Patent Publication Number: US-2023151206-A1

Title: Soil Biodegradable Blown Film Bag Formulation

Description:
CROSS REFERENCE TO RELATED PATENT APPLICATIONS 
     This patent application is a continuation of application Ser. No. 16/436,052, filed Jun. 10, 2019, which claims priority from U.S. Provisional Patent Application No. 62/683,103, filed Jun. 11, 2018, which is hereby incorporated by reference. 
    
    
     FIELD OF THE INVENTION 
     This invention generally relates to an improved formulation for blown film processing of soil biodegradable film for agricultural film, bags for packaging landscaping material particularly ground cover, and other applications. 
     BACKGROUND OF THE INVENTION 
     Soil biodegradable bioplastics are typically polyesters produced from primarily aliphatic monomers, such as succinic acid, butanediol, hexanediol, and aliphatic hydroxy carboxylic acids. A small content of aromatic monomers such as terephthalic acid may also be used along with some polyfunctional monomers for branching. The more common soil biodegradable bioplastics are polybutylene succinate (PBS) and polyhydroxy alkanoate (PHA). 
     Examples of uses for soil biodegradable film can be found in U.S. Pat. No. 8,522,476 issued Sep. 3, 2013, U.S. Pat. No. 8,615,926 issued Dec. 31, 2013 and U.S. Pat. No. 9,445,552 issued Sep. 20, 2016. 
     One use of blown film is for a mulch bag that may be used as a weed barrier that then soil biodegrades over time and thus does not leave any plastic residue and does not lead to multiple layers of plastic as each layer of mulch is laid down; additionally, the weed barrier does not need to be removed and disposed of prior to laying down a new layer. 
     Another use of blown film is for agricultural field cover on farms or residential vegetable gardens. These films maintain moisture in the soil, prevent weeds, and with appropriate additives can do soil amendment, insect control, and other beneficial uses. An agricultural film that is soil biodegradable eliminates the need to remove and disposing of the film before tilling and planting a new crop. 
     Showa Denko (Japan) produced Bionolle PBS for several years using a glycidyl ether containing monomer as a chain terminator, chain extender, branching agent, and/or melt strength enhancer. This branching agent produced a PBS resin with melt strength high enough to process well in a blown film extrusion process and to provide good tear resistance in both machine and transverse directions. However, the downside to the glycidyl ether containing monomer is the difficulty to remove the unreacted monomer or to react enough of the monomer to obtain FDA indirect food additive (or direct food contact) compliance. This attribute eliminated the Bionolle PBS from a primary use for the material in food packaging which is often produced by blown film or thermoforming processing. Because of this and other reasons, Showa Denko discontinued the Bionolle product line two years ago. 
     Several other companies now produce PBS but none has the melt strength and properties of the Showa Denko Bionolle PBS for consistent blown film processing to produce film with acceptable tear resistance and ductility, including tensile elongation, in both machine and transverse directions in a finished film. 
     SUMMARY OF THE INVENTION 
     The present invention addresses the need to improve the blown film and thermoforming processability of soil biodegradable aliphatic polyesters produced primarily from diacid and diol monomers. The diacid monomers may be of any type including succinic acid, adipic acid, and hexanedioic acid. The diol monomer may be of any type including ethylene glycol, propanediol, butanediol, and hexanediol. Commercial aliphatic polyesters produced from diacid and diol monomers include polybutylene succinate (PBS), polybutylene adipate succinate (PBAS), and polybutylene adipate (PBA). Comonomers may also be added for branching, adding functionality or chain termination. These comonomers may be of any type but are typically less than 10% of the total monomer content. Such comonomers include chemicals with a single carboxylic acid, hydroxy, or amine moiety, which act as chain terminators, chemicals with three or more carboxylic acid, epoxy, and/or hydroxy moieties which act as branching agents. Other possible comonomers include any other chemical that will incorporate into the polymer chain backbone. 
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     As indicated, the present invention is an improved blown film of soil biodegradable aliphatic polyesters produced primarily from diacid and diol monomers. The processability of the aliphatic polyesters is improved by adding melt strength enhancers that can be oligomers or polymers. Preferred melt strength enhancers include styrene-acrylic and styrene-methacrylic copolymers or oligomers containing glycidyl groups incorporated as side chains. Several useful examples are described in the International Patent Application WO 03/066704 A1 assigned to Johnson Polymer, LLC, which is incorporated herein by reference. These materials are based on oligomers with styrene and acrylate building blocks that have desirable glycidyl groups incorporated as side chains. A high number of epoxy groups per oligomer chain is desired, at least about 10, preferably greater than about 15, and more preferably greater than about 20. These polymeric materials generally have a molecular weight greater than about 3000, preferably greater than about 4000, and more preferably greater than about 6000. These are commercially available from Johnson Polymer, LLC under the Joncryl® trade name such as Joncryl® ADR 4368. Another example copolymer is styrene-methyl methacrylate copolymerized with glycidyl methacrylate. Any melt strength enhancer or melt strength enhancer combination may be added neat or in a masterbatch with or without other additives included in the same masterbatch. Ideally, the masterbatch would use the aliphatic polyester being blended into as the carrier resin. 
     In another embodiment, the polymer compositions of the present disclosure can include formulations that are modified with one or more of stabilizers, plasticizers, flow promoters, polymer processing aids, slip agents, viscosity modifiers, nanoparticles, ductility modifiers, colorants, anti-microbial agents, and the like. The additional components can be added to the polymer composition at any suitable time in the manufacturing process. 
     Some non-limitative examples of suitable thermal stabilizers include Irganox® Antioxidant 1010, B-225, B-900, and Irgastab® FS 301 and FS 210 FF, each commercially available from BASF (Ludwigshafen, Germany). A further example of a suitable thermal stabilizer is Irganox® 168. 
