Controlled flow polymer blends and products including the same

Abstract

The present invention is directed to polymer blends having controlled flow properties. The polymer blends can be useful in various applications including bonding systems and additive delivery systems, which can provide durable binding and/or delivery and/or affixing of additives. The polymer blends can include at least two different components, at least one being a polymer component having a higher molecular than the other of the components. When heated to an activating temperature, the resultant blend exhibits desirable flow or wet out properties without applied pressure. Despite the controlled flow properties, the blends do not exhibit blocking or fusing properties typically associated with high flow polymer materials.

1 . A polymer blend capable of substantially wetting out a surface at a flow activating temperature without requiring the application of substantial pressure, said polymer blend further having blocking resistance properties, said polymer blend comprising: at least about 10 percent by weight, based on the total weight of the polymer blend, of a first blend component comprising at least one polymer having a first molecular weight; and at least about 10 percent by weight, based on the total weight of the polymer blend, of a second blend component comprising at least one compound having a second molecular weight that is less than the first molecular weight of the at least one polymer of the first blend component, wherein the first molecular weight of the at least one polymer of said first blend component is sufficiently high to prevent the substantial wet out without the application of substantial pressure of the at least one polymer of the first blend component at said activating temperature, and wherein the second molecular weight of the at least one compound of said second blend component is sufficiently low so that the at least one compound of the second blend component exhibits sufficiently high molecular mobility to substantially prevent processing of the at least one compound of the second blend component alone. 
   
   
       2 . The polymer blend of  claim 1 , wherein said blend comprises at least about 20 percent by weight of the first blend component. 
   
   
       3 . The polymer blend of  claim 2 , wherein said blend comprises at least about 30 percent by weight of the first blend component. 
   
   
       4 . The polymer blend of  claim 1 , wherein said blend comprises at least about 20 percent by weight of the second blend component. 
   
   
       5 . The polymer blend of  claim 4 , wherein said blend comprises at least about 30 percent by weight of the second blend component. 
   
   
       6 . The polymer blend of  claim 1 , wherein the polymer blend substantially wets out a surface without requiring the application of substantial pressure in about one hour or less at said activating temperature. 
   
   
       7 . The polymer blend of  claim 6 , wherein the polymer blend substantially wets out a surface without requiring the application of substantial pressure in about two minutes or less at said activating temperature. 
   
   
       8 . The polymer blend of  claim 6 , wherein said activating temperature comprises a temperature of about 150° C. or less. 
   
   
       9 . The polymer blend of  claim 8 , wherein said activating temperature is comprises a temperature ranging from about 100° C. to about 150° C. 
   
   
       10 . The polymer blend of  claim 8 , wherein said activating temperature is comprises a temperature of about 100° C. 
   
   
       11 . The polymer blend of  claim 8 , wherein said activating temperature is comprises a temperature of about 125° C. 
   
   
       12 . The polymer blend of  claim 6 , wherein said activating temperature is comprises a temperature of about 150° C. or higher. 
   
   
       13 . The polymer blend of  claim 1 , wherein the first blend component comprises at least one polymer having a molecular weight at least about three times higher than the molecular weight of the at least one compound of the second blend component. 
   
   
       14 . The polymer blend of  claim 13 , wherein the first blend component comprises at least one polymer having a molecular weight at least about five times higher than the molecular weight of the at least one compound of the second blend component. 
   
   
       15 . The polymer blend of  claim 1 , wherein the second component comprises at least one compound having a number average molecular weight of about 6000 or less. 
   
   
       16 . The polymer blend of  claim 1 , wherein the first blend component comprises at least one polymer having a first melt flow rate and the second blend component comprises at least one compound having a second melt flow rate that is greater than the melt flow rate of the at least one polymer of the first blend component. 
   
   
       17 . The polymer blend of  claim 16 , wherein the second blend component comprises at least one compound having a melt flow rate of at least about five times greater than the melt flow rate of the at least one polymer of the first blend component. 
   
   
       18 . The polymer blend of  claim 17 , wherein the second blend component comprises at least one compound having a melt flow rate of at least about ten times greater than the melt flow rate of the at least one polymer of the first blend component. 
   
