Note: Descriptions are shown in the official language in which they were submitted.
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HIGH MOLECULAR WEIGHT POLYOLEFIN AND CATALYST AND PROCESS
FOR POLYMERISING SAID POLYOLEFIN
Field of application of the invention
The present invention relates to polyolefins and in particular to polyolefins
comprising a C3 Coo monomer. The present invention further relates to a
catalyst
and a process for making such polyolefins.
Background of the invention
Polyolefinic material are widely used in industry for a large variety of
different
applications. In particular their low cost and their versatility have led to
polyolefins
replacing conventional material from metal to rubber and have further led to
polyolefins making accessible entirely new applications.
A great proportion of the specific material properties of polyolefins stems
from the
fact that such material are not entirely crystalline but rather comprise
crystallites
of varying size. Many macroscopic properties can be linked to size of the
crystallites more or less directly. One such property is the stress strain
behaviour,
the tensile forces required to strain the material need to be higher if. the
size of
the crystallites becomes larger. Another macroscopic property linked to the
size
of the crystallites is the colour or transparency of the material. If the
crystallite
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sizes are of the same size as the wavelength of visible light, the light is
dispersed.
It is further known that an increase in molecular weight leads to an increase
in
required tensile forces for straining the material, to a higher melting
temperature,
improved compressive creep, improved hysteresis properties, and others more.
This is at least in part due to an increase of entangling between the
molecules.
Hence, it is an object of the present invention to provide a polyolefin
comprising a
C3 C2o monomer which overcomes the disadvantages of the prior polyolefins.
It is a further object of the present invention to provide a polyolefin
comprising a
C3 C2o monomer and having a high molecular weight.
Various polymerising processes having described in the art for polyolefins.
Recently, the class of metallocene catalysts has attracted a lot of interest
for their
desirable polymerisation catalysis characteristics.
Hence, it is an object of the present invention to provide a metallocene
catalyst
for polyolefin polymerisation which overcomes the disadvantages of the prior
art
metallocene catalysts.
It is a further object of the present invention to provide a metallocene
catalyst for
polyolefin polymerisation which enables polymerisation of a polyolefin
comprising
a C3 C2o monomer and having a molecular weight of at least 700kg/mol,
preferably at least 1000 kg/mol.
Summary of the invention
The present invention provides a polymeric material, preferably a
stereohomopolymer, comprising substantially linear polyolefin molecules
comprising a C3-C2o monomers. The molecular weight of said linear polyolefin
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molecules is at least 700kg/mol, preferably at least 1000 kg/mol.
The relative content of [mmmm] of said polyolefin is between 10% and 60% and
said polymeric material has a ratio k of at least 0.05 where k is defined as
~m~~m~- ~m~2 ~1- ~m~~2
k ~j ~~1-~ ~~-~ ~2(1-~mba
The present invention further provides a polymeric material wherein said
monomer is propene.
The present invention further provides a catalyst combination for polymerising
linear polyolefin molecules comprising a C3 C2o monomers wherein said catalyst
combination comprises a metallocene of the general formula
where
- R, through R8 refer to linear or branched C, to Coo alkyl, 5- to 7-linked
cycloalkyl
which in its turn, can carry one ore several C~ to Cs alkyl residues as
substituents,
C6 to C~$ arylalkyl or alkylaryl, in which case R~/R~, R3/R4, R6/R~ can be
partially or
simultaneously integrated into 5- to 7-linked cycloalkyl or aryl rings fused
thereto
- R9 and R,o refer to H, C, to C8 alkyl, 4- to 7-linked cycloalkyl, aryl in
which case
R9, R,o can jointly with E form a 4- to 7-linked cycloalkyl
- X refers to a C, to Ca alkyl, aryl, or benzyl, preferably methyl
- E refers to carbon, silicon, germanium, or 1.2-ethyl, 1.3-propyl, or 1.4-
butyl,
- E2 refers to methyl, oxygen or sulphur, and n is 1 or 2.
and
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an activator selected from B(C6F5)3 , R93 C[B(C6F5)4], [R93 NH] [B(C6F5)4]
where R9
is a C, - C4 alkyl group or an aryl group.
