Flushable poly(ethylene oxide) films with balanced mechanical properties

Abstract

Flushable film compositions and methods of making flushable film compositions are disclosed. The film compositions comprise poly(ethylene oxide). The modification of the poly(ethylene oxide) can be accomplished by grafting polar vinyl monomers, such as poly(ethylene glycol) methacrylate and 2-hydroxyethyl methacrylate, onto poly(ethylene oxide). The modified poly(ethylene oxide) has improved melt processability and is used to melt process thin poly(ethylene oxide) films of less than 5 mils in thickness. Films can be produced that have balanced mechanical properties and that are water-dispersible and flushable.

Description

FIELD OF THE INVENTION

[0001] The present invention is directed to poly(ethylene oxide) films. More particularly, the present invention is directed to films comprising a modified poly(ethylene oxide) composition. In a preferred embodiment, the films comprise poly(ethylene oxide) modified by grafting polar, vinyl monomer(s) onto a poly(ethylene oxide).

BACKGROUND OF THE INVENTION

[0002] Disposable personal care products such as pantiliners, diapers, tampons etc. are a great convenience. Such products provide the benefit of one time, sanitary use and are convenient because they are quick and easy to use. However, disposal of many such products is a concern due to limited landfill space. Incineration of such products is not desirable because of increasing concerns about air quality and the costs and difficulty associated with separating such products from other disposed, non-incineratable articles. Consequently, there is a need for disposable products which may be quickly and conveniently disposed of without dumping or incineration.

[0003] It has been proposed to dispose of such products in municipal and private sewage systems. Ideally, such products would be flushable and degradable in conventional sewage systems. Products suited for disposal in sewage systems and that can be flushed down conventional toilets are termed “flushable”. Disposal by flushing provides the additional benefit of providing a simple, convenient and sanitary means of disposal. Personal care products must have sufficient strength under the environmental conditions in which they will be used and be able to withstand the elevated temperature and humidity conditions encountered during use and storage yet still lose integrity upon contact with water in the toilet. Therefore, a water-disintegratable material which is thermally processable into thin films having mechanical integrity when dry is desirable.

[0004] Due to its unique interaction with water and body fluids, poly(ethylene oxide) (hereinafter PEO) is currently being considered as a component material in films and flushable products. PEO,

—(CH2CH2O)n—

[0005] is a commercially available water-soluble polymer that can be produced from the ring opening polymerization of the ethylene oxide, 1

[0006] Because of its water-soluble properties, PEO is desirable for flushable applications. However, there is a dilemma in utilizing PEO in thermal processes. Low molecular weight PEO resins have desirable melt viscosity and melt pressure properties for extrusion processing but have limited solid state properties when melt processed into structural articles such as thin films. An example of a low molecular weight PEO resin is POLYOX® WSR N-80 PEO which is commercially available form Union Carbide. POLYOX® WSR N-80 PEO has an approximate molecular weight of 200,000 g/mol as determined by Theological measurements. As used herein, low molecular weight PEO compositions are defined as PEO compositions with an approximate molecular weight of less than and including about 200,000 g/mol.

[0007] In personal care product industry, flushable thin-gauged films are desired for commercial viability and ease of disposal. The low melt strength and low melt elasticity of low molecular weight PEO limit the ability of the low molecular weight PEO to be drawn into films having a thickness of less than about 1.25 mil. Although low molecular weight PEO can be thermally processed into films, thin-gauged films of less than about 1 mil in thickness cannot be obtained due to the lack of melt strength and melt elasticity of the low molecular weight PEO. Efforts have been attempted to improve the processability of PEO by blending the PEO with a second polymer, a copolymer of ethylene and acrylic acid, in order to increase the melt strength. The PEO/ethylene acrylic acid copolymer blend was able to be processed into films of about 1.2 mils in thickness. However, the blend and resulting film are not water-soluble, especially at high levels of ethylene acrylic acid copolymer, i.e. about 30 weight percent ethylene acrylic acid copolymer. More importantly, thin films made from low molecular weight PEO are too weak and brittle to be useful for personal care applications. Low molecular weight PEO films have low tensile strength, low ductility, and are too brittle for commercial use. Further, films produced from low molecular weight PEO and blends containing low molecular weight PEO become brittle during storage at ambient conditions. Such films shatter and are not suited for commercial applications.

[0008] High molecular weight PEO resins are expected to produce films with improved mechanical properties compared to films produced from low molecular weight PEO. An example of a high molecular weight PEO is POLYOX® WSR 12K PEO which is commercially available from Union Carbide. POLYOX® WSR 12K PEO has a reported approximate molecular weight of 1,000,000 g/mol as determined by rheological measurements. As used herein, high molecular weight PEO compositions are defined as PEO compositions with an approximate molecular weight of greater than and including about 300,000 g/mol.

[0009] High molecular weight PEOs have poor processability due to their high melt viscosities and poor melt drawabilities. Melt pressure and melt temperature are significantly elevated during melt extrusion of high molecular weight PEO. During extrusion of high molecular weight PEO, severe melt fracture is observed. Only very thick sheets can be made from high molecular weight PEO. High molecular weight PEO cannot be thermally processed into films of less than about 3-4 mil in thickness. High molecular weight PEO suffers from severe melt degradation during extrusion processes. This results in breakdown of the PEO molecules and formation of bubbles in the extrudate. The inherent deficiencies of high molecular weight PEO make it impossible to utilize high molecular weight PEO in film applications. Even the addition of high levels of plasticizer to the high molecular weight PEOs does not improve the melt processability of high molecular weight PEOs sufficiently to allow the production of thin films without melt fracture and film breakage occurring. Further, the use of plasticizer causes latent problems due to migration of the plasticizer to the film surface.

[0010] Thus, currently available PEO resins are not practical for melt extrusion, thin films and for personal care applications. What is needed in the art, therefore, is a means to overcome the difficulties in melt processing of currently available PEO resins into films.

SUMMARY OF THE INVENTION

[0011] To overcome the disadvantages of the prior art, this invention teaches a method of grafting polar functional groups onto PEO in the melt. Modification of PEO reduces the melt viscosity, melt pressure and melt temperature. Additionally, modification of high molecular weight PEO in accordance with the invention eliminates the severe melt fracture observed when extruding unmodified high molecular weight PEO. Films as thin as 0.3 to 0.5 mils can be processed using conventional processing techniques. Commercially available PEO resins cannot be made into thin films using conventional thermal processing techniques. The thin, flushable PEO films are useful as components in personal care products and cold water-soluble packaging materials.

[0012] The present invention is directed to films comprising modified PEO compositions. More particularly, the present invention relates to films comprising modified PEO which have improved processability over conventional PEO resins, thereby allowing the modified PEO to be thermally extruded into thinner films. Preferably, the modification of the PEO is achieved by grafting a polar vinyl monomer, such as a poly(ethylene glycol) methacrylate or 2-hydroxyethyl methacrylate, onto the PEO. The grafting is accomplished by mixing the PEO, monomer(s) and initiator and applying heat.

[0013] The modification of the PEO allows thin gauged films to be thermally extruded from the modified PEO and produces films with balanced mechanical properties that are approximately equal in the machine direction and cross direction. Such balanced mechanical properties are unusual for films that are uniaxially extruded during film making and thus possess directional properties. Additionally, the overall tensile properties of the thin films are excellent, possessing high elongation at break, tensile strength, and energy to break.

