Polymer-based foam compositions comprising inorganic particulate fillers
There is disclosed a polymer-based foam composition comprising a polymer and up to 20 M.-% particles of one or more inorganic particulate materials, based on the total weight of the composition, wherein the one or more inorganic particulate materials comprise less than 20 wt.-% Al, calculated as Al 2 O 3 -content. According to one aspect, the one or more inorganic particulate materials comprise phyllosilicates. Also part of the present invention is the use of such polymer-based foam compositions and their method of production.
1. A polymer-based foam composition comprising a polymer; and
from 1 to 20 wt.-% inorganic particulate materials, based on the total weight of the polymer-based foam composition;
wherein the inorganic particulate materials comprise chlorite and at least one phyllosilicate selected from mica, talc, kaolin, and combinations thereof;
wherein the inorganic particulate materials comprise from 1 wt.-% Al to 10 wt.-% Al; and
wherein the inorganic particulate materials have a d 50 from 3 to 4.5 microns.
2. A polymer-based foam composition comprising inorganic particulate materials that comprise chlorite and at least one phyllosilicate selected from mica, talc, kaolin and combinations thereof;
wherein the inorganic particulate materials comprise from 1 wt.-% Al to 10 wt.-% Al; the polymer-based foam composition contains N f =100,000 or more cells per cm 3 ; and
the inorganic particulate materials have a d 50 from 3 to 4.5 microns.
3. The polymer-based foam composition according to claim 1 , wherein the polymer-based foam composition comprises a polymer-based foam film having a thickness ranging from 1 to 850 μm.
4. The polymer-based foam composition according to claim 1 , wherein the polymer is a thermoplastic polymer or a rubber.
5. The polymer-based foam composition according to claim 4 , wherein the thermoplastic polymer is a polyolefin.
6. The polymer-based foam composition according to claim 1 , wherein the polymer is present in a greater weight amount than any other component of the polymer-based foam composition.
7. The polymer-based foam composition according to claim 1 having an average cell size of φ=600 μm or less in either the vertical direction (φ VD ), or the width direction (φ WD ) or both.
8. The polymer-based foam composition according to claim 1 having a ratio φ VD /φ WD of the average cell size in a vertical direction φ VD to the average cell size in a width direction φ WD of 1 or more.
9. The polymer-based foam composition according to claim 1 containing N f =100,000 or more cells per cm 3 .
10. The polymer-based foam composition according to claim 1 produced by an extrusion process.
11. The polymer-based foam composition according to claim 1 produced by a blown film process.
12. A method of manufacturing a good, the method comprising incorporating the polymer-based foam composition of claim 1 in the good, wherein the good comprises packaging, a food packaging product, a plastic part for automotive vehicles, or a thermal and/or noise insulation foam, pipe, consumer good or appliance.
13. A method of formation of the polymer-based foam composition as defined in claim 1 , comprising:
a) providing a polymer composition;
b) providing the inorganic particulate materials;
c) introducing the inorganic particulate materials into the polymer composition in a blown film process; and
d) foaming the polymer composition using a gas.
14. The method of claim 13 , wherein the gas is CO 2 , nitrogen, or a noble gas.