Abstract: A film that contains a core layer positioned adjacent to an outer layer is provided. The core layer contains a relatively high percentage of thermoplastic biopolymers that are both biodegradable and renewable. Despite being biodegradable and renewable, many biopolymers tend to be relatively stiff in nature. The present inventors have discovered, however, that through selective control over the components in the core and outer layers, a film can be readily formed having good mechanical properties. Among other things, this is accomplished by blending the biopolymer in the core layer with a polyolefin. A polyolefin is also employed in the outer layer. In addition to providing functionality to the film (e.g., heat sealing, printing, etc.), the polyolefin-containing outer layer also helps counteract the stiffness of the biopolymer in the core layer, and helps improve processability, stiffness, and ductility.

Abstract: A method and system for melt processing a thermoplastic composition that contains a starch and plasticizer is provided. The composition is melt blended and extruded through a die to form an extrudate, which is thereafter cooled using a multi-stage system of the present invention that includes at least one water-cooling stage and at least one air-cooling stage. More particularly, the extrudate is initially contacted with water for a certain period time so that it becomes partially cooled and solidified on its surface. After the water-cooling stage(s), the extrudate is also subjected to at least one air-cooling stage in which a stream of air is placed into contact with the extrudate.

Abstract: A film that contains a thermoplastic polyurethane and water-soluble polymer is provided. The film is both elastic and water-sensitive (e.g., water-soluble, water-dispersible, etc.) in that it loses its integrity over time in the presence of water. The dual attributes of elasticity and water-sensitivity may be achieved by reducing the tendency of the thermoplastic polyurethane and water-soluble polymer to form separate phases. Namely, phase separation may cause the elastomer to act as a barrier and limit the ability of the water-soluble polymer to contact water and thereby disperse. To minimize such phase separation, a variety of aspects of the film construction may be selectively controlled, such as the nature of the thermoplastic polyurethane and water-soluble polymer, the relative amount of each component, and so forth.

Abstract: A film that is both elastic and water-sensitive (e.g., water-soluble, water-dispersible, etc.) in that it loses its integrity over time in the presence of water is provided. To achieve these dual attributes, the film contains an olefinic elastomer and a water-soluble polymer. Although these polymers are normally chemically incompatible due to their different polarities, the present inventors have discovered that phase separation may be minimized by selectively controlling certain aspects of the film, such as the nature of the polyolefin, water-soluble polymer, and other film components, the relative amount of the film components, and so forth. For example, certain water-soluble polymers may be selected that have a low molecular weight and viscosity to enhance their melt compatibility with nonpolar polyolefins. This, in turn, may result in a film that is generally free of separate phases, which would otherwise limit the ability of the water-soluble polymer to contact water and disperse.

Abstract: A biodegradable and renewable film that may be employed in a wide variety of applications is provided. The film is formed from a thermoplastic composition that contains at least one starch and at least one plant protein. Even at a high renewable material content, the present inventors have discovered that films may be readily formed from plant proteins and starches by selectively controlling the individual amount of the starch and plant proteins, the nature of the starch and plant proteins, and other components used in the film. Balancing the amount of starches and plant proteins within a certain range, for instance, can reduce the likelihood of plant protein aggregation and enhance the ability of the composition to be melt processed. The composition also contains at least one plasticizer that improves the thermoplastic nature of the protein and starch components. The selection of the plasticizer may also help reduce the tendency of the plant protein to aggregate during melt processing.

Abstract: An injection molding material that includes a renewable resin containing a combination of renewable polymers (e.g., starch and plant protein) and a plasticizer is provided. Although such compounds are normally difficult to process into thermoplastics, the present inventors have discovered that injection molding materials may nevertheless be formed by melt blending the renewable resin with a synthetic resin (e.g., polyolefin) while selectively controlling the nature of the resins and their relative concentrations. In this manner, a morphology may be achieved in which the renewable resin is present as a discontinuous phase that is dispersed within a continuous phase of the synthetic resin (e.g., “island-in-the-sea” morphology). The discontinuous and continuous phases may each constitute from about 30 vol. % to about 70 vol. %, and in some embodiments, from about 40 vol. % to about 60 vol. %.

