BRPI0816027B1 - SYNTHETIC LAWN SURFACE - Google Patents

Abstract

A synthetic lawn surface is shown and described including a synthetic lawn surface including a synthetic grass carpet having a flexible base sheet, and a shock absorber pad, the shock absorber pad comprising a non-crosslinked polyolefin foam. The foam may be recyclable as it is not crosslinked.

Description

SYNTHETIC LAWN SURFACE

History of the invention

Field of the Invention [0001] The embodiments described herein generally refer to a shock absorbing layer in thermoplastic foam. In another aspect, the embodiments described here refer to a synthetic lawn that includes a shock-absorbing layer in thermoplastic foam, where the foam can be recyclable.

History of the invention [0002] The artificial lawn consists of a profusion of tufts of artificial grass that extend upwards on a laminar substrate. The lawn is usually laid on a flat ground surface and prepared to form a field for playing sports, in order to imitate a field surface for playing sports on natural grass.

[0003] For some types of games, a resilient bottom cushion is placed under the grass on the firm ground support surface to allow for a shock absorbing effect. Likewise, in some cases, a layer of sand or other particulate material is placed on the upper surface of the carpet's base sheet and around the filaments. An example of this type of construction is shown in US Patent No. 4,389,435, issued on June 21, 1983, to Frederick T. Haas, Jr. Another example is shown in American Patent No. 4,637,942, issued on June 20, 1983. January 1987 to Seymour A. Tomarin.

[0004] In addition, other examples of artificial lawns, formed with grass-like carpet

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2/45 placed on a resilient lower cushion are described in U.S. Patent No. 3,551,263 issued December 29, 1971 to Carter et al., Which describes a lower polyurethane foam cushion, U.S. Patent No. 3,332. 828 issued on July 25, 1967 to Faria et al., Which describes a lower cushion made of PVC or polyurethane plastic foam; U.S. Patent No. 4,637,942 issued on January 20, 1987 to Seymour A. Tomarin that describes a rubber-like bottom cushion; U.S. Patent No. 4,882,208, issued on November 21, 1989, to Han-Urich Brietschidel, which illustrates a closed cell cross-linked polyethylene foam cushion; US Patent No. 3,597,297 issued on August 3, 1971, to Theodore Bucholz et al., which describes a lower polyurethane pad with empty spaces; and U.S. Patent No. 4,505,960, issued March 19, 1985 to James W. Leffingwell, which describes shock absorbing pads made of elastomeric foams of polyvinyl chloride, polyethylene, polyurethane, polypropylene, etc.

[0005] Shock absorbing layers can, of course, be used more widely in other applications, such as energy damping on floors, for example. Therefore, materials and methods are still needed to form shock-absorbing layers, including recyclable shock-absorbing layers.

Summary of the invention [0006] In one aspect, the embodiments described herein relate to a synthetic grass surface, comprising a synthetic grass carpet having a flexible base sheet, and a shock absorbing pad, the pad being

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3/45 shock absorber comprises a non-crosslinked polyolefin foam.

[0007] Other aspects and advantages of the invention will be evident based on the description and attached claims described below.

Brief description of the figures [0008] Figure 1 illustrates the instrumentation and experimentation for a shock absorption test according to FIFA standards;

[0009] At Figures 2a and 2b compare the results of analysis in behavior stress-strain compressive in foams, in according to achievements on here described, with

the results of cross-linked polyethylene foams;

[0010] Figures 3a and 3b compare the results of the compressive strain versus time test for foams according to the embodiments described here, with the results of cross-linked polyethylene foams;

[0011] Figure 4 compares the results of the creep compression behavior test for foams according to the embodiments described here, with the results of cross-linked polyethylene foams; and [0012] Figure 5 illustrates synthetic grass that can be formed using embodiments of non-crosslinked polyolefin foams described herein.

Detailed description of the invention

General Definitions and Measurement Methods [0013] The following terms have the meaning given to them for the purposes of the invention:

[0014] Polymer means a substance composed of molecules with large molecular mass consisting of units

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4/45 repeating structures, or monomers, connected by covalent chemical bonds. The term polymer generally includes, but is not limited to, homopolymers, copolymers, such as copolymers, terpolymers, etc. en bloc, grafted, random or alternate and their mixtures and modifications.

In addition, unless otherwise specified, the term polymer includes all possible geometric configurations of the molecular structure. These settings include similar isotactic, syndiotactic, random configurations.

[0015]

Interpolymer means a polymer prepared by polymerizing at least two different types of monomers. The generic term interpolymer includes the term copolymer (which is generally used to refer to a polymer prepared from two different monomers), as well as the term terpolymer (which is generally used to refer to a polymer prepared from three different types of monomers) . The class of materials known as interpolymers also encompasses polymers prepared through the polymerization of four or more types of monomers.

[0016] The density of resins and compositions is measured according to ASTM D792.

[0017] Foam density is measured according to ASTM D3575 / W / B.

[0018] The Melting Index (I ₂ ) is determined according to ASTM D1238 using a weight of 2.16 kg at 190 ^o C for polymers comprising ethylene as the main component in the polymer. The Melt Flow Rate (MFR) is determined according to ASTM D1238 using a weight of 2.16 kg at 230 ^o C for polymers comprising propylene as a component

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Main 5/45 in the polymer.

[0019] The molecular weight distribution of the polymers is determined using gel permeation chromatography (GPC) in a PL-GPC220 high temperature chromatographic unit from Polymer Laboratories equipped with four linear mixed bed columns (Polymer Laboratories (particle size 20 microns) )). The oven temperature is 160 ^o C with the automatic sampler heated to 160 ^o C and the moderate heat zone to 145 ^o C. The solvent is 1,2,4-trichlorobenzene containing 200 ppm 2,6-di -t-butyl-4-methylphenol. The flow rate is 1.0 milliliter / minute and the injection size is 100 microliters. Solutions with approximately 0.2% by weight of the samples are prepared for injection by dissolving the sample in 1,2,4-trichlorobenzene purged with nitrogen, containing 200 ppm 2,6-di-t-butyl-4-methylphenol for 2 , 5 hours at 160 ^o C with light mixing.

[0020] The molecular weight determination is deduced using ten polystyrene standards with narrow molecular weight distribution (from Polymer Laboratories, EasiCal PS1 ranging from 580 - 7,500,000 g / mol) together with their elution volumes. The equivalent molecular weights of polypropylene are determined using appropriate Mark-Houwink coefficients for polypropylene (as described by Th.G.Scholte, NLJ Meijerink, HMSchoffellers, and AMGBrands, J.Appl.Polym.Sci., 29, 3763 - 3782 (1984) and polystyrene (as described by EPOtocka, RJRoe, NYHellman, PMMuglia, Macromolecules, 4, 507 (1971)) in the Mark-Houwink equation:

[0021] {N} = KM ^a where Kpp = 1.90E-04, app = 0.725 and _S = 1.2 Kp 6E04, 02 = 0.7 _ps.

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6/45 [0022] Molecular weight distribution or MWD is measured using conventional GPC according to the procedure described by Williams, T .; Ward, I.M.Journal of Polymer Science, Polymer Letters Edition (1968), 6 (9), 621-624. Coefficient B is 1. Coefficient A is 0.4316.

The term high pressure, low density type resin means that the polymer partially or totally homopolymerized or copolymerized in autoclave or in tubular reactors at pressures above 14,500 psi (100

MPa) with the use of free radical initiators, such as, for example,

US 4,599,392, incorporated herein by reference), and includes

LDPE which can also be referred to as a high pressure ethylene polymer or highly branched polyethylene.

The cumulative detection fraction (CDF) of these materials is greater than about 0.02 for molecular weight greater than 1000000 g / mol, as measured by light scattering. CDF can be determined as described in WO2005 / 023912 A2, incorporated herein by reference for its teachings on CDF. The preferred low density, high pressure polyethylene material (LDPE) has a melting index MI (I2) less than about 20, more preferably less than about 15, most preferably less than 10, and greater than about 0 , 1, more preferably greater than about 0.2, most preferably greater than 0.3 g / 10 min. The preferred LDPE will have a density between about 0.915 g / cm ³ and 0.930 g / cm ³ , with less than 0.925 g / cm ³ being more preferred.

