US2012231242A1PendingUtilityA1

Microporous material

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Assignee: BOYER JAMES LPriority: Apr 15, 2010Filed: May 16, 2012Published: Sep 13, 2012
Est. expiryApr 15, 2030(~3.8 yrs left)· nominal 20-yr term from priority
Inventors:James L. BoyerChristine GardenrCarol L. KnoxLuciano M. ParrinelloRobert Swisher
Y10T428/249986Y10T428/24942Y10T428/24998A61L 9/042B01D 39/00Y10T428/249978C08J 2201/0502A61L 9/12C08J 5/18Y10T428/249992C08J 2429/00C08J 9/0066C08J 2205/044B01D 39/1676Y10T428/249921Y10T428/249991C08J 9/28C08J 9/365B01D 2239/0471C08J 3/20B01D 67/00B01D 71/26B29C 55/00C08J 5/22C08K 3/00C08L 23/00
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Claims

Abstract

Microporous materials that include thermoplastic organic polyolefin polymer (e.g., ultrahigh molecular weight polyolefin, such as polyethylene), particulate filler (e.g., precipitated silica), and a network of interconnecting pores, are described. The microporous materials of the present invention possess controlled volatile material transfer properties. The microporous materials can have a density of at least 0.8 g/cm 3 ; and a volatile material transfer rate, from the volatile material contact surface to the vapor release surface of the microporous material, of from 0.04 to 0.6 mg/(hour*cm 2 ). In addition, when volatile material is transferred from the volatile material contact surface to the vapor release surface, the vapor release surface is substantially free of volatile material in liquid form.

Claims

exact text as granted — not AI-modified
1 . A microporous material comprising:
 (a) a matrix of substantially water-insoluble thermoplastic organic polymer comprising polyolefin;   (b) finely divided, substantially water-insoluble particulate filler, said particulate filler being distributed throughout said matrix and constituting from 40 to 90 percent by weight, based on the total weight of said microporous material; and   (c) a network of interconnecting pores communicating substantially throughout said microporous material;   wherein said microporous material has,
 a density of at least 0.8 g/cm 3 , 
 a volatile material contact surface, 
 a vapor release surface, wherein said volatile material contact surface and said vapor release surface are substantially opposed to each other, and 
 a volatile material transfer rate, from said volatile material contact surface to said vapor release surface, of from 0.04 to 0.6 mg/(hour*cm 2 ), and 
 wherein when volatile material is transferred from said volatile material contact surface to said vapor release surface, said vapor release surface is substantially free of volatile material in liquid form. 
   
     
     
         2 . The microporous material of  claim 1  wherein said microporous material has a density of from 0.8 to 1.2 g/cm 3 . 
     
     
         3 . The microporous material of  claim 1  wherein said volatile material transfer rate is from 0.30 to 0.55 mg/(hour*cm 2 ). 
     
     
         4 . The microporous material of  claim 1  wherein said volatile material transfer rate is from 0.35 to 0.50 mg/(hour*cm 2 ). 
     
     
         5 . The microporous material of  claim 1  wherein said volatile material contact surface and said vapor release surface are each free of a coating material. 
     
     
         6 . The microporous material of  claim 1  wherein at least a portion of said volatile material contact surface has a first coating thereon, and/or at least a portion of said vapor release surface has a second coating thereon. 
     
     
         7 . The microporous material of  claim 6  wherein said first coating and said second coating each independently is formed from an aqueous coating composition selected from the group consisting of aqueous poly(meth)acrylate dispersions, aqueous polyurethane dispersions, aqueous silicon oil dispersions, and combinations thereof. 
     
     
         8 . The microporous material of  claim 7  wherein each aqueous coating composition has a particle size of from 200 to 400 nm. 
     
     
         9 . The microporous material of  claim 8  wherein said first coating and said second coating each independently have a coating weight of from 0.01 to 5.5 g/m 2 . 
     
     
         10 . The microporous material of  claim 1  wherein said polyolefin comprises ultrahigh molecular weight polyethylene having an intrinsic viscosity of at least 10 deciliters/gram. 
     
     
         11 . The microporous material of  claim 10  wherein said ultrahigh molecular weight polyolefin is ultrahigh molecular weight polyethylene having an intrinsic viscosity of at least 18 deciliters/gram. 
     
     
         12 . The microporous material of  claim 11  wherein said ultrahigh molecular weight polyethylene has an intrinsic viscosity in the range of from 18 to 39 deciliters/gram. 
     
     
         13 . The microporous material of  claim 1  wherein said polyolefin comprises a mixture of substantially linear ultrahigh molecular weight polyethylene having an intrinsic viscosity of at least 10 deciliters/gram and lower molecular weight polyethylene having an ASTM D 1238-86 Condition E melt index of less than 50 grains/10 minutes and an ASTM D 1238-86 Condition F melt index of at least 0.1 grams/10 minutes. 
     
     
         14 . The microporous material of  claim 13  wherein said substantially linear ultrahigh molecular weight polyethylene constitutes at least one percent by weight of said matrix and said substantially linear ultrahigh molecular weight polyethylene and said lower molecular weight polyethylene together constitute substantially 100 percent by weight of the polymer of the matrix. 
     