[0014] As used herein, the term “graft copolymer” means a copolymer produced by the combination of two or more chains of constitutionally or configurationally different features, one of which serves as a backbone main chain, and at least one of which is bonded at some point(s) along the backbone and constitutes a side chain. As used herein, the term “grafting” means the forming of a polymer by the bonding of side chains or species at some point(s) along the backbone of a parent polymer. (See Sperling, L. H., Introduction to Physical Polymer Science 1986 pp. 44-47 which is incorporated by reference herein in its entirety.)

[0015] Currently available PEO resins are unsuitable for film applications. Low molecular weight PEO resins, less than 300,000 g/mol can be processed into films with thickness of about 1 to 2 mil but not any thinner due to the low melt strengths of the low molecular weight resins. Films produced from low molecular weight PEO resins have strain values only up to 300 percent and stress values only up to 13 MPa in the machine direction. In the cross direction, the films produced from low molecular weight PEO resins have strain values of less than 75 percent and stress values only up to 12 MPa . In addition to poor tensile properties, the films produced from low molecular weight PEO resins have extremely poor tear resistance and exhibit adverse decreases in properties with aging. Although films produced from unmodified high molecular weight PEO resins have better tensile properties, they can only be processed into thick sheets of thicknesses greater than about 7 mil. Even at these thickness, the films produced with unmodified high molecular weight PEO have very weak cross direction properties and very low tear resistance. Thus, films produced from unmodified PEO resins are not desirable for films and personal care applications.

[0016] In contrast, modification of PEO resins with starting molecular weights of between about 300,000 g/mol to about 8,000,000 g/mol produces PEO compositions which be drawn into films with thicknesses of less than 0.5 mil. Modification of PEO resins with starting molecular weights of 500,000 g/mol to about 8,000,000 g/mol are desirable and the modification of PEO resins with starting molecular weights of 800,000 g/mol to about 6,000,000 are most desirable.

[0017] Films in accordance with the invention have better softness and greater clarity than films drawn from conventional, unmodified low molecular weight PEO resins. Thermal processing of films from modified PEO also produces films with improved mechanical properties over films similarly processed from unmodified PEO resins.

[0018] These and other features and advantages of the present invention will become apparent after a review of the following detailed description of the disclosed embodiments.

BRIEF DESCRIPTION OF THE FIGURES

[0019] FIG. 1 compares the melt rheology curve of an unmodified PEO resin of 600,000 g/mol approximate molecular weight, Example 1, and the melt rheology curves of PEO compositions modified from the 600,000 g/mol molecular weight PEO resin, Examples 2-5.

[0020] FIG. 2 compares the melt rheology curve of unmodified PEO resin of 1,000,000 g/mol approximate molecular weight, Example 6, and the melt rheology curves of PEO compositions modified from the 1,000,000 g/mol molecular weight PEO resin, Examples 7-10.

[0021] FIG. 3 displays the results of Fourier transform infrared spectra analysis of films from an unmodified PEO of 600,000 g/mol approximate molecular weight, Example 1; a PEO of an initial approximate molecular weight of 600,000 g/mol modified with 4.9 weight % HEMA and 0.28 weight % initiator, Example 3; and a PEO of an initial approximate molecular weight of 600,000 g/mol modified with 4.9 weight % PEG-MA and 0.32 weight % initiator, Example 5.

[0022] FIG. 4 compares the melt rheology curve of an unmodified PEO resin of 600,000 g/mol approximate molecular weight, Example 1, and the melt rheology curves of PEO compositions modified from the PEO resin having an initial approximate molecular weight of 600,000 g/mol with low monomer and initiator levels, Examples 11-13.

[0023] FIG. 5 compares the melt rheology curve of an unmodified PEO of 300,000 g/mol approximate molecular weight, Example 14, and the melt rheology curves of PEO compositions modified from the PEO resin having an initial approximate molecular weight of 300,000 g/mol, Examples 15 and 16.

[0024] FIG. 6 compares the melt rheology curve of an unmodified PEO of 400,000 g/mol approximate molecular weight, Example 17, and the melt rheology curves of PEO compositions modified from the PEO having an initial approximate molecular weight of 400,000 g/mol, Examples 18 and 19.

DETAILED DESCRIPTION

[0025] Improved films can be melt processed using conventional methods from commercially available PEO resins when modified in accordance with this invention. The PEO resins useful for modification include, but are not limited to, PEO resins having initial reported approximate molecular weights ranging from about 300,000 g/mol to about 8,000,000 g/mol as determined by Theological measurements. Such PEO resins are commercially available from Union Carbide Corporation and are sold under the trade designations POLYOX® WSR N-750 and POLYOX® UCARFLOC® Polymer 309, respectively. Modification of PEO resins with starting molecular weights from about 500,000 g/mol to about 8,000,000 g/mol are more desirable and modification of PEO resins with starting molecular weights from about 800,000 g/mol to about 6,000,000 are most desirable. Commercially available resins within the desirable ranges include but are not limited to POLYOX® WSR N-205 and POLYOX® WSR N-12K.

[0026] Other PEO resins available from Union Carbide Corporation within the above approximate molecular weight ranges are sold under the trade designations WSR N-750, WSR N-3000, WSR-3333, WSR-205, WSR-N-12K, WSR-N-60K, WSR-301, WSR Coagulant, WSR-303. (See POLYOX®: Water Soluble Resins, Union Carbide Chemicals & Plastic Company, Inc., 1991 which is incorporated by reference herein in its entirety.) Both PEO powder and pellets of PEO can be used in this invention since the physical form of PEO does not affect its behavior in the melt state for grafting reactions. This invention has been demonstrated by the use of PEO in the form of powder as supplied by Union Carbide. However, the PEO resins to be modified may be obtained from other suppliers and in other forms, such as pellets. The PEO resins and modified compositions may optionally contain various additives such as plasticizers, processing aids, rheology modifiers, antioxidants, UV light stabilizers, pigments, colorants, slip additives, antiblock agents, etc. which may be added before or after modification.

[0027] A variety of polar vinyl monomers may be useful in the practice of this invention. Monomer as used herein includes monomers, oligomers, polymers, mixtures of monomers, oligomers and/or polymers, and any other reactive chemical species which is capable of covalent bonding with the parent polymer, PEO. Ethylenically unsaturated monomers containing a polar functional group, such as hydroxyl, carboxyl, amino, carbonyl, halo, thiol, sulfonic, sulfonate, etc. are appropriate for this invention and are desirable. Desirable ethylenically unsaturated monomers include acrylates and methacrylates. Particularly desirable ethylenically unsaturated monomers containing a polar functional group are 2-hydroxyethyl methacrylate (hereinafter HEMA) and poly(ethylene glycol) methacrylates (hereinafter PEG-MA). A particularly desirable poly(ethylene glycol) methacrylate is poly(ethylene glycol) ethyl ether methacrylate. However, it is expected that a wide range of polar vinyl monomers would be capable of imparting the same effects as HEMA and PEG-MA to PEO and would be effective monomers for grafting. The amount of polar vinyl monomer relative to the amount of PEO may range from about 0.1 to about 20 weight percent of monomer to the weight of PEO. Preferably, the amount of monomer should exceed 0.1 weight percent in order to sufficiently improve the processability of the PEO. More preferably, the amount of monomer should be at the lower end of the above disclosed range, 0.1 to 20 weight percent, in order to decrease costs.

