초록 ▼

Olefin polymer-based, durable, open-cell foam compositions, structures and articles derived from same; methods for preparation of such foams; and use of the dry durable foams in various applications are disclosed. Further described is use of the foams and structures and articles made of same in abso

Olefin polymer-based, durable, open-cell foam compositions, structures and articles derived from same; methods for preparation of such foams; and use of the dry durable foams in various applications are disclosed. Further described is use of the foams and structures and articles made of same in absorption, filtration, insulation, cushioning and backing applications, and in particular for odor removal, hygiene and medical applications due to, among other properties, good absorption capabilities, softness and/or flexibility of the foams and their recyclable nature.

대표청구항 ▼

The invention claimed is: 1. A method of making a durable, open-cell foam comprising the steps of: (1) generating a stable, aqueous froth comprising a) one or more copolymers or interpolymers of ethylene and/or 1-propene with or without other monomers selected from C4 to C10 olefins and having an e

The invention claimed is: 1. A method of making a durable, open-cell foam comprising the steps of: (1) generating a stable, aqueous froth comprising a) one or more copolymers or interpolymers of ethylene and/or 1-propene with or without other monomers selected from C4 to C10 olefins and having an ethylene or 1-propene content from about 2-98 weight percent; b) water; c) a frothing surfactant; and d) a gas; where the components comprise about: a) 35 to 75 percent, b) 35 to 75 percent and c) 1 to 6 percent of the combined weight of a), b) and c), and d) is present in an amount such that d) comprises at least 80 percent of the total volume of all components present in the froth; (2) thereafter subjecting said froth to at least one drying energy source to provide a durable, open-cell foam, in a fashion such that the volume of said resulting foam consists of not less than 70 volume percent of the volume of said froth; and (3) thereafter recovering the durable, open-cell foam. 2. The method of claim 1 wherein the froth of component (1) further comprises component e) a foam stabilizer selected from: alkylcellulose ethers, hydroxyalkyl cellulose ethers, hydroxyalkyl alkylcellulose ethers, guar gum, xanthan gum, and polyoxyethylene resins of at least 20,000 molecular weight, said component e) present in the amount of from about 0.05 to about 2 percent based on the dry weight of component a) polymer. 3. The method of claim 1 where, in the froth of component (1), component a) is a copolymer of ethylene with an alpha-olefin comonomer of from 3 to 10 carbon atoms. 4. The method of claim 3 where the alpha-olefin comonomer of component a) is selected from 1-propene, 1-butene, 1-hexene and 1-octene and component a) has a melt index between about 0.5 and about 30 g/10 min as determined by ASTM D1238 (condition 190 deg C./2.16 kg). 5. The method of claim 1 wherein step (2) the drying energy source is selected from a heated air generator, an infrared ray generator, a dielectric heating device, and any combination or multiplicity thereof. 6. The method of claim 1 further characterized in that the froth is continuously generated and thereafter said froth is continuously subjected to the at least one drying energy source. 7. The method of claim 1 further characterized in that said froth in step (2) is subjected to a combination of at least two drying energy sources, either simultaneously or in sequence. 8. The method of claim 7 where in step (2) the drying energy sources are selected from at least one heated air generator, at least one infrared ray generator and at least one dielectric heating device. 9. The method of claim 1 further characterized in that prior to or after recovery the open cell foam is, on at least one major surface, subjected to heating that softens substantially all of such major surface to a distance of at least 2 percent of the foam's initial thickness below the surface, and while so softened a major portion of that major surface is compressed with a pressure sufficient to convert a plurality of cells, at or near that major surface, to a three-dimensional ellipsoidal shape the major axis of which is aligned generally parallel to said major surface.