Abstract: A film that contains a thermoplastic polyurethane and water-soluble polymer is provided. The film is both elastic and water-sensitive (e.g., water-soluble, water-dispersible, etc.) in that it loses its integrity over time in the presence of water. The dual attributes of elasticity and water-sensitivity may be achieved by reducing the tendency of the thermoplastic polyurethane and water-soluble polymer to form separate phases. Namely, phase separation may cause the elastomer to act as a barrier and limit the ability of the water-soluble polymer to contact water and thereby disperse. To minimize such phase separation, a variety of aspects of the film construction may be selectively controlled, such as the nature of the thermoplastic polyurethane and water-soluble polymer, the relative amount of each component, and so forth.

Abstract: A film that contains a thermoplastic polyurethane and water-soluble polymer is provided. The film is both elastic and water-sensitive (e.g., water-soluble, water -dispersible, etc.) in that it loses its integrity over time in the presence of water. The dual attributes of elasticity and water-sensitivity may be achieved by reducing the tendency of the thermoplastic polyurethane and water-soluble polymer to form separate phases. Namely, phase separation may cause the elastomer to act as a barrier and limit the ability of the water-soluble polymer to contact water and thereby disperse. To minimize such phase separation, a variety of aspects of the film construction may be selectively controlled, such as the nature of the thermoplastic polyurethane and water-soluble polymer, the relative amount of each component, and so forth. For example, thermoplastic polyurethanes are polar in nature and thus may be generally compatible with water-soluble polymers (e.g., polyvinyl alcohol), which are also polar in nature.

Abstract: Polylactic acid fibers formed from a thermoplastic composition that contains polylactic acid and a polymeric toughening additive are provided. The present inventors have discovered that the specific nature of the components and process by which they are blended may be carefully controlled to achieve a composition having desirable morphological features. More particularly, the toughening additive can be dispersed as discrete physical domains within a continuous phase of the polylactic acid. These domains have a particular size, shape, and distribution such that upon fiber drawing, they absorb energy and become elongated. This allows the resulting composition to exhibit a more pliable and softer behavior than the otherwise rigid polylactic acid. Through selective control over the components and method employed, the present inventors have discovered that the resulting fibers may thus exhibit good mechanical properties, both during and after melt spinning.

Abstract: A multicomponent fiber that contains a high-melting aliphatic polyester and a low-melting aliphatic polyester is provided. The multicomponent fibers are substantially biodegradable, yet readily processed into nonwoven structures that exhibit effective fibrous mechanical properties.

Abstract: A biodegradable, substantially continuous filament is provided. The filament contains a first component formed from at least one high melting polyester and a second component formed from at least one low melting polyester. The low melting point polyester is an aliphatic-aromatic copolyester formed by melt blending a polymer and an alcohol to initiate an alcoholysis reaction that results in a copolyester having one or more hydroxyalkyl or alkyl terminal groups. By selectively controlling the alcoholysis conditions (e.g., alcohol and copolymer concentrations, catalysts, temperature, etc.), a modified aliphatic-aromatic copolyester may be achieved that has a molecular weight lower than the starting aliphatic-aromatic polymer. Such lower molecular weight polymers also have the combination of a higher melt flow index and lower apparent viscosity, which is useful in the formation of substantially continuous filaments.

Abstract: An injection molding material that includes a renewable resin containing a combination of renewable polymers (e.g., starch and plant protein) and a plasticizer is provided. Although such compounds are normally difficult to process into thermoplastics, the present inventors have discovered that injection molding materials may nevertheless be formed by melt blending the renewable resin with a synthetic resin (e.g., polyolefin) while selectively controlling the nature of the resins and their relative concentrations. In this manner, a morphology may be achieved in which the renewable resin is present as a discontinuous phase that is dispersed within a continuous phase of the synthetic resin (e.g., “island-in-the-sea” morphology). The discontinuous and continuous phases may each constitute from about 30 vol. % to about 70 vol. %, and in some embodiments, from about 40 vol. % to about 60 vol. %.

Abstract: A biodegradable and renewable film that may be employed in a wide variety of applications is provided. The film is formed from a thermoplastic composition that contains at least one starch and at least one plant protein. Even at a high renewable material content, the present inventors have discovered that films may be readily formed from plant proteins and starches by selectively controlling the individual amount of the starch and plant proteins, the nature of the starch and plant proteins, and other components used in the film. Balancing the amount of starches and plant proteins within a certain range, for instance, can reduce the likelihood of plant protein aggregation and enhance the ability of the composition to be melt processed. The composition also contains at least one plasticizer that improves the thermoplastic nature of the protein and starch components. The selection of the plasticizer may also help reduce the tendency of the plant protein to aggregate during melt processing.

