Patent Description:
Bead foam is used to make lightweight plastic articles that are difficult to produce using other methods such as foam extrusion and injection molding. Unlike extrusion and injection molding processes, bead foam processes have few constraints as to the geometry of the product, and can produce much lower density foams.

Bead foam product is made by forming polymer beads that are infused with a blowing agent and then partially or fully expanded. The expanded beads are molded by pouring them into a mold and heating them enough to soften their surfaces and fuse ("sinter") them together to form a unitary mass.

PLA has to-date shown limited suitability for use in bead foaming processes. There are two main problems. The first is one of insufficient expansion. It has proven difficult to produce expanded PLA beads at the low densities seen when other polymers such as polystyrene and polypropylene are used. The other main problem is one of processing. Foaming conditions must be maintained within tight limits that are difficult to maintain consistently on industrial production lines. It has proven to be very difficult to obtain good sintering when making PLA bead foam without collapsing the beads. The resulting foamed products often have defects and inadequate mechanical properties.

<CIT> and <CIT> describe attempts to improve PLA bead foam processing. In these processes, the expanded PLA bead foams have a crystalline structure characterized by two melting ranges whose peaks are separated by about <NUM>° to <NUM> in a DSC (differential scanning calorimetry) thermogram. This leads to some improvements, but the processing window during sintering remains small.

<CIT> describes an attempt to solve the processing issues by using PLA beads that have a core-shell structure. This does not represent a practical solution due to the difficulty and expense of producing the core-shell bead structure.

<NPL>, describe a method of producing microcellular sheet foam from a mixture of a poly-L-lactic acid (PLLA) and a poly-D-lactic acid (PDLA). In this process, low crystallinity sheets are made from a blend of the PLLA and PDLA. The sheets are saturated with carbon dioxide at <NUM> at superatmospheric pressure. The carbon-dioxide-saturated sheets are depressurized while cold to prevent expansion. The sheets are thereafter expanded by immersing them in a liquid bath at <NUM>° to <NUM>. This process achieves a volumetric expansion ratio of up to about <NUM>, which is still less than is wanted. No subsequent molding takes place because the starting material is a sheet rather than beads.

<CIT> describes a process for preparing CO<NUM> impregnated polymer beads which comprises i) contacting polymer granules with pressurized CO<NUM> comprising liquid CO<NUM> to absorb CO<NUM> into the polymer granules, and ii) contacting the CO<NUM> absorbed polymer granules with pressurized CO<NUM> comprising gaseous CO<NUM> to obtain CO<NUM> impregnated polymer granules. <CIT> describes expandable polylactic acid resin particles comprising i) a base resin comprising a polylactic acid resin having at least <NUM> mol % of lactic acid monomer component units, ii) a polyolefin wax in an amount of <NUM> to <NUM> part by weight per <NUM> parts by weight of said base resin, and iii) a blowing agent in an amount of <NUM> to <NUM> % by weight based on the weight of said expandable polylactic acid resin particles.

What is wanted is a process for producing expanded PLA beads, the process being characterized in being economically feasible and in producing high expansion ratios and foams in which the expanded beads are well-sintered and therefore have good mechanical properties.

This invention is a process for making expanded PLA beads, comprising:.

The process is suitable for industrial application and provides for a high bead expansion ratio. The resulting expanded PLA beads therefore have a low density. Another advantage of the invention is that the entire expansion process can be carried out in a single production vessel.

The invention is in a second aspect expanded PLA beads made in the foregoing process.

The invention is in a third aspect an expanded PLA bead comprising a blend of PLA resins, wherein the expanded PLA bead has a density of <NUM> to <NUM>/cm<NUM> and a volume of <NUM> to <NUM><NUM>, and the PLA resin blend contains PLA stereocomplex crystals having a crystalline peak melting temperature of <NUM>-<NUM> and PLA homocrystals having a peak melting temperature of <NUM>-<NUM>.

