CA2484122A1

CA2484122A1 - Multilayered polymer based thin film structure for medical grade products

Info

Publication number: CA2484122A1
Application number: CA 2484122
Authority: CA
Inventors: Gregg Nebgen; Keith M. K. Anderson; Michael W. Scharf
Original assignee: Baxter International Inc.; Gregg Nebgen; Keith M. K. Anderson; Michael W. Scharf
Current assignee: Baxter International Inc
Priority date: 2002-03-21
Filing date: 2003-03-17
Publication date: 2003-10-02
Anticipated expiration: 2023-03-17
Also published as: AU2003220331A1; WO2003080333A1; HK1075230A1; AU2003220331B2; US6964798B2; JP5022559B2; KR20040094822A; CN1642736A; JP2005527401A; BR0308565A; US20020164492A1; EP1490220A1; MXPA04009143A; EP1490220A4; CA2484122C; CO5611185A2; CN1642736B

Abstract

A multiple layer structure comprising a first and a second skin layer, each skin layer comprised of a polypropylene containing polymer, and a radio frequency ("RF") susceptible layer adhered to and between the first and seco nd skin layers. The RF layer has a first component of a propylene based polymer , a second component of a non-propylene polyolefin, a third component of a rad io frequency susceptible polymer, and a fourth component of a polymeric compatibilizing agent.

Claims

1. A multiple layer structure comprising:
a first skin layer;
a radio frequency ("RF") susceptible layer adhered to the first skin layer, the RF layer having a first component of a propylene based polymer, a second component of a non-propylene polyolefin, a third component of a radio frequency susceptible polymer, and a fourth component of a polymeric compatibilizing agent; and a second skin layer adhered to the RF layer and opposed to the first skin layer;
the structure having physical properties within the range a< 40,000 psi;
b>= 70%;
c< 30%;
d> 1.0;
e< 0.1 %;
f< 0.1 %;
g>= 0.05 h<= 60%;
i= 0;
wherein:
a is the mechanical modulus of the composition measured according to ASTM
D-882;
b is the percent recovery in length of the composition after an initial 20%
deformation;
c is the optical haze of the composition processed into a film 9 mils in thickness measured in accordance to ASTM D-1003;
d is the loss tangent of the composition at 1 Hz measured at melt processing temperatures;
e is the elemental halogen content by weight of the composition;
f is the low molecular weight water soluble fraction of the composition;
g is the dielectric loss between 1 and 60 MHZ and over temperatures of 25 to 250°C of the composition;

h is the sample creep measured at 121°C for a 1 inch strip of the composition under 27 psi loading; and, i the composition exhibits no strain whitening after being strained at moderate speeds of about 20 inches (50cm) per minute to about 100% elongation (twice the original length) and the presence of strain whitening (indicated by 1) or lack thereof (indicated by 0) is noted.

2. A multiple layer structure comprising:
a first skin layer of a propylene-containing polymer;
a radio frequency ("RF") susceptible layer adhered to the first skin layer, the RF layer having a first component of a propylene based polymer, a second component of a non-propylene polyolefin, a third component of a radio frequency susceptible polymer, and a fourth component of a polymeric compatibilizing agent; and a second skin layer adhered to the RF layer and opposed to the first skin layer, the second skin layer being a propylene-containing polymer.

3. The structure of claim 2 wherein the non propylene polyolefin of the RF
layer is selected from the group of ethylene copolymers including ultra low density polyethylene, polybutene, butene ethylene copolymers, ethylene vinyl acetate copolymers with vinyl acetate contents between approximately 18-50%, ethylene methyl acrylate copolymers with methyl acrylate contents being between approximately 20-40%, ethylene n-butyl acrylate copolymers with n-butyl acrylate content of between 20-40%, ethylene acrylic acid copolymers with the acrylic acid content of greater than approximately 15%.

4. The structure of claim 2 wherein the radio frequency susceptible polymer is selected from the group consisting of polyamides, ethylene vinyl acetate with vinyl acetate in an amount of 18-50% by weight, ethylene methyl acrylate copolymers with methyl acrylate in an amount between 20%-40% by weight, ethylene vinyl alcohol with vinyl alcohol in an amount of 15%-70%.

5. The structure of claim 4 wherein the polyamide is selected from a group consisting of: aliphatic polyamides resulting from the condensation reaction of di-amines having a carbon number within a range of 2-13, aliphatic polyamides resulting from a condensation reaction of di-acids having a carbon number within a range of 2-13, polyamides resulting from the condensation reaction of dimer fatty acids, and amide containing copolymers.

6. The structure of claim 2 wherein the polymeric compatibilizing agent of the RF layer is a styrene ethylene-butene styrene block copolymer.

7. The structure of claim 6 wherein the styrene ethylene-butene styrene block copolymer is maleic anhydride functionalized.

8. The structure of claim 2 further including a first non radio frequency susceptible core layer interposed between the first skin layer and the RF
layer.