The present invention further provides a process for making polymeric material
comprising substantially linear polyolefin molecules comprising a C3 C2o
monomers wherein said process comprises a step of polymerising said
monomers using the catalyst combination according to Claim 6.
The present invention further provides a process for making a polymeric
material
comprising linear polyolefin molecules wherein the molecular weight of said
linear
polyolefin molecules is at least 700kg/mol, preferably using bulk
polymerization
and in-situ activation; under such conditions, the use of the catalyst
combination
of the present invention, allows the catalysts herein to exhibit an activity
of from
20,000 to 150,000 kg/mol cat/hours, peferably 40,000 to 120,000 kg/mol
cat/hour.
Detailed description of the invention
The present invention relates to substantially linear polyolefins comprising a
C3
Coo monomers. The presence of such a monomer leads to the presence of stereo
centres along the backbone. Two consecutive C atoms in the backbone either
have a meso configuration (m dyad) or a rac configuration (r dyad) as is well
known in the art. Such polymers having only m dyads are called isotactic, such
polymers having only r dyads are syndiotactic. If the polymer comprises a
random series of m and r dyads, it is called atactic. For the polymer of the
present invention, the isotacticity is defined as the relative content of mmmm
pentads, [mmmm]. In theory, [mmmm] can vary between 100% and ([m])~. The
content of mmmm pentads, [mmmm], can be determined by '3C-NMR
spectroscopy having a sufficiently high resolution to separate the individual
pentads.
Preferably, the first monomer of the polymer of the present invention is a C3-
CZo
alk-1-ene, such as for example propene, 1-butene, 2-butene, 1-pentene, 1-
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hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, 1-dodecene, 1-hexadecene,
1-octadecne, 1-eicosene, and the like. Alternatively, the first monomer may be
a
cycloolefin such as for example cyclopentene, cyclohexene, norbornadiene and
its derivatives.
5
The polymer of the present invention may be a homopolymer or may be a
copolymer of two or more different monomers. In order for the polymer of the
present invention to have the above stereo characteristics at least the first
monomer must be at least C3. The second monomer and other additional
monomers are preferably C3 C3o as defined above or may further be cycloolefins
such as those specified above. Preferably, the polymer is a homopolymer
comprising propene monomers, and is a polyolefinic stereohomopolymer.
The term "polyolefinic stereohomopolymer" as used herein refers to those
polyolefins which
a) comprise only one phase of molecules all of which exhibit a similar
stereochemical configuration
b) do not comprise blocks of differing stereochemical configuration
For example, blends of atactic and isotactic polymers where the two phases
have
polymerized simultaneously are excluded when this term is used. Such mixtures
of atactic and isotactic polypropylene are fractionable by dissolving in
pentane
yielding a pentane soluble fraction and a pentane insoluble fraction. The term
stereohomopolymer includes copolymers where all molecules exhibit a similar
stereochemical configuration. Furthermore, stereoblock polymers such as
isotactic-atactic stereoblock polymers are excluded when this term is used.
The molecular weight of the polymer of the present invention is at least
700kg/mol, preferably 1000 kg/mol, more preferably at least 1250 kg/mol, yet
more preferably 1500 kg/mol, yet more preferably 1750kg/mol, most preferably
at
least 2000kg/mol. The molecular weight is determined for example by Gel
Permeation Chromatography (GPC) with microstyragel as the column material,
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with 1, 2, 4- trichlorobenzole as solvent, and with the appropriate closely
distributed calibration standards such as polyethylene, polystyrene, or the
like.
For some applications, the molecular weight distribution MW/M~ of the polymer
of
the present invention, also measured by the above GPC method, is preferably
less than 6, more preferably less than 5, yet more preferably less than 4, yet
more preferably less than 2. Alternatively and for improved processability of
the
polymeric material of the present invention, it may be preferred for the
material to
have a broad molecular weight distribution. Preferably Mw/Mn is at least 5,
more
preferably at least 10, yet more preferably at least 15, yet more preferably
at least
20, most preferably at least 30. These are known in the art various techniques
such as blending different grades of material including reactor blends (the
different grades may be produced in separate polymerisation reactions or in a
single multistage polymerisation reaction), controlling the temperature during
the
polymerisation reaction such as through increasing the temperature,
controlling
the supply of the catalyst over time during the polymerisation reaction,
choosing a
specific type of catalyst system particularly including a mixture of two or
more
metallocene catalysts a mixture of metallocene catalysts and non-metallocene
catalysts, using catalyst with more than one active site also in combination
with
other catalysts, using a second monomer, using a particular support material
for
the catalyst(s), using hydrogen during the polymerisation reaction, and the
like.
