WO2012138265A1

WO2012138265A1 - Highly purified material comprising expanded polylactid acid resin

Info

Publication number: WO2012138265A1
Application number: PCT/SE2011/050394
Authority: WO
Inventors: Ulrika ANDREASSON; Tomas GERDSDORFF; Kent Malmgren
Original assignee: Sca Packaging Sweden Ab
Priority date: 2011-04-04
Filing date: 2011-04-04
Publication date: 2012-10-11

Abstract

A material comprising expanded polylactic acid (PLA) resin which comprises a total amount of extractives of 0-0,035 % by weight, calculated on the total weight of PLA, said extractives being substances that can be extracted from PLA with diethyl ether as extraction medium according to the method of determination of extractives in PLA as described in the description of this patent application.

Description

Highly purified material comprising expanded polylactid acid resin

TECHNICAL FIELD The present invention relates to a material comprising expanded polylactic acid (PLA) resin.

BACKGROUND OF THE INVENTION There is an increasing demand for polylactic acid (PLA) resin foams for use in packaging applications, since such polymers are bio-derived and bio-degradable. These foams have good performance and are economic, and are often preferred over petroleum-derived foams such as polystyrene foam, due to increasing environmental awareness and consumer demands.

Carbon dioxide is a useful blowing agent for PLA foams, being an environmentally friendly blowing agent without any ozone depletion potential. Some processes that use carbon dioxide as a blowing agent involve foaming and moulding, and PLA resin beads impregnated with carbon dioxide may then be used. Such processes generally involve impregnating the beads with gaseous or supercritical C0₂, pre- expanding the impregnated beads, resting and sometimes treating the pre- expanded beads, before re-impregnating them with more C0₂ or another blowing agent and further expanding and fusing them in a mould, see e.g. EP 1 378 538. Another known process involving impregnation of PLA resin beads with carbon dioxide is disclosed in WO 2008/093284.

In some packaging applications, in particular in food or medical grade packaging applications, it is important that the packaging foam material does not contain any undesired substances, to avoid any possible transfer of extractives from the packaging foam to the package contents. SUMMARY OF THE INVENTION

An object of the present invention is to provide a foamed PLA material with very high purity useful for packaging application.

The present invention thus relates to a material comprising expanded polylactic acid (PLA) resin that comprises a total amount of extractives of 0-0,035 % by weight, calculated on the total weight of PLA, said extractives being substances that can be extracted from PLA with diethyl ether as extraction medium according to the method of determination of extractives in PLA as described in the description of this patent application. This material can be used for example in packaging applications, especially for packaging of foodstuff. Said extractives may comprise oligomers of lactic acid of which lactide is 0-0,020 % by weight, calculated on the total weight of PLA.

The above material is obtainable by a process in which PLA beads are subject to a liquid C0₂ ^"treatment, which involves impregnation and extraction with liquid C0₂.

The process may preferably comprise the following steps: subjecting PLA resin beads to a liquid C0₂ treatment, which involves impregnation and extraction comprising at least one impregnation and extraction step, in which the PLA resin beads are brought into contact with 0,01 -1000 kg pure liquid C0₂ /kg PLA, preferably 2-20 kg liquid C0₂ /kg PLA, in a reactor for a predetermined time period, at a temperature and pressure that prevents the beads from sticking together and foaming; and a portion of the liquid C0₂ is drained from the PLA beads after completion of the impregnation and extraction step, at a temperature that prevents the beads from sticking together and foaming, and at which the C0₂ is in liquid form, while leaving at least 0,01 kg liquid C0₂/kg PLA, preferably 0,01 -1 kg liquid C0₂/kg PLA in the reactor containing the PLA resin beads; followed by evacuation of C0₂ gas from the reactor so as to decrease the pressure to ambient pressure, whereby the remaining liquid C0₂ is evaporated, thereby decreasing the temperature so as to prevent foaming at ambient pressure; conditioning the impregnated and extracted PLA beads at a temperature and a pressure that prevents the beads from sticking together and foaming, to reduce the C0₂ content to 5-18 % by weight; increasing the temperature to a pre-expansion temperature, so as to pre-expand the PLA beads; and increasing the temperature to a fusing temperature to allow moulding of the PLA beads. The liquid C0₂ treatment involving impregnation and extraction may alternatively comprise impregnation and extraction in a continuous process, wherein PLA resin beads are held in a reactor, in which the PLA resin beads are brought into contact with liquid C0₂ for a predetermined time period, at a temperature that prevents the beads from sticking together and foaming, and at which the C0₂ is in liquid form, and pure liquid C0₂ is continuously fed at one end of the reactor, and is drained from another end of the reactor; and wherein a portion of the liquid C0₂ is drained from the PLA beads upon completion of the impregnation and extraction, at a temperature that prevents the beads from sticking together and foaming, and at which the C0₂ is in liquid form, while leaving at least 0,01 kg liquid C0₂/kg PLA, preferably 0,01 -1 kg liquid C0₂/kg PLA in the reactor containing the PLA resin beads; followed by evacuation of C0₂ gas from the reactor so as to decrease the pressure to ambient pressure, whereby the remaining liquid C0₂ is evaporated, thereby decreasing the temperature so as to prevent foaming at ambient pressure. By means of draining the liquid C0₂ from the reactor, instead of evaporating the C0₂, extractable substances can conveniently be removed from the PLA material, since such substances will be present in the liquid C0₂. In the method, the impregnation and extraction step may preferably comprise 2 or more successive steps, wherein the PLA resin beads are brought into contact with pure liquid C0₂ in each successive step for a predetermined time period at a temperature and pressure that prevents the beads from sticking together and foaming, and wherein at least a portion of the liquid C0₂ is drained from the PLA beads at the end of each step, at a temperature that prevents the beads from sticking together and foaming, and at which the C0₂ is in liquid form.