   
       19 . The polymer blend of  claim 18 , wherein the first blend component comprises at least one polymer having a melt flow rate of about 1 or less and the second blend component comprises at least one compound having a melt flow rate of about 100 or more. 
   
   
       20 . The polymer blend of  claim 1 , wherein said polymer blend comprises at least one polymer selected from the group consisting of polyolefins, polyesters, acrylics, polyamides, elastomeric polymers, polyacrylonitrile, acetals, fluoropolymers, epoxies, phenoxies, vinyl alcohol polymers, polyesterimides, polyhydroxyl alkanoates (PHA), polysulfone, polyetheretherketone, cellulose acetate, rayons, biopolymers, polyurethanes, hot melt adhesives, and copolymers, terpolymers and ionomers thereof, and combinations thereof. 
   
   
       21 . The polymer blend of  claim 20 , wherein said polymer blend comprises at least one elastomeric polymer. 
   
   
       22 . The polymer blend of  claim 1 , wherein the second blend component comprises a substantially crystalline or semicrystalline polymer. 
   
   
       23 . The polymer blend of  claim 22 , wherein the first blend component comprises at least one polymer having a glass transition temperature (T g ) and wherein the substantially crystalline or semicrystalline polymer has a melting point that is greater than the T g  of the at least one polymer of the first blend component. 
   
   
       24 . The polymer blend of  claim 20 , wherein at least one of the first and second blend components comprises a functionalized polymer. 
   
   
       25 . The polymer blend of  claim 1 , wherein at least one of the first and second blend components comprises a polyolefin. 
   
   
       26 . The polymer blend of  claim 25 , wherein both of the first and the second blend components comprise a polyolefin. 
   
   
       27 . The polymer blend of  claim 25 , wherein the polyolefin is selected from the group consisting of polypropylene, polyethylene, polybutylene, and copolymers, terpolymers, and combinations thereof. 
   
   
       28 . The polymer blend of  claim 25 , wherein the polyolefin is functionalized. 
   
   
       29 . The polymer blend of  claim 25 , wherein the polyolefin is elastomeric. 
   
   
       30 . The polymer blend of  claim 28 , wherein the polyolefin is functionalized by reaction with at least one unsaturated anhydride, unsaturated acid or unsaturated ester. 
   
   
       31 . The polymer blend of  claim 30 , wherein the polyolefin is modified by reaction with at least one unsaturated anhydride, unsaturated acid or unsaturated ester selected from the group consisting of maleic anhydride, citraconic anhydride, itaconic anhydride, glutaconic anhydride, 2,3-dimethylmaleic anhydride, maleic acid, fumaric acid, citraconic acid, itaconic acid, mesaconic acid, glutaconic acid, acrylic acid, methacrylic acid, crotonic acid, 2-pentenoic acid, 2-methyl-2-pentenoic acid, dimethyl malcate, diethyl maleatc, di-n-propyl malcate, diisopropyl maleate, dimethyl fumarate, diethyl fumarate, di-n-propyl fumarate, di-isopropyl maleate, dimethyl itaconate, methyl acrylate, ethyl acrylate, methyl methacrylate, ethyl methacrylate, methyl crotonate, and ethyl crotonate. 
   
   
       32 . The polymer blend of  claim 31 , wherein the polyolefin comprises a maleic anhydride modified polyolefin. 
   
   
       33 . The polymer blend of  claim 27 , wherein said polymer is functionalized by oxidation. 
   
   
       34 . The polymer blend of  claim 1 , further comprising at least one additive. 
   
   
       35 . The polymer blend of  claim 34 , wherein said at least one additive comprises an additive selected from the group consisting of antimicrobials, biocides, flame retardants, toxic absorbers, conductive agents, abrasives, antioxidants, UV stabilizers, optically active compounds, tracers, plating catalysts, fungicides, mildewcides, phosphorescents, reflectants, smart fabric components, polytetrafluoroethylene (PTFE), repellants, particulates, reinforcing agents, fillers, pigments, talc, glass fibers, clays, silicas, mineral silicates, mica, odor absorbers, nano-particles, chemical deactivators, antistats, markers, counterfeit tracers, fluorescents, ointments, and combinations thereof. 
   