[0028] This invention has been demonstrated in the following Examples by the use of PEG-MA and HEMA as the polar vinyl monomers. Both the PEG-MA and HEMA were supplied by Aldrich Chemical Company. The HEMA used in the Examples was designated Aldrich Catalog number 12,863-5 and the PEG-MA was designated Aldrich Catalog number 40,954-5. The PEG-MA was a poly(ethylene glycol) ethyl ether methacrylate having a number average molecular weight of approximately 246 grams per mol. PEG-MA with a number average molecular weight higher or lower than 246 g/mol are also applicable for this invention. The molecular weight of the PEG-MA can range up to 50,000 g/mol. However, lower molecular weights are desirable for faster grafting reaction rates. The desirable range of the molecular weight of the monomers is from about 246 to about 5,000 g/mol and the most desirable range is from about 246 to about 2,000 g/mol. Again, it is expected that a wide range of polar vinyl monomers as well as a wide range of molecular weights of monomers would be capable of imparting similar effects to PEO resins and would be effective monomers for grafting and modification purposes.

[0029] A variety of initiators may be useful in the practice of this invention. If grafting is achieved by the application of heat, as in a reactive-extrusion process, it is preferable that the initiator generates free radicals through the application of heat. Such initiators are generally referred to as thermal initiators. In order for the initiator to function as a useful source of radicals for grafting, the initiator should be commercially and readily available, stable at ambient or refrigerated conditions, and generate radicals at reactive-extrusion temperatures.

[0030] Compounds containing an O—O, S—S, or N═N bond may be used as thermal initiators. Compounds containing O—O bonds, peroxides, are commonly used as initiators for polymerization. Such commonly used peroxide initiators include: alkyl, dialkyl, diaryl and arylalkyl peroxides such as cumyl peroxide, t-butyl peroxide, di-t-butyl peroxide, dicumyl peroxide, cumyl butyl peroxide, 1,1 -di-t-butyl peroxy-3,5,5-trimethylcyclohexane, 2,5-dimethyl-2,5-di(t-butylperoxy)hexane, 2,5-dimethyl-2,5-bis(t-butylperoxy)hexyne-3 and bis(a-t-butyl peroxyisopropylbenzene); acyl peroxides such as acetyl peroxides and benzoyl peroxides; hydroperoxides such as cumyl hydroperoxide, t-butyl hydroperoxide, p-methane hydroperoxide, pinane hydroperoxide and cumene hydroperoxide; peresters or peroxyesters such as t-butyl peroxypivalate, t-butyl peroctoate, t-butyl perbenzoate, 2,5-dimethylhexyl-2,5-di(perbenzoate) and t-butyl di(perphthalate); alkylsulfonyl peroxides; dialkyl peroxymonocarbonates; dialkyl peroxydicarbonates; diperoxyketals; ketone peroxides such as cyclohexanone peroxide and methyl ethyl ketone peroxide. Additionally, azo compounds such as 2,2′-azobisisobutyronitrile abbreviated as AIBN, 2,2′-azobis(2,4-dimethylpentanenitrile) and 1,1′-azobis(cyclohexanecarbonitrile) may be used as the initiator. This invention has been demonstrated in the following Examples by the use of a liquid, organic peroxide initiator available from Elf Atochem North America, Inc. of Philadelphia, Pa., sold under the trade designation LUPERSOL® 101. LUPERSOL® 101 is a free radical initiator and comprises 2,5-dimethyl-2,5-di(t-butylperoxy) hexane. Other initiators and other grades of LUPERSOL® initiators may also be used, such as LUPERSOL® 130.

[0031] A variety of reaction vessels may be useful in the practice of this invention. The modification of the PEO can be performed in any vessel as long as the necessary mixing of PEO, the monomer and the initiator is achieved and enough thermal energy is provided to effect grafting. Preferably, such vessels include any suitable mixing device, such as Bradender Plasticorders, Haake extruders, single or multiple screw extruders, or any other mechanical mixing devices which can be used to mix, compound, process or fabricate polymers. In a preferred embodiment, the reaction device is a counter-rotating twin-screw extruder, such as a Haake extruder available from Haake, 53 West Century Road, Paramus, N.J. 07652 or a co-rotating, twin-screw extruder, such as a ZSK-30 twin-screw, compounding extruder manufactured by Werner & Pfleiderer Corporation of Ramsey, New Jersey. It should be noted that a variety of extruders can be used to modify the PEO in accordance with the invention provided that mixing and heating occur.

[0032] The ZSK-30 extruder allows multiple feeding, has venting ports and is capable of producing modified PEO at a rate of up to 50 pounds per hour. If a higher rate of production of modified PEO is desired, a commercial-scale ZSK-58 extruder manufactured by Werner & Pfleiderer may be used. The ZSK-30 extruder has a pair of co-rotating screws arranged in parallel with the center to center distance between the shafts of the two screws at 26.2 mm. The nominal screw diameters are 30 mm. The actual outer diameters of the screws are 30 mm and the inner screw diameters are 21.3 mm. The thread depths is 4.7 mm. The lengths of the screws are 1328 mm and the total processing section length was 1338 mm.

[0033] This ZSK-30 extruder had 14 processing barrels, which are numbered consecutively 1 to 14 from the feed barrel to the die for the purposes of this disclosure. The first barrel, barrel #1, received the PEO and was not heated but cooled by water. The other thirteen barrels were heated. The monomer, HEMA or PEG-MA, was injected into barrel #5 and the initiator was injected into barrel #6. Both the monomer and the initiator were injected via a pressurized nozzle injector, also manufactured by Werner & Pfleiderer. The order in which the PEO, monomer and initiator are added is not critical and the initiator and monomer may be added at the same time or in reverse order. However, the order used in the following Examples is preferred. The die used to extrude the modified PEO strands has four openings of 3 mm in diameter which are separated by 7 mm. The modified PEO strands were extruded onto an air-cooling belt and then pelletized. The extruded PEO melt strands were cooled by air on a fan-cooled conveyor belt 20 feet in length.

EXAMPLES

[0034] Examples 1-21 have been demonstrated by the use of the ZSK-30 extruder as detailed above. For the following Examples, the extruder barrel temperatures were set at 180°C. for all of the seven zones of the extruder. The screw speed was set at 300 rpm. The PEO resin was fed into the extruder with a K-Tron gravimetric feeder at a throughput of 20 pounds per hour. The selected monomer and the initiator were fed by Eldex pumps into the extruder at the various rates reported in Table 1. The extrusion conditions, actual barrel temperatures for the seven zones of the extruder, polymer melt temperature, melt pressure, and percent torque, were monitored during the reactive-extrusion for each of the twenty Examples and are reported in Table 2. The modified PEO strands were cooled by air on a fan-cooled conveyor belt 20 feet in length. The solidified strands were then pelletized in a Conair pelletizer available from Conair of Bay City, Mich.

[0035] The weight percentages of the components used in the Examples were calculated relative to the weight of the base resin, PEO, unless otherwise indicated. In the following Examples, five different approximate molecular weight PEO resins were used and tested: POLYOX® WSR 205 PEO having a reported initial approximate molecular weight of 600,000 g/mol was used in Examples 1-5, 11-13 and 20; POLYOX® WSR 12K PEO having a reported initial approximate molecular weight of 1,000,000 g/mol was used in Examples 6-10; POLYOX® WSR N-750 PEO having a reported initial approximate molecular weight of 300,000 g/mol was used in Examples 14-16; POLYOX® WSR N-3000 PEO having a reported initial approximate molecular weight of 400,000 g/mol was used in Examples 17-19; and POLYOX® WSR N-80 PEO having a reported initial approximate molecular weight of 200,000 g/mol was used in Example 21.