The PLA beads are impregnated and extracted with liquid C0₂ advantageously at a pressure of above 1 MPa, preferably 4,5-8 MPa. The PLA beads are impregnated and extracted with liquid C0₂ at a temperature suitably above -50 °C, but below the glass transition temperature of PLA at the pressure used, preferably -10 to +15 °C, for 10 to 240 minutes, preferably 30 to 90 minutes.

The PLA beads are impregnated and extracted with liquid C0₂ that may contain additives such as coloring agents, anti-static agents, flame retardants, adhesives.

The PLA resin beads may comprise 50-100% by weight of PLA, preferably 80-100% by weight. The PLA is preferably amorphous PLA. If desired the material of the invention may further comprise one or more of fillers, reinforcing agents, coloring agents.

DRAWINGS

Figure 1 shows a schematic view of a system, useful for performing impregnation and purification of PLA resin beads.

Figure 2 shows a schematic view of a system, similar to the one of Figure 1 , and which includes a pump.

DETAILED DESCRIPTION

The material of the present invention is an expanded polylactic acid (PLA) resin having a total content of extractives of 0-0,035 % by weight, calculated on the total weight of PLA, said extractives being substances that can be extracted from PLA with diethyl ether as extraction medium according to the method of determination of extractives in PLA as described in the description of this patent application. The extractives comprise oligomers of lactic acid, of which lactide is 0-0,020 % by weight, calculated on the total weight of PLA.

The material may be obtained by a process utilizing C0₂ as blowing agent, and in which PLA beads are subject to an a liquid C0₂ treatment, which involves impregnation and extraction with liquid C0₂, which preferably includes at least one impregnation and extraction step, and draining of the C0₂ in liquid form. The process may further include conditioning and pre-expanding the PLA beads, before increasing the temperature to a fusing temperature to allow moulding of the PLA beads.

In the present context the term "extractables" refers to substances that are extracted from PLA during impregnation with carbon dioxide.

The term "extractives" refers to substances that can be extracted from PLA with diethyl ether as extraction medium according to the method of determination of extractives in PLA as described in the description of this patent application.

Additives or coating materials can be added to the PLA resin beads during impregnation and extraction. Accordingly, by means of the present invention various functionalities can effectively be added to the material, since impregnation, extraction and addition of additives can be performed in one process, without any need for additional process steps.

Polylactic acid or PLA is a polymer or copolymer comprising lactic acid monomer units. For the purposes of the present invention references to polylactic acid includes crystalline and amorphous polymers and mixtures thereof. The PLA resin beads may comprise about 50-100 % by weight of PLA. The PLA may comprise amorphous PLA or a blend of amorphous PLA and crystalline PLA. Preferred blends comprise at least about 50 % by weight of amorphous PLA and about 0-50 % by weight of crystalline PLA. The lactic acid in the resin beads may comprise one or more lactic acid isomers including L-lactic acid, D-lactic acid or DL-lactic acid. The lactic acid is preferably L-lactic acid. The PLA may be produced industrially by polymerisation of lactic acid obtained by the bacterial fermentation of biomass such as beet, sugarcane, cornstarch or milk products.

Commercially available PLA resin beads can be impregnated without any pre- treatment using liquid C0₂. Amorphous, crystalline, and amorphous-crystalline blends may be used but results with highly crystalline grades are sometimes of lesser quality at the preferred pressure and temperature ranges. Reference to resin "beads" is intended to mean the crude resin material (often in the form of pellets) obtained from manufacturers and the terms beads, granules and pellets may be used interchangeably. The beads may also be in the form of fibres. Beads may be resized by extrusion and pelletizing of the commercially available material using known techniques.

The present invention is based on the use of liquid C0₂for the impregnation of PLA. In liquid C0₂ impregnation the PLA beads have little tendency to stick to each other, especially when using sub-cooled liquid C0₂, i.e. liquid C0₂ at higher pressure than equilibrium pressure at a given temperature.