[0024] Crystallinity means the atomic dimension or structural order of a polymeric composition. Crystallinity is often represented by a fraction or percentage of the volume of the material that is crystalline or as

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7/45 a measure of how likely the arrangement of atoms or molecules should be in a regular pattern, that is, in a crystal. The crystallinity of polymers can be adjusted very precisely and to a very wide extent by heat treatment. A crystalline or semi-crystalline polymer has a crystalline melting point or first order transition (Tm) as determined by differential scanning calorimetry (DSC) or equivalent technique. The term can be used alternatively with the term semi-crystalline. The term amorphous refers to a polymer without a crystalline melting point as determined by differential scanning calorimetry (DSC) or equivalent technique.

[0025] Differential Scanning Calorimetry (DSC) is a common technique that can be used to examine the melting and crystallization of semi-crystalline polymers. The general principles of DSC measurement and DSC applications for studying semi-crystalline polymers are described in standard texts (eg E.A.Turi, ed., Thermal Characterization of Polymeric

Materials, Academic Press, 1981)

DSC is an appropriate method for determining the melting characteristics of a polymer.

[0026]

DSC analysis was performed using TA Instruments model Q1000 DSC equipment,

Inc. DSC is calibrated using the method described below.

First, a reference line is obtained by operating the DSC from -90 ^o C

290 ^o C without sample in its aluminum container.

Then 7 milligrams of a fresh sample of indium is analyzed, heating the sample to 180 ^o C, cooling the sample to

140 ^o C at a cooling rate of 10 ^o C / min, then keeping the sample isothermally at 140 ^o C for 1 minutes, followed by heating the sample from 140 ^o C to 180 ^o C at a rate

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8/45 heating at 10 ^o C / min. The heat of fusion and the start of fusion of the indium sample are determined and verified to be in the range of 0.5 ^o C to 156.6 ^o C for the start of fusion and in the range of 0.5J / ga 28.71 J / g for the heat of fusion. Then, deionized water is analyzed by cooling a fresh sample droplet in the DSC container from 25 ^o C to -30 ^o C at a cooling rate of 10 ^o C / min. The sample is kept isothermally at -30 ^o C for 2 minutes, and heated to 30 ^o C at a heating rate of 10 ^o C / min. The start of fusion is determined and verified to be in the range of 0.5 ^o C to 0 ^o C.

[0027] The polymer samples were pressed into a thin film at an initial temperature of 190 ^o C (referred to as initial temperature). About 5 to 8 mg of sample is weighed and placed in the DSC container. The lid is closed by compression over the container to ensure an airtight atmosphere. The DSC vessel is placed in the DSC cell and then heated at a rate of about 100 ^o C / min to a temperature (To) of about 60 ^o C above the sample melting temperature. The sample is kept at this temperature for about 3 minutes. Then, it is cooled at a rate of 10 ^o C / min to -40 ^o C, and isothermally maintained at that temperature for 3 minutes.

Consequently, the sample is heated to a rate of

10 ^o C / minute until complete melting.

The enthalpy curves resulting from this experiment are analyzed for peak melting temperature, initial and peak crystallization temperature, melting heat and crystallization heat, and any other DSC analyzes of interest.

[0028] For an analyzed polymer comprising

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9/45 polypropylene crystallinity, T _o is 230 ^o C. AT _o is 190 ^o C when polyethylene crystallinity is present and no polypropylene crystallinity is present in the sample.

[0029] The percentage weight crystallinity is calculated according to the following formula:

kÀZ

Crystallinity (% by weight) = --x100% so that the heat of fusion (AH) is divided by the heat of fusion for the perfect polymeric crystal (AH _o ) and then multiplied by 100%. For ethylene crystallinity, AH is considered to be 290 J / g. For example, an ethylene-octene copolymer that, by melting its polyethylene crystallinity, has a melting heat of 29 J / g when measured; the corresponding crystallinity is 10% by weight. For propylene crystallinity, AH is considered to be 165 J / g. For example, a propyleneoctene copolymer that, by melting its propylene crystallinity, has a melting heat of 20 J / g when measured; the corresponding crystallinity is 12.1% by weight.

[0030] Non-crosslinked, as used herein, refers to polymers having between 0-10% gel, more preferably 0-5%, and more preferably 0-1%. It should not be interpreted that a crosslink of absolutely zero is present, since some crosslinking can inevitably occur during processing; however, the crosslinking must be kept to a minimum to allow recyclability.

Foam shock absorbing layer [0031] In one aspect, the embodiments described here

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10/45 refer to a shock absorbing layer in thermoplastic foam. In another aspect, the embodiments described herein refer to a synthetic lawn including a shock-absorbing layer in thermoplastic foam. In

selected applications, the achievements here described refer to a layer shock absorber in foam of in thermoplastic dimer not cross-linked with next characteristics: 1) foam thickness : between 8 and 30 mm; 2) foam density : between 30 and 150 kg / m3; 3) cell size foam: between 0.2 and 3 mm; and

4) the volume of the open cell is low, to avoid water intake; typically less than 35%.

Polymer [0032] The thermoplastic polymer used to form the shock absorbing layer can vary depending on the specific application and the desired result. In one embodiment, for example, the polymer is an olefinic polymer. As used herein, an olefinic polymer in general refers to a class of polymers formed from hydrocarbon monomers having the general formula CnH2n. The olefinic polymer may be

gift in the form of a copolymer, such how one interpolymer, a copolymer in block, or a interpolymer or multiblock copolymer. [0033] In one embodiment specific, per example, O polymer olefinic can comprise a interpolymer in ethylene alpha-olefinic with at least one comonomer

selected from the group consisting of a linear, branched or cyclic C3-C20 diene, or an ethylene vinyl compound, such as vinyl acetate, and a compound represented by

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11/45 formula H ₂ C = CHR where R is a linear, branched or cyclic C ₁ -C ₂₀ alkyl group or C ₆ -C ₂₀ aryl group. Examples of comonomers include propylene, 1-butene, 3-methyl-1-butene, 4-methyl-1-pentene, 3-methyl-1-pentene, 1-heptene, 1-hexene, 1octene, 1-decene, and 1-dodecene .

[0034] In other embodiments, the polymer may be an alpha-olefinic propylene interpolymer with at least one comonomer selected from the group consisting of ethylene, a linear, branched or cyclic diene C4-C20 and a compound represented by the formula H2C = CHR, where R is a linear, branched or cyclic C1-C20 alkyl group or C6-C20 aryl group. Examples of comonomers include ethylene, 1-butene, 3-methyl-1-butene, 4-methyl-1-pentene, 3-methyl-1-pentene, 1-heptene, 1hexene, 1-octene, 1-decene, and 1-dodecene . In some embodiments, the comonomer is present in about 5% by weight to about 25% by weight of the interpolymer. In one embodiment, a propylene-ethylene interpolymer is used. [0035] Other examples of polymers that can be used in the present description include homopolymers and copolymers (including elastomers) of an olefin, such as ethylene, propylene, 1-butene, 3-methyl-1-butene, 4-methyl-1 -pentene, 3-methyl-1-pentene, 1-heptene, 1-hexene, 1-octene, 1-decene and 1dodecene as typically represented by polyethylene, polypropylene, poly-1-butene, poly-3-methyl-1-butene, poly-3-methyl-1-pentene, poly-4-methyl-1-pentene, ethylene-propylene copolymer, ethylene-1-butene copolymer, and propylene-1-butene copolymer; copolymers (including elastomers) of an alpha-olefin with a conjugated or unconjugated diene as typically represented by ethylene-butadiene copolymer and ethylene copolymer Petition 870180143054, 10/22/2018, p. 21/61

