초록

A formulation for producing a polymeric material including high-density polyethylene, a chemical blowing agent, and other optional components is described.

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1. A formulation comprising (a) at least one high density polyethylene (HDPE) base resin,(b) a chemical blowing agent which is up to about 2 wt % of the formulation,(c) a physical blowing agent,(d) a nucleating agent which is up to about 15 wt % of the formulation,(e) a slip agent which is up to abo

1. A formulation comprising (a) at least one high density polyethylene (HDPE) base resin,(b) a chemical blowing agent which is up to about 2 wt % of the formulation,(c) a physical blowing agent,(d) a nucleating agent which is up to about 15 wt % of the formulation,(e) a slip agent which is up to about 3 wt % of the formulation, and(f) a colorant which is up to about 4 wt % of the formulation,wherein the formulation has a density of about 0.4 g/cm3 to about 0.9 g/cm3, the HDPE base resin is about 50 wt % to about 99.9 wt % of the formulation, and the formulation is non-aromatic. 2. The formulation of claim 1, wherein the HDPE is a high melt strength HDPE. 3. The formulation of claim 1, wherein the HDPE is long-chain branching HDPE. 4. The formulation of claim 1, wherein the HDPE is a hexene copolymer. 5. The formulation of claim 4, wherein the HDPE base resin is about 85 wt % to about 99.9 wt % of the formulation. 6. The formulation of claim 5, wherein the HDPE base resin is about 10% to about 100% virgin HDPE. 7. The formulation of claim 1, wherein the chemical blowing agent is about 0.1 wt % to about 2 wt % of the formulation. 8. The formulation of claim 1, wherein the nucleating agent is selected from the group consisting of talc, CaCO3, mica, and mixtures of at least two of the foregoing. 9. The formulation of claim 1, wherein the nucleating agent is about 0.1 wt % to about 7 wt % of the formulation. 10. The formulation of claim 9, wherein the formulation lacks talc. 11. The formulation of claim 1, wherein the base resin is 100% virgin HDPE. 12. The formulation of claim 1, wherein the HDPE base resin comprises a first HDPE base resin that comprises 100% virgin HDPE and a second HDPE base resin that comprises regrind. 13. A formulation comprising at least one high density polyethylene (HDPE) base resin, a chemical blowing agent, a physical blowing agent, a nucleating agent, a slip agent, and a colorant, wherein (a) the HDPE base resin is about 80 wt % to about 99.9 wt % of the formulation,(b) the chemical blowing agent is up to about 2 wt % of the formulation,(c) the nucleating agent is up to about 15 wt % of the formulation,(d) the slip agent is up to about 3 wt % of the formulation,(e) the colorant is up to about 4 wt % of the formulation, and wherein the formulation has a density of about 0.4 g/cm3 to about 0.9 g/cm3, and wherein the formulation is non-aromatic. 14. The formulation of claim 13, wherein (a) the HDPE is about 95 wt % of the formulation, (b) the chemical blowing agent is about 1.5 wt % of the formulation, (c) the nucleating agent is about 0.5 wt % of the formulation, (d) the slip agent is about 2 wt % of the formulation, and (e) the colorant is about 1 wt % of the formulation. 15. The formulation of claim 1, wherein the formulation has a density of about 0.5 g/cm3 to about 0.75 g/cm3. 16. The formulation of claim 1, wherein the physical blowing agent is selected from the group consisting of N2, CO2, helium, argon, and air. 17. The formulation of claim 1, wherein the physical blowing agent is N2 or CO2. 18. The formulation of claim 1, wherein the physical blowing agent is introduced to the formulation as a supercritical fluid. 19. The formulation of claim 17, wherein the physical blowing agent is introduced to the formulation as a supercritical fluid. 20. The formulation of claim 1, wherein the physical blowing agent is introduced to the formulation at a rate of about 0.02 pounds per hour to about 1.3 pounds per hour. 21. The formulation of claim 1, wherein the physical blowing agent is introduced to the formulation at a rate of about 0.05 pounds per hour to about 0.15 pounds per hour. 22. The formulation of claim 19, wherein the physical blowing agent is introduced to the formulation at a rate of about 0.05 pounds per hour to about 0.15 pounds per hour. 23. The formulation of claim 1, wherein the HDPE base resin is about 92 wt % to about 99.9 wt % of the formulation. 24. A formulation comprising (a) at least one high density polyethylene (HDPE) base resin,(b) a chemical blowing agent which is up to about 2 wt % of the formulation,(c) a physical blowing agent,(d) a nucleating agent which is up to about 15 wt % of the formulation, and(e) a slip agent which is up to about 3 wt % of the formulation,wherein the formulation has a density of about 0.4 g/cm3 to about 0.9 g/cm3, and the HDPE base resin is about 92 wt % to about 99.9 wt % of the formulation.