Liquid C0₂ impregnation requires moderate temperature and pressure. The impregnated beads do not stick together and after releasing the pressure from the impregnation reactor they can be handled as a bulk commodity. In the method of impregnating and purifying polylactic acid (PLA) according to the present invention PLA resin beads are subjected to a liquid C0₂ treatment, which involves impregnation and extraction. The liquid C0₂ treatment comprises at least one impregnation and extraction step, in which the PLA resin beads are brought into contact with 0,01 -1000 kg pure liquid C0₂/kg PLA in a reactor for a predetermined time period, at a temperature and pressure that prevents the beads from sticking together and foaming. During the impregnation and extraction step, C0₂ is impregnated into the PLA resin beads, and at the same time extractable substances are dissolved into the liquid C0₂. After completion of the impregnation and extraction step a portion of the liquid C0₂ is drained from the PLA beads, at a temperature that prevents the beads from sticking together and foaming, and at which the C0₂ is in liquid form, while leaving at least 0,01 kg liquid C0₂/kg PLA, preferably 0,01 -1 kg liquid C0₂/kg PLA in the reactor containing the PLA resin beads. Thereafter, evacuation of C0₂ gas from the reactor is performed so as to decrease the pressure to ambient pressure, whereby the remaining liquid C0₂ is evaporated, thereby decreasing the temperature so as to prevent foaming at ambient pressure.

It has been found that liquid C0₂ is effective in extracting undesired substances from the PLA. By ensuring that the C0₂ is drained from the reactor in liquid form, the substances extracted from the PLA beads are effectively removed. By leaving a small portion of the liquid C0₂ in the reactor after draining it can thus be ensured that the temperature of the beads is kept low to prevent foaming when the pressure is decreased to ambient pressure at the end of the process.

The impregnation and extraction step preferably comprises 2 or more successive steps, wherein the PLA resin beads are brought into contact with pure liquid C0₂ in each successive step for a predetermined time period at a temperature and pressure that prevents the beads from sticking together and foaming. In the first of these impregnation and extraction steps, a part of the total impregnation is obtained. The following steps continue the impregnation and the PLA resin beads are extracted with liquid C0₂, each time further lowering the content of extractable substances in the PLA resin beads. At the end of each successive step at least a portion of the liquid C0₂ is drained from the PLA beads, at a temperature that prevents the beads from sticking together and foaming, and at which the C0₂ is in liquid form. By draining away the liquid C0₂ after each successive step, substances extracted into the liquid C0₂ are removed from the PLA beads, and pure liquid C0₂ is then added so that the next successive impregnation and extraction step can be carried out. Thus, the content of extractable undesired substances is successively reduced until a desired purity has been reached. If desired, the first impregnation and extraction step be continued until the impregnation is completed, and extraction steps are then performed subsequently. The total treatment time will then be longer than necessary from a removal of extractives point of view, but may be desired for other reasons, such as addition of additives to the PLA.

The liquid C0₂ treatment, involving impregnation and extraction treatment may be carried out in a batch process or in a continuous process.

In a batch process the PLA resin beads are held in a reactor to which an amount of liquid C0₂ is added, and after a certain time period the liquid C0₂ is drained from the reactor, while substantially maintaining the pressure. A new amount of pure liquid C0₂ is then added to the reactor at the same pressure. After completion of the last impregnation and extraction step, a portion of the liquid C0₂ is drained from the PLA beads, and a smaller amount of liquid C0₂ is left in the reactor. As said above, the remaining liquid C0₂ is evaporated when C0₂ gas is evacuated from the reactor and the temperature is thereby decreased so as to prevent sticking together and foaming at ambient pressure. The PLA beads may be placed in a rotating drum during the impregnation and extraction step. When gas is evacuated from the drum, the cold liquid C0₂ is distributed evenly in the PLA material, which gives a thorough and even cooling of the PLA beads.

When carrying out the liquid C0₂ treatment in a continuous process the PLA resin beads are held in a reactor, in which the PLA resin beads are brought into contact with liquid C0₂ for a predetermined time period, at a temperature that prevents the beads from sticking together and foaming, and at which the C0₂ is in liquid form. Pure liquid C0₂ is continuously fed at one end of the reactor, and the liquid C0₂ is continuously drained from another end of the reactor, so that the liquid C0₂ flows through the reactor. The reactor is dimensioned so that the time of contact between the PLA resin beads and the liquid C0₂ is sufficient to achieve the desired impregnation and extraction. Upon completion of the impregnation and extraction a portion of the liquid C0₂ is drained from the PLA beads, and a smaller amount of liquid C0₂ is left in the reactor, and is evaporated during evacuation of C0₂ gas from the reactor whereby the temperature is decreased. Also in a continuous process, the PLA beads may be placed in a rotating drum during the impregnation and extraction step. When gas is evacuated from the drum, the cold liquid C0₂ is distributed evenly in the PLA material, which gives a thorough and even cooling of the PLA beads.

The pressure and temperature during the impregnation and extraction are chosen so as to prevent the PLA resin beads from sticking together and foaming, and to provide the C0₂ in liquid phase. The impregnation and extraction may be performed at a pressure above 1 MPa, to ensure that the C0₂ can be present in liquid phase in a workable temperature range, and to avoid formation of solid C0₂. More preferably the pressure during impregnation and extraction is 4,5-8 MPa, so as to provide conditions under which C0₂ can be in liquid phase at temperatures around 0 °C, and which leads to reasonable treatment time. The temperature of the impregnation and the extraction is advantageously performed at above -50 °C to ensure liquid phase C0₂ during the treatment, but below the glass transition temperature of PLA at the C0₂ pressure used to avoid the PLA beads from sticking together. The temperature of the impregnation and the extraction is more preferably -10 to +15 °C, in order to achieve reasonable treatment time and ensures that C0₂ is liquid at the pressure chosen in the range of 4,5-8 MPa. The total amount of liquid C0₂ used in the liquid C0₂ treatment is advantageously in the range of 2-20 kg C0₂/kg PLA.