The invention is also a method for producing a molded article, comprising introducing expanded PLA beads of the second or third aspect into a mold and sintering, and optionally further expanding, the expanded PLA beads to form the molded article. The molding process is characterized by a wide processing latitude, which simplifies operation and reduces defects.

The resin beads expanded in this invention to produce the bead foam are made from a PLA resin blend. The PLA resin blend is formed from at least two starting PLA resins, i.e., a first PLA resin and a second PLA resin.

For purposes of this invention, a PLA resin contains at least <NUM>%, such as at least <NUM>% or at least <NUM>% by weight of lactic (-O-C(CH<NUM>)-C(O)-) repeating units. These polymers are readily produced by polymerizing lactic acid or, more preferably, by polymerizing lactide.

The first PLA resin is a PLLA polymer containing at least <NUM>% L-lactic units based on the total weight of the first PLA copolymer. The first PLA resin may contain at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, or at least <NUM>% L-lactic units, on the same basis. It may contain up to <NUM>% L-lactic units. The remaining weight of the PLLA polymer, if any, may be D-lactic units. The first PLA resin may be a mixture of two or more polymers having the aforementioned proportions of L-lactic units.

The second PLA resin is a PDLA polymer containing at least <NUM>% D-lactic units, based on the total weight of the first PLA copolymer. The second PLA resin may contain at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, or at least <NUM>% D-lactic units, on the same basis. It may contain up to <NUM>% D-lactic units. The remaining weight of the PDLA polymer, if any, may be L-lactic units. The second PLA resin may be a mixture of two or more polymers having the aforementioned proportions of D-lactic units.

The first and second PLA resins each may have molecular weights that are high enough for melt processing applications. A number average molecular weight in the range of <NUM>,<NUM> to <NUM>,<NUM>/mol, as measured by gel permeation chromatography against a polystyrene standard, is generally suitable, although somewhat higher and lower values can be used in some circumstances. The molecular weight of the high-D and high-L starting resins may be similar to each other (such as a number average molecular weight difference of <NUM>,<NUM>/mol or less).

The first and second PLA copolymers are present in the PLA resin blend at a weight ratio of <NUM>:<NUM> to <NUM>:<NUM> or <NUM>:<NUM> to <NUM>:<NUM>. The first and second PLA copolymers may be present in the PLA resin blend at a weight ratio of <NUM>:<NUM> to <NUM>:<NUM> or <NUM>:<NUM> to <NUM>:<NUM>. A preferred weight ratio is <NUM>:<NUM> to <NUM>:<NUM> or <NUM>:<NUM> to <NUM>:<NUM>.

The starting unfoamed beads are conveniently made by melt-blending the first and second PLA resin. A melt of the two resins is formed, preferably at a temperature equal to or above the peak melting temperature of PLA stereocomplex crystals (<NUM>° to <NUM>). The melt is solidified by cooling and simultaneously or thereafter formed into particles. It is preferred to perform the cooling step by rapidly reducing the temperature of the melted blend from at or above the stereocomplex melting temperature to below the glass transition temperature of PLA (<NUM>), to minimize crystallization during the cooling process. The PLA blend in the particles preferably has a crystallinity of no greater than <NUM> J/g by DSC to pressurizing them with carbon dioxide. The DSC measurement is performed with a temperature increase from <NUM>° to <NUM> at a rate of <NUM>/minute.

A suitable way of forming beads from the PLA resin blend is to extrude the melt-blended resins into strands that are chopped to length as or after they are cooled and solidified. Note that for purposes of this invention, the beads are not necessarily spherical in shape. They may be, for example, cylindrical, ellipsoidal, or of other geometry. If cylindrical, the cross-section of the beads may be circular, elliptical, polygonal, or irregular. The beads should have an aspect ratio (ratio of longest to shortest orthogonal dimensions) of no more than <NUM>, especially no more than <NUM>, or no more than <NUM>, as this facilitates good packing and the development of uniform properties in the final product.