[0036] Additionally, two monomers, HEMA and PEG-MA, and several levels of monomer addition, ranging from as low as 0.80 weight percent to as high as 5.00 weight percent of monomer to weight of PEO resin, were used and tested in the Examples. The relative amount of initiator used in the Examples varied from 0.12 to 0.32 weight percent of initiator to weight of PEO resin. The trade designation of the PEO, the monomer, and the amounts of PEO, monomer and initiator used in the Examples are listed in Table 1. Examples 1 represents a control sample of unmodified PEO of initial approximate molecular weight of 600,000 g/mol. Example 6 represents a control sample of unmodified PEO of initial approximate molecular weight of 1,000,000 g/mol. Example 14 represents a control sample of unmodified PEO of initial approximate molecular weight of 300,000 g/mol. Example 17 represents a control sample of unmodified PEO of initial approximate molecular weight of 400,000 g/mol. Example 20 represents a comparative example of PEO of initial approximate molecular weight of 600,000 g/mol modified only by the addition of initiator without monomer. And, Example 21 represents a comparative example of unmodified PEO of initial approximate molecular weight of 200,000 g/mol.

[0037] Although the invention has been demonstrated by the Examples, it is understood that the PEO, the polar vinyl monomer, the initiator and the conditions can be varied depending on the type of modified PEO composition and properties desired.

TABLE 1
Components and Process Conditions of the Examples
Exam-		Resin		Monomer		Initiator
ple		Rate		Rate		Rate
Number	Resin	(lb/hr)	Monomer	(lb/hr)	Initiator	(lb/hr)
1	POLYOX	20	—	0	—	0
	205
2	POLYOX	20	HEMA	0.60	L101	0.048
	205
3	POLYOX	20	HEMA	0.98	L101	0.056
	205
4	POLYOX	20	PEG-MA	0.62	L101	0.042
	205
5	POLYOX	20	PEG-MA	0.98	L101	0.064
	205
6	POLYOX	20	—	0	—	0
	12K
7	POLYOX	20	HEMA	0.70	L101	0.052
	12K
8	POLYOX	20	HEMA	1.00	L101	0.062
	12K
9	POLYOX	20	PEG-MA	0.70	L101	0.052
	12K
10	POLYOX	20	PEG-MA	1.00	L101	0.064
	12K
11	POLYOX	20	HEMA	0.16	L101	0.038
	205
12	POLYOX	20	HEMA	0.22	L101	0.032
	205
13	POLYOX	20	HEMA	0.36	L101	0.038
	205
14	POLYOX	20	—	0	—	0
	N-750
15	POLYOX	20	HEMA	0.20	L101	0.034
	N-750
16	POLYOX	20	HEMA	0.62	L101	0.037
	N-750
17	POLYOX	20	—	0	—	0
	N-3000
18	POLYOX	20	HEMA	0.22	L101	0.039
	N-3000
19	POLYOX	20	HEMA	0.66	L101	0.034
	N-3000
20	POLYOX	20	—	0	L101	0.024
	205
21	POLYOX	25	—	0	—	0
	N-80

[0038] The actual processing conditions during extrusion of the unmodified and modified PEO Examples listed in Table 1 were recorded and are reported in Table 2. Two extrusion runs were made for each of the reactive-extrusion Examples, 2-5 and 7-10, and are reported as second values 2′-5′and 7′-10′, respectively. T1 through T7 represent the actual barrel temperatures of the seven zones of the extruder during the extrusion of the Examples. T1 corresponds to barrels #2 and #3, T2 corresponds to barrels #4 and #5, T3 corresponds to barrels #6 and #7, T4 corresponds to barrels #8 and #9, T5 corresponds to barrels #10 and #11, T6 corresponds to barrels # 12 and #13, and T7 corresponds to barrel #14, the die. Barrel #1 was not heated and remained at ambient conditions.

TABLE 2
Extrusion Conditions Observed
Example	Screw Speed	T1	T2	T3	T4	T5	T6	T7	Tmelt	Pmelt	Torque
Number	(rpm)	(° C.)	(° C.)	(° C.)	(° C.)	(° C.)	(° C.)	(° C.)	(° C.)	(psi)	(%)
N-80	300	171	180	179	180	180	180	179	192	300-400	30-35
1	300	174	181	179	180	182	180	186	204	1770-1810	32-36
2	300	175	180	180	181	180	179	186	198	970-1130	29-31
2′	300	175	180	180	181	180	179	186	198	970-1130	29-31
3	300	177	180	182	182	180	183	176	189	920-1120	28-31
3′	300	185	180	179	180	181	180	175	189	940-1140	29-31
4	300	180	181	180	180	182	179	180	192	680-760	25-29
4′	300	178	180	180	179	182	180	182	192	670-750	25-29
5	300	175	180	180	181	181	179	180	192	690-860	27-30
5′	300	178	179	181	180	181	180	181	192	670-840	28-30
6	300	166	181	183	182	179	182	192	209	1540-1660	40-44
7	300	182	180	179	181	181	180	178	190	990-1080	28-30
7′	300	176	180	179	180	180	181	178	190	990-1070	28-30
8	300	173	180	182	180	180	181	173	186	1140-1200	31-33
8′	300	176	178	178	180	181	181	181	187	1010-1150	29-31
9	300	177	180	180	179	179	180	179	191	640-870	26-29
9′	300	181	180	182	182	181	181	179	191	620-850	27-30
10	300	174	179	178	180	182	180	177	188	710-890	30-32
10′	300	175	180	178	182	179	183	171	183	690-800	28-30
11	300	177	180	180	181	180	181	190	200	713	28
12	300	179	181	180	181	179	180	191	202	800	28
13	300	177	180	181	180	180	180	192	202	899	30
14	300	178	180	180	180	180	181	184	198	1379	33
15	300	180	181	180	180	180	180	192	202	644	26
16	300	180	180	180	180	180	180	194	204	628	28
17	300	180	181	180	180	180	180	182	200	1659	33
18	300	181	181	180	180	181	180	190	201	644	26
19	300	179	180	179	180	180	180	190	201	779	27
20	300	179	180	181	181	180	180	190	198	313	26

[0039] When the unmodified high molecular weight PEO resins, Examples 1 and 6, were extruded under the above processing conditions, the melt pressure during extrusion of the unmodified PEO resins was very high. The melt pressure of the unmodified 600,000 molecular weight PEO of Example 1 was 1770-1810 psi and the melt pressure of the unmodified 1,000,000 molecular weight PEO of Example 6 was 1540-1660 psi. Intense shear heating in the extruder caused the melt temperatures of the unmodified PEO resins to significantly increase, by 24 and 29°C., over the extruder barrel temperature of 180°C. The melt temperature increased to 204°C. during the extrusion of the unmodified 600,000 molecular weight PEO of Example 1 and increased to 209°C. during the extrusion of unmodified 1,000,000 molecular weight PEO of Example 6. These factors contributed to severe melt fracture and thermal degradation during the extrusion of unmodified high molecular weight PEO resins resulting in the production of undesirable strands. The undesirable strands were characterized by wider strands than intended, broken strands, bead-connected strands and rough strands.