The liquid C0₂ drained from the impregnation and extraction may be transferred to a recovery equipment, in which the C0₂ is recovered by separation of extractives from the C0₂ by distillation. The recovered C0₂ may then be recycled to an impregnation and extraction step of PLA resin beads. Accordingly, the C0₂ can be recirculated in a closed circuit, which is advantageous from both an environmental and an economical point of view.

In the impregnation and extraction step the PLA resin beads are placed the reactor (a pressure vessel) under impregnation pressure and temperature, and liquid C0₂ is then added to the reactor until the PLA resin beads are at least partially submerged, or if a rotating drum is used, until the amount of liquid C0₂ is sufficient to wet the PLA beads. The PLA resin beads are left in contact with the liquid C0₂ for a predetermined time, preferably 10 to 240 minutes, to achieve sufficient C0₂ content and at the same time avoid unnecessary treatment time in order to save costs.

Achieving equilibrium takes approximately 30-90 minutes when using PLA Ingeo 4060D™ (NatureWorks LLC, USA), a commonly available commercial amorphous grade but may take longer or shorter depending on the size of the beads and the grade and composition of the beads. After substantially achieving equilibrium at the preferred temperature and pressure ranges, the beads comprise about 18-35 % C0₂ by weight. When using PLA Ingeo 4060D™ and C0₂ at 6 MPa and 10 °C equilibrium results in the beads having around 30 % by weight C0₂.

After the impregnation and extraction of the liquid C0₂ treatment, the impregnated and extracted PLA resin beads are stored in a freezer until C0₂ is desorbed and dispersed evenly throughout the impregnated bead, and leads to even foaming and good cell structure. Pre-expansion is conducted at different temperatures and for different times according to the individual foaming characteristics of impregnated beads which in turn depends on blend and C0₂ content and the differences in minimum foaming temperatures that are the consequence of these factors. Preferably the pre- expansion is conducted at temperatures ranging from 50 °C to 90 °C at ambient pressure and more preferably commercially available amorphous PLA beads having been impregnated to about 30 % by weight C0₂, refrigerated until the C0₂ percentage reduces to 5-18 %, and pre-expanded at 50-75 °C. The pre-expanded beads are promptly transferred into a mould and steam (or other heating providing a temperature higher than the pre-expansion temperature) is applied to further expand the beads and fuse them together in the mould. A vacuum may also be applied before cooling and removal from the mould. The mould is preferably adapted to produce a moulded product including moulded blocks and shaped moulded products, especially blocks adapted to form packing material and shaped moulded products in the form of packaging material or convenience items such as packaging and storage products. Preferred convenience items include containers such as clamshell containers, pots, boxes, bowls, cups, plates and trays. A person skilled in the art will be aware that the absorption percentages, temperatures and pressures can be manipulated relative to each other at the different stages of the method of the invention to achieve substantially the same result with the major limiting factors being the preference for keeping the C0₂ weight percentage within or close to the optimum range of percentages, avoiding the excessive formation of solid C0₂ in the pressure vessel, and retaining control of the foaming steps.

METHOD OF DETERMINATION OF EXTRACTIVES IN PLA

The material of the present invention is an expanded polylactic acid (PLA) resin which comprises a total amount of extractives of 0-0,035 % by weight. The total amount of extractives is calculated based on the total weight of PLA, said extractives being substances that can be extracted from PLA with diethyl ether as extraction medium.

The total amount of extractives is determined by means of the following method, which accordingly is a method used to describe the quantitative determination of extractable compounds in PLA (polylactic acid). 2.6-diethylnaphtalene (DiEN) is used as internal standard (ISTD). No correction is made to compensate for the individual extractives detector responses in relation to the internal standard. In the determination method standard solutions are prepared, said solutions being an internal standard stock solution (ISTDO) and an internal standard working solution (ISTD1 ).

Preparation of internal standard solution - stock solution, ISTD 0

The stock solution is prepared by dissolving 0.04 to 0.05 g of DiEN in 50 mL of acetone (99.9%). The concentration of DiEN will be approximately 0.9 g/L. The true concentration is calculated.

Preparation of internal standard solution - working solution, ISTD 1

Dilute 5 mL of stock solution to 25 mL with acetone (99.9%). The concentration of DiEN will be approximately 180 mg/L. The true concentration is calculated.

