untreated control film with only HIPS after processing on the patcher revealed the primary mode of operation, softening or lubrication of the test waxes, in preventing film dust formation. Comparison revealed an equivalent degree of scratching and abrasion even though the control film dusted and the film containing the polyethylene wax did not. Photomicrographs of the furrows of individual scratches on the film containing the polyethylene wax indicated a folding back of film material dislocated to the lip sides of the furrows of the scratch. Also, the bottoms of the furrows of individual scratches were generally smooth and unabraded. In contrast, photomicrographs of the furrows of the scratches in the untreated polystyrene control film with only a hazing agent indicated only a slight folding back of dislocated furrow film material on the lip sides of the furrows. Also, the bottoms of the furrows were scratched and abraded. The significance of only slight folding back of dislocated film material and abraded furrow surfaces is that most of the material affected by the surface abrasions was displaced instead of dislocated. The displaced film material is manifested in the form of film dust. Comparative Example 2 Lubrication of the film surface by the wax does play a role in reducing film dusting, but this role is secondary compared to the plasticization or softening of the film. A non-wax lubricant, propylene glycol, was compounded in a test film at 1 percent by weight along with 10 percent by weight HIPS and the balance polystyrene. Friction tests revealed static and kinetic coefficents of friction of 0.18 and 0.20, respectively. Friction tests for the same film with polyethylene wax substituted for the propylene glycol at the same weight percent revealed static and kinetic coefficients of friction of 0.29 and 0.30, respectively. However, an on-line run on the HSP Patcher of the film having propylene glycol added thereto indicated dusting to the same extent as a film with only HIPS and no anti-flecking or softening agent whatsoever. As indicated above, the film with the polyethylene wax did not dust to any perceptible degree when tested on the HSP Patcher. Therefore, a reduction in friction between the surface of the film and the surface of the vacuum drum is insufficient in itself to eliminate or substantially reduce the film dusting problem. Example 4 Film abrasion tests with a rubbing plate revealed additional waxes suitable as anti-flecking agents. Various film samples containing 1 percent by weight of the candidate waxes were rubbed 30 times across the surface of a POLYOND® nickel-polytetrafluoroethyleneplate (of Polyplating, Inc.) in the machine direction of the film and examined for evidence of dusting on the plate surface. Additives shown to be suitable in reducing window envelope film dusting included oxidized polyethylene wax, montanic acid tri-ester wax, montanic acid di-ester wax, and bis-stearamide wax.

Claims: A window envelope having one or more window openings, the window openings being entirely closed by a non-opaque plastic window patch being formed of a window envelope film comprising polystyrene, characterized in that the window envelope film comprises a dust-reducing quantity of an anti-flecking agent or a combination of two or more anti-flecking agents comprising a wax having a vapor pressure at 177°C (350°F) of less than about 66.65 mbar (50 mmHg) and a melting point of from 32.2°C to 149°C (90°-300°F). The window envelope of claim 1, characterized in that the polystyrene window envelope film comprises from 0.1 to 5.0 percent by weight of one or more waxes. The window envelope of claim 2, characterized in that the polystyrene window envelope film comprises from 0.5 to 1.2 percent by weight of one or more waxes. The window envelope of claim 1, characterized in that the wax is an oxidized polyethylene wax, a non-oxidized polyethylene way, a bis-stearic acid amide, a montanic acid tri-ester or a montanic acid di-ester. The window envelope of claim 4, characterized in that the wax is a non-oxidized polyethylene wax having a density of from 0.90 to 0.98 g/cm³ and an average molecular weight of from 5,000 to 10,000. The window envelope of claim 5, characterized in that the non-oxidized polyethylene wax having a density of from 0.95 to 0.97 g/cm³ and an average molecular weight of from 8,500 to 9,500. The window envelope of claim 1, characterized in that the window envelope film comprises a hazing agent in an amount sufficient to provide a hazing effect reducing the film gloss. The window envelope of claim 7, characterized in that the hazing agent is present in an amount of from 0.1 to 1.0 percent by weight. A method for preparing an extruded non-opaque window envelope film comprising polystyrene, characterized by incorporating into the window envelope film composition before extrusion a dust-reducing quantity of an anti-flecking agent or a combination of two or more anti-flecking agents comprising a wax having a vapor pressure at 177°C (350°F) of less than about 66.65 mbar (50 mmHg) and a melting point of from 32.2°C to 149°C (90°-300°F). The method of claim 9, characterized by using a window enelope film composition comprising from 0.1 to 5.0 percent by weight of one or more waxes. The method of claim 10, characterized by using a window envelope film composition comprising from 0.5 to 1.2 percent by weight of one or more waxes. The method of any of claims 9 to 11, characterized by using a window envelope film composition comprising an oxidized polyethylene wax, or a non-oxidized polyethylene wax, a bis-stearic acid amide, a montanic acid tri-ester or a montanic acid di-ester as one or more waxes. The method of claim 12, characterized in that the wax in the window envelope film composition is a non-oxidized polyethylene wax having a density of from 0.90 to 0.98 g/cm³ and an average molecular weight of from 5,000 to 10,000. The method of claim 12, characterized in that the wax in the window envelope film composition is a non-oxidized polyethylene wax having a density of from 0.95 to 0.97 g/cm³ and an average molecular weight of from 8,500 to 9,500. The method of claim 9, characterized by using a window envelope film composition comprising a hazing agent in an amount sufficient to provide a hazing effect reducing the film gloss. The method of claim 15, characterized in that the hazing agent is present in an amount of from 0.1 to 1.0 percent by weight. Use of the window envelope film prepared according to any of claims 9 to 16 for patching a window envelope.

Inventors: FOSTER, STEPHEN I., STIMLER, JEFFREY J.
Applicants: THE DOW CHEMICAL COMPANY
Application year: 1989
Main classification: B29D7
IPC codes: C08K5, B65D27