12/45 ethylbornene norbornene; and polyolefins (including elastomers) such as copolymers of two or more alpha-olefins, with a conjugated or unconjugated diene, as typically represented by ethylene-propylene-butadiene copolymer, ethylene-propylene-dicyclopentadiene copolymer, ethylene-copolymer propylene-1,5-hexadiene, and ethylenepropylene-ethylidene norbornene copolymer; copolymers of ethylene-vinyl compound such as copolymers of ethylene-vinyl acetate with comonomers with N-methylol functionality, copolymers of ethylene-vinyl alcohol with comonomers with N-methylol functionality, ethylene-vinyl chloride copolymer, ethylene-chloride copolymers acrylic or ethylene acid (meth) acrylic acid, and ethylene- (meth) acrylate copolymer, styrenic copolymers (including elastomers), such as polystyrene, ABS, styrene copolymer, acrylonitrile-styrene copolymer; and styrene block copolymers (including elastomers) such as styrene-butadiene copolymer and its hydrate; and styrene-isoprene-styrene triblock copolymer; polyvinyl compounds such as polyvinyl chloride, polyvinylidene chloride, vinyl chloride-vinylidene chloride copolymer, polymethyl acrylate, and polymethyl methacrylate; polyamides, such as nylon 6, nylon 6.6 and nylon 12; thermoplastic polyesters such as polyethylene terephthalate and polybutylene terephthalate; polycarbonate, polyphenylene oxide, and the like. These resins can be used alone or in combination with two or more.

[0036] In specific embodiments, polyolefins such as polypropylene, polyethylene, and their copolymers and mixtures, as well as ethylene-propylene-diene terpolymers,

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13/45 can be used. In some embodiments, olefinic polymers include homogeneous polymers described in U.S. Patent No. 3,645,992 to Elston; high density polyethylene (HDPE) as described in U.S. Patent No. 4,076,698 to Anderson; heterogeneously branched linear low density polyethylene (LLDPE) copolymers; heterogeneously modified ultra-low density linear (ULDPE);

heterogeneously branched linear ethylene-alpha-olefin copolymers; homogeneously branched, substantially linear ethylene / alpha-olefin polymers that can be prepared, for example, through a process described in U.S. Pat. 5,272,236 and

5,278,272, the description of which is incorporated herein by reference;

heterogeneously branched linear ethylene / alpha-olefin polymers;

and ethylene polymers and copolymers polymerized via free radical under high pressure, such as low density polyethylene (LDPE).

[0037]

In another embodiment, the polymers can include an ethylene-carboxylic acid copolymer, such as ethylene-vinyl acetate copolymers, ethylene-acrylic acid (EAA) and ethylene-methacrylic acid copolymers, such as, for example, those available under the trade names of

Dow's PRIMACOR ™

Chemical Company, NUCREL ^TM da

DuPont, and

ESCOR ^TM from ExxonMobil, and described in US patents

We.

4,599,392, 4,988,781 and

59,384,373, each of which is incorporated herein by reference in its entirety.

Representative polymers include polypropylene (both impact-modified polypropylene, isotactic polypropylene, atactic polypropylene, as well as random ethylene / propylene copolymers), various types of polyethylene,

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14/45 including free radical LDPE under high pressure,

LLDPE

Ziegler Natta, metallocene PE, including PE in multiple reactor (in reactor), mixtures of

PE Ziegler-Natta and PE metallocene, such as products described in U.S. Patent Nos. 6,545,088,

6,538,070,

6,566,446,

5,844,045,

5,869,575 and 6,448,341.

Homogeneous polymers such as olefinic plastomers and elastomers, ethylene and propylene-based copolymers (for example, polymers available under the trade name VERSIFY ™ from The Dow Chemical Company and VISTAMAXX ™ from ExxonMobil) may also be useful in some embodiments. Of course, mixtures of polymers can also be used. In some embodiments, mixtures include two different Ziegler-Natta polymers.

other embodiments, mixtures may include mixtures of a Ziegler-Natta polymer and a metallocene polymer.

at

In from

In yet other embodiments, the thermoplastic resin used here can be a mixture of two different metallocene polymers.

In a specific embodiment, the polymer may comprise an alpha-olefin ethylene interpolymer with a comonomer comprising an alkene, such as 1-octene. The ethylene and octene copolymer can be present alone or in combination with another polymer, such as a combination copolymer, of ethylene-acrylic acid. When present in the weight ratio between the ethylene and octene copolymer and the ethylene-acrylic acid copolymer can be about

1:10 about

10: 1, such as from about 3: 2 to about

2: 3. The polymer, such as the ethyleneoctene copolymer, can have a crystallinity of less than about 50%, such as less than about 25%. In some embodiments,

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15/45 the crystallinity of the polymer can be from 5 to 35 percent. In other embodiments, crystallinity can vary from 7 to 20 percent.

[0039] In a specific embodiment, the polymer can comprise at least one low density polyethylene (LDPE). The polymer can comprise LDPE prepared through autoclave or tubular processes. The appropriate LDPE for this embodiment is defined elsewhere in this document.

[0040] In a specific embodiment, the polymer may comprise at least two low density polyethylenes. The polymer can comprise LDPE prepared through autoclave or tubular processes or combinations thereof. LDPEs appropriate for this embodiment are defined elsewhere in this document.

[0041] In a specific embodiment, the polymer may comprise an alpha-olefinic ethylene interpolymer with a comonomer comprising an alkene, such as 1-octene. The ethylene and octene copolymer can be present alone or in combination with another polymer, such as a low density polyethylene (LDPE). When present in combination, the weight ratio between the ethylene and octene copolymer and LDPE can be from about 60:40 to about 97: 3, such as from about 80:20 to about 96: 4. The polymer, such as the ethylene-octene copolymer, may have a crystallinity of less than about 50%, such as less than about 25%. In other embodiments, crystallinity can vary from 7 to 20 percent. LDPEs appropriate for this embodiment are defined elsewhere in this document.

[0042] In a specific embodiment, the polymer may comprise an alpha-olefinic ethylene interpolymer with a

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16/45 comonomer comprising an alkene, such as 1-octene.

[0043] The ethylene and octene copolymer may be present alone or in combination, with at least two other [0044] polymers in the group; low density polyethylene, medium density polyethylene, and high density polyethylene (HDPE). When present in combination, the weight ratio between the ethylene and octene copolymer, LDPE, and HDPE is such that the composition comprises a component of 3 to 97% by weight of the total composition and the remainder comprises the other two components. The polymer, such as the ethylene-octene copolymer, may have a crystallinity of less than about 50%, such as less than about 25%. In some embodiments, the crystallinity of the polymer can be 5 to 35 percent. In other embodiments, crystallinity can vary from 7 to 20 percent.

[0045] The embodiments described herein may also include a polymeric component which may include at least one olefinic multiblock interpolymer. Suitable multi-block olefinic interpolymers may include those described in provisional U.S. patent application No. 60 / 818,911, for example. The term multi-block copolymer refers to a polymer comprising two or more chemically distinct regions or segments (called blocks) preferably joined in a linear fashion, that is, a polymer comprising chemically differentiated units, which are joined end to end in relation to each other. to polymerized ethylene functionality, rather than in pending or grafted form. In certain embodiments, the blocks differ in the amount or type of comonomer in them

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17/45 incorporated, in the density, in the amount of crystallinity, in the size of the crystallite attributable to a polymer of such composition, in the type or degree of tacticity (isotactic or syndiotactic), in the regularity or regio-irregularity, in the amount of branching , including long-chain branching or hyper-branching, in homogeneity or any other chemical or physical property. Multiblock copolymers are characterized by unprecedented distributions of the polydispersity index (PDI or Mw / Mn), distribution of the block length, and / or distribution of the number of blocks due to the unprecedented process of preparing the copolymers. More specifically, when produced in a continuous process, the polymer embodiments can have a PDI ranging from about 1.7 to about 8; from about 1.7 to about 3.5 in other embodiments; from about 1.7 to about 2.5 in other embodiments; and from about 1.8 to about 2.5 or about 1.8 to 2.1 in other embodiments. When produced in a batch or semi-batch process, the polymer embodiments can have a PDI ranging from about 1.0 to about 2.9; from about 1.3 to about 2.5 in other embodiments; from about 1.4 to about 2.0 in other embodiments; and from about 1.4 to about 1.8 in yet other embodiments.