Sample preparation and extraction of extractives

PLA beads are ground in a centrifugal mill (Retsch ZM1 ) under cooling with liquid nitrogen. The sample is ground to a size of 0.5 mm. An amount of approximately 1 g ground sample is put into a round bottom flask for reflux and 100 mL of diethyl ether is added (the true amount of PLA sample is noted). A few anti-bumping granules are put into the round bottom flask. Before starting the reflux, the sample is standing for 5 minutes. The reflux is performed for 1 hour and the diethyl ether is thereafter collected and reduced to 10 mL and 10 μί of ISTD 1 is added.

Analysis of extractives.The extractives were analysed by Thermo Finnigan Trace gas chromatograph-mass spectrometer (GC-MS) Instrument parameters and settings

Column: Zebron zb-5MSi, 30 m, id 0.25 mm, thickness 0.25 μηη.

Column temperature: 80^°C for 1 min and then 10^°C/min until 350^°C is reached and finally, 350^°C for 8 min

Carrier gas: 0.7 mL/min of helium at a constant flow

Inlet temperature: 250^°C

Splitless injection for 1 minute, where the whole sample is let into to the column. Transfer temperature (temperature between GC and MS): 320^°C

Temperature in ion source: 200^°C

MS mode: Total ion current (TIC)

Calculations

The concentration of extractives (Ci) in sample extract is calculated as follows Ci (mg/L) = Cis ^* (Ai/Ais)

Cis = concentration of ISTD in sample extract (mg/L)

Ai = peak area of extractives

Ais = peak area of ISTD

Amount of extractives in PLA (Cp) is calculated

Cp (mg/kg) = Ci ^* V / m V = volume of sample extract (L)

m = dry content of PLA (kg)

Gas analysis performed for Example 2 below The followed procedure was applied for gas analysis (example 2). 5-hexen-1 -ol was used as internal standard, and a working solution was prepared by dissolving approximately 1 gram of 5-hexen-1 -ol in 250 mL methanol. The true concentration was calculated. From the working solution 2 μί was injected into the gas-tight bag used in example 2. The bag was conditioned in room temperature for 1 hour before analysis. Solid phase microextraction (SPME) supplied with Carboxen 0,75 μηι absorption phase was inserted into the gas-tight bag. After the SPME phase has been exposed to the sampled gas for 30 minutes it was transferred to the GC-MS for analysis.

Instrument parameters and settings:

Column: Zebron zb-624, 30 m, id 0.25 mm, film thickness 1 .40 urn

Column temperature: 40^°C for 4 min and then 10^°C/min until 250^°C followed by 250^°C for 6 min

Carrier gas: 1 mL/min of helium at a constant flow

Inlet temperature: 240^°C

Splittless injection for 1 minute

Transfer temperature (temperature between GC and MS): 240^°C

Temperature in ion source: 200^°C

MS mode: Total ion current (TIC)

EXAMPLES

The invention will now be illustrated in non-limiting ways by reference to the following examples of impregnation of PLA resin beads. In the examples below PLA beads were used without additional treatment, i.e. as commercially available.

Example 1 - analysis of reference sample

PLA Ingeo 4060D™ (NatureWorks LLC, USA) as commercially available was extracted with diethyl ether according to the above described procedure for determining extractives in PLA, and analysed with GC-MS regarding extractable low molecular compounds. Among detected extractives, lactide was dominating followed by other lactic acid oligomers. The result is shown in Table 1. Example 2 - liquid CO? drained off

The aim of Example 2 was to determine extractable substances extracted from the PLA, which may not have been detected by the extraction with diethylether. PLA Ingeo 4060D (NatureWorks LLC, USA) as commercially available was placed in an autoclave which was filled with liquid carbon dioxide and pressurised to 60 bars at 0-2 °C. The ratio by weight between PLA and carbon dioxide was 1/10. After four hours, liquid C0₂ was drained off and C0₂ was collected in a gas-tight bag (1 L, Tedlar, SKC). The gas-tight bag was carefully cleaned and checked for background before sample collection. The C0₂ liquid level was allowed to decrease until the ratio by weight between PLA and C0₂ was 1/2. The remaining liquid C0₂ was evaporated during the evacuation of C0₂, thereby decreasing the temperature below Tg for PLA impregnated with C0₂.

The impregnated beads were stored at -19 °C over night and thereafter pre- expanded in hot water. A mould was filled with pre-expanded beads and moulded by applying steam mixed with air. Extractable substances in the gas phase were analysed according to the gas analysis procedure as described above. Lactide was dominating followed by other lactic acid oligomers.

Example 3 - liquid phase C0₂ removed by evaporation

The aim of Example 3 was to determine substances extracted from the PLA, which may not have been detected by the extraction with diethyl ether, by a method different to the one used in Example 2.

PLA Ingeo 4060D™ (NatureWorks LLC, USA) as commercially available was placed in an autoclave which was filled with liquid carbon dioxide (PLA/C0₂; 1/10 by weight) and pressurised to 50 bars at 0 °C. After 80 minutes, the liquid phase C0₂ was removed by evaporation and the pressure released. Substances released from PLA during impregnation were collected from the reactor chamber by extraction of the reactor with acetone, and analysed with GC-MS.