     Some light stabilizers are commercially available from BASF under the tradenames CHIMASSORB®. Further available from BASF is Tinuvin 770 DF, which is a light stabilizer belonging to the class of hindered amine light stabilizers, as well as Tinuvin® 944, Tinuvin® 123, and Tinuvin® 328. 
     Any stabilizer or stabilizer combination may be added neat or in a masterbatch with or without other additives included in the same masterbatch. Ideally, the masterbatch would use the aliphatic polyester being blended into as the carrier resin. 
     If a color concentrate is desired, the mixture may further include one or more colorants, such as pigment(s) and/or dye(s). Organic or inorganic filler or pigment particles can be used. The pigments may be chosen from a list including clays, calcium carbonate, titanium dioxide, and synthetic organic pigments. The color concentrate may be formulated with or without other additives included in the same concentrate. Ideally, the concentrate would use the aliphatic polyester being blended into as the carrier resin. Any colorant or colorant combination may be added neat, as a liquid or dry colorant or in a masterbatch with or without other additives included. Ideally, a masterbatch would use the aliphatic polyester being blended into as the carrier resin. 
     Nanofillers may comprise any suitable compound. In an embodiment, the nanofiller comprises an organoclay. Some non-limitative examples of suitable organoclay materials include Cloisite® Na+, Cloisite® 30B, Cloisite® 10A, Cloisite® 25A, Cloisite® 93A, Cloisite® 15A, Cloisite® 20A. The Coisite clays are proprietary nanoclays commercially available from Southern Clay Products, a subsidiary of Rockwood Specialties, Inc. (Princeton, N.J.). Suitable organoclay may also be obtained from Nanocor, a subsidiary of Minerals Technologies, Inc. (Bethlehem, Pa.). Nanofillers may be added neat or in a masterbatch with or without other additives included in the same masterbatch. Ideally, the masterbatch would use the aliphatic polyester being blended into as the carrier resin. Adding nanofillers neat may require compounding or mixing the nanofillers in was two passes through the compounder or mixer to get full dispersion. 
     The anti-microbial agents can be metal-based agents such as zinc oxide, copper and copper compounds, silver and silver compounds, colloidal silver, silver nitrate, silver sulphate, silver chloride, silver complexes, metal-containing zeolites, surface-modified metal-containing zeolites, or combinations thereof. The metal-containing zeolites can comprise a metal such as silver, copper, zinc, mercury, tin, lead, bismuth, cadmium, chromium, cobalt, nickel, zirconium, and combinations thereof. In another embodiment, the anti-microbial agents can be organic-based agents such as o-benzyl-phenol, 2-benzyl-4-chloro-phenol, 2,4,4′-trichloro-2′-hydroxydiphenyl ether, 4,4′-dichloro-2-hydroxydiphenyl ether, 5-chloro-2-hydroxy-diphenyl-methane, mono-chloro-o-benzyl-phenol, 2,2′-methylenbis-(4-chloro-phenol), 2,4,6-trichlorophenol, and combinations thereof. Any anti-microbial agent or anti-microbial agent combination may be added neat or in a masterbatch with or without other additives included in the same masterbatch. Ideally, the masterbatch would use the aliphatic polyester being blended into as the carrier resin. 
     Slip agents can be any one or more of additives known to reduce static or make it easier to separate to layers of film; known slip agents include, but are not limited to, talc, calcium carbonate, erucamide, and zinc stearate. Any slip agent or slip agent combination may be added neat or in a masterbatch with or without other additives included in the same masterbatch. Ideally, the masterbatch would use the aliphatic polyester being blended into as the carrier resin. 
     The plasticizers can be, for example, any suitable material that softens and/or adds flexibility to the materials they are added to. The plasticizers can soften the final product increasing its flexibility. Non-limiting examples of the plasticizers include, for example, polyethylene glycol, sorbitol, glycerine, soybean oil, castor oil, TWEEN 20, TWEEN 40, TWEEN 60, TWEEN 80, TWEEN 85, sorbitan monolaurate, sorbitan monooleate, sorbitan monopalmitate, sorbitan trioleate, sorbitan monostearate, PEG, derivatives of PEG, N,N-ethylene bis-stearamide, N,N-ethylene bis-oleamide, tributyl o-acetyl citrate, Hallstar Hallcoaid PA-6D, polycarprolactone, polymeric plasticizers such as poly(1,6-hexamethylene adipate), or combinations thereof. 
     The higher strength or more ductile aliphatic polyester material can be converted into articles by any suitable process such as, for example, foam extrusion and molding, injection molding, thermoforming, blown film, film extrusion, stretch blow molding, extrusion blow molding, extrusion coatings, profile extrusion, cast films, cast products, or combinations thereof. Sheet extrusion includes cast sheet as well as sheet produced by uniaxial and biaxial orientation. Blown film processing includes both processes typically used for low density polyethylene and used for high density polyethylene, i.e. from not too low to medium to high stalk. 
     Articles that can be produced from the inventive composition include, for example, films, trash bags, grocery bags, container sealing films, pipes, drinking straws, and sheets. The sheet can be further processed to produce articles such as cups, plates, and other objects, including those used outside of the food service industry. 
     Specifically, the higher strength or more ductile aliphatic polyester can be converted into a film to produce a bag for mulches, such as pine straw, chipped wood bark, grain straws, shredded wood materials, or other mulches known to those of ordinary skill in the landscaping art. The ground cover may also include rock, including sand, crushed stone, gravel, pea gravel, graded stone, shale, or other rock materials known to those of ordinary skill in the landscaping art. The ground cover may also include ground synthetic particles, such as ground rubber particles and ground plastic particles. The ground cover may also include composted soil. The higher strength or more ductile aliphatic polyester may also be converted into weed block film, agricultural film, and other applications desiring soil and water biodegradability as a property. 
     The converted film may be further modified by being perforated, microperforated, sealed, or printed or by any other known method for modifying film. 
     By way of example and not limitation, the following examples are illustrative of various embodiments of the present invention. 
     