   
       36 . The polymer blend of  claim 26 , wherein at least one of said first or second components comprises a maleic anhydride modified polyolefin, said second component comprises a substantially crystalline polyolefin, and said blend has a melting point within 20° C. of the flow activation temperature of the blend. 
   
   
       37 . A polymer blend capable of substantially wetting out a surface at a flow activating temperature without requiring the application of substantial pressure, said polymer blend further having blocking resistance properties, said polymer blend comprising at least one polymer having a first molecular weight and a glass transition temperature T g , and a substantially crystalline compound having a second molecular weight that is less than the first molecular weight of the at least one polymer and having a melting point that is greater than the T g  of the at least one polymer. 
   
   
       38 . The polymer blend of  claim 37 , wherein said blend comprises a functionalized polyolefin. 
   
   
       39 . The polymer blend of  claim 38 , wherein the functionalized polyolefin comprises a maleic anhydride modified polyolefin. 
   
   
       40 . The polymer blend of  claim 37 , wherein said blend comprises an elastomeric polyolefin. 
   
   
       41 . A polymer blend capable of substantially wetting out a surface at a flow activating temperature without requiring the application of substantial pressure, said polymer blend further having blocking resistance properties, said polymer blend comprising a phenoxy having a first molecular weight and a glass transition temperature T g ; and a substantially crystalline plasticizer having a second molecular weight that is less than the first molecular weight of the phenoxy and having a melting point that is greater than the T g  of the phenoxy. 
   
   
       42 . An article comprising the polymer blend of  claim 41 , wherein said article is selected from the group consisting of fibers, nonwoven fabrics, permeable films, impermeable films, foams, and coatings. 
   
   
       43 . A polymeric bonding system, comprising:
 an article comprising a polymer blend capable of substantially wetting out a surface at a flow activating temperature without requiring the application of substantial pressure, said polymer blend further having blocking resistance properties, said polymer blend comprising at least about 10 percent by weight, based on the total weight of the polymer blend, of a first blend component comprising at least one polymer having a first molecular weight and at least about 10 percent by weight, based on the total weight of the polymer blend, of a second blend component comprising at least one compound having a second molecular weight that is less than the first molecular weight of the at least one polymer of the first blend component, wherein the first molecular weight of the at least one polymer of said first blend component is sufficiently high to prevent the substantial wet out without the application of substantial pressure of the at least one polymer of the first blend component at said activating temperature, and wherein the second molecular weight of the at least one compound of said second blend component is sufficiently low so that the at least one compound of the second blend component exhibits sufficiently high molecular mobility to substantially prevent processing the at least one compound of the second blend component alone.   
   
   
       44 . The polymeric bonding system of  claim 43 , wherein the polymeric bonding system is in the form of an article selected from the group consisting of fibrous materials, films, foams, coatings, particulate materials, and combinations thereof. 
   
   
       45 . A polymeric bonding system, comprising:
 an article comprising a polymer blend capable of substantially wetting out a surface at a flow activating temperature without requiring the application of substantial pressure, said polymer blend further having blocking resistance properties, said polymer blend comprising at least one polymer having a first molecular weight and a glass transition temperature T g , and at least one substantially crystalline compound having a second molecular weight that is less than the first molecular weight of the at least one polymer and having a melting point that is greater than the T g  of the at least one polymer.   
   
   
       46 . A polymeric delivery system, comprising:
 a polymer blend capable of substantially wetting out a surface at a flow activating temperature without requiring the application of substantial pressure, said polymer blend further having blocking resistance properties, said polymer blend comprising at least about 10 percent by weight, based on the total weight of the polymer blend, of a first blend component comprising at least one polymer having a first molecular weight and at least about 10 percent by weight, based on the total weight of the polymer blend, of a second blend component comprising at least one compound having a second molecular weight that is less than the first molecular weight of the at least one polymer of the first blend component, wherein the first molecular weight of the at least one polymer of said first blend component is sufficiently high to prevent the substantial wet out without the application of substantial pressure of the at least one polymer of the first blend component at said activating temperature, and wherein the second molecular weight of the at least one compound of said second blend component is sufficiently low so that the at least one compound of said second blend component exhibits sufficiently high molecular mobility to substantially prevent processing the at least one compound of said second blend component alone; and   at least one additive.   
   