[0046] An example of a multi-block olefinic interpolymer is a block ethylene / a-olefin interpolymer. Another example of a multi-block olefinic interpolymer is a propylene / α-olefin interpolymer. The following description focuses on the polymer as having ethylene as the major monomer, although it applies similarly to propylene-based multiblock interpolymers in relation to

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18/45 to the general characteristics of the polymer.

[0047] Ethylene / aolefin multiblock interpolymers may comprise ethylene and one or more copolymerizable a-olefin comonomers in polymerized form, characterized by multiple blocks or segments (ie two or more) of two or more polymerized monomer units, differing in physical or chemical properties (block interpolymer), preferably a multiblock interpolymer.

In some embodiments, multiblock interpolymer can be represented by the following formula:

(AB) n where at least

1, preferably an integer greater than

1, such as 2,

3, 4, 5, 10, 15,

20,

30, 40,

50, 60, hard; and, 100 or greater;

A represents a block or segment

B represents a block or soft segment.

Preferably,

A's and B's are connected in a linear fashion, not in a branched or star shape. Hard segments refer to blocks of polymerized units in which ethylene is present in an amount greater than 95 percent by weight in some embodiments, and in other embodiments, greater than percent by weight.

In other words, the comonomer content in the hard segments is less than 5 percent by weight in some embodiments in other embodiments, less than 2 percent by weight of the total weight of the hard segments. In some embodiments, the hard segments comprise all or substantially all of the ethylene.

Soft segments, on the other hand, refer to blocks of polymerized units in which the comonomer content is greater than 5 percent by weight of the total weight of the soft segments in

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19/45 some embodiments, greater than 8 weight percent, greater than 10 weight percent, or greater than 15 weight percent in various other embodiments. In some embodiments, the comonomer content in the soft segments can be greater than 20 percent by weight, greater than 25 percent by weight, greater than 30 percent by weight, greater than 35 percent by weight, greater than 40 percent in weight, greater than 45 weight percent, greater than 50 weight percent, or greater than 60 weight percent in various other embodiments.

[0048] In some embodiments, blocks A and blocks B are randomly distributed along the polymeric chain. In other words, block copolymers do not have a structure like the following:

AAA-AA-BBB-BB [0049] In other words, block copolymers do not have a third block. In still other embodiments, neither block A nor block B comprises two or more segments (or sub-blocks), such as a terminating segment.

[0050] Multiblock interpolymers can be characterized by an average block index, ABI, ranging from greater than zero to about 1.0, and a molecular weight distribution, M _w / M _n greater than about 1.3 . The average block index, ABI, is the average weight of the block index (BI) for each of the polymer fractions obtained in preparative TREF of 20 ° C and 110 ° C, with an increase of 5 ° C:

where BIi is the block index for ai ^the fraction of the multiblock interpolymer obtained in preparative TREF, and w _± is the weight percentage of the i ^the fraction.

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20/45 [0051] Similarly, the square root of the second moment with respect to the mean, hereinafter referred to as the block weight average index of the second moment, can be defined as follows:

Weight average BI of the second polymer moment, BI is defined by one of the following two equations (both giving the same value of

BI ντ _χ -ντ _χ0 υτ _Α -ι / τ _ΛΒ or Bi =

LnP _x IaTiP _X Q

LNP _A - LNP "where T _x and elution temperature by fractionation and lifting analytical temperature (ATREF) to (preferably expressed in Kelvin), P _x is the mole fraction of ethylene to al fraction which can be measured by NMR or IR, as described below. P _AB is the molar ethylene fraction of the total ethylene / aolefin interpolymer (before fractionation), which can also be measured using NMR or IR. T _A and P _A are the elution temperature ATREF and the molar fraction of ethylene for the pure hard segments (which refer to crystalline segments of the interpolymer). As an estimate or for polymers in which the hard segment composition is unknown, the values of T _A and P _A are adjusted to those values of high density polyethylene homopolymer.

[0053] T _AB is the ATREF elution temperature for a random copolymer of the same composition (having a molar fraction of ethylene from P _AB ), and molecular weight as the multiblock interpolymer. T _AB can be calculated from

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21/45 of the molar fraction of ethylene (measured by NMR) using the following equation:

Ln PaB = M / Tab + β where a and β are two constants that can be determined by calibration using a number of TREF fractions preparatory to a well-characterized wide-composition random copolymer and / or to well-characterized randomly characterized ethylene copolymers with narrow composition . It should be noted that a and β may vary from instrument to instrument. In addition, it would be necessary to create an appropriate calibration curve with polymeric composition of interest, using types of comonomer of molecular weight appropriate for the fractions of

Preparative TREF and / or random copolymers used to create the calibration.

There is a slight molecular weight effect. If the calibration curve is obtained from similar molecular weight ranges, such an effect would be essentially negligible.

In some embodiments, random ethylene copolymers and / or TREF fractions preparatory to random copolymers satisfy the following relationship:

LnP

-237.83 / Tatref + 0.63 9 [0054] The above calibration equation relates the molar fraction of ethylene, P, with the temperature of elution by analytical TREF, T _ATREF , for random copolymers of narrow composition and / or fractions of TREF preparatory for random copolymers of wide composition. TXO is the ATREF temperature for a random copolymer of the same composition and having a molar ethylene fraction of PX. TXO can be calculated from LnPx = a / TXO + β. On the contrary, PXO is the molar fraction of ethylene for a random copolymer of the same composition and

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22/45 having an ATREF temperature of T _X , which can be calculated from Ln P _XO = a / T _X + β.

[0055]

Obtained the block index (BI) of each fraction of

Preparative TREF, the block average weight index, ABI, for total polymer can be calculated.

In some embodiments,

ABI is greater than zero, but less than about 0.4 or about 0.1 to about 0.3.

In other embodiments,

ABI is greater than about 0.4 and about up to 1.0. Preferably, ABI should be in the range of about

0.4 to about 0.7, from about 0.5 to about

0.7, or from about 0.6 to about 0.9. In some embodiments, ABI is in the range of about 0.3 to about 0.9, about 0.3 to about 0.8, or about 0.3 to about 0.7, about from 0.3 to about 0.6, from about 0.3 to about 0.5, or from about 0.3 to about 0.4. In other embodiments, ABI is in the range of about 0.4 to about 1.0, about 0.5 to about 1.0, or about 0.6 to about 1.0, about from 0.7 to about 1.0, from about 0.8 to about 1.0, or from about 0.9 to about 1.0.

[0056] Another characteristic of the multiblock interpolymer is that the interpolymer can comprise at least a fraction of polymer that can be obtained through preparative TREF, where the fraction has a block index greater than about 0.1 and about up to 1.0, with the polymer having a molecular weight distribution, Mw / Mn, greater than about 1.3. In some embodiments, the polymer fraction has a block index greater than about 0.6 and about up to 1.0, greater than about 0.7 and about up to 1.0, greater than about 0 , 8 and about up to 1.0, or greater than about 0.9 and about up to 1.0. In other embodiments, the polymer fraction has a

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23/45 block index greater than about 0.1 and about up to 1.0, greater than about 0.2 and about up to 1.0, greater than about 0.3 and about up to 1.0, greater than about 0.4 and about up to 1.0, or greater than about 0.4 and about up to 1.0. In still other embodiments, the polymer fraction has a block index greater than about 0.1 and about up to 0.5, greater than about 0.2 and about up to 0.5, greater than about 0.3 and about up to 0.5, or greater than about 0.4 and about up to 0.5. In still other embodiments, the polymer fraction has a block index greater than about 0.2 and about up to 0.9, greater than about 0.3 and about up to 0.8, greater than about 0.4 and about up to 0.7, or greater than about 0.5 and about up to 0.6.