Abstract: A method for forming a biodegradable polyester suitable for use in fibers is provided. Specifically, a biodegradable polyester is melt processed at a controlled water content to initiate a hydrolysis reaction. Without intending to be limited by theory, it is believed that the hydroxyl groups present in water are capable of attacking the ester linkage of the polyester, thereby leading to chain scission or “depolymerization” of the polyester molecule into one or more shorter ester chains. By selectively controlling the reaction conditions (e.g., water content, temperature, shear rate, etc.), a hydrolytically degraded polyester may be achieved that has a molecular weight lower than the starting polymer. Such lower molecular weight polymers have a higher melt flow rate and lower apparent viscosity, which are useful in a wide variety of fiber forming applications, such as in the meltblowing of nonwoven webs.

Abstract: A method for forming a biodegradable polylactic acid suitable for use in fibers is provided. Specifically, a polylactic acid is melt processed at a controlled water content to initiate a hydrolysis reaction. Without intending to be limited by theory, it is believed that the hydroxyl groups present in water are capable of attacking the ester linkage of polylactic acids, thereby leading to chain scission or “depolymerization” of the polylactic acid molecule into one or more shorter ester chains. The shorter chains may include polylactic acids, as well as minor portions of lactic acid monomers or oligomers, and combinations of any of the foregoing. By selectively controlling the hydrolysis conditions (e.g., moisture and polymer concentrations, temperature, shear rate, etc.), a hydrolytically degraded polylactic acid may be achieved that has a molecular weight lower than the starting polymer.

Abstract: A method for forming a fiber is provided. The method comprises supplying at least one aromatic polyester to a melt processing device and modifying the aromatic polyester with at least one polyether copolymer within the device to form a thermoplastic composition having a melt flow rate that is greater than the melt flow rate of the aromatic polyester. The polyether copolymer contains a repeating unit (A) having the following formula: ?C2H4O?x ??(A) wherein, x is an integer from 1 to 250, the polyether copolymer further containing a repeating unit (B) having the following formula: ?CnH2nO?y ??(B) wherein, n is an integer from 3 to 20; and y is an integer from 1 to 150.

Abstract: A film that contains a thermoplastic polyurethane and water-soluble polymer is provided. The film is both elastic and water-sensitive (e.g., water-soluble, water-dispersible, etc.) in that it loses its integrity over time in the presence of water. The dual attributes of elasticity and water-sensitivity may be achieved by reducing the tendency of the thermoplastic polyurethane and water-soluble polymer to form separate phases. Namely, phase separation may cause the elastomer to act as a barrier and limit the ability of the water-soluble polymer to contact water and thereby disperse. To minimize such phase separation, a variety of aspects of the film construction may be selectively controlled, such as the nature of the thermoplastic polyurethane and water-soluble polymer, the relative amount of each component, and so forth. For example, thermoplastic polyurethanes are polar in nature and thus may be generally compatible with water-soluble polymers (e.g., polyvinyl alcohol), which are also polar in nature.

Abstract: A film that is both elastic and water-sensitive (e.g., water-soluble, water-dispersible, etc.) in that it loses its integrity over time in the presence of water is provided. To achieve these dual attributes, the film contains an olefinic elastomer and a water-soluble polymer. Although these polymers are normally chemically incompatible due to their different polarities, the present inventors have discovered that phase separation may be minimized by selectively controlling certain aspects of the film, such as the nature of the polyolefin, water-soluble polymer, and other film components, the relative amount of the film components, and so forth. For example, certain water-soluble polymers may be selected that have a low molecular weight and viscosity to enhance their melt compatibility with nonpolar polyolefins. This, in turn, may result in a film that is generally free of separate phases, which would otherwise limit the ability of the water-soluble polymer to contact water and disperse.

Abstract: A multicomponent fiber that contains a high-melting aliphatic polyester and a low-melting aliphatic polyester is provided. The multicomponent fibers are substantially biodegradable, yet readily processed into nonwoven structures that exhibit effective fibrous mechanical properties.

Abstract: This invention relates, in general, to blend compositions of an unmodified poly vinyl alcohol and a thermoplastic elastomer and thermoplastic film and fiber structures comprising these blend compositions. More specifically, this invention relates to substantially water-free films and fibers comprising unmodified polyvinyl alcohol and a thermoplastic elastomer.