     
         15 . The microporous material of  claim 14  wherein said lower molecular weight polyethylene comprises high density polyethylene. 
     
     
         16 . The microporous material of  claim 1  wherein said particulate filler constitutes from 20 to 90 percent by weight of said microporous material, based on the total weight of said microporous material. 
     
     
         17 . The microporous material of  claim 16  wherein said particulate filler comprises siliceous particles comprising particulate silica. 
     
     
         18 . The microporous material of  claim 17  wherein said particulate silica comprises particulate precipitated silica. 
     
     
         19 . The microporous material of  claim 1  wherein said pores constitute from 35 to 95 percent by volume of said microporous material, based on the total volume of said microporous material. 
     
     
         20 . A microporous material comprising:
 (a) a matrix of substantially water-insoluble thermoplastic organic polymer comprising polyolefin;   (b) finely divided, substantially water-insoluble particulate filler, said particulate filler being distributed throughout said matrix and constituting from 40 to 90 percent by weight, based on the total weight of said microporous material; and   (c) a network of interconnecting pores communicating substantially throughout said microporous material;   wherein said microporous material has,
 a density of less than 0.8 g/cm 3 , 
 a volatile material contact surface, 
 a vapor release surface, wherein said volatile material contact surface and said vapor release surface are substantially opposed to each other, wherein (i) at least a portion of said volatile material contact surface has a first coating thereon, and/or (ii) at least a portion of said vapor release surface has a second coating thereon, and 
 a volatile material transfer rate, from said volatile material contact surface to said vapor release surface, of from 0.04 to 0.6 mg/(hour*cm 2 ), and 
 wherein when volatile material is transferred from said volatile material contact surface to said vapor release surface, said vapor release surface is substantially free of volatile material in liquid form. 
   
     
     
         21 . The microporous material of  claim 20  wherein said microporous material has a density of from 0.4 g/cm 3  to less than 0.8 g/cm 3 . 
     
     
         22 . The microporous material of  claim 20  wherein said microporous material has a density of from 0.40 g/cm 3  to 0.7 g/cm 3 . 
     
     
         23 . The microporous material of  claim 20  wherein said volatile material transfer rate is from 0.30 to 0.55 mg/(hour*cm 2 ). 
     
     
         24 . The microporous material of  claim 20  wherein said volatile material transfer rate is from 0.35 to 0.55 mg/(hour*cm 2 ). 
     
     
         25 . The microporous material of  claim 20  wherein said first coating and said second coating each independently is formed from an aqueous coating composition selected from the group consisting of aqueous poly(meth)acrylate dispersions, aqueous polyurethane dispersions, aqueous silicon oil dispersions, and combinations thereof. 
     
     
         26 . The microporous material of  claim 25  wherein each aqueous coating composition has a particle size of from 200 to 400 nm. 
     
     
         27 . The microporous material of  claim 26  wherein said first coating and said second coating each independently have a coating weight of from 0.1 to 3 g/m 2 . 
     
     
         28 . The microporous material of  claim 20  wherein said polyolefin comprises ultrahigh molecular weight polyethylene having an intrinsic viscosity of at least 10 deciliters/gram. 
     
     
         29 . The microporous material of  claim 28  wherein said ultrahigh molecular weight polyolefin is ultrahigh molecular weight polyethylene having an intrinsic viscosity of at least 18 deciliters/gram. 
     
     
         30 . The microporous material of  claim 29  wherein said ultrahigh molecular weight polyethylene has an intrinsic viscosity in the range of from 18 to 39 deciliters/gram. 
     
     
         31 . The microporous material of  claim 20  wherein said matrix comprises a mixture of substantially linear ultrahigh molecular weight polyethylene having an intrinsic viscosity of at least 10 deciliters/gram and lower molecular weight polyethylene having an ASTM D 1238-86 Condition E melt index of less than 50 grams/10 minutes and an ASTM D 1238-86 Condition F melt index of at least 0.1 grams/10 minutes. 
     
     
         32 . The microporous material of  claim 31  wherein said substantially linear ultrahigh molecular weight polyethylene constitutes at least one percent by weight of said matrix and said substantially linear ultrahigh molecular weight polyethylene and said lower molecular weight polyethylene together constitute substantially 100 percent by weight of the polymer of the matrix. 
     
     
         33 . The microporous material of  claim 32  wherein said lower molecular weight polyethylene is high density polyethylene. 
     
     
         34 . The microporous material of  claim 20  wherein said particulate filler constitutes from 20 to 90 percent by weight of said microporous material, based on the total weight of said microporous material. 
     
     
         35 . The microporous material of  claim 34  wherein said particulate filler comprises siliceous particles comprising particulate silica. 
     
     
         36 . The microporous material of  claim 35  wherein said particulate silica comprises particulate precipitated silica. 
     
     
         37 . The microporous material of  claim 20  wherein said pores constitute from 35 to 95 percent by volume of said microporous material, based on the total volume of said microporous material.

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