The multi-block ethylene / a-olefin interpolymers used in the embodiments of the present invention can be ethylene interpolymers with at least one C3-C20 aolefin. The interpolymers can further comprise C4-C18 diolefin and / or alkenylbenzene. Suitable unsaturated comonomers useful for polymerization with ethylene include, for example, ethylenically unsaturated monomers, conjugated or unconjugated dienes, polyenes, alkenylbenzenes, etc. Examples of such comonomers include C ₃ -C ₂₀ α-olefins such as propylene, isobutylene, 1-butene, 1-hexene, 1 pentene, 4-methyl-1-pentene, 1-heptene, 1-octene, 1-nonene, 1decene and the like. 1-butene and 1-octene are especially preferred. Other suitable monomers include styrene, halo or alkyl substituted styrenes, vinylbenzocyclobutane, 1,4-hexadiene, 1,7-octadiene, and naphthenics (such as cyclopentene, cyclohexene, and cycloocene, for example).

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24/45 [0058] The multiblock interpolymers described here can be differentiated from conventional random copolymers, physical mixtures of polymers and block copolymers prepared via sequential addition of monomer, fluxional catalysts, and live anionic or cationic polymerization techniques. In particular, compared to a random copolymer of the same monomers and with the monomer content at crystallinity or equivalent modulus, interpolymers have better thermal resistance (higher), as measured by melting point, higher TMA penetration temperature, resistance the highest tensile at high temperature, and / or the highest torsion storage module at high temperature, as determined by dynamic mechanical analysis. The properties of the filling (infill) can benefit from the use of embodiments of multiblock interpolymers, compared to a random copolymer containing the same monomers and monomer content, multiblock interpolymers have less permanent compression deformation, especially at high temperatures, less stress relaxation, greater creep resistance, greater tear resistance, greater blocking resistance, faster hardening due to higher crystallization temperature (solidification), greater recovery (especially at elevated temperatures), better abrasion resistance, greater strength retraction, and better acceptance of oil and filling (load).

[0059] Other olefinic interpolymers include polymers comprising aromatic monovinylidene monomers, including styrene, o-methyl styrene, p-methyl styrene, t

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25/45 butyl styrene, and the like. In particular, interpolymers comprising ethylene and styrene can be used. In other embodiments, copolymers comprising ethylene, styrene and a C ₃ -C ₂₀ α-olefin, optionally comprising a C ₄ C20 diene, can be used.

[0060] Suitable unconjugated diene monomers may include straight, branched or cyclic hydrocarbon diene having 6 to 15 carbon atoms. Examples of suitable unconjugated dienes include, but are not limited to, acyclic straight chain dienes, such as

1.4- hexadiene, 1,6-octadiene, 1,7-octadiene, 1,9-decadiene, branched-chain acyclic dienes, such as 5-methyl-1,4hexadiene; 3,7-dimethyl-1,6-octadiene; 3,7-dimethyl-1,7octadiene and mixed isomers of dihydromyricene and dihydrookynene, single ring alicyclic dienes, such as 1,3-cyclopentadiene; 1,4-cyclohexadiene; 1,5-cyclooctadiene and

1.5- cyclododecadiene, and multi-ring and fused or bridged ring alicyclic dienes, such as tetrahydroindene, methyl tetrahydroindene, dicyclopentadiene, bicyclo- (2,2,1) -hepta-

2.5- diene; alkenyl, alkylidene, cycloalkenyl and cycloalkylidene norbornenes, such as 5-methylene-2-norbornene (MNB); 5-propenyl-2-norbornene, 5-isopropylidene2-norbornene, 5- (4-cyclopentenyl) -2-norbornene, 5cyclohexylidene-2-norbornene, 5-vinyl-2-norbornene, and norbornadiene. Of the dienes typically used for preparing EPDMs, the most preferred dienes are 1,4hexadiene (HD), 5-ethylidene-2-norbornene (ENB), 5-vinylidene2-norbornene (VNB), 5-methylidene-2-norbornene ( MNB) and dicyclopentadiene (DCPD).

[0061] A class of desirable polymers that can be

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26/45 used according to embodiments described herein includes elastomeric interpolymers of ethylene, a C ₃ C ₂₀ α-olefin, especially propylene, and optionally, one or more diene monomers. α-olefins preferred for use in the present embodiment are designated by the formula CH2 = CHR *, where R * is a linear or branched alkyl group of 1 to 12 carbon atoms. Examples of suitable α-olefins include, but are not limited to, propylene, isobutylene, 1-butene, 1-pentene, 1-hexene, 4-methyl-1-pentene, and 1-octene. An especially preferred α-olefin is propylene. Propylene-based polymers are generally referred to in the art as EP or EPDM polymers. Dienes suitable for use in the preparation of such polymers, especially EPDM polymers in multiblock include conjugated or unconjugated dienes, linear or branched, cyclic or polycyclic, from 4 to 20 carbons. Preferred dienes include 1,4-pentadiene, 1,5-hexadiene, 5-ethylidene-2-norbornene, dicyclopentadiene, cyclohexadiene and 5-butylidene-2-norbornene. An especially preferred diene is 5-ethylidene-2-norbornene.

[0062] The polymers (homopolymers, copolymers, interpolymers, and multiblock interpolymers) described herein can have a melt index, I2, of 0.01 to 2000 g / 10 minutes in some embodiments; from 0.01 to 1000 g / 10 minutes in other embodiments; from 0.01 to 500g / 10 minutes in other embodiments; and from 0.01 to 100g / 10 minutes in other embodiments. In certain embodiments, the polymers can have a melting index, I2, of 0.01 to 10g / 10 minutes, of 0.5 to 50g / 10 minutes, of 1 to 30g / 10 minutes, of 1 to 6g / 10 minutes , or 0.3 to 10 g / 10 minutes. In certain

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In the embodiments, the melt index for the polymers can be approximately 1 g / 10 minutes, 3 g / 10 minutes or 5 g / 10 minutes. In other embodiments, the polymers can have a melt index greater than 20dg / min;

greater than 40dg / min in other embodiments;

greater than achievements yet.

[0063]

The molecular polymers described here, Mw, of

1,000 g / mol to embodiments;

in

1000 g / mol embodiments;

in

10,000 g / mol embodiments;

and from 10,000 g / mol to 300,000 embodiments yet. The density of

60dg / 1

5,000,000 to 500,000 to 1,000

0 min in others fear Tue weights g / mol in some .000 in others g / mol in others g / mol in others polymers on here

described can be from 0.80 to 0.99 g / cm ³ embodiments; for polymers containing 0.97 g / cm ³ ethylene and in some embodiments, between 0.94 g / cm ³ .

in some 0.85 g / cm ³

0.87 g / cm ³ and [0064] In some embodiments, the polymers described here may have a tensile strength above 10 MPa; a tensile strength> 11 MPa in other embodiments; and a tensile strength> 13 MPa in other embodiments. In some embodiments, the polymers described herein may have an elongation at break of at least 600 percent at a crosshead separation rate of 11 cm / minute; at least 700 percent in other embodiments; at least 800 percent in other embodiments; and at least 900 percent in yet other embodiments.

[0065] In some embodiments, the polymers described herein may have a storage module ratio, G '(25 ° C) / G' (100 ° C), from 1 to 50; from 1 to 20 in other embodiments; and from 1 to 10 in other embodiments yet.

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28/45

In some embodiments, the polymers may have a permanent compression strain of 70 ^o C less than 80 percent; less than 70 percent in other embodiments; less than 60 percent in other embodiments; and less than 50 percent, less than 40 percent, to a permanent 0% compression strain in other embodiments.

[0066] In some embodiments, ethylene / a-olefin interpolymers may have a melting heat of less than 85 J / g. In other embodiments, the ethylene / aolefin interpolymer may have a pellet blocking resistance equal to or less than 100 pounds / square foot (4800 Pa); equal to or less than 50 pounds / square foot (2400 Pa) in other embodiments; equal to or less than 5 pounds / square foot (240 Pa) and as low as 0 pounds / square foot (0 Pa) in other embodiments.