The strand diameter and length of the chopped particles each may be, for example, <NUM> to <NUM>, especially at least <NUM>, and up to <NUM>, or up to <NUM>. Diameters for purpose of this invention are the diameter of a circle having the same cross-sectional area as the strand. The strands can be extruded into a cooling bath such as a water or other liquid bath to cool and solidify them rapidly to prevent significant crystallization from occurring before their temperature has been reduced to below the glass transition temperature. A suitable bath temperature is up to <NUM> or up to <NUM>.

The starting particles are unfoamed prior to being pressurized with carbon dioxide in step a) of the process.

In step a), the PLA resin blend particles are pressurized with carbon dioxide. This step is performed by contacting the PLA resin beads with carbon dioxide under conditions that include a superatmospheric pressure and a temperature of no greater than <NUM>. The pressure is preferably at least <NUM> MPa gauge and can be, for example, at least <NUM> MPa gauge, at least <NUM> MPa gauge, or at least <NUM> MPa gauge. The pressure may be, for example, up to <NUM> MPa gauge or up to <NUM> MPa gauge. The temperature may be, for example, at least -<NUM> or at least <NUM> and may be up to, for example, <NUM>. An especially preferred temperature is <NUM> to <NUM>. The pressurization step typically takes up to <NUM> minutes.

Once the beads have been pressurized, they are heated under superatmospheric pressure to a temperature between <NUM> and <NUM> to at least partially crystallize the PLA resin blend without expanding the beads (step (b)). This heating step may be performed in a thermal fluid as described below. The superatmospheric pressure may be the same as in the pressurization step a). The beads may be held within this temperature range for a period, for example of at least <NUM> minutes or at least <NUM> minutes and, for example, up to <NUM> minutes, up to <NUM> minutes, or up to <NUM> minutes. A preferred temperature is <NUM> to <NUM>, and an especially preferred temperature is <NUM> to <NUM>. This step (b) produces carbon-dioxide-saturated, partially crystallized, unfoamed resin beads.

Two types of crystals form during the partial crystallization step (b). PLA stereocomplex crystals form when PLLA and PDLA crystallize together to form into a <NUM><NUM> helical conformation. PLA stereocomplex crystals have peak melting temperatures (as measured by DSC) of approximately <NUM>-<NUM>. In addition, PLA homocrystals form when either PLLA or PDLA (usually the one present in excess in the PLA resin blend) crystallizes with itself. PLA homocrystals are characterized by peak melting temperatures of approximately <NUM>-<NUM>. As a result of the formation of these two types of crystals during the partial crystallization step, the partially crystallized particles exhibit two peak melting temperatures that are separated by approximately <NUM>° to <NUM>, and preferably <NUM> to <NUM>.

The extent of crystallization that takes place during the partial crystallization step may be, for example, <NUM>% to <NUM>% of the total weight of the PLA resin blend in the particles. A preferred amount is <NUM>% to <NUM>% or <NUM>% to <NUM>% on the same basis. The extent of crystallization is determined by measuring the enthalpy of melting of the PLA stereocomplex and the PLA homocrystals in a weighed sample using DSC. A fully crystallized PLA stereocomplex is defined as having <NUM> J/g of stereocomplex crystals and a fully crystallized PLA homopolymer is defined as having <NUM> J/g of PLA homocrystals, in each case as measured by DSC. The extent of crystallization in the sample is therefore calculated as: <MAT> where Sc is the measured quantity of PLA stereocomplex crystallinity in Joules/gram and Hc is the measured quantity of PLA homocrystals in Joules/gram.

The PLA stereocomplex crystallinity may represent, for example, <NUM>% to <NUM>%, <NUM>% to <NUM>%, <NUM>% to <NUM>%, or <NUM>% to <NUM>% of the total crystallinity in the particles after the partial crystallization step as measured using DSC.

The pressure during the partial pressurization step is sufficient to prevent the particles from expanding until partial crystallinity has been produced in the particles as described above. Pressures as described with regard to the saturation step a) are suitable.