The tacticity, i.e. the relative content of [mmmm] pentads, of the polymer of
the
present invention is at least 10.0%, preferably at least 15.0%, yet more
preferably
at least 20.0%, most preferably at least 22.5%. The tacticity of the polymer
of the
present invention is less than 60%, preferably less 50%, yet more preferably
less
than 40%, most preferably less than 35%.
Due to the specific stereo chemistry of the catalyst of the present invention,
the
polymeric material of the present invention preferably comprises a relatively
high
amount of mrrm pentads. This pentad is characteristic for a polymer side chain
which exhibits a stereo chemistry opposite its two neighbouring polymer side
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chains. In particular in combination with additional neighbouring side chains
which are also opposite to the central side chain, i.e. a mmrrmm heptad, the
opposing central side chain is referred to as a single stereo error. For
comparison, isotactic polymers and syndiotactic polymers are considered to
have
[mrrm]=0 and atactic polymers for statistical reasons have [mrrm] _ [m]2[r]2 =
[m]2(1-[m])2. Preferably, the polymer of the present invention has a [mrrm]
content
substantially higher than an atactic polymer, i.e. a ratio k of at least 0.05,
more
preferably at least 0.1, yet more preferably at least 0.15, yet more
preferably at
least 0.2, yet more preferably at least 0.25, yet more preferably at least
0.3, yet
more preferably at least 0.4 most preferably at least 0.5, where k is defined
as
_ ~m~nm~- ~m]z ~1- ~m~~z
amyl- ~m~)-Cm]z(1- ~rnbz
Preferably, the polymer of the present invention only has a low content of
atactic
sequences or rather regular sequences as can be seen from its low content of
rmrm pentads. Preferably, for the polymer of the present invention [rmrm] is
less
than 7%, preferably less than 6.5%, more preferably less than 6% of the entire
pentad range; in certain embodiments herein, [rmrm] can be less than 5%, more
preferably less than 3%; in another embodiment herein, the level of {rmrm} is
between 2.5% and 7% of the total pentad area.
The melting point of the polymer of the present invention is preferably at
least
80°C, more preferably at least 100°C, more preferably at least
120°C, yet more
preferably at least 130°C. The glass transition temperature of the
polymer of the
present invention is preferably below 30°C, more preferably below
10°C, yet
more preferably below 0°C, most preferably below -5°C. High
melting points and
low glass transition temperatures ensure stability and usability of the
polymeric
material of the present invention over a wide range of temperatures. Melting
point
and glass transition temperature may be determined for example by Differential
Scanning Calorimetry (DSC) methods such as well known art.
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The polymer material of the present invention preferably has a low density of
below 0.96g/cm3, more preferably below 0.92g/cm3, yet more preferably below
0.88g/cm3.
The polymer of the present material shows elastomeric behaviour as can be seen
from its relaxation characteristics after stretching and as is quantified by
the
following measure of inelasticity. The 'Measure of Inelasticity' refers to a
protocol
(ASTM D174-90) of stretching the sample to 220%, 150%, and 115%,
respectively of its original length, at a cross-head speed of 25 mm/min.,
holding .
the sample for 3 minutes at 23°C, then releasing tension and allowing
the sample
to recover to an equilibrium length. A suitable machine for this set of
experiments
is a standard universal tensile tester manufactured by Instron Corp., Canton,
MA., model 5564. The results reported for strain are true strain values versus
engineering strain values. According to this test method, the material of the
present invention preferably recovers after having been stretched to 220% of
its
original length to less than 120% of its original length, more preferably to
less
than 115% of its original length, yet more preferably to less than 110% of its
original length, yet more preferably to less than 108% of its original length,
most
preferably to less than 106% of its original length. According to this test
method,
the material preferably recovers after having been stretched to 150% of its
original length to less than 110% of its original length, more preferably to
less
than 108% of its original length, yet more preferably to less than 106% of its
original length, yet more preferably to less than 105% of its original length,
most
preferably to less than 104% of its original length. According to this test
method
the material of the present invention preferably recovers after having been
stretched to 120% of its original length to less than 108% of its original
length,
more preferably to less than 106% of its original length, yet more preferably
to
less than 105% of its original length, yet more preferably to less than 104%
of its
original length, most preferably to less than 103% of its original length.