[0067] In some embodiments, block polymers prepared with two catalysts incorporating different amounts of comonomer can have a weight ratio of blocks formed by the same ranging from 95: 5 to 5:95. Elastomeric interpolymers, in some embodiments, have an ethylene content of 20 to 90 percent, a diene content of 0.1 to 10 percent and an a-olefin content of 10 to 80 percent, based on weight total polymer. In other embodiments, multiblock elastomeric polymers have an ethylene content of 60 to 90 percent, a diene content of 0.1 to 10 percent, and an a-olefin content of 10 to 40 percent, based on in the total weight of the polymer. In other embodiments, the interpolymer may have a Mooney viscosity (ML (1 + 4) 125 ^o C) ranging from 1 to 250. In other embodiments, such polymers may have an ethylene content of 65 to 75 percent, a content of diene from 0 to 6 percent and

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29/45 an a-olefin content of 20 to 35 percent.

[0068] In certain embodiments, the polymer can be a propylene-ethylene copolymer or interpolymer having an ethylene content between 5 and 20% by weight and a melt flow rate (230 ^o C with 2.16 kg weight) of 0.5 to 300g / 10 min. In other embodiments, the propylene-ethylene copolymer or interpolymer may have an ethylene content between 9 and 12% by weight and a melt flow rate (230 C with 2.16 kg weight) from 1 to 100 g / 10 min.

[0069] In some specific embodiments, the polymer is a propylene-based copolymer or interpolymer. In some embodiments, a propylene / ethylene copolymer or interpolymer is characterized as having substantially isotactic propylene sequences. The term substantially isotactic propylene sequences and similar terms, mean that the sequences have an isotactic triad (mm) measured by ¹³ C NMR greater than about 0.85, preferably greater than about 0.90, more preferably greater than about 0.92 and most preferably greater than about 0.93. Isotactic triads are well known in the state of the art and are described, for example, in US Patent No. 5,504,172 and WO 00/01/01745, which refer to the isotactic sequence in terms of a triad unit in the determined copolymer molecular chain by ¹³ C NMR spectra. In other specific embodiments, the ethylene-olefin copolymer can be copolymers or interpolymers of ethylenebutene, ethylene-hexene or ethylene-octene. In other specific embodiments, the propylene / aolefin copolymer can be a propylene ethylene or propylene ethylene butene copolymer or interpolymer.

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30/45 [0070] The polymers described here (homopolymers, copolymers, interpolymers, multiblock interpolymers) can be produced using a single site catalyst

and can Tue a weight molecular weight average of about in 15,000 to about 5 million, as well as about 20,000 The about 1 million. The molecular weight distribution of polymer can be of about 1.01 to about 80, such as in about 1.5 about 40, such as from about 1.8 to about of 20. [0071] In some embodiments, the polymer may have a

Shore A hardness of 30 to 100. In other embodiments, the polymer can have a Shore A hardness of 40 to 90; 30 to 80 in other embodiments; and 40 to 75 in other embodiments yet.

[0072] Polymers, copolymers, interpolymers and interpolymers in olefinic multiblock can be functionalized by incorporating at least one functional group in their polymeric structure. Representative functional groups may include, for example, ethylenically unsaturated mono and difunctional carboxylic acids, mono and ethylenically unsaturated difunctional carboxylic acids, their salts and esters. Such functional groups can be grafted to an olefinic polymer, or they can be copolymerized with ethylene and with an additional optional comonomer to form an ethylene interpolymer, the functional comonomer and optionally other comonomer (s). Means for grafting functional groups into polyethylene are described, for example, in U.S. Pat. 4,762,890, 4,927,888 and 4,950,541, the descriptions of which are incorporated herein by reference in their entirety. A group

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Functional useful is maleic anhydride.

[0073] The amount of functional group present in the functional polymer may vary. The functional group may be present in an amount of at least 1.0 weight percent in some embodiments; about at least 5 weight percent in other embodiments; about at least 5 weight percent in other embodiments; and about at least 7 weight percent in other embodiments. The functional group may be present in an amount less than about 40 weight percent, in some embodiments; less than about 30 weight percent in other embodiments; and less than about 25 weight percent in other embodiments.

[0074] The foam sheets according to embodiments described herein can include a single layer or multiple layers, as desired. Foam articles can be produced in any way that results in at least one layer of foam. The foam layers described herein can be prepared using a pressurized melt processing method such as an extrusion method. The extruder can be a tandem system, a mono-screw extruder, a twin screw extruder, etc. The extruder can be equipped with multilayer ring dies, flat film dies, and feeder blocks, multilayer feeder blocks, such as those described in U.S. Patent No.

4,908,278 (Bland et al.), Multi-pocket or multi-channel dies such as Cloeren's three-layer matrix,

Orange,

Tex. A foaming composition can also be prepared by combining a chemical blowing agent and polymer at a temperature below

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32/45 decomposition temperature of the chemical blowing agent, and then foamed later. In some embodiments, the foam can be coextruded with one or more barrier layers. [0075] One method for producing the foams described here is to use an extruder, as mentioned above. In this case, the foaming mixture (polymer + blowing agent) is extruded. As the mixture leaves the extruder die and upon exposure to reduced pressure, the fugitive gas nucleates and forms cells in the polymer creating a foam article. The resulting foam article can then be deposited on the temperature-controlled casting drum. The speed of the casting drum (ie produced by drum RPM) can affect the total thickness of the foam article. As the speed of the casting cylinder increases, the total thickness of the foam article may decrease. However, the thickness of the barrier layer at the exit of the matrix, which is where the defoaming occurs, is the extent of diffusion to the system. As the foam article is styrene and quickly cooled over the casting drum, the thickness of the barrier layer may decrease until the foam article solidifies. In other words, the important factor for controlling fugitive gas diffusion is the diffusion extent of the barrier layer (that is, the thickness).

[0076] Blowing agents suitable for use in forming the foams described herein can be physical blowing agents, which are typically the same material as the fugitive gas, for example, CO2, or a chemical blowing agent that produces the fugitive gas. More than one physical or chemical blowing agent can be used, which can be

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33/45 used together.

[0077] Physical blowing agents useful in the present invention include any naturally occurring atmospheric material, which is a vapor at the temperature and pressure at which the foam is found when emanating from the matrix. The physical blowing agent can be introduced, that is, injected into the polymeric material in the form of a supercritical gas, fluid or liquid, preferably in the form of a supercritical fluid or liquid, most preferably in the form of a liquid. The physical blowing agents used will depend on the properties sought in the resulting foam articles. Other factors considered in the selection of a blowing agent are its toxicity, vapor pressure profile, ease of handling, and solubility with respect to the polymeric materials used. Non-flammable, non-toxic, non-ozone depleting blowing agents are preferred, due to their ease of use, involving less environmental and safety issues, and because they are generally less soluble in thermoplastic polymers. Suitable physical blowing agents include, for example, carbon dioxide, nitrogen, SF sub.6, nitrous oxide, perfluorinated fluids, such as C ₂ F ₆ , argon, helium, noble gases such as xenon, air (nitrogen mixture and oxygen), and mixtures of these materials.

[0078]

Chemical blowing agents that can be used in the present invention include, for example, a mixture of sodium bicarbonate and citric acid, dinitrosopentamethylenetetramine, p-toluenesulfonyl hydrazide,

4,4'-oxybis (benzenesulfonyl hydrazide, azodicarbonamide), (1,1'-azobisformamide), p-toluenesulfonyl semicarbazide, 5-phenyltetrazole, 5-phenyltetrazole analogs,

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34/45 diisopropylidrazodicarboxylate, 5-phenyl-3,6-dihydro-1,3,4oxadiazin-2-one, and sodium borohydride. Preferably, the blowing agents are, or produce, one or more fugitive gases having a vapor pressure greater than 0.689 MPa at 0 ^o C.

[0079] The total amount of blowing agent used depends on conditions, such as conditions of the extrusion process in mixing, the blowing agent used, the composition of the extrudate, and the desired density of the foamed article. The extrudate is defined in the present invention as including the blowing agent mixture, a polyolefinic resin (s), and any additives. For a foam with a density of about 1 to about 15 pounds / cubic foot, the extrudate typically comprises from about 18 to about 1% by weight of blowing agent. In other embodiments, 1 to 10% blowing agent can be used.