Among detected extractable substances, lactide was dominating followed by other lactic acid oligomers. Example 4 - liquid C0₂ drained off (1 impregnation and extraction step)

PLA Ingeo 4060D™ (NatureWor s LLC, USA) as commercially available was placed in an autoclave and treated with liquid carbon dioxide (PLA C0₂, 1/100 by weight) at 53 bars at 0°C for 90 minutes. The liquid phase was drained off until the ratio by weight between PLA and C0₂ was 1/20 and the remaining liquid C0₂ was evaporated during evacuation of C0₂ gas in order to lower the temperature below Tg for C0₂ impregnated PLA.

The remaining low molecular substances in the purified PLA was determined by extraction with diethyl ether according to the above described method and analysed with GC-MS. Detected substances were lactide and other lactic acid oligomers. The result is shown in Table 1.

The impregnated beads were also stored, pre-expanded, foamed and moulded according to the method described in example 2.

Example 5 - liquid C0₂ drained off (2 impregnation and extraction steps)

PLA Ingeo 4060D™ (NatureWorks LLC, USA) as commercially available was placed in an autoclave and treated with liquid carbon dioxide (PLA/C0₂; 1/100 by weight) at 53 bars at 0 °C for 90 minutes. The liquid phase was drained off until the ratio by weight between PLA and C0₂ was 1/20. A second treatment in which pure liquid C0₂ was added at 53 bars was done at 53 bars, -5-0 °C for 90 minutes. The liquid phase was drained off until the ratio by weight between PLA and C0₂ was 1/20 and the remaining liquid C0₂ was evaporated during evacuation of C0₂ gas in order to lower the temperature below Tg for C0₂ impregnated PLA. .

The remaining low molecular substances in the purified PLA were determined by extraction with diethyl ether according to the described method and analysed with GC-MS. Detected substances was lactide and other lactic acid oligomers. The result is shown in Table 1 .

Example 6 - liquid C0₂ drained off (3 impregnation and extraction steps)

PLA Ingeo 4060D™ (NatureWorks LLC, USA) as commercially available was placed in an autoclave. PLA was treated with liquid carbon dioxide (PLA/C02, 1/100 by weight) at 53 bars, 0 °C for 90 minutes. The liquid phase was drained off until the ratio by weight between PLA and C0₂ was 1/20. The procedure was repeated with pure liquid C0₂ two more times. The liquid phase was drained off until the ratio by weight between PLA and C0₂ was 1/20 and the remaining liquid C0₂ was evaporated during evacuation of C0₂ gas in order to lower the temperature below Tg for C0₂ impregnated PLA. The result is shown in Table 1 .

The remaining low molecular substances in the purified PLA were determined by extraction with diethyl ether according to the described method and analysed with GC-MS. Detected substances were lactide and other lactic acid oligomers.

Example 7 - liquid C0₂ drained off (4 impregnation and extraction steps)

PLA Ingeo 4060D™ (NatureWor s LLC, USA) as commercially available was placed in an autoclave. PLA was treated with liquid carbon dioxide (PLA/C02, 1/100 by weight) at 53 bars, 0 °C for 90 minutes. The liquid phase was drained off until the ratio by weight between PLA and C0₂ was 1/20. The procedure was repeated with pure liquid C0₂ three times. The liquid phase was drained off until the ratio by weight between PLA and C0₂ was 1/20 and the remaining liquid C0₂ was evaporated during evacuation of C0₂ gas in order to lower the temperature below Tg for C0₂ impregnated PLA. The result is shown in Table 1 .

The remaining extractives in PLA beads after impregnation and extraction in Examples 1 and 4-7 are shown in Table 1.

Table 1

Example Number of Total amount of Lactide Others^*

impregnation and extractives^* % by weight % by weight extraction steps % by weight

1 0 0,043 0,026 0,017

4 1 0,031 0,017 0,014

5 2 0,027 0,014 0,013 6 3 0,013 0,005 0,008

7 4 0,013 0,006 0,007

* dominating substances were lactic acid oligomers.

The results shown in Table 1 indicate that draining off the liquid C0₂ in liquid phase after the impregnating and extraction step, is very effective to remove extractable substances, and that repeated impregnating and extraction steps further enhances this effect.

The results in Table 1 shows that three impregnation and extraction steps may be sufficient to decrease the amount of extractives to a reasonable level, which is considerably lower than the initial levels in the PLA material.

Example 8 -dying

PLA Nature Works Ingeo 4060D, re-extruded to beads with the appropriate size of 1 ,5 x1 ,5 mm, was placed in an autoclave together with a cotton bag containing, the colouring agent 1 ,4-diamino anthraquinone (Sigma-Aldrich) 0,4% by weight PLA . Liquid C0₂ was added at 47 bars and 0-1 °C until the ratio by weight between PLA and C0₂ was 1/10 . After 90 minutes treatment liquid C0₂ was drained off until the ratio by weight between PLA and C0₂ was 1/2, and the remaining liquid C0₂ was evaporated during evacuation of C0₂ gas in order to lower the temperature below Tg for C0₂ impregnated PLA. Purple PLA pellets were collected from the reactor. After storage at -19 °C, the impregnated beads were foamed and moulded according to the method described in example 2. The foam was light purple.