9. The structure of claim 8 wherein the first core layer includes:
a first component of a polyolefin;
a second component selected from the group consisting of ultra low density polyethylene, polybutene copolymers, and, a third component of a compatibilizing agent.

10. The structure of claim 9 wherein the polyolefin of the first component of the first core layer is a polypropylene.

11. The structure of claim 9 wherein the second component of the first core layer is an ultra low density polyethylene.

12. The structure of claim 9 wherein the third component of the first core layer is a styrene ethylene-butene styrene block copolymer.

13. The structure of claim 9 wherein the first core layer includes a fourth component consisting of a scrap material.

14. The structure of claim 9 further including a layer of scrap material interposed between the first core layer and the first skin layer.

15. The structure of claim 9 further including a layer of scrap material interposed between the first core layer and the radio frequency susceptible layer.

16. The structure of claim 9 further including:

a scrap layer adhered to the first core layer on a side opposite the first skin layer; and, a second core layer attached to the scrap layer on a side opposite the first core layer.

17. The structure of claim 9 further including a barrier layer.

18. The structure of claim 17 wherein the barrier layer is interposed between the first core layer and the RF layer.

19. The structure of claim 17 wherein the barrier layer is interposed between the first core layer and the first skin layer.

20. The structure of claim 9 further including:
a barrier layer adhered to the first core layer on a side opposite the first skin layer; and, a second core layer adhered to the barrier layer on side opposite the first core layer.

21. The structure of claim 20 further including two tie layers one of each tie layers being adhered to opposite sides of the barrier layer.

22. The structure of claim 17 wherein the barrier layer is selected from the group consisting of ethylene vinyl alcohols, and highly glassy, crystalline polyamides.

23. The structure of claim 21 wherein the tie layers are modified ethylene and propylene copolymers.

24. A multiple layer structure comprising:
a first skin layer of a propylene-containing polymer;
a radio frequency ("RF") susceptible layer adhered to the first skin layer, the RF layer having a first component of a propylene based polymer in an amount in a range of 30-60% by weight of the RF layer, a second component of a non-propylene polyolefin in an amount within the range of 0-60% by weight of the RF layer, a third component of a radio frequency susceptible polymer in an amount within the range of 3-40% by weight of the RF

layer, and a fourth component of a polymeric compatibilizing agent in an amount within the range of 5-40% by weight of the RF layer; and a second skin layer adhered to the RF layer and opposed to the first skin layer, the second skin layer being a propylene-containing polymer.

25. The structure of claim 24 wherein the first component of the RF
susceptible layer is polypropylene.

26. The structure of claim 25 wherein the second component of the RF
susceptible layer is selected from the group of ultra low density polyethylene and polybutene-1.

27. The structure of claim 26 wherein the third component is a fatty acid polyamide.

28. The structure of claim 27 wherein the fourth component is styrene ethylene-butene styrene block copolymer.

29. The structure of claim 28 wherein the styrene ethylene-butene styrene block copolymer is maleic anhydride functionalized.

30. The structure of claim 29 wherein the components of the RF layer are in an amount within the range as a weight percentage of the RF layer as follows:
first component 35-45%;
second component 35-45%;
third component 7-13%; and, fourth component 7-13%.

31. The structure of claim 30 wherein the fatty acid polyamide is a dimer fatty acid polyamide.

32. A multiple layer structure comprising:
a first skin layer of a propylene-containing polymer;
a core layer having a side adhered to the first skin layer;
a radio frequency ("RF") susceptible layer adhered to the core layer on a side opposite the first skin layer, the RF layer being composed of a first component of a propylene based polymer in an amount in a range of 30-60% of the weight of the RF layer, a second component of a non-propylene polyolefin in an amount within the range of 25-50% of the weight of the RF layer, a third component of a radio frequency susceptible polymer in an amount within the range of 3-40% by weight of the RF layer, and a fourth component of a polymeric compatibilizing agent in an amount within the range of 5-40% by weight of the RF
layer; and a second skin layer adhered to the RF layer and opposed to the first skin layer, the second skin layer being a propylene-containing polymer.

33. The structure of claim 32 wherein the core layer is non radio frequency susceptible.

34. The structure of claim 33 wherein the second component of the RF
susceptible layer is selected from the group of ultra low density polyethylene and polybutene-1, the radio frequency susceptible polymer is a dimer fatty acid polyamide, the fourth component of the RF susceptible layer is an SEBS block copolymer, the core layer includes:
a first component of a polyolefin;
a second component selected from the group consisting of ultra low density polyethylene, and polybutene copolymers; and a third component of a compatibilizing agent.

35. The structure of claim 34 wherein the polyolefin of the first component of the core layer is a polypropylene.

36. The structure of claim 35 wherein the second component of the core layer is an ultra low density polyethylene.

37. The structure of claim 36 wherein the compatibilizing agent of the third component of the core layer is a styrene ethylene-butene styrene block copolymer.