[0040] At higher screw speed, 400 rpm, and lower throughput, approximately 5-10 pounds per hour, the melt fracture was reduced somewhat. However, under these conditions, the degradation of PEO appeared to be even more severe with significantly more bubbles evolving inside the strands as they exited the die due to the increase in residence time in the extruder. The exiting polymer strands had a foam-like appearance which is undesirable. Additionally, extruder setting of 5 pounds per hour is an extremely low setting and is not practical for commercial applications.

[0041] For the grafting process of modified high molecular weight PEO resins under the same conditions, Examples 2-5 and 7-10, melt fracture was not visible producing strands with smooth surfaces. Melt temperatures were significantly reduced as shown in Table 2. The melt temperatures grafting HEMA and PEG-MA to POLYOX® WSR 205 PEO powders of Examples 2-5 were in the range of 189 to 198°C., a reduction of 6 to 15°C. compared to the melt temperature of the same PEO resin without grafting of Example 1 at 204°C. The strands also appeared to undergo less degradation, as the polymer strands contained less bubbles and were significantly smoother as they exited the die. The melt temperatures for the grafting of HEMA or PEG-MA to POLYOX( WSR 12K PEO, Examples 7-10, were also substantially reduced, down to the range of 183 to 191°C. compared to 209°C. without grafting, Example 6, a reduction of 18 to 26°C. This reduction in the melt temperature also apparently reduced the degradation inside the extruder, as the polymer strands contained less bubbles as they exited the die compared to the same PEO resin without grafting.

[0042] Examples 14 and 17 showed some melt fracture and thermal degradation, although not as bad as observed for Examples 1 and 6. The most obvious problems with extrusion of Examples 14 and 17 were the elevated melt pressure, 1379 and 1659 psi, and increased torque, 33 and 33 %. For the modified PEO of Examples 15, 16, 18, and 19, the melt pressure was reduced by greater than 50% compared to the unmodified PEO of the same starting molecular weight and the torque was reduced slightly for each, from 33% down to 26-28%. The melt temperature was not reduced for these Examples.

[0043] Example 20 , POLYOX® WSR 205 PEO modified by the addition of initiator only, showed a remarkable change in melt extrusion compared to Example 1, the unmodified POLYOX® WSR 205 PEO. Melt pressure was reduced from 1770-1890 psi to 313 psi. Torque was reduced from 32-36% to 26%. And, melt temperature was reduced from 204°C. to 198°C. These changes were expected to have resulted primarily from chemical degradation of PEO in the presence of the free radical initiator, the same mechanism of chemical degradation that occurred for Examples 2-5, 7-13, 15, 16, 18 and 19. However, because Example 20 was modified without the use of a monomer, the preferential reaction was crosslinking as opposed to grafting. The resulting material was filled with crosslinked gel particles, some as large as 0.5 to 1 mm. The gels rendered the resulting PEO useless.

[0044] Crosslinked gels were not observed, or were significantly reduced in both size and number, for the modified PEOs of Examples 2-5, 7-13, 15-16 and 18-19. It is believed that the initiator preferentially reacted with the monomer causing grafting and chain scission instead of crosslinking. The modified PEOs of Examples 2-5, 7-13, 15-16 and 18-19 have beneficial 5 properties for thermal processing into thin films and are useful for producing commercially useful articles, such as disposable personal care products

[0045] In general, the modified PEO of Examples 2-5, 7-13, 15-16 and 18-19 exhibited reduced melt temperature and melt pressure compared to the corresponding unmodified high molecular weight PEO. This allows for easier and more economical processing of PEO. The appearance of extrusion-processed PEO modified in accordance with this invention is greatly improved compared to unmodified high molecular weight PEO. Strands extruded from PEO modified in accordance with this invention are much smoother and much more uniform compared to strands extruded from the same initial unmodified PEO. The smoothness and uniformity of strands extruded from the modified PEO of Example 2-5, 7-13, 15-16 and 18-19 is comparable with the smoothness and uniformity of strands extruded from much lower approximate molecular weight PEO but with the greater mechanical properties of higher molecular weights.

[0046] GPC Analysis

[0047] The number-average molecular weight (Mn), the weight-average molecular weight (Mw), the z-average molecular weight (Mz), and the polydispersity index (Mw/Mn) of the Examples were determined by gel permeation chromatography (hereinafter GPC). The GPC analysis was conducted by American Polymer Standards Corporation of Mentor, Ohio, for the Examples of Table 1 and also for unmodified and unextruded POLYOX® WSR 205 and POLYOX® WSR 12K PEO powders. The results of the GPC analysis are reported in Table 3. The first two rows of Table 3 report the results of the GPC analysis for the POLYOX® WSR 205 and POLYOX® WSR 12K PEO powders before extrusion. Examples 1 and 6 are the results for the GPC analysis of the unmodified and extruded POLYOX® WSR 205 and POLYOX® WSR 12K PEOs of Examples 1 and 6 of Table 1, respectively. That is Examples 1 and 6 represent the extrustion of the above POLYOX® PEO resins at 180°C., 300 rpm and 20 pounds per hour in the ZSK-30 extruder without the additions of either monomer or initiator. The other Example numbers correspond to the respective Example numbers of 1.

TABLE 3
Molecular Weights and Polydispersity Indices
Example	Mn	Mw	Mz	Mw/Mn
POLYOX 205	77,400	1,000,000	6,560,000	12.92
POLYOX 12K	56,000	1,120,000	7,980,000	20.00
1	46,500	582,000	4,470,000	12.52
2	44,200	227,900	1,100,000	5.16
3	48,800	224,700	1,100,000	4.60
4	44,100	179,400	780,000	4.07
5	47,200	210,500	940,000	4.46
6	47,000	671,800	6,060,000	14.29
7	55,800	248,100	1,140,000	4.45
8	57,800	279,800	1,340,000	4.84
9	45,900	211,600	1,650,000	4.61
10	52,400	213,200	1,500,000	4.07

[0048] Significant reductions in molecular weights and the polydispersity indices were observed after reactive-extrusion of PEO with the monomer and the initiator of Examples 2-5 and 7-10 compared to the unmodified, extruded PEO of Examples 1 and 6. Along with the changes in molecular weight and the polydispersity index, a vast improvement in processability was observed. The most remarkable change in molecular weight distribution is observed in the reduction of the polydispersity index, which decreased from 12.52 for unmodified 600,000 g/mol PEO down to 4.07-5.16 for the same starting PEO modified in accordance with the invention and from 14.29 for unmodified 1,000,000 g/mol PEO down to 4.07-4.84 for the same starting PEO modified in accordance with the invention.

[0049] GPC analysis was not conducted for Examples 11-20: However, it is believed that the modified PEOs of Examples 11-13, 15-16 and 18-19 would have reduced weight average molecular weights and polydispersity indices compared to the corresponding unmodified PEOs.

[0050] DSC Analysis of Thermal Properties

[0051] The unmodified and modified PEO compositions of Examples 1-19 were analyzed by Differential Scanning Calorimetry (DSC) to determine differences in thermal properties between the modified and unmodified PEO resins. Example 20 was not analyzed by DSC because the PEO of Example 20 modified without the addition of a monomer was determined to not be useful for film-making. The melting points (Tm) and enthalpy of melting (ΔH) values for Examples 1-19 are reported in Table 4.