       
         
           
               
             
               
                 TABLE 1 
               
             
            
               
                   
               
               
                 Material Composition 
               
            
           
           
               
               
               
            
               
                   
                 MATERIALS 
                 QTY  
               
               
                   
                 Blend #1 
                 (lbs) 
               
               
                   
                   
               
            
           
           
               
               
               
            
               
                   
                 Polybutylene Succinate 
                 96 
               
               
                   
                 Color Masterbatch in PBS 
                 3 
               
               
                   
                 Melt Strength Enhancer Masterbatch in PBS 
                 1 
               
               
                   
                   
               
            
           
         
       
     
     For this example, all the blend components were added separately to the feed throat of a 65 mm diameter single screw extruder using a temperature profile of between 160° C. and 180° C. The material was blown into a 70 mm lay flat film using a 127 mm diameter blown film die. As an alternative, the material composition can first be compounded in an appropriate single-screw extruder, twin-screw extruder, continuous mixer (e.g., Farrel continuous mixers), or batch mixers (e.g., Banbury mixers), and then the compounded resin can be added neat or with additional additives to the feed throat of a blown film extruder. 
     
       
         
           
               
             
               
                 TABLE 2 
               
             
            
               
                   
               
               
                 Formulation ranges of the Aliphatic  
               
               
                 Polyester Composition in an embodiment 
               
            
           
           
               
               
               
               
            
               
                   
                 General  
                 Preferred 
                 Most  
               
               
                   
                 Range (by  
                 (by  
                 Preferred 
               
               
                   
                 weight) 
                 weight) 
                 (by weight) 
               
               
                   
               
            
           
           
               
               
               
               
            
               
                 Aliphatic Polyester 
                   53-99.89% 
                 64.5-94.8% 
                   71-89.7% 
               
               
                 Melt Strength 
                 0.1-1.0% 
                 0.15-0.75% 
                 0.2-0.5% 
               