Step (b) produces partially crystallized, carbon-dioxide-saturated, unfoamed beads having a temperature of <NUM> to <NUM>. In step (c), these beads are depressurized. The pressure is reduced such that the carbon dioxide infused into the beads at least partially vaporizes to expand the beads. The pressure may be reduced in the depressurization step to, for example, no greater than <NUM> kPa absolute, no greater than <NUM> kPa absolute, or no greater than <NUM> kPa absolute. The pressure reduction should take place rapidly, such as over a time period of <NUM> to <NUM> seconds.

The drop in pressure and vaporization of carbon dioxide expands the beads. The beads may expand to at least <NUM> times their original (pre-expanded) volume. An advantage of this invention, however, is that very large expansions are easily obtained. In some embodiments, the beads may expand to at least <NUM> times, at least <NUM> times, at least <NUM> times, or even at least <NUM> times their original volume. Bead densities after expansion may be, for example, from <NUM> to <NUM>/cm<NUM>. In preferred embodiments, the expanded beads have densities of <NUM> to <NUM>/cm<NUM>, especially <NUM> to <NUM>/cm<NUM>.

Some additional crystallization may take place during the expansion step due to strain-induced crystallization.

In step (d), the beads are cooled simultaneously and/or after the expansion step to below <NUM>, preferably to below <NUM>, to solidify them and produce a tack-free surface that prevents them from sticking prematurely.

Steps (a)-(c) can be performed in any vessel that can be pressurized to the requisite pressure and, with regard to step (b), withstand the requisite temperatures. Different apparatus can be used in the various steps, but it is preferred to perform at least steps (a)-(c) and preferably each of steps (a)-(d) in a single vessel. An autoclave or other pressure vessel is suitable.

Steps (a)-(c) may be performed while the beads are suspended in a thermal fluid. The thermal fluid can be, for example, water, an alkylene glycol, or polyalkylene glycol, a silicone oil, or other material that is a liquid under the temperature and pressure conditions of the various steps. Step (d) also may be performed with the beads suspended in the thermal fluid.

In a preferred process, the starting unfoamed beads are suspended in a thermal fluid in a vessel. The vessel is pressurized with carbon dioxide to saturate the beads and the beads are then heated, still within the vessel, to partially crystallize the PLA resin blend in the beads. The depressurization step is likewise performed in the same vessel by releasing the pressure.

The expanded beads, like the partially crystallized beads, are characterized in having both PLA stereocomplex crystals having peak melting temperatures of <NUM>-<NUM> and PLA homocrystals having peak melting temperatures of approximately <NUM>-<NUM>. The extent of crystallization in the expanded beads again may be, for example, <NUM>% to <NUM>% of the total weight of the PLA resin blend in the particles.

The expanded beads are suitable for making molded articles in a bead molding process. In such a process the expanded beads are introduced into a mold, the internal walls of which define the dimensions and geometry of the part to be produced. The expanded beads are heated to soften their surfaces so adjacent beads adhere to form a unitary molded body. Some further expansion of the beads may take place during the molding step. It may be desirable, for example, to only partially expand the beads in step (c) above, so further bead expansion can take place during the molding process.

Bead molding can be performed, for example, in a steam chest molding machine. In such a device, the expanded or partially expanded beads are introduced into the mold, which is positioned in a steam cabinet. High-pressure steam is introduced into the cabinet to heat and soften the surfaces of the beads, which allows adjacent beads to fuse together.

An advantage of this invention is the wide processing latitude permitted through the use of the expanded beads made in accordance with the invention. Previously, bead molding of expanded PLA beads has been difficult because the steam temperature had to be controlled within a tight range. Because the steam temperature varies with its pressure, tight temperature control also requires careful control over the steam pressure, which is difficult using industrial-scale equipment.

Much broader temperature ranges (and therefore wider variations in steam pressure) can be tolerated with this invention. It is believed that the greater processing latitude is due at least in part to the presence of the two different types of crystals that form in the PLA resin blend, and the wide separation of their respective melting temperatures. Molding can be performed at any intermediate temperature and so close temperature control is less important and the beads are easier to mold.

