Olefin Block Copolymers in Health and Hygiene Ron Weeks The Dow Chemical Company Trademark of The Dow Chemical Company Trademark of The Dow Chemical Company 1
Breakthrough Performance & Cost Olefin block copolymers deliver Elasticity competitive to styrenic block copolymers (SBCs) Adhesive formulation performance comparable to styrene-isoprene-styrene (SIS) Compression set similar to thermoplastic vulcanizates (TPVs) All at improved cost-in-use 2
Uniqueness of Olefin Block Copolymers Random vs. Block Copolymer Structures Random Copolymers Less co-monomer and higher density More co-monomer and lower density Ethylene/Alpha Olefin Random Copolymers Adding more co-monomer lowers the polymer s density and crystallinity while increasing flexibility. However the melt temperature, crystallization temperature and heat resistance also drop as density is lowered. Block Copolymers Soft blocks Hard blocks Proprietary Chain Shuttling technology OBC s use the same raw materials arranged into alternating soft and hard blocks The soft blocks deliver flexibility and the hard blocks deliver heat resistance Note: denotes substantially random 3
Higher Heat Resistance OBCs exhibit 50 C - 60 C higher melting temperatures versus random ethylene copolymers of similar density and modulus This results in higher upper service temperatures for OBCs Note: denotes substantially random 4
Stress Relaxation Performance 100 Relative Scale 1.0 Absolute Scale 80 0.8 Load (%) 60 40 Stress (MPa) 0.6 0.4 20 OBC Random PE SBC 0.2 0 0.0 0 2 4 6 8 10 12 14 0 2 4 6 8 10 12 14 Time (hr) Time (hr) (@ Body Temperature, 50% Strain) OBC polymers show less stress-relaxation compared to SBC. Improved stress-relaxation performance translates to improved fit (less sag) in end-use. 5
Higher Crystallization Temperature OBCs exhibit 50 C -60 C higher recrystallization temperatures versus random ethylene copolymers of similar density and modulus The result is improved processing, such as increased throughput, higher spinning speeds and broader bonding window Faster Set Up during extrusion, lamination, fiber spinning, etc. Random propylene-copolymers are difficult to crystallize hence have a negative impact on processing Note: denotes substantially random 6
Lower Permanent Set OBCs offer elastic recovery comparable to SBCs at high strain The result is olefin elastic films that can be stretched further with excellent recovery 7
250 Permanent Set Performance Random Ethylene-based Random propylene-based Olefin Block Copolymer Permanent Set (%) 200 150 100 ethylene-based propylene-based OBC SBC 50 0 100 300 500 Applied Strain (%) 100 300 500 Applied Strain (%) 100 300 500 Applied Strain (%) OBC closes the performance gap between random copolymers and SBCs. Note: denotes substantially random 8
Positioning of OBC in H&H Health & Hygiene Diapers, Fem Hy & Adult Incontinence Extensible and Elastic Components Ears Side Panel Back- & Top-sheet Waist Band Leg Cuffs Closure Systems Adhesive Components Low Temperature Hot Melt Adhesives Pressure Sensitive Adhesives 9
Excellent Positioning of Olefin Block Copolymers Heat Resistance vs. Processability Heat Resistance SIS SEBS SBS Polypropylene Propylene-based Plastomers PBP Ethylene-based Elastomers OBCs Polyethylene Poor Propylene-based Elastomers Poor Processability Excellent 10
Excellent Positioning of Olefin Block Copolymers Extensibility vs. Processability Extensibility SIS SEBS SBS Ethylene-based Elastomers Propylene-based Plastomers OBCs Propylene-based Elastomers Polyethylene PE Poor Polypropylene PP Poor Processability Excellent 11
Excellent Positioning of Olefin Block Copolymers Elasticity vs. Processability SIS SEBS SBS OBCs Propylene-based Elastomers Elasticity Poor Ethylene-based Elastomers Propylene-based Plastomers Polypropylene Polyethylene Poor Processability Excellent 12
Olefin Block Copolymers in Spunbond Grade of olefin block copolymer Melt Index (2.16 kg @ 190 C) = 15 g/10 min, Density = 0.866 g/cm³ Successful trials (Reicofil 3 & 4 technology) Mono-component Spinning excellent Touch Rubbery Bicomponent trials Spinning excellent Broad bonding window (70 C to 125 C) Core sheath ratios varied from 90/10 to 70/30 Bonding Window Broad bonding window (70 C to 125 C) in both Mono and Bico 13
Olefin Block Copolymer on Reicofil 4 OBC/PE High Through put Standard hpp/pe Bico SPINNABILITY: Bicomponent OBC-based Nonwovens Throughput (ghm) 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 OBC-A OBC-B OBC/PE @ standard Output hpp/pe OBC-C OBC-D OBC-E OBC-F OBC-G OBC-H OBC-I OBC-J OBC-K OBC-L OBC-M OBC-N OBC-O Random-A Random-B Propylene Based Elastomers OBC nonwovens can be produced at competitive rates compared to conventional Bicomponent (PP/PE) and Mono-component (PP or PE) nonwovens. Rates are significantly improved over current random propylene-ethylene copolymers. 14
Elastic Behavior 100 90 ELASTICITY: Recovery after Tensile Deformation 80 Elastic Recovery (%) 70 60 50 40 30 20 10 0 OBC-1 OBC-2 OBC-3 OBC-4 OBC-5 OBC-6 OBC-7 OBC-8 OBC-9 OBC-10 Conventional (Propylene- based) Elastomeric materials OBC nonwovens exhibit elasticity necessary to meet current market needs. Elasticity can be optimized based on core sheath ratios 15
Tensile Properties Nonwovens made with OBC vs Conventional Polymers Tensile Strength (N/gsm) 2.5 2.0 1.5 1.0 0.5 0.0 OBC-based PP-based Random propylene-based PE-based Can be engineered based on OBC and Fiber design 0 200 400 600 800 Maximum Elongation (%) Elongation is significantly improved over PP/PE bi-component nonwovens. Tensile strength/elongation properties can be designed 16
Olefin Block Copolymer Grades Nine grades have been recently launched in multiple markets for a variety of products and applications. OBCs are marketed with the best-in-class cost-performance position, competitive with incumbent solutions and expanding the possibilities for further innovation in comfort-fitting applications. Density (g / cc) Melt Index (g / 10 min) 0.877 0.5 0.866 0.5 0.877 1 0.866 1 0.877 5 0.866 5 0.887 5 0.877 15 0.866 15 17
Conclusions Olefin block copolymers in Spunbond: Total Polyolefin approach for Elastic/Extensible applications in Health & Hygiene Applications Polyolefin processing conditions on standard spunbond technology Similar throughput comparable to hpp, however significant higher than other Elastomeric resins Can manipulate Elastic/Extensible properties to desired end use requirements Olefin block copolymers in Films and Laminates: High line-speed without draw resonance Fast crystallization kinetics / fast development of elasticity Lower permanent set Reduced stress-relaxation at body temperature Formulation flexibility Our Health and Hygiene group specializes in several areas of expertise which can be leveraged to customers to improve current and to develop future products: Material selection and blend design Processing optimization Strong IP Portfolio Mechanical characterization Trademark of The Dow Chemical Company 18
Thank You! Contact: Ron Weeks, rjweeks@dow.com All data in this presentation were internally generated. Trademarks of The Dow Chemical Company 19