   
       47 . The polymeric delivery system of  claim 46 , wherein the polymeric delivery system is in the form of an article selected from the group consisting of fibrous materials, films, foams, coatings, particulate materials, and combinations thereof. 
   
   
       48 . The polymeric delivery system of  claim 47 , wherein the polymeric delivery system comprises a fibrous material. 
   
   
       49 . The polymeric delivery system of  claim 48 , wherein the fibrous material is selected from the group consisting of continuous filaments, staple fibers, yarns, tows, meltblown fibers, and spunbonded filaments. 
   
   
       50 . The polymeric delivery system of  claim 47 , wherein the polymeric delivery system comprises a particulate material. 
   
   
       51 . The polymeric delivery system of  claim 50 , wherein the particulate material comprises a powder having an average diameter of less than about 1 millimeter (mm). 
   
   
       52 . The polymeric delivery system of  claim 50 , wherein the particulate materials comprises a powder having an average diameter of less than about 200 microns. 
   
   
       53 . The polymeric delivery system of  claim 46 , wherein the at least one additive comprises an additive selected from the group consisting of antimicrobials, biocides, flame retardants, toxic absorbers, conductive agents, abrasives, antioxidants, UV stabilizers, optically active compounds, tracers, plating catalysts, fungicides, mildewcides, phosphorescents, reflectants, smart fabric components, polytetrafluoroethylene (PTFE), repellants, particulates, reinforcing agents, fillers, pigments, talc, glass fibers, clays, silicas, mineral silicates, mica, odor absorbers, nano-particles, chemical deactivators, antistats, markers, counterfeit tracers, fluorescents, ointments, and combinations thereof. 
   
   
       54 . A polymeric delivery system, comprising:
 a polymer blend capable of substantially wetting out a surface at a flow activating temperature without requiring the application of substantial pressure, said polymer blend further having blocking resistance properties, said polymer blend comprising at least one polymer having a first molecular weight and a glass transition temperature T g , and at least one substantially crystalline compound having a second molecular weight that is less than the first molecular weight of the at least one polymer and having a melting point that is greater than the T g  of the at least one polymer; and   at least one additive.   
   
   
       55 . A composite article comprising:
 a matrix material; and   a polymer blend capable of substantially wetting out a surface of the matrix material at a flow activating temperature without requiring the application of substantial pressure, said polymer blend further having blocking resistance properties, said polymer blend comprising at least about 10 percent by weight, based on the total weight of the polymer blend, of a first blend component comprising at least one polymer having a first molecular weight and at least about 10 percent by weight, based on the total weight of the polymer blend, of a second blend component comprising at least one compound having a second molecular weight that is less than the first molecular weight of the at least one polymer of the first blend component, wherein the first molecular weight of the at least one polymer of said first blend component is sufficiently high to prevent the substantial wet out without the application of substantial pressure of the at least one polymer of the first blend component at said activating temperature, and wherein the second molecular weight of the at least one compound of said second blend component is sufficiently low so that the at least one compound of the second blend component exhibits sufficiently high molecular mobility to substantially prevent processing the at least one compound of the second blend component alone.   
   
   
       56 . The composite article of  claim 55 , wherein the matrix material is selected from the group consisting of fibrous materials, cellulosic materials, and combinations thereof. 
   
   
       57 . The composite article of  claim 56 , wherein the matrix material comprises a fibrous material selected from the group consisting of synthetic fibrous materials, natural fibrous materials, and combinations thereof. 
   
   
       58 . The composite article of  claim 57 , wherein the natural fibrous material comprises cotton fibers. 
   
   
       59 . The composite article of  claim 58 , further comprising an antimicrobial agent. 
   