TABLE 4
Thermal Properties
Example
Number	Tm (° C.)	ΔH (J/g)
1	71.66	137.7
2	66.63	139.1
3	64.94	136.7
4	65.26	137.7
5	63.46	138.2
6	70.72	137.4
7	66.07	131.5
8	65.45	134.2
9	65.99	138.9
10	64.75	135.3
11	68.7	136.6
12	67.4	134.1
13	68.2	137.3
14	68.6	142.7
15	66.9	141.7
16	67.0	138.5
17	70.3	128.4
18	65.9	137.0
19	65.7	135.3
20	—	—

[0052] The melting points as determined by DSC of the modified PEOs of Examples 2-5 and 11-13 are lower than for the initial unmodified PEO of Example 1. Likewise, decreases in melting points were observed for the modified PEOs of Examples 7-10 compared to the initial unmodified PEO of Example 6, for the modified PEOs of Examples 15 and 16 compared to the unmodified PEO of Example 14, and for the modified PEOs of Examples 18 and 19 compared to the initial unmodified PEO of Example 17. These measured decreases in melting points for the modified PEOs are additional evidence of modification and are beneficial for thermal processing.

[0053] Melt Rheology

[0054] The melt rheology curves for unmodified, Example 1, and modified, Examples 2-5, 600,000 g/mol initial approximate molecular weight resin compositions are provided in FIG. 1. The melt rheology curves for unmodified, Example 6, and modified, Examples 7-10, 1,000,000 g/mol initial approximate molecular weight resin compositions are provided in FIG. 2. The melt rheology curves for unmodified, Example 1, and modified, Examples 11- 13, 600,000 g/mol initial approximate molecular weight resin compositions are provided in FIG. 4. The melt rheology curves for unmodified, Example 14, and modified, Examples 15 and 16, 300,000 g/mol initial approximate molecular weight resin compositions are provided in FIG. 5. The melt rheology curves for unmodified, Example 17, and modified, Examples 18 and 19, 400,000 g/mol initial approximate molecular weight resin compositions are provided in FIG. 6.

[0055] The results show that the melt viscosities of the modified PEOs are significantly reduced at low shear rates, 50-100 s−1, than the melt viscosities of the unmodified PEO. For example, the melt viscosity of unmodified 12K 1,000,000 approximate molecular weight PEO resin is 6,433 Pa*s at 50 s1and the melt viscosity of the same 12K resin modified with 5% PEG-MA and 0.32% L101 initiator is 2,882 Pa*s at the same shear rate, 50 s−1. This is a reduction in melt viscosity of 55%.

[0056] However, at higher shear rates, especially 500-2,000 s−1, the melt viscosities of the modified PEOs appear to be comparable or greater than the melt viscosities of the unmodified PEO. The melt viscosity of unmodified 12K resin was 275 Pa*s at 2,000 s−1 and the melt viscosity of the same 12K resin modified with 5% PEG-MA and 0.32% L101 initiator is 316 Pa*s at the same shear rate, 2,000 s−1. This is an increase in melt viscosity of 15%.

[0057] Overall, the slopes of the apparent viscosity versus shear rate decreased after modification.

[0058] NMR Analysis

[0059] The modified PEO of the Examples were analyzed by NMR spectroscopy. The results of this analysis confirmed that modified PEO did in fact contain grafted HEMA or PEG-MA units as side chains on the PEO backbone. By NMR spectroscopy, it was determined that the PEOs produced in the Examples 2-5, 7-13, 15-16 and 18-19 contained 0.65 to 2.58 percent grafted HEMA or PEG-MA side chains and 0 to 2.39 percent unreacted or ungrafted HEMA or PEG-MA.

[0060] Film-Casting Process

[0061] The unmodified, extruded PEO resins of Examples 1, 6, 14, 17, and 21 were pelletized and attempts were made to process these unmodified, extruded PEO resins into thin films. For the film processing, a Haake counter-rotating twin screw extruder was used with either a 4 inch or 8 inch wide film die attachment. The temperature profile for the heating zones of the Haake extruder was 170, 180, 180 and 190°C. The screw speed was adjusted in the range of 15-50 rpm depending on the film thickness attempted. Screw speed and wind-up speed were adjusted such that a film with a thickness within the range of 2-4 mil was produced. The process was allowed to stabilize so that film samples could be collected and observed. The extruded films were collected onto a chilled wind-up roll maintained at 15-20°C.

[0062] The Haake extruder that was used to cast the films from the PEO compositions was a counter-rotating, twin-screw extruder that contained a pair of custom-made, counter rotating conical screws with the 4 inch wide film die attachment. The Haake extruder comprised six sections as follows: Section 1 comprised a double-flighted forward pumping section having a large screw pitch and high helix angle. Section 2 comprised a double-flighted forward pumping section having a smaller screw pitch than Section 1. Section 3 comprised a double flighted forward pumping section having a smaller screw pitch than Section 2. Section 4 comprised a double-flighted and notched reverse pumping section where one complete flight was notched. Section 5 comprised a double flighted and notched forward pumping section containing two complete flights. And, Section 6 comprised a double flighted forward pumping section having a screw pitch intermediate that of Section 1 and Section 2. The extruder had a length of 300 millimeters. Each conical screw had a diameter of 30 millimeters at the feed port and a diameter of 20 millimeters at the die. Although the above extruder is described in detail, it should be noted that a variety of extruders and apparatuses can be used to process PEO films.

[0063] The unmodified, extruded PEO resins of Examples 1 and 6 were not able to be processed into thin films. Only thick sheets of thicknesses greater than about 7 mil were able to be produced. Even these thick sheets exhibited severe melt fracture. The rigidity and the melt fracture of the sheets gave the sheets an undesirable saw-like appearance with sharp “teeth” at the edges. Unmodified PEO resins are not able to be thermally processed into thin films under normal processing conditions.

[0064] The unmodified, extruded PEO resin of Example 14, having the lowest weight of the high molecular weight PEO resins tested, was the most processable of the unmodified, high molecular weight PEOs. However, the unmodified PEO of Example 14, the POLYOX® WSR N-750 PEO with an initial approximate molecular weight of 300,000 g/mol, was still very difficult to process into a uniform sheet of about 4 mil thickness. All attempts to process a film of less than 4 mil thickness, resulted in breaking, surging, and very uneven films. The minimum thickness film that was able to be processed from the unmodified 400,000 g/mol PEO of Example 17 was only about 5 mil.

[0065] The PEO composition of Example 20 could only be processed into a film of about 3-4 mil in thickness. However, the 3-4 mil films of the PEO of Example 20 contained numerous fish-eye holes. Even though the torque and pressure during the processing of films of Example 20 were low, the films contained so many gel inclusions that the gel inclusions propagated defects in the films. At less than 3-4 mil, the fish-eye holes would became so large that they interconnected and caused breaks in the films.

[0066] The only unmodified PEO that was able to be processed into a thin film was the low molecular weight, 200,000 g/mol, POLYOX® WSR N-80 PEO of Example 21. However, the films processed from the unmodified low molecular weight PEO of Example 21 possess insufficient mechanical properties, such as low tensile strength and low ductility, and also exhibit increased brittleness during storage under ambient conditions. Additionally, the film processed from the unmodified PEO of Example 21 contained undesirable, grainy particles. These deficiencies make unmodified PEO resins impractical for commercial use in personal care products.