EXEMPLIFYING EMBODIMENTS

Figure 1 shows a schematic view of a system for performing a process including the method of impregnating and purifying PLA resin.

In the start-up phase of the process an extraction chamber 1 is loaded with PLA resin beads through an inlet 2. The extraction chamber may be a reactor in the form of an autoclave or any other vessel that may be pressurised. Air present in the extraction chamber 1 is evacuated by means of a vacuum pump. During start-up of the process, C0₂ gas is supplied to the extraction chamber 1 from a C0₂ storage tank 3, so as to pressurize the extraction chamber 1 to approximately 6 MPa with C02 gas. Sensors in the system monitor the level of C0₂ in the storage tank 3, and additional C0₂ is added to the extraction chamber 1 from a storage tank 3_from an external source (not shown in figure 1 ) if necessary.

In the impregnation and extraction phase, the pressures in the extraction chamber 1 and the storage tank 3 are balanced to a pressure P0. Liquid C0₂ is added from the storage tank 3 to the extraction chamber 1 at the pressure P0, and the temperature TO, by means of a compressor, which sucks gas from extraction chamber 1 and pushes out liquid C0₂from the bottom of the storage tank 3 by adding it to the top. If desired additives for coating or impregnating into the PLA material can be added to the liquid C0₂. The temperature in the extraction chamber 1 is decreased by evaporation of liquid C0₂ to a pressure P1 and temperature T1 . C0₂ gas is taken from the storage tank 3 by the compressor and is supplied at the top of the extraction chamber 1 to a pressure P2 at a temperature T1 , thereby achieving a subcooling of the liquid C0₂, thus preventing the PLA resin beads from sticking together. The temperature T1 should be below the glass transition temperature Tg of PLA for the actual C0₂ pressure. Evaporation and addition of C0₂ gas so as to achieve subcooling of the liquid C0₂ is repeated as often as necessary to maintain the desired conditions in the extraction chamber 1 . After a predetermined treatment time period, the pressures between the extraction chamber 1 and the distiller tank 4 are balanced, and liquid C0₂ is drained off from the extraction chamber to the distiller tank 4. The impregnation and extraction phase may be repeated several times, as desired.

When the impregnation and extraction treatment in the liquid C0₂ ^"treatment of the PLA resin beads is completed a last draining of the liquid C0₂ is carried out, in which the liquid C0₂ is partially drained off from the extraction chamber to the distiller tank 4. The remaining liquid C0₂ is evaporated and is transferred via a compressor via a heat exchanger/cooler to the storage tank 3. Thereby, the impregnated PLA resin beads are cooled and undesired expansion is prevented, while the pressure in the extraction chamber is lowered to atmospheric pressure. Rotation of the PLA beads during this step is preferred in order to get a uniform cooling of PLA. The impregnated PLA resin beads can then be taken out from the extraction chamber and be transferred to further processing.

Liquid C0₂ received in the distiller tank 4 comprises extractable substances originating from the PLA resin beads. The C0₂ is separated from these extractable substances by distillation, and the pure C0₂ thereby obtained is recycled to the storage tank 1 . The extractable substances remain at the bottom of the distiller tank

4, and can be removed as a concentrate. The above system relates to a batch process. However, the process may as well be performed continuously, and the system is then adapted thereto.

Figure 2 shows a schematic view of a system for performing a process including the method of impregnating and purifying PLA resin. In the start-up phase of the process an extraction chamber 1 is loaded with PLA resin beads through an inlet 2. The extraction chamber may be a reactor in the form of an autoclave or any other vessel that may be pressurized. Air present in the extraction chamber 1 is evacuated by means of a vacuum pump. During start-up of the process, C0₂ gas is supplied to the extraction chamber 1 from a C0₂ storage tank 3, so as to pressurize the extraction chamber 1 to approximately 6 MPa with C0₂ gas. Sensors in the system monitor the level of C0₂ in the storage tank 3, and additional C0₂ is added to the extraction chamber 1 from an external source if necessary.

In the impregnation and extraction phase, the pressures between the extraction chamber 1 and the storage tank 3 are balanced to a pressure P0. Liquid C0₂ is added from the storage tank 3 to the extraction chamber 1 using a liquid C0₂ pump

5. The setpoint temperature is maintained using a cooling unit. The pump is used to maintain the setpoint pressure in the extraction chamber during the extraction/impregnation. The PLA particles are rotated in a drum in the extraction chamber 1. The C0₂ in the extraction chamber 1 is drained to the distiller tank 4 after a predetermined time. New C0₂ is added from the storage tank 3 to the extraction chamber 1 while C0₂ in the distiller tank 4 is distilled and transported to storage tank 3 while extraction/impregnation of PLA occurs in the extraction chamber 1 in the same way as in the first bath. The number of C0₂ baths can vary depending on purity level of the PLA. In any of the baths an additive can be added to the extraction chamber 1 to modify the properties of the PLA.