The polymeric material of the present invention preferably has a shore A
hardness of at least 15, more preferably of at least 25, yet more preferably
at
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least 35. Further, the polymeric material of the present invention has a shore
A
harness of less than 90, more preferably less than 80, yet more preferably
less
than 70. It is to be noted, however, that for certain application a different
hardness may be required.
The polymeric material of the present invention is preferably transparent. As
used
herein, the term "transparent" refers to materials which show only a low level
of
light dispersion in the visible range and preferably substantially no such
dispersion. Because of its transparency, the polymeric material of the present
invention may be coloured by adding dyes, oligomeric colouring agents, and the
like such as those well known in the art.
The polymeric material of the present invention may be processed on
conventional polymer processes such as cast film, injection moulding, blow
moulding, melt spunbond, blow film, compression moulding, extruders, gel
spinning, and the like.
It is another aspect of the present invention to provide a catalyst
combination for
polymerising olefins and in particular for polymerising the polymers of the
present
invention as specified above. The catalyst combination comprises a metallocene
catalyst and an activator.
The catalyst of the present invention has the following chemical structure
R3
R2 ~R
4
R1
R~
(I)
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or preferably
Rs
R~
(II)
5
or more preferably
10 or yet more preferably
R~
I2)n
(IV)
or most preferably
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(V) H2
where
R, through R8 refer to linear or branched C, to Coo alkyl, 5- to 7-linked
cycloalkyl
which in its turn, can carry one ore several C~ to Cs alkyl residues as
substituents,
C6 to C~$ arylalkyl or alkylaryl, in which case R,/R2, R3/R4, R6/R, can be
partially or
simultaneously integrated into 5- to 7-linked cycloalkyl or aryl rings fused
thereto
R9 and R,o refer to H, C, to C$ alkyl, 4- to 7-linked cycloalkyl, aryl in
which case
R9, R,o can jointly with E form a 4- to 7-linked cycloalkyl
X refers to C, to C$ alkyl, aryl, benzyl, preferably alkyl, more preferably
methyl
E refers to carbon, silicon, germanium, or 1.2-ethyl, 1.3-propyl, or 1.4-
butyl,
E2 refers to methyl, oxygen or sulphur, and n is 1 or 2.
The catalyst combination of the present invention also surprisingly been found
to
yield the high molecular weight of the polymer of the present invention as
well as
the other beneficial properties of the polymer, while not conpromising on the
catalyst activity.
Preparation of the catalyst can be carried out in analogy to the catalyst
preparation described in W099/52955, pages 12 through16, except for the
substitution of Zr with Hf.
The catalyst of the present invention may be precipitated on a suitable
carrier
system such as those well known in the art.
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It is another aspect of the present invention to provide a process for
polymerising
the polymer of the present invention.
The polymerisation process of the present invention involves the catalyst of
the
present invention and an activator according to one of the general formulas
V B(CgFS)3
VI R93 C[B(C6F5)4]
(VII) [R93 NH] [B(C6F5)a]
Herein, R9 signifies a C,-C4 alkyl group or an aryl group. The preferred
activator
species herein are those of formulae (VI).
Preferably, the catalyst of the present invention and the above activators are
employed in such quantities that the atomic ratio between the boron from the
activator and hafnium from the catalyst is at least 1:1 and more preferably is
less
than 100:1, yet more preferably less than 10:1, most preferably less than 2:1.
Preferably, the process of the present invention is carried out at a
temperature of
at least 0°C, more preferably at least 5°C. Preferably, the
process of the present
invention is carried at a temperature of less than 50°C, more
preferably less than
40°C. The optimum temperature for the process will depend on other
factors and
may be adjusted accordingly within the above limits.