The expanded beads can be used to make foamed articles such as cups, plates, coolers and other thermal insulation, buoys and other flotation devices, shock absorbing devices such as automotive bumper components.

The following examples are provided to illustrate the invention. All parts and percentages are by weight unless otherwise indicated.

PLA Blend <NUM> is made by melt blending <NUM>% of a PLLA resin containing <NUM>% L-lactic units and <NUM>% D-lactic units and having a relative viscosity of about <NUM>/dL with <NUM>% of a PDLA having a weight average molecular weight of <NUM>,<NUM>/mol (GPC, relative to polystyrene). Pellets of the starting resins are melted in a twin-screw extruder to a melt temperature, extruded through a strand die into a water bath where the strands are immediately quenched to a temperature below <NUM>. The strands are chopped into spherical beads having a diameter of about <NUM> to <NUM>.

PLA Blend <NUM> is made in the same manner, but at a weight ratio of <NUM>% PLLA and <NUM>% PDLA.

Example <NUM> is made by expanding PLA Blend <NUM>. Example <NUM> is made by expanding PLA Blend <NUM>. Comparative Sample A is made by expanding pellets of the PLLA.

In each case the beads are expanded as follows: A <NUM>-L autoclave is filled with <NUM> room temperature water. <NUM> of the beads and <NUM> of a suspension aid are added. The autoclave is sealed and pressured to <NUM> MPa gauge with carbon dioxide at room temperature. The contents of the sealed autoclave are then heated to <NUM>-<NUM> and held at that temperature for <NUM> minutes to saturate the beads with carbon dioxide and partially crystallize them. The autoclave is then depressurized to atmospheric pressure over several seconds. Cooling to room temperature takes place simultaneously with the depressurization.

In Example <NUM>, the beads expand <NUM> to <NUM> times their original volume. In Example <NUM>, the beads expand to about <NUM> times their original volume. SEM micrographs of the expanded Examples <NUM> and <NUM> reveal a uniform, regular cell structure. Comparative Sample A expands to <NUM> to <NUM> times its original volume. It has a highly irregular cell structure characterized by many large cells.

DSC thermographs are taken of the expanded beads. Example <NUM> is found to contain both PLA stereocomplex crystals (about <NUM> J/g) and about <NUM> J/g of PLLA homocrystals. Its total crystallinity is about <NUM>%.

Example <NUM> is found to contain about <NUM> J/g of PLA stereocomplex crystals and about <NUM> J/g of PLLA homocrystals. Total crystallinity is about <NUM>%.

Comparative Sample A contains only PLA homocrystals. Total crystallinity is about <NUM>%.

Claim 1:
A process for making expanded poly(lactide) beads, comprising:
(a) pressurizing unfoamed beads of a PLA resin blend having a crystallinity of no greater than <NUM> J/g as measured by differential scanning calorimetry with carbon dioxide to a superatmospheric pressure while maintaining the temperature at or below the <NUM>;
(b) heating the pressurized unfoamed beads to a temperature between <NUM> and <NUM> to at least partially crystallize the PLA resin blend to form carbon dioxide-saturated, partially crystallized, unfoamed beads; and then
(c) depressurizing the carbon-dioxide-saturated, partially crystallized, unfoamed beads such that the carbon dioxide at least partially vaporizes to expand the beads; and then
(d) simultaneously and/or after step (c), cooling the expanded beads to below <NUM>,
wherein the PLA resin blend includes:
i) a first PLA polymer containing at least <NUM>% L-lactic units, based on the total weight of the first PLA polymer;
ii) a second PLA polymer containing at least <NUM>% D-lactic units based on the total weight of the second PLA polymer;
the first and second PLA copolymers being present in the PLA resin blend at a weight ratio of <NUM>:<NUM> to <NUM>:<NUM> or <NUM>:<NUM> to <NUM>:<NUM>.