High-clarity blended ionomer compositions and articles comprising the same

Abstract

An ionomer blend composition comprises a blend of a first ionomer and a second ionomer that is different from the first ionomer. The first ionomer is derived from a first precursor acid copolymer that has a melt flow rate of about 10 to about 4000 g/10 min and that comprises copolymerized units of an α-olefin and about 20 to about 30 wt % of copolymerized units of an α,β-ethylenically unsaturated carboxylic acid. Moreover, the first precursor acid can be neutralized to a level of about 40% to about 90% to form a sodium ionomer that has a MFR of about 0.7 to about 25 g/10 min and a freeze enthalpy that is less than about 3.0 j/g or that is not detectable, when determined by differential scanning calorimetry (DSC). A variety of articles may comprise or be produced from the ionomer blend composition, for example by injection molding.

1 . A composition comprising an ionomer blend, said ionomer blend comprising, based on the total weight of the ionomer blend, about 5 to about 95 wt % of a first ionomer and about 95 to about 5 wt % of a second ionomer, said ionomer blend having a neutralization level of 10% to 90%, based on the total number of neutralized and unneutralized carboxylic acid groups in the ionomer blend, wherein:
 (A) said first ionomer is the neutralization product of a first precursor acid copolymer; and i) the first precursor acid copolymer comprises copolymerized units of a first α-olefin having 2 to 10 carbon atoms and further comprises about 20 to about 30 wt %, based on the total weight of the first precursor acid copolymer, of copolymerized units of a first α,β-ethylenically unsaturated carboxylic acid having 3 to 8 carbon atoms; ii) the first precursor acid copolymer has a melt flow rate of about 70 to about 1000 g/10 min; and iii) the first precursor acid copolymer, when neutralized to a level of about 40% to about 90% and when comprising counterions that consist essentially of sodium cations, produces a sodium ionomer; and said sodium ionomer has a melt flow rate of about 0.7 to about 25 g/10 min and a freeze enthalpy that is not detectable or that is less than about 3.0 j/g, when determined by differential scanning calorimetry (DSC) in accordance with ASTM D3418;   (B) said second ionomer is the neutralization product of a second precursor acid copolymer, wherein i) the second precursor acid copolymer comprises copolymerized units of a second α-olefin having 2 to 10 carbon atoms; and about 18 to about 30 wt %, based on the total weight of the second precursor acid copolymer, of copolymerized units of a second α,β-ethylenically unsaturated carboxylic acid having 3 to 8 carbon atoms; the second α-olefin may be the same as or different from the first α-olefin; the amount of the second α-olefin may be the same as or different from the amount of the first α-olefin; the second α,β-ethylenically unsaturated carboxylic acid may be the same as or different from the first α,β-ethylenically unsaturated carboxylic acid; and the amount of the second α,β-ethylenically unsaturated carboxylic acid may be the same as or different from the amount of the first α,β-ethylenically unsaturated carboxylic acid; ii) the second precursor acid copolymer has a melt flow rate of about 60 g/10 min or less; and iii) the second ionomer has a melt flow rate of about 10 g/10 min or less at the neutralization level of the ionomer blend; and the melt flow rate of the second ionomer at the neutralization level of the ionomer blend is different from the melt flow rate of the first ionomer at the same neutralization level; and   (C) the melt flow rates are determined in accordance with ASTM method D1238 at a polymer melt temperature of 190° C. and under a weight of 2.16 kg.   
   
   
       2 . The composition of  claim 1 , wherein the first precursor acid copolymer has a melt flow rate of about 150 to about 400 g/10 min and the second precursor acid copolymer has a melt flow rate of about 30 g/10 min or less. 
   
   
       3 . The composition of  claim 1 , wherein the first precursor acid copolymer comprises about 20 to about 25 wt % of copolymerized units of the first α,β-ethylenically unsaturated carboxylic acid; and wherein the second precursor acid copolymer comprises about 20 to about 25 wt % of copolymerized units of the second α,β-ethylenically unsaturated carboxylic acid; and wherein the second α,β-ethylenically unsaturated carboxylic acid may be the same as or different from the first α,β-ethylenically unsaturated carboxylic acid; and the amount of the second α,β-ethylenically unsaturated carboxylic acid may be the same as or different from the amount of the first α,β-ethylenically unsaturated carboxylic acid. 
   
   
       4 . The composition of  claim 1 , wherein the neutralization level of the ionomer blend is from about 15% to about 70%, wherein the ionomer blend comprises carboxylate groups and cations, and wherein the cations consist essentially of sodium cations. 
   