38. The structure of claim 37 wherein the core layer further includes a component of scrap material.

39. A multiple layer structure of stacked layers comprising:
a first skin layer of a propylene-containing polymer;

a radio frequency ("RF") susceptible layer, the RF layer being composed of a first component of a propylene based polymer in an amount in a range of 30-60%
of the weight of the RF layer, a second component of a non-propylene polyolefin in an amount within the range of 25-50% of the weight of the RF layer, a third component of a radio frequency susceptible polymer in an amount within the range of 3-40% by weight of the RF
layer, and a fourth component of a polymeric compatibilizing agent in an amount within the range of 5-40% by weight of the RF layer;
a first core layer between the first skin layer and the RF layer; and, a scrap layer attached to the core layer; and a second skin layer adhered to the RF layer and opposed to the first skin layer, the second skin layer being a propylene-containing polymer.

40. The structure of claim 39 wherein one side of the first skin layer is attached to the core layer, the scrap layer is attached to the core layer on the side opposite the first skin layer, and the RF susceptible layer is attached to the scrap layer on the side opposite the core layer.

41. The structure of claim 39 wherein one side of the first skin layer is attached to the scrap layer, the core layer is attached to the scrap layer on a side opposite the first skin layer, and the RF susceptible layer is attached to the core layer on the side opposite the scrap layer.

42. The structure of claim 41 further including a second core layer interposed between the core layer and the RF susceptible layer.

43. The structure of claim 39 wherein the second component of the RF
susceptible layer is selected from the group of ultra low density polyethylene and polybutene-1, the radio frequency susceptible polymer is a dimer fatty acid polyamide, the fourth component of the RF susceptible layer is an SEBS block copolymer, the first core layer includes:
a first component of a polyolefin;
a second component selected from the group consisting of ultra low density polyethylene, and polybutene copolymers; and, a third component of a compatibilizing agent.

44. A multiple layer structure comprising:
a first skin layer of a propylene-containing polymer;
a radio frequency ("RF") susceptible layer, the RF layer being composed of a first component of a propylene based polymer in an amount in a range of 30-60%
of the weight of the RF layer, a second component of a non-propylene polyolefin in an amount within the range of 25-50% of the weight of the RF layer, a third component of a radio frequency susceptible polymer in an amount within the range of 3-40% by weight of the RF
layer, and a fourth component of a polymeric compatibilizing agent in an amount within the range of 5-40% by weight of the RF layer;
a first core layer between the first skin layer and the RF layer;
a barrier layer attached to the core layer; and a second skin layer adhered to the RF layer and opposed to the first skin layer, the second skin layer being a propylene-containing polymer.

45. The structure of claim 44 wherein one side of the first skin layer is attached to the barrier layer, the core layer is attached to the barrier layer on a side opposite the first skin layer, and the RF susceptible layer is attached to the core layer on the side opposite the barrier layer.

46. The structure of claim 39 wherein one side of the first skin layer is attached to the core layer, the barrier layer is attached to the core layer on the side opposite the first skin layer, and the RF susceptible layer is attached to the barrier layer on the side opposite the core layer.

47. The structure of claim 45 wherein a second core layer is interposed between the core layer and the RF susceptible layer.

48. The structure of claim 44 wherein the second component of the RF
susceptible layer is selected from the group of ultra low density polyethylene and polybutene-1, the radio frequency susceptible polymer is a dimer fatty acid polyamide, the fourth component of the RF susceptible layer is an SEBS block copolymer, wherein the barrier layer is selected from the group consisting of ethylene vinyl alcohols, and highly glassy polyamides.

49. The structure of claim 44 further including two tie layers one on each side of the barrier layer.

50. The structure of claim 49 wherein the tie layers are modified ethylene and propylene copolymers.

51. A multiple layer structure comprising:
a first skin layer of a propylene-containing polymer;
a core layer having one side adhered to the first skin layer;
a radio frequency ("RF") susceptible layer adhered to the core layer on a side opposite the first skin layer, the RF layer being composed of a high melting temperature and flexible polypropylene in an amount in a range of 30-60% of the weight of the RF layer, a radio frequency susceptible polymer in an amount within the range of 5-20% by weight of the RF layer, and a polymeric compatibilizing agent in an amount within the range of 5-20% by weight of the RF layer; and a second skin layer adhered to the RF layer and opposed to the first skin layer, the second skin layer being a propylene-containing polymer.

52. The structure of claim 51 wherein the radio frequency susceptible polymer of the RF susceptible layer is a dimer fatty acid polyamide and the polymeric compatibilizing agent is a styrene ethylene-butene styrene block copolymer.

53. The structure of claim 52 wherein the core includes:
a first component of a polyolefin;
a second component selected from the group consisting of ultra low density polyethylene, and polybutene copolymers; and a third component of a compatibilizing agent.