   
       60 . The composite article of  claim 56 , wherein the matrix material comprises a cellulosic material selected from the group consisting of cellulosic fibrous materials, cellulosic particles, and combinations thereof 
   
   
       61 . The composite article of  claim 55 , wherein the polymer blend is in the form of an article selected from the group consisting of fibrous materials, films, foams, coatings, particulate materials, and combinations thereof. 
   
   
       62 . The composite article of  claim 55 , wherein the polymer blend further comprises an additive. 
   
   
       63 . A composite article comprising:
 a matrix material; and   a polymer blend capable of substantially wetting out a surface at a flow activating temperature without requiring the application of substantial pressure, said polymer blend further having blocking resistance properties, said polymer blend comprising at least one polymer having a first molecular weight and a glass transition temperature T g , and at least one substantially crystalline compound having a second molecular weight that is less than the first molecular weight of the at least one polymer and having a melting point that is greater than the T g  of the at least one polymer.   
   
   
       64 . A chenille yarn comprising at least one core yarn and at least one effect yarn, wherein said core yarn comprises a polymer blend capable of substantially wetting out a surface at a flow activating temperature without requiring the application of substantial pressure, said polymer blend further having blocking resistance properties, said polymer blend comprising a first blend component comprising at least one polymer having a first molecular weight and a second blend component comprising at least one compound having a second molecular weight that is less than the first molecular weight of the at least one polymer of the first blend component, wherein the first molecular weight of the at least one polymer of said first blend component is sufficiently high to prevent the substantial wet out without the application of substantial pressure of the at least one polymer of the first blend component at said activating temperature, and wherein the second molecular weight of said at least one compound of the second blend component is sufficiently low so that the at least one compound of the second blend component exhibits sufficiently high molecular mobility to substantially prevent processing the at least one compound of the second blend component alone, wherein said effect yarn is bound by said polymer blend of said core yarn. 
   
   
       65 . The chenille yarn of  claim 64 , wherein said polymer blend is present in the form of one or more fibers blended with said core yarn. 
   
   
       66 . The chenille yarn of  claim 64 , wherein said core yarn comprises a coating formed of said polymer blend. 
   
   
       67 . The chenille yarn of  claim 64 , wherein said core yarn comprises a multicomponent fiber comprising at least one component formed of said polymer blend. 
   
   
       68 . A polymer additive system comprising a water soluble additive and a plurality of particles formed of a polymer blend capable of substantially wetting out a surface at a flow activating temperature without requiring the application of substantial pressure, said polymer blend further having blocking resistance properties, said polymer blend comprising a first blend component comprising at least one polymer having a first molecular weight and a second blend component comprising at least one compound having a second molecular weight that is less than the first molecular weight of the at least one polymer of the first blend component, wherein the first molecular weight of the at least one polymer of said first blend component is sufficiently high to prevent the substantial wet out without the application of substantial pressure of the at least one polymer of the first blend component at said activating temperature, and wherein the second molecular weight of the at least one compound of said second blend component is sufficiently low so that the at least one compound of the second blend component exhibits sufficiently high molecular mobility to substantially prevent processing the at least one compound of the second blend component alone. 
   
   
       69 . The polymer additive system of  claim 68 , wherein said water soluble additive comprises a flame retardant additive. 
   
   
       70 . A waterborne coating system comprising a water soluble additive encapsulated in a plurality of emulsified particles comprising a polymer blend, wherein said polymer blend comprises a first blend component comprising at least one polymer having a first molecular weight and a second blend component comprising at least one compound having a second molecular weight that is less than the first molecular weight of the at least one polymer of the first blend component, wherein the first molecular weight of the at least one polymer of said first blend component is sufficiently high to prevent the substantial wet out without the application of substantial pressure of the at least one polymer of the first blend component at said activating temperature, and wherein the second molecular weight of the at least one compound of said second blend component is sufficiently low so that the at least one compound of the second blend component exhibits sufficiently high molecular mobility to substantially prevent processing the at least one compound of the second blend component alone. 
   