When the liquid C0₂ treatment, which involves impregnation and extraction of the PLA resin beads, is completed a last draining of the liquid C0₂ is carried out, in which the liquid C0₂ is partially drained off from the extraction chamber to the distiller tank 4. The remaining liquid C0₂ is evaporated and is transferred via a compressor via a heat exchanger/cooler to the storage tank 3. Thereby, the impregnated PLA resin beads are cooled and an undesired expansion is prevented, while the pressure in the extraction chamber is lowered to atmospheric pressure. Rotation of the PLA beads during this step is preferred in order to get a uniform cooling of PLA. The impregnated PLA resin beads can then be taken out from the extraction chamber and be transferred to further processing.

Claims

1 . A material comprising expanded polylactic acid (PLA) resin characterized in that it comprises a total amount of extractives of 0-0,035 % by weight, calculated on the total weight of PLA, said extractives being substances that can be extracted from PLA with diethyl ether as extraction medium according to the method of determination of extractives in PLA as described in the description of this patent application.

2. The material of claim 1 , wherein said extractives comprise oligomers of lactic acid of which lactide is 0-0,020 % by weight, calculated on the total weight of PLA.

3. The material of claim 1 or 2, wherein the material is obtainable by a process in which PLA beads are subjected to a liquid C0₂ treatment, which involves impregnation and extraction with liquid C0₂.

4. The material of claim 3, wherein the process comprises the following steps:

subjecting PLA resin beads to a liquid C0₂ treatment, which involves impregnation and extraction comprising

at least one impregnation and extraction step, in which the PLA resin beads are brought into contact with 0,01 -1000 kg pure liquid C0₂ /kg PLA, preferably 2-20 kg liquid C0₂ /kg PLA, in a reactor for a predetermined time period, at a temperature and pressure that prevents the beads from sticking together and foaming, and that a portion of the liquid C0₂ is drained from the PLA beads after completion of the impregnation and extraction step, at a temperature that prevents the beads from sticking together and foaming, and at which the C0₂ is in liquid form, while leaving at least 0,01 kg liquid C0₂/kg PLA, preferably 0,01 -1 kg liquid C0₂/kg PLA in the reactor containing the PLA resin beads, followed by

evacuation of C0₂ gas from the reactor so as to decrease the pressure to ambient pressure, whereby the remaining liquid C0₂ is evaporated, thereby decreasing the temperature so as to prevent foaming at ambient pressure;

conditioning the impregnated and extracted PLA beads at a temperature and a pressure that prevents the beads from sticking together and foaming, to reduce the C0₂ content to 5-18 % by weight;

increasing the temperature to a pre-expansion temperature, so as to pre-expand the PLA beads; and

increasing the temperature to a fusing temperature to allow moulding of the PLA beads.

5. The material of claim 4, wherein the impregnation and extraction step comprises 2 or more successive steps, wherein

the PLA resin beads are brought into contact with pure liquid C0₂ in each successive step for a predetermined time period at a temperature and pressure that prevents the beads from sticking together and foaming, and wherein

at least a portion of the liquid C0₂ is drained from the PLA beads at the end of each step, at a temperature that prevents the beads from sticking together and foaming, and at which the C0₂ is in liquid form.

6. The material of claim 3, wherein the liquid C0₂ treatment, which involves impregnation and extraction, comprises

impregnation and extraction in a continuous process, wherein PLA resin beads are held in a reactor, in which the PLA resin beads are brought into contact with liquid C0₂ for a predetermined time period, at a temperature that prevents the beads from sticking together and foaming, and at which the C0₂ is in liquid form, and

pure liquid C0₂ is continuously fed at one end of the reactor, and is drained from another end of the reactor, and wherein

a portion of the liquid C0₂ is drained from the PLA beads upon completion of the impregnation and extraction, at a temperature that prevents the beads from sticking together and foaming, and at which the C0₂ is in liquid form, while leaving at least 0,01 kg liquid C0₂/kg PLA, preferably 0,01 -1 kg liquid C0₂/kg PLA in the reactor containing the PLA resin beads, followed by evacuation of C0₂ gas from the reactor so as to decrease the pressure to ambient pressure, whereby the remaining liquid C0₂ is evaporated, thereby decreasing the temperature so as to prevent foaming at ambient pressure.

7. The material of any one of claims 4-6, wherein the beads are impregnated and extracted with liquid C0₂ at a pressure of above 1 MPa, preferably 4,5-8 MPa.

8. The material of any one of claims 4-7, wherein the beads are impregnated and extracted with liquid C0₂ at a temperature above -50 °C but below the glass transition temperature of PLA at the pressure used, preferably -10 to +15 °C, for 10 to 240 minutes, preferably 30 to 90 minutes.

9. The material of any one of claims 4-8, wherein the beads are impregnated and extracted with a liquid C0₂ containing additives chosen from coloring agents, anti- static agents, flame retardants, adhesives and fragrances.

10. The material of any one of claims 1 -9, wherein the PLA resin beads comprise 50-100% by weight of PLA, preferably 80-100 % by weight.

1 1 . The material of any one of claims 1 -10, wherein the PLA is amorphous PLA.

12. The material of any one of claims 1 -1 1 , further comprising one or more of fillers, reinforcing agents and coloring agents.