The blowing agent mixture used in the present invention comprises less than about 99 mole percent isobutane. The blowing agent mixture generally comprises from about 10 mole percent to about 60 or 75 mole percent isopentane. The blowing agent mixture most typically comprises from about 15 mole percent to about 40 mole percent isopentane. More specifically, the blowing agent mixture comprises from about 25 or 30 mole percent to about 40 mole percent isobutane. The blowing agent mixture generally comprises about at least 15 or 30 mole percent of blowing coagent (s). More specifically, the blowing agent mixture comprises from about 40 to about 85 or 90 mole percent of blowing coagent (s). The blowing agent mixture most typically comprises from about 60 mole percent to about

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35/45 of 70 or 75 mole percent of blowing coagent (s).

[0081] A nucleating agent or combination of such agents can be employed in the present invention to obtain advantages such as the ability to regulate cell formation and morphology. A nucleating agent, or cell size control agent, can be any conventional or useful nucleating agent (s). The amount of nucleating agent used depends on the desired cell size, the selected blowing agent mixture, and the desired foam density. The nucleating agent is generally added in amounts of about 0.02 to about 20 weight percent of the polyolefin resin composition.

[0082] Some predicted nucleating agents include inorganic materials (in the form of small particles) such as clay, talc, silica, and diatomaceous earth. Other anticipated nucleating agents include organic nucleating agents that decompose or react to the heating temperature inside an extruder to release gases, such as carbon dioxide, and / or nitrogen. An example of an organic nucleating agent is a combination of an alkali metal salt of a polycarboxylic acid with a carbonate or bicarbonate. Some examples of alkali metal salts of a polycarboxylic acid include, but are not limited to, the 2,3-dihydroxybutanedioic acid monosodium salt (commonly called sodium hydrogen tartrate), the butanedioic acid monopotassium salt (commonly called potassium hydrogen succinate), the trisodium and tripotassium salts of 2-hydroxy-1,2,3propanotricarboxylic acid (commonly referred to as sodium and potassium citrate, respectively), and the disodium salt of

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36/45 ethanedioic acid (commonly called sodium oxalate), or polycarboxylic acid such as 2-hydroxy-1,2,3propanotricarboxylic acid. Some examples of a carbonate or bicarbonate include, but are not limited to, sodium carbonate, sodium bicarbonate, potassium carbonate, potassium bicarbonate, and calcium carbonate.

[0083] It is envisaged that mixtures of different nucleating agents can be added to the present invention. Some more desirable nucleating agents include talc, microcrystalline silica, and a stoichiometric mixture of citric acid and sodium bicarbonate (the stoichiometric mixture having a concentration of 1 to 100 percent, when the carrier is an appropriate polymer, such as polyethylene). Talc can be added in a carrier or in the form of a powder.

[0084] Agents for gas permeation or stability control agents can be employed in the present invention to help prevent or inhibit foam collapse. Stability control agents suitable for use in the present invention may include the partial esters of long chain fatty acids with polyols described in U.S. Patent No. 3,644,230, upper saturated alkylamines, upper saturated fatty acid amides, complete esters of fatty acids such as those described in U.S. Patent No. 4,214,054 and combinations thereof, described in U.S. Patent No. 5,750,584.

[0085] The partial fatty acid esters that may be desirable as a stability control agent include members of the generic class known as surfactants or surfactants. A preferred class of surfactants includes a partial fatty acid ester having 12 to 18 atoms of

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37/45 carbon and a polyol having three to six hydroxyl groups. More preferably, the partial esters of a long-chain fatty acid with a polyol component of the stability control agent are glycerol monesterate, glycerol distearate or mixtures thereof. It is envisaged that other gas permeation agents or stability control agents can be employed in the present invention to help prevent or inhibit foam collapse.

Additives [0086] If desired, fillers, dyes, thermal and light stabilizers, antioxidants, acid scavengers, flame retardants, processing aids, extrusion aids, and foaming additives can be used in the preparation of the foam. The foam of the invention may contain filler materials in quantities, depending on the application for which they are designed, ranging from about 2100 percent (dry basis) of the weight of the polymeric component. Such optional ingredients may include, but are not limited to, calcium carbonate, titanium dioxide powder, polymer particles, hollow glass beads, polymeric fibers, such as polyolefin-based batch monofilaments and the like.

[0087] In selected embodiments, foams useful for the described embodiments may have a thickness between 1 and 500 mm, and in some embodiments, from 5 to 100 mm, and in some embodiments, 8 and 30 mm. In selected embodiments the foams can have a density between about 20 and 600 kg / m ³ , preferably from 25 to 300 kg / m ³ , and more preferably from 30 to 150 kg / m ³ . In selected embodiments, foams can have a cell size between

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38/45 about 0.1 to 6 mm, preferably 0.2 to 4.5 mm, and more preferably 0.2 to 3 mm.

[0088] In some embodiments, the foam layer can be perforated to facilitate drainage, so that, in the event of rain, water can be drained from the playing surface.

[0089] In some embodiments, the foams described above can be used as a shock-absorbing layer on synthetic turf. In addition, tests can be conducted to analyze the temperature and aging performance, as well as the rebound and ball spin properties on the resulting lawn. In summary, the significant tests and desired results for artificial turf performance as specified in the FIFA Quality Concept Manual (March 2006 edition) are shown in the table below. Those skilled in the art will appreciate that this is just one of the uses of the foams described here, and that the artificial grass and foams described here can be useful in various other applications and in other sports, such as rugby and field hockey, for example. .

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39/45

LABORATORY TESTS - BALL / SURFACE INTERACTION Test conditions Requirements Property Test method Test method Preparation Temp. Condition Recommended FIFA ** (best ranking) Recommended FIFA * Vertical ball rebound FIFA 01 / 05-01 and FIFA 09 / 05-1 Preconditioning 23 ^o C Dry wet 0.60m-0.85m 0.60m-1m Simulated wear 23 ^o C Dry 0.60m-1m Shock absorption FIFA 04 / 05-01 and FIFA 10 / 05-1 2 ^o / 3 ^the average flat foot impact Preconditioning 23 ^o C dry wet 60% - 70% 55% -70% Simulated wear 23 ^o C dry 55% -70% - 40 ^o C dry - 1 ^the average flat foot impact -5 ^o C frozen 60% -70% Vertical deformation FIFA 05 / 05-01 and FIFA 10 / 05-1 2 ^o / 3 ^the average flat foot impact Pre- conditioning. 23 ^o C dry wet 4mm - 8mm 4mm-9mm Simulated wear 23 ^o C dry 4mm-9mm

39/45

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40/45

Shock Absorption [0090] Principle: A mass (20 kg) falls, as discussed in the FIFA Quality Concept Manual (March 2006 edition), incorporated herein by reference in its entirety. The maximum applied force is recorded. The% reduction of this force in relation to the maximum force measured on a concrete surface is reported as Force Reduction.

FIFA requirement:

FIFA 2 stars: 60% - 70%

FIFA 1 star: 55% - 70%

Vertical Deformation [0091] Principle: A mass is dropped on a resting spring and the maximum deformation of the surface is determined. FIFA requirement:

FIFA 2 stars: 4mm - 8mm

FIFA 1 star: 4mm - 9mm

Examples [0092] The utility of polyolefin resins with selected foam densities and thicknesses is investigated. Specifically, several polyethylene resins, marketed by The Dow Chemical Company, Midland, MI are studied. Tables 1 and 2 show several compounds used. In Table 1, the performance of cross-linked polyethylene (comparative examples 1c-4c) versus non-cross-linked polyethylene (examples 1-4) is investigated. Specifically, in relation to Table 1, (LDPE 300E, and LDPE PG-7004, and their mixtures, LDPE 6201, and XU 60021.24 are used to generate the data. The formulations used to generate the Table are shown below.