[0067] In contrast, films were successfully processed from the extruded, modified PEO compositions. Films were melt processed from the PEO compositions of Examples 2-5, 7-13, 15-16, and 18-19 using the same processing apparatus and conditions as attempted for films processed from the unmodified PEO compositions, Examples 1, 6, 14, 17, 20 and 21, as detailed above. Uniform films of about 3 mil in thickness were made. The screw speed, torque, pressure and die temperature for the processing of films from the Examples were measured and averages of the measurements are reported in Table 5.

TABLE 5
Film Processing Conditions
				Die
	Screw Speed	Torque	Pressure	Temperature
Example	(rpm)	(m*g)	(psi)	(° C.)
1	150	5922	1850	216
2	50	4411	746	208
3	40	4906	647	207
4	20	4195	497	206
5	20	3820	499	207
6	—	—	—	—
7	40	5130	771	207
8	50	5531	882	208
9	20	4276	528	207
10	25	4211	532	207
11	100	3800	540	213
12	100	4100	630	213
13	100	4500	700	213
14	100	7000	1350	216
15	100	4100	550	215
16	100	4000	520	214
17	100	5200	1400	215
18	100	3800	480	212
19	100	3700	600	213
20	100	2500	330	212
21	15	4211	532	207

[0068] Attempts were made to process films with acceptable solid state properties from higher molecular weight, unmodified PEO resins. These attempts were made using unmodified POLYOX® WSR 205 PEO and unmodified POLYOX® WSR 12K PEO, approximate molecular weights of 600,000 g/mol and 1,000,000 g/mol, respectively. The POLYOX® WSR 12K PEO could not be processed into a film. Thus, torque and pressure data were not collected for unmodified POLYOX® WSR 12K PEO, Example 6 of Table 5. The unmodified POLYOX® WSR 205 PEO could not be extruded at lower screw speeds. The torque and pressure observed during film processing of the modified POLYOX® WSR 205 PEO compositions of Examples 2-5 were dramatically reduced compared to unmodified POLYOX® WSR 205 PEO, Example 1. The unmodified higher molecular weight PEO resins were found to be impractical for extrusion into thin films due to their poor melt processability and inability to be processed into films of less than about 7 mil in thickness. Thus, high molecular unmodified PEO resins are impractical for melt processing.

[0069] In contrast, modified PEO compositions were able to be melt processed into films with thicknesses of less than 0.5 mil without tearing or breakage. This is a significant improvement compared to thicknesses of about 7 mil for films from the unmodified high molecular weight PEOs of Examples 1 and 6.

[0070] The grafting of polar vinyl monomers onto PEO transforms the melt properties and processability, improving the processability by increasing the melt strength and melt drawability of the PEO, thereby allowing thin films to be readily and easily processed. This is also an improvement over the difficulties of producing a less than 1 mil film of unmodified low molecular weight PEO such as Example 21 which possesses desirable processing conditions of low torque, pressure and die temperature but lacks mechanical properties desirable in a usable film.

[0071] The modified PEO compositions of Examples 11-13 with lower levels of monomer addition processed comparably to the modified PEO compositions of Examples 2-5 also exhibiting reduced torque and pressure during processing compared to unmodified PEO processed under similar conditions. The modified PEO compositions of Examples 15 and 16 also exhibited significantly reduced torque and pressure and slightly reduced die temperature during processing compared to unmodified PEO of Example 14 when processed under similar conditions. Generally, the melt viscosity during film processing of the modified PEO compositions was reduced and the die pressure was reduced by greater than 50 %.

[0072] Very thin films were able to be processed from the modified PEO compositions of Examples 15 and 16, exhibiting excellent processability. In contrast, the unmodified POLYOX® WSR N-750 PEO having an initial approximate molecular weight of 300,000 g/mol was not able to be processed into a film of less than 4 mil in thickness and would break or surge and become uneven in thickness during attempts to process films at 4 mil in thickness. Similarly, the modified PEO compositions of Examples 18 and 19 also exhibited significantly reduced torque and pressure and slightly reduced die temperature during processing compared to unmodified PEO of Example 17 when processed under similar conditions and were able to be processed into very thin films exhibiting excellent processability. In contrast, the unmodified POLYOX® WSR N-3000 PEO of Example 17 was not able to be processed into a film of less than 5 mil in thickness and produced 5 mil films with jagged saw-toothed edges similar to those observed form Example 1.

[0073] In general, the modified PEO films did not stick to the chill roll. The modified PEO films produced were smooth and soft and did not contain any grainy particles, as did the extruded films of the unmodified low molecular weight PEO of Example 21. The films produced from the modified PEO compositions generally have better smoothness, softness and greater clarity than films similarly produced form unmodified PEO compositions. Thus, it has been discovered that the films from modified PEO compositions exhibit significantly improved film processability and may be more easily and economically processed into thin films useful for personal care applications in contrast to films from unmodified PEO compositions.

[0074] Tensile Properties of Modified PEO Films

[0075] Tensile tests were performed on the films produced from the compositions of Examples 2-13, 15, 16, 18-20 and the POLYOX® WSR N-80 PEO resin as detailed above. The tensile properties of each of the films were tested and measured in the machine direction (MD) and the cross direction (CD) and are presented in Table 6.

TABLE 6
Tensile Properties of Films
Sample		% Strain-	Peak	Energy-
or	Thickness	to-	Stress	to-Break	Modulus
Example	(mil)	Break	(MPa)	(In*Lb)	(MPa)
No.	MD	CD	MD	CD	MD	CD	MD	CD	MD	CD
2	3.7	4.2	653	635	25.2	22.2	8.9	8.0	244	237
3	3.8	4.0	591	570	17.5	17.5	5.6	5.6	158	286
4	3.1	3.0	718	529	20.0	14.2	5.9	3.4	151	206
5	3.2	3.4	736	641	24.4	17.7	7.3	5.2	205	207
6	7.4	—	814	—	27.6	—	6.4	—	252	—
7	3.2	3.5	693	551	29.2	15.4	8.2	4.1	241	253
8	3.1	3.4	718	532	37.4	15.1	11.6	3.7	277	265
9	3.0	3.2	722	538	24.3	16.7	6.8	4.2	218	305
10	3.2	3.2	739	638	25.8	17.8	7.8	4.9	214	192
11	3.5	4.0	701	730	26.3	25.3	8.7	9.8	340	412
12	3.9	4.2	764	698	33.2	28.0	12.2	10.5	294	427
13	3.6	3.7	753	659	37.0	27.0	11.9	8.4	289	390
15	2.6	2.5	742	709	27.1	23.8	7.0	5.8	307	407
16	3.2	2.9	768	736	30.6	24.6	9.1	6.9	242	303
18	3.3	3.2	788	723	30.4	26.3	10.0	8.0	359	425
19	2.0	2.4	554	577	26.7	23.3	3.8	4.5	293	413
20	7.0	7.0	9	8	8.2	8.4	0.08	0.07	255	263
21	3.5	3.5	121	53	12.1	12.0	0.8	0.3	283	321

[0076] Films processed from the unmodified POLYOX® WSR-80 PEO resin of Example 21 possess low elongation-to-break values. The mechanical properties of the POLYOX® WSR N-80 PEO film were tested and measured within 24 hours of the processing of the film and are expected to decrease considerably with aging. Only thick films are able to be processed from the unmodified POLYOX® WSR 12K PEO resin, Example 6. No cross direction properties could be measured for the films of Example 6 due to the large variations in thicknesses in the cross direction of the films.