Preferably, the polymerisation process of the present invention is carried at
a
pressure of at least 1 ~ bar more preferably at least 3 bars, yet more
preferably at
least 5 bars. Preferably, the polymerisation process of the present invention
is
carried out at a pressure of less than 100 bars, more preferably less than 20
bars, yet more preferably less than 15 bars. It is to be noted, however, that
the
pressure during the reaction of course depends on the reaction temperature.
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The polymerisations can be carried out in the gas phase, in suspension, in
supercritical monomers and in solvents inert under polymerisation conditions.
Suitable inert solvents are such solvents that do not contain any reactive
group in
the molecule, i.e. aromatic solvents such as benzene, toluene, xylene, ethyl
benzene, or alkanes such as propane, pentane, hexane, heptane, mixtures
thereof and the like.
Preferably, the polymerisation is carried out in supercritical monomers such
as
propene (bulk polymerization). Also, the polymerization herein are achieved
using in-situ activation; under such a process, a stable precursor of the
Hafnium-
based catalyst herein is used wherein X in the general formula herein is a
halogen, preferably chlorine, and said precursor is added together with a
alkyl-
based reactant (preferably TIBA) and the activator herein, as a pre-mix into
the
reaction blend.
In the preferred conditions stipulated above, i.e. bulk polymerization and in-
situ
activation, the use of the Catalyst Combination of the present invention, has
allowed to yeld a suprisingly high activity for the catalyst, namely in the
range of
from 20,000 to 150,000 kg/mol cat./hour, preferably 40,000 to 120,000
by/mol.cat/hour at reaction temperatures under 40°C.
Under the above conditions, the preferred catalyst species of formulae (V)
herein,
when used in combination with preferred activators of formula (VI) herein)
were
shown to attain activity values of respectively, 45,000 kglmol. Cat/hour at
10°C,
yielding a polymer of a molecular weight of 2000 kg/mole; and of 100,000
kg/mol.cat/hour at 30°C, yielding a polymer of a molecular weight of
750 kg/mole.
It is another aspect of the present invention to provide bodies, films,
fibres, web
materials, coatings, foams, adhesives, and the like comprising the polymer of
the
present invention.
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The present invention provides an article comprising a first element and a
second
element separated from and joined to said first element, said first element
being a
body of polymeric material. The present invention further provides a method
for
manufacturing a body from. polymeric material comprising a step of processing
said polymeric material selected from the group of to injection moulding,
extrusion blow moulding, extrusion, casting, solution sedimentation, and
combinations thereof. The present invention further provides a method for
processing a body of polymeric material comprising a step selected from the
group of thermoforming, laser forming, carving, and combinations thereof.
There are known in the art a wide variety of suitable methods to manufacture
and
/or to further process bodies from the polymer of the present invention
including
but not being limited to injection moulding, extrusion blow moulding,
extrusion,
casting, solution sedimentation, thermoforming, laser forming, carving,
combination thereof, and the like.
The body of the present invention has been found to exhibit a relative low
tackiness at room temperature due to the high molecular weight of the polymer.
Various additives may be added to the homopolymer of the present invention to
change the properties of the polymer such as is well known in the art.
For at least some of the manufacturing techniques and .in particular for the
moulding processes, it may useful to add to the homopolymer having a low
isotacticity a homopolymer having a high isotacticity such as those
conventionally
known isotactic polypropylenes. Preferably, the isotactic homopolymer is added
at a level of at least 20% of the total weight of the polymeric body, more
preferably at a level of at least 40%, yet more preferably at a level of at
least
50%, most preferably at a level of at least 60%. Preferably, the low
isotacticity
homopolymer of the present invention is present in the polymeric body of the
present invention at a level of at least 20%, more preferably at least 30%,
yet
more preferably at least 40%, most preferably at least 50% by total weight of
the
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polymeric body. Preferably, the shrinkage of the moulded is less than 10%,
more
preferably less than 8%, yet more preferably less than 6%, most preferably
less
than 4%. Compared to processing substantially pure polypropylene, the blending
with the homopolymer of the present invention when making the body of the
5 present invention allows processes such as extrusion to be performed at
higher
speeds since the required forces, pressure, or torques respectively are
lowered.