   
       5 . The composition of  claim 1 , wherein, at the neutralization level of the ionomer blend, the first ionomer has a melt flow rate of about 0.7 to about 10 g/10 min and the second ionomer has a melt flow rate of about 5 g/10 min or less. 
   
   
       6 . The composition of  claim 1 , wherein the ionomer blend comprises about 60 to about 95 wt % of the first ionomer and about 5 to about 40 wt % of the second ionomer. 
   
   
       7 . An article comprising or produced from the composition of  claim 1 . 
   
   
       8 . The article of  claim 7 , which is in the form of a film or a sheet or a molded article. 
   
   
       9 . The article of  claim 8 , which is a film or sheet prepared by a process selected from the group consisting of dipcoating, solution casting, lamination, melt extrusion, blown film, extrusion coating, and tandem extrusion coating. 
   
   
       10 . The article of  claim 8 , which is a molded article prepared by a process selected from the group consisting of compression molding, injection molding, extrusion molding, and blow molding. 
   
   
       11 . The article of  claim 10 , which is an injection molded article. 
   
   
       12 . The article of  claim 11 , having a minimum thickness of at least about 3 mm. 
   
   
       13 . The article of  claim 11 , wherein the injection molded article has a multi-layer structure having at least one layer that consists essentially of the composition recited in  claim 1 , said at least one layer having a minimum thickness of at least about 3 mm. 
   
   
       14 . The article of  claim 13  that is a container. 
   
   
       15 . The article of  claim 11  that is a sheet, a container, a cap or stopper, a tray, a medical device or instrument, a handle, a knob, a push button, a decorative article, a panel, a console box, or a footwear component. 
   
   
       16 . The article of  claim 15  that is a container. 
   
   
       17 . The article of  claim 11 , which is produced by a process selected from the group consisting of co-injection molding; over-molding; injection blow molding; injection stretch blow molding and extrusion blow molding. 
   
   
       18 . An article prepared by injection molding, said article consisting essentially of the composition of  claim 1  and having a thickness of about 1 to about 100 mm. 
   
   
       19 . An ionomer blend composition that is produced by the process of:
 a. providing a first ionomer, said first ionomer being the neutralization product of a first precursor acid copolymer; wherein i) the first precursor acid copolymer comprises copolymerized units of a first α-olefin having 2 to 10 carbon atoms and further comprises about 20 to about 30 wt %, based on the total weight of the first precursor acid copolymer, of copolymerized units of a first α,β-ethylenically unsaturated carboxylic acid having 3 to 8 carbon atoms; ii) the first ionomer has a neutralization level of 40% to 90% and a melt flow rate of about 0.7 to about 25 g/10 min; iii) the first precursor acid copolymer has a melt flow rate of about 70 to about 1000 g/10 min; and iv) the first precursor acid copolymer, when neutralized to a level of about 40% to about 90% and when comprising counterions that consist essentially of sodium cations, produces a sodium ionomer; and said sodium ionomer has a melt flow rate of about 0.7 to about 25 g/10 min and a freeze enthalpy that is not detectable or that is less than about 3.0 j/g, when determined by differential scanning calorimetry (DSC) in accordance with ASTM D3418;   b. providing a second ionomer, said second ionomer being the neutralization product of a second precursor acid copolymer, wherein i) the second precursor acid copolymer comprises copolymerized units of a second α-olefin having 2 to 10 carbon atoms; and about 18 to about 30 wt %, based on the total weight of the second precursor acid copolymer, of copolymerized units of a second α,β-ethylenically unsaturated carboxylic acid having 3 to 8 carbon atoms; the second α-olefin may be the same as or different from the first α-olefin; the amount of the second α-olefin may be the same as or different from the amount of the first α-olefin; the second α,β-ethylenically unsaturated carboxylic acid may be the same as or different from the first α,β-ethylenically unsaturated carboxylic acid; and the amount of the second α,β-ethylenically unsaturated carboxylic acid may be the same as or different from the amount of the first α,β-ethylenically unsaturated carboxylic acid; ii) the second precursor acid copolymer has a melt flow rate of about 60 g/10 min or less; and iii) the second ionomer has a neutralization level of 10% to 35% and a melt flow rate of about 10 g/10 min or less; and iv) the melt flow rate of the second ionomer at the neutralization level of the ionomer blend is different from the melt flow rate of the first ionomer at the same neutralization level; and   c. blending the first ionomer and the second ionomer;   wherein the melt flow rates are determined in accordance with ASTM method D1238 at a polymer melt temperature of 190° C. and under a weight of 2.16 kg.   
   
   
       20 . An article comprising or produced from the ionomer blend composition of  claim 19 .