               
                 Enhancer 
                   
                   
                   
               
               
                 Color Masterbatch 
                 0-5% 
                 0-4% 
                 0-3% 
               
               
                 Antioxidant 
                 0.01-1.0%  
                 0.05-0.75% 
                 0.1-0.5% 
               
               
                 Ductility Modifier 
                  0-40% 
                  5-30% 
                 10-25% 
               
               
                 (Plasticizer) 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
               
               
               
               
             
               
                 TABLE 3 
               
               
                   
               
               
                 % Loading 
                 Control 
                 Eaxmple 1 
                 Example 2 
                 Example 3 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
               
               
            
               
                 PBS 
                 100 
                 91 
                 70.75 
                 70.75 
               
               
                 25% MSE in 
                   
                 1 
                 1 
                 1 
               
               
                 PBS 
                   
                   
                   
                   
               
               
                 10% Slip in PBS 
                   
                 2.5 
                 2.5 
                 2.5 
               
               
                 10% Antioxidant 
                   
                 2.5 
                 2.5 
                 2.5 
               
               
                 in PBS 
                   
                   
                   
                   
               
               
                 30% Color in 
                   
                 3 
                 3 
                 3 
               
               
                 PBS 
                   
                   
                   
                   
               
               
                 Plasticizer 1 
                   
                   
                 15 
                 10 
               
               
                 Plasticizer 2 
                   
                   
                 5 
                 10 
               
               
                 Plasticizer 3 
                   
                   
                 0.25 
                 0.25 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
               
               
               
               
             
               
                   
                 TABLE 4 
               
             
            
               
                   
                   
               
               
                   
                 Control 
                 Example 1 
                 Example 2 
                 Example 3 
               
            
           
           
               
               
               
               
               
               
               
               
               
            
               
                 Sample ID 
                 MD 
                 TD 
                 MD 
                 TD 
                 MD 
                 TD 
                 MD 
                 TD 
               
               
                   
               
            
           
           
               
            
               
                 Tensile @ Max (psi) 
               
            
           
           
               
               
               
               
               
               
               
               
               
            
               
                 Thickness 
                 2.44 
                 2.82 
                 3.19 
                 3.19 
                 2.46 
                 2.40 
                 2.63 
                 2.30 
               
               
                 Ave (mils) 
               
               
                 Ave 
                 5335 
                 5047 
                 5300 
                 5332 
                 5136 
                 3674 
                 5918 
                 5300 
               
               
                 Std Dev 
                 536 
                 332 
                 196 
                 141 
                 374 
                 375 
                 363 
                 303 
               
            
           
           
               
            
               
                 Elongation @ Max (%) 
               
            
           
           
               
               
               
               
               
               
               
               
               
            
               
                 Ave 
                 18 
                 13 
                 14 
                 13 
                 598 
                 409 
                 647 
                 563 
               
               
                 Std Dev 
                 3 
                 2 
                 3 
                 1 
                 52 
                 48 
                 23 
                 41 
               
            
           
           
               
            
               
                 Tensile @ Break (psi) 
               
            
           
           
               
               
               
               
               
               
               
               
               
            
               
                 Ave 
                 3457 
                 4795 
                 4746 
                 5332 
                 5136 
                 3666 
                 5918 
                 4766 
               
               
                 Std Dev 
                 1445 
                 840 
                 748 
                 141 
                 374 
                 375 
                 363 
                 872 
               
            
           
           
               
            
               
                 Elongation @ Break (%) 
               
            
           
           
               
               
               
               
               
               
               
               
               
            
               
                 Ave 
                 311 
                 13 
                 16 
                 13 
                 598 
                 409 
                 647 
                 564 
               
               
                 Std Dev 
                 46 
                 2 
                 1 
                 1 
                 52 
                 48 
                 23 
                 41 
               
               
                   
               
            
           
         
       
     
     For this example, all the blend components were added separately to the feed throat of a CPeX Farrel Continuous Mixer using a temperature profile of between 160° C. and 180° C. and turned into pellets using an underwater pelletizer. The resulting pellets were then turned into film using a lab blown film line with a lay flat 4 to 6″ wide. As an alternative, the material composition can first be compounded in an appropriate single-screw extruder, twin-screw extruder, or batch mixers (e.g., Banbury mixers) and then the compounded resin can be added neat or with additional additives to the feed throat of a blown film extruder. 
     It should be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present subject matter and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims. 
     While this invention has been described with reference to preferred embodiments thereof, it is to be understood that variations and modifications can be affected within the spirit and scope of the invention as described herein and as described in the appended claims.