The second element of the article of the present invention can preferably be
made from the same homopolymer as the first element, either having the same
10 low isotacticity or a different isotacticity depending on the intended use
of the
second element. The configuration of the polymeric material of the second
element can also be a body or it could be a foam, a fibre, a film, or the
like.
Making articles from different grades of the same material is beneficial when
recycling material from a disposed article. If the same homopolymer is used
for
15 the different elements of the article, no separation step into the various
materials
is necessary before recycling of the material.
It may be useful to blend additives into the homopolymer of the present
invention.
A broad variety of such additives is known in the art and can be used
accordingly.
For example, small amounts of a thermal stabilizer, such as 0.1 %-0.25% of a
phenol/phosphite blend, can be mixed into the homopolymer of the present
invention to increase the thermal stability of the polymer during processing.
The article according to the present invention may be a hygienic article. The
term
"hygienic article" as used herein refers to articles which are intended to be
used
in contact with or in proximity to the body of a living being. Such hygienic
articles
may be disposable or intended for multiple or prolonged use. Such hygienic
articles include but are not limited to catheters, tubing, drainage systems,
syringes, grafts, prosthetics, body implants, instrumentation, support means,
toothbrushes, bed covers, stents, gaskets, pump diaphragms, baby bottle
nipples, pacifiers, and the like. Having regard to the specific advantages of
the
polymers used for the articles of the present invention, it will be readily
apparent
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to the skilled practitioner to apply the bodies of polymeric material
according to
the present invention in the above and similar hygienic articles.
The article according to the present invention may be a household article. The
term "household article" as used herein refers to articles intended to be used
when running a household. The household articles of the present invention
include but are not limited to garbage bins, storage containers, hoses, toys,
kitchenware, clothing and in particular heavy duty clothing up to bullet proof
clothing, shoes and in particular show soles, scuba fins and the like,
furniture in
particular garden furniture, sporting goods, bellows, and the like. Having
regard to
the specific advantages of the polymers used for the articles of the present
invention, it will be readily apparent to the skilled practitioner to apply
the bodies
of polymeric material according to the present invention in the above and
similar
household articles.
The article according to the present invention may further be an automotive
part
including but not being limited to bumper fascia, air dams, side mouldings,
fender
flares. Grills, body panels, ducts; tires, vibration dampers, flexible joints,
window
seals, interior parts, door gaskets, automotive boots, and the like. Having
regard
to the specific advantages of the polymers used for the articles of the
present
invention, it will be readily apparent to the skilled practitioner to apply
and to
optionally modify the bodies of polymeric material according to the present
invention in the above and similar automotive parts.
The body of polymeric material according to the present invention may also be
used as a construction element in an article. Thereby, the functionalities of
the
body of polymeric material includes but is not limited to supporting,
carrying,
fixing, protecting other elements of the article and the like. Such articles
include
but are not limited to cover parts, complex constructions such as buildings
(weather stripping, expansion joints, door gaskets and seals, water gaskets,
window seals, hoses, ducts, tubes, wire and cable insulation, floor coverings,
and
the like), cars, household appliances, horticultural and agricultural
constructions,
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17
and the like. Having regard to the specific advantages of the polymers used
for
the articles of the present invention, it will be readily apparent to the
skilled
" practitioner to apply and to optionally modify the bodies of polymeric
material
according to the present invention as construction elements in the above and
similar articles.
The present invention provides an article comprising a first element and a
second
element joined to the first element, the first element comprising a film web
material. The present invention further provides a method for manufacturing a
film web material comprising a step of processing the aforementioned polymeric
material, the step of processing selected from the group of casting,
extruding,
blowing, and combinations thereof. The present invention further provides a
method for processing a film web material comprising the aforementioned
polymer, the process comprising a step selected from the group of orienting,
bi-
axially stretching, crazing, stretching, shrinking, and combinations thereof.
Various additives may be added to the homopolymer of the present invention to
change the properties of the polymer such as is well known in the art. For
example, blending the polymer with between 2% and 6% by weight of talc and
optionally with between 0.1 % and 0.25% by weight of phenol/phosphite
stabilizer,
the processability of the film material of the present invention can be
greatly
enhanced.