[0077] The mechanical properties of films processed from four PEO compositions, Examples 2-5, modified from PEO resins having a molecular weight of 600,000 g/mol before modification were tested. These films have high elongation-to-break values ranging from 570 to 736 percent. These modified PEO compositions have molecular weights and molecular weight distributions similar to the molecular weights and molecular weight distribution of unmodified POLYOX® WSR N-80 PEO but have significantly improved mechanical properties compared to films processed from this unmodified, low molecular weight PEO resin. It is believed that these improved mechanical properties are brought about, at least in part, by increased interchain interactions between the modified PEO chains introduced by the grafting of HEMA and PEG-MA strands onto the PEO. Additionally, it is believed that the grafted polar groups result in hydrogen bonding between neighboring PEO chains linking the chains in both the melt and solid states.

[0078] Even modification of PEO resins with low levels of monomers produces improved mechanical properties. This is demonstrated by the high elongation-to-break, peak stress and energy-to-break measurements observed for the films of Examples 11, 12 and 13. The grafting, even at low levels, improves the fundamental properties of PEO thereby allowing thin films to be processed from PEO

[0079] Overall, the films processed form the modified PEO compositions were found to have improved mechanical properties over films similarly processed from conventional resins. The modified PEO films showed dramatic improvements in tensile properties, greater than 600 percent in strain and 200 percent in stress in the machine direction and greater than 1400 percent in strain and 200 percent in stress in the cross direction.. Additionally, the films produced from the modified PEO compositions were observed to have balanced properties in the machine direction versus the cross direction. These films exhibit improved high peak stresses and energy-to-break values. Most importantly, these films have reduced modulus values which demonstrates their improved flexibilities compared to films from unmodified PEO. The improved flexibility of the films containing modified PEO are particularly desirable for flushable applications, specifically, for flushable personal care products.

[0080] Qualitative FT-IR Analysis

[0081] Fourier transform infrared spectroscopy analysis (FT-IR) was performed on thin films processed from the compositions of Examples 1, 3 and 5. The spectra that were obtained from this analysis are shown in FIG. 3. The lower line is the spectra observed for Example 1, the unmodified and extruded 600,000 g/mol approximate molecular weight PEO. The middle line is the spectra observed for Example 3, the 600,000 g/mol approximate molecular weight PEO grafted with 5% HEMA. And the upper line is the spectra observed for Example 5, the 600,000 g/mol approximate molecular weight PEO grafted with 5% PEG-MA.

[0082] The small peaks observed at approximately 1,725 cm−1 in the upper and middle spectra of Examples 5 and 3 respectively are the absorption peaks for PEG-MA and HEMA, respectively. This absorption peak, at approximately 1725 cm−1, is not observed for unmodified PEO as shown in the lower spectra of FIG. 3.

[0083] Crystal Morphology

[0084] The film from the unmodified POLYOX® WSR 205 PEO having a reported initial approximate molecular weight of 600,000 g/mol of Example 1 and a film produced from a modified sample of the same initial resin were analyzed using polarized light microscopy. In addition to being of a greater thickness, the unmodified film possessed larger spherulite crystals than the film produced from the modified PEO under the same processing conditions. The spherulites in the unmodified sample were observed to be in the order to 20 to 50 micron in size, whereas the spherulites in the modified sample were not observable under the same magnification and are believed to be in the order of less than 1 micron in size. The crystalline structures of the films change dramatically due to grafting. It is believed that the improved mechanical properties of the films containing modified PEO are brought about, at least in part, by the changes in crystal morphology. Additionally, the resistance of the modified films to physical aging is expected to improve as a result of the observed improvement in crystalline structure.

[0085] Although not wishing to be bound by the following theory, it is believed that during the reactive-extrusion processing of PEO resins, the peroxide initiator initiated three competing reactions: 1) grafting of vinyl monomer onto the PEO, 2) degradation of the PEO, and 3) crosslinking of the PEO. A novel method of achieving improved properties has been developed that is contrary to traditional methodology and thinking in polymer development. The method degrades the polymer into shorter chains as opposed to only increasing the molecular weight. The resulting modified PEO compositions have improved melt strength and melt elasticity, overcoming the inherent deficiencies of both low molecular weight PEO and high molecular weight PEO. These improved melt properties allow the modified PEO to be processed into useful films with thicknesses of less than 0.5 mil and with balanced and improved tensile properties.

[0086] The present invention has been illustrated in great detail by the above specific Examples. It is to be understood that these Examples are illustrative embodiments and that this invention is not to be limited by any of the Examples or details in the Description. Those skilled in the art will recognize that the present invention is capable of many modifications and variations without departing from the scope of the invention. Accordingly, the Detailed Description and Examples are meant to be illustrative and are not meant to limit in any manner the scope of the invention as set forth in the following claims. Rather, the claims appended hereto are to be construed broadly within the scope and spirit of the invention.

Claims

1. A film comprising poly(ethylene oxide) that is water-dispersible, melt processable and has an average thickness of not greater than about 5 mils.

2. The film of claim 1, wherein film consists substantially of poly(ethylene oxide) crystals having an average diameter less than 10 microns.

3. The film of claim 1, wherein the film is poly(ethylene oxide)-based.

4. A film comprising a modified poly(ethylene oxide).

5. The film of claim 5, wherein the poly(ethylene oxide) has an initial molecular weight before modification within the range of about 300,000 g/mol to about 8,000,000 g/mol.

6. The film of claim 5, wherein the poly(ethylene oxide) has an initial molecular weight before modification within the range of about 500,000 g/mol to about 8,000,000 g/mol.

7. The film of claim 6, wherein the poly(ethylene oxide) has an initial molecular weight before modification within the range of about 800,000 g/mol to about 6,000,000 g/mol.

8. The film of claim 5, wherein the modified poly(ethylene oxide) is modified by the addition of an initiator.

9. The film of claim 5, wherein the modified poly(ethylene oxide) is modified by the addition of a monomer and an initiator.

10. The film of claim 9, wherein the monomer is a polar vinyl monomer.

11. The film of claim 10, wherein the polar vinyl monomer is selected from the group consisting of poly(ethylene glycol) methacrylates and 2-hydroxyethyl methacrylate.

12. The film of claim 11, wherein the polar vinyl monomer is a poly(ethylene glycol) ethyl ether methacrylate and has an average molecular weight of not greater than about 5,000 grams per mol.

11. The film of claim 9, wherein the monomer is added within the range of about 0.1 to about 20 weight percent relative to the weight of the poly(ethylene oxide).

14. The film of claim 5, wherein the modified poly(ethylene oxide) is a grafted poly(ethylene oxide).

15. The film of claim 5, wherein the modified poly(ethylene oxide) has a polydispersity index less than 10.

16. The film of claim 5, wherein the modified poly(ethylene oxide) has a melting temperature less than 68°C.

17. A method for processing poly(ethylene oxide) films comprising: adding a poly(ethylene oxide), a monomer and an initiator into a reaction vessel; mixing the poly(ethylene oxide), the monomer and the initiator under conditions sufficient to graft the monomer onto the poly(ethylene oxide); and drawing a film from the grafted poly(ethylene oxide).

18. The method of claim 17, wherein the monomer is a polar vinyl monomer.

19. The method of claim 18, wherein the polar, vinyl monomer is selected from the group consisting of poly(ethylene glycol) methacrylates and 2-hydroxyethyl methacrylate.

20. A film produced by the method of claim 17.