   
       71 . A method of bonding an article, comprising activating a polymer blend applied to an article to be bonded at a flow activating temperature sufficient to substantially wet out a surface of the article to be bonded with the polymer blend at said activating temperature without the application of substantial pressure, wherein said polymer blend has blocking resistance properties and comprises at least about 10 percent by weight, based on the total weight of the polymer blend, of a first blend component comprising at least one polymer having a first molecular weight and at least about 10 percent by weight, based on the total weight of the polymer blend, of a second blend component comprising at least one compound having a second molecular weight that is less than the first molecular weight of the at least one polymer of the first blend component, wherein the first molecular weight of the at least one polymer of said first blend component is sufficiently high to prevent the substantial wet out without the application of substantial pressure of the at least one polymer of the first blend component at said activating temperature, and wherein the second molecular weight of the at least one compound of said second blend component is sufficiently low so that the at least one compound of the second blend component exhibits sufficiently high molecular mobility to substantially prevent processing the at least one compound of the second blend component alone. 
   
   
       72 . A method of bonding an article, comprising activating a polymer blend applied to an article to be bonded at a flow activating temperature sufficient to substantially wet out a surface of the article to be bonded with the polymer blend at said activating temperature without the application of substantial pressure, wherein said polymer blend comprises at least one polymer having a first molecular weight and a glass transition temperature T g , and at least one substantially crystalline compound having a second molecular weight that is less than the first molecular weight of the at least one polymer and having a melting point that is greater than the T g  of the at least one polymer. 
   
   
       73 . A method of delivering an additive to an article, comprising activating a polymer blend comprising an additive to be delivered at a flow activating temperature sufficient to substantially wet out a surface of an article to which the additive is to be delivered at said activating temperature without requiring the application of substantial pressure to effectively deliver the additive to the article, wherein said polymer blend has blocking resistance properties and comprises at least about 10 percent by weight, based on the total weight of the polymer blend, of a first blend component comprising at least one polymer having a first molecular weight and at least about 10 percent by weight, based on the total weight of the polymer blend, of a second blend component comprising at least one compound having a second molecular weight that is less than the first molecular weight of the at least one polymer of the first blend component, wherein the first molecular weight of the at least one polymer of said first blend component is sufficiently high to prevent the substantial wet out without the application of substantial pressure of the at least one polymer of the first blend component at said activating temperature, and wherein the second molecular weight of the at least one compound of said second blend component is sufficiently low so that the at least one compound of the second blend component exhibits sufficiently high molecular mobility to substantially prevent processing of the at least one compound of the second blend component alone. 
   
   
       74 . A method of delivering an additive to an article, comprising activating a polymer blend comprising an additive to be delivered at a flow activating temperature sufficient to substantially wet out a surface of an article to which the additive is to be delivered at said activating temperature without requiring the application of substantial pressure to effectively deliver the additive to the article, wherein said polymer blend comprises at least one polymer having a first molecular weight and a glass transition temperature T g , and at least one substantially crystalline compound having a second molecular weight that is less than the first molecular weight of the at least one polymer and having a melting point that is greater than the T g  of the at least one polymer. 
   
   
       75 . An activatable yarn comprising a plurality of fibrous material, said fibrous material comprising a synthetic polymer having a first molecular weight and a functionalized additive for promoting adhesion of the synthetic polymer to another material and having a second molecular weight that is less than the first molecular weight of the synthetic polymer. 
   
   
       76 . The activatable yarn of  claim 75 , wherein said synthetic polymer comprising a polymer selected from the group consisting of polyolefins, polyesters, polyamides, and combinations thereof. 
   
   
       77 . The activatable yarn of  claim 76 , wherein said functionalized additive comprises a maleic anhydride modified polyolefin. 
   
   
       78 . The activatable yarn of  claim 76 , wherein said functionalized additive comprises an amine functionalized additive. 
   
   
       79 . The activatable yarn of  claim 46 , wherein said fibrous material comprises at least one polymer having a first molecular weight and a glass transition temperature T g , and a substantially crystalline compound having a second molecular weight that is less than the first molecular weight of the at least one polymer and having a melting point that is greater than the T g  of the at least one polymer.