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41/45

Ex. A / B resin Resin density (kg / m ³ ) Foam density (kg / m ³ ) Thickness (mm) Reticulate 1 XU 60021.24 * 0.922 33 10 no 2 90/10 (LDPE 300E / LDPE PG7004) 0.923 45 10 no 3 70/30 (LDPE 300E / LDPE PG7004) 0.923 64 10 no 4 LDPE 620I 0.923 144 51 no

Table 1

Ex. Resin THE Resin B Foam (% Weight) Polymer type Densid. (g / cm ³⁾ (ASTM D792) I2 (g / 10 min) (% Weight) Polymer type Densid. (g / cm ³⁾ (ASTM D792) I2 (g / 10 min) Density (kg / m ³ ) Thickness (mm) Reticulated 1 100 LDPE 0.922 3.3 - - - - 33 10 no 2 90 LDPE 0.9235 0.8 10 LDPE 0.9215 4.1 45 10 no 3 70 LDPE 0.9235 0.8 30 LDPE 0.9215 4.1 64 10 no 4 100 LDPE 0.9239 1.85 - - - - 144 51 no

41/45

Table 1 - Comparative Examples

Example Comparative Designation Foam density (kg / m ³ ) Thickness (mm) Reticulate (yes / no) 1c Qycell T-20 * 33 10 Yes 2c Qycell T-30 * 45 10 Yes 3c Qycell T-40 * 64 10 Yes 4c Qycell T-80 * 119 11.5 no

* denotes foam from Qycell Corporation (Ontario, California, USA)

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42/45 [0093] Returning to shock absorption, vertical deformation and energy redistribution, the performance of non-crosslinked polyethylene foams in Table 1, marketed by The Dow Chemical Company, Midland, MI, was investigated. The results of this investigation are summarized in Figure 1. With respect to Table 1, the compressive stress-strain, compressive creep, and compressive stress-strain behavior is analyzed using an Instron Model 5565 Universal Test Device (Norwood, MA) , equipped with compression plates and a 2kN load cell. When tests are conducted at 65 ^o C, an Instron environmental chamber (Model 3119-405-21) is also used.

[0094] Samples 2.5 to 5 cm wide by 5 cm deep are cut from foam sheets. To measure the compressive stress-strain behavior, samples are inserted between the centers of the compression plates. The thickness direction of the foam is aligned parallel to the crosshead movement. A 2.5N preload is applied at 5mm / min and the crosshead position is zeroed again. The sample was then compressed at 10 mm / min until the load approached the load cell capacity. The stress is calculated by dividing the compression force measured by the product of the width and depth of the foam. The stress is quantified in units of megapascals (MPa). The deformation in terms of percentage is calculated by dividing the crosshead displacement by the initial foam thickness and multiplying by one hundred. The results for the compressive stress-strain behavior tests are illustrated in Figures 2 and 2c (comparative samples).

[0095] To measure hysteresis behavior

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43/45 compression, a foam sample is loaded onto the Instron in the same way as mentioned above. A pre-load of 2.5N is applied at 5mm / min, and the crosshead position is zeroed again. The sample is then compressed at 10 mm / min until the tension reaches 0.38 MPA, referred to as the compression step. Immediately, the crosshead is then inverted until a load of 0.0038 MPa is reached, designated as decompression. Without interruption, the sample is compressed and decompressed for 10 cycles.

[0096] To measure creep compression behavior, a foam sample is loaded onto Instron in the same way as above, except that the environmental chamber is already in place and preheated to a temperature of 65 ^o C. sample is placed between the compression plates, at 65 ^o C. After allowing the foam sample to equilibrate inside the chamber for an hour, a 2.5N preload is applied at 5mm / min and the crosshead position is reset again. Load is then applied at 0.16 MPa. The crosshead position is then automatically adjusted by the Instron computer, to maintain a tension of 0.16 MPa for 12 hours. Compressive stress versus time is measured, and the results shown in Figures 3 and 3c. After 12 hours, the crosshead returns to its initial position. After two more hours, the foam is removed and allowed to cool until it reaches ambient conditions (20 ^o C, 50% relative humidity). The foam thickness is then measured again. The corresponding voltage is called the release voltage, 2 hours. The results of the compression creep behavior test are shown in Figure 4.

[0097] To measure the energy absorption behavior of the foams, the

Petition 870180143054, of 10/22/2018, p. 53/61

44/45 FIFA quality, as described in Requirements for Artificial Turf Surfaces according to the FIFA Quality Concept, March 2006, the FIFA manual of methods and test requirements for artificial turf for soccer fields, incorporated herein by reference. These foams are tested according to such methodology, having been found that foams that have a density of 144 kg / m ³ , for example, have acceptable performance. More detailed test results on shock absorption are described below. Returning to the compression performance, the graphs below illustrate that the foam performance is not compromised by the elimination of crosslinking. In addition, embodiments of the invention can be useful in any field that may use artificial turf, such as rugby and field hockey.

[0098] Figures 3, 3c and 4 illustrate that substantially equal creep performance and subsequent recovery can be achieved, despite the elimination of crosslinking.

[0099] The synthetic grass, using embodiments of the present invention, is shown in Figure 5. Specifically, a non-crosslinked polyethylene foam is provided as a shock-absorbing layer, which can be bonded to a later reinforcement. Artificial grass is connected to the posterior reinforcement, and the spaces between the grass can be filled with a filling.

[0100] Embodiments using non-crosslinked polyethylene can be advantageous, since non-crosslinked polyethylene is recyclable, and thus does not involve environmental issues. Embodiments of the polymer foams described here can also be useful as heavy layers for

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45/45 dampen noise and vibrations, among others.

[0101] Although the invention has been described with respect to a limited number of embodiments, those skilled in the art, benefiting from the present invention, will appreciate that other embodiments are developed without departing from the scope of the invention, as described herein. Consequently, the scope of the invention should be restricted to the attached embodiments only.

[0102] All priority documents are hereby incorporated in full, by reference to all the jurisdictions in which such incorporation is permitted. In addition, all documents cited in the present invention, including testing procedures, are hereby fully incorporated by reference for all jurisdictions in which such incorporation is permitted, insofar as such description is compatible with the description of the present invention.

Claims (7)

1. Synthetic lawn surface, characterized by the fact that it comprises: (a) a carpet of synthetic grass having a flexible base sheet, and (b) a shock absorbing pad, which comprises a non-crosslinked polyolefin foam; the polyolefin having a density of 0.80 to 0.99 g / cm ³ ; the thickness of the foam being between 8 and 30 mm; the density of the foam being between 30 and 150 kg / mm ³ ; the foam having a cell size of between 0.2 and 3 mm; where the synthetic lawn has at least one of: - a vertical ball rebound from 0.60 to 1 m, as measured according to FIFA regulations; - a shock absorption of 55% to 70%, as measured in accordance with FIFA regulations; and - a vertical deformation of 4 mm to 9 mm, as measured in accordance with FIFA regulations. 2. Synthetic lawn surface according to claim 1, characterized in that the polyolefin foam comprises a polyethylene foam. 3. Surface in synthetic lawn, in wake up with The claim 2, characterized by the fact of the polyethylene Tue a density of 0, 865 to 0.96 g / cm ³ . 4. Surface in synthetic lawn, in wake up with The claim 1, characterized by the fact of the lawn Tue one vertical rebound in 0.60 to 1 m ball, as measured in according to FIFA regulations. Petition 870180143054, of 10/22/2018, p. 56/61 2/2 5. Synthetic lawn surface according to claim 1, characterized by the fact that the lawn has a shock absorption of 55% to 70%, as measured according to FIFA regulations. 6. Synthetic lawn surface, according to claim 1, characterized by the fact that the lawn has a vertical deformation of 4 mm to 9 mm, as measured according to FIFA regulations. 7. Synthetic lawn surface according to claim 1, characterized in that the polyolefin foam comprises at least two layers of foam. 8. Synthetic lawn surface according to claim 1, characterized in that the polyolefin has a melting index, I2, of 0.01 to 100 g / 10 minutes. 9. Synthetic lawn surface according to claim 1, characterized in that the polyolefin has a molecular weight, Mw, from 10,000 g / mol to 500,000 g / mol.