Compared to processing of conventional, isotactic polypropylene, the addition
of
the low isotacticity homopolymer of the present invention reduces the requires
forces, pressures, or torques respectively to process the polymer.
In the prior art, a wide variety of suitable techniques to manufacture film
web
materials are known including but not being limited to casting, extruding,
blowing,
and combinations thereof. In addition, there are known a, wide variety of
techniques for further processing of film web materials including but nor
being
limited to orienting, bi-axially stretching, crazing, stretching, shrinking,
and
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combinations thereof. The aforementioried methods for manufacturing and
processing film web materials all have specific advantages which are known to
the skilled person. Hence, the skilled person will be able to select a
suitable
method for manufacturing and processing the film web material of the present
invention depending on the specific requirement of the respective application
of
the film web material.
In order to reduce shrinkage in the transverse direction, it may be useful to
place
air jets at the die exit to add additional cooling.
When storing the film of the present invention on a take-up roll, the use of a
release paper may improve the downstream handling of the film.
In order to render the film of the present invention breathable, the polymer
may
be mixed with a particulate filler material such as calcium carbonate prior to
manufacturing the film and be stretched subsequent to manufacturing the film
in
order to create micro pores at the location of the included filler material by
stretching the film material. Preferably, the breathable film material of the
present
invention has a moisture vapour transmission rate (MVTR) of at least 1000 g
per
24 hours per square meter, more preferably at least 2000 g/24hours/m2, yet
more
preferably at least 3000 g/24h/m2, most preferably at least 4000 g/24h/m2. The
method of determining MVTR is well known in the art and should be applied
accordingly.
The film web material according to the present invention may also be used as a
construction element in an article. Thereby, the functionalities of the film
web
material includes but is not limited to supporting, carrying, fixing,
protecting other
elements of the article and the like. Such articles include but are not
limited to
adhesive tapes, video/audio/data storage tapes, cables, and complex
constructions such as buildings (floor coverings, house wraps, and the like),
cars,
household appliances, horticultural and agricultural constructions, and the
like.
Having regard to the specific advantages of the polymers used for the articles
of
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the present invention, it will be readily apparent to the skilled practitioner
to apply
and to optionally modify the film web materials according to the present
invention
as construction elements in the above and similar articles.
The article of the present invention may also be a packaging article such as
produce bags, trash bags, ice bags, shipping sacks, containers, pouches, and
the
like. The term "packaging article" as used herein refers to articles which are
intended to at least partially envelope other articles. The first element of
such an
article is a specifically contoured piece of the film web material and the
second
element may be a sealing such as a thermobond seal of the film web material
onto itself.
The article of the present invention may also be a package article where the
first
element of the article is the wrap material used for packaging the second
element.
The present invention provides a fibrous web material comprising a plurality
of
fibres of the polymer of the present invention. The present invention further
provides a method for manufacturing fibres from the aforementioned polymeric
material comprising a step of processing the polymeric material selected from
the
group of wet spinning, dry spinning, melt spinning, semi dry spinning (solvent
evaporation or sedimentation), and combinations thereof. The present invention
further provides a method for manufacturing a fibrous web material comprising
the steps of providing fibres of the aforementioned polymeric material and of
combining the fibres into a web material. The present invention further
provides a
method for stabilizing a fibrous web material according to the present
invention
comprising the steps of providing a fibrous web material and of stabilizing
step
the fibrous web material.
Various additives may be added to the homopolymer of the present invention to
change the properties of the polymer such as is well known in the art.
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There are known in the art a wide variety of suitable methods to manufacture
and
/or processing fibres from the polymer of the present invention including but
not
being limited to wet spinning, dry spinning, melt spinning, semi dry spinning
(solvent evaporation or sedimentation), crazing, and combinations thereof.
Fibres
5 suitable for the web materials of the present invention may be mono fibres
or the
may comprise filaments.
It is a further aspect of the present invention to provide an article
comprising a
fibrous web material according to the present invention. The article according
to
10 the present invention may be a hygienic article.
The article of the present invention may also be a clothing article or a
household
article including but not being limited to bed covers, underwear, tights,
socks,
gloves, sport clothing, outdoor clothing, low temperature clothing, shoes and
15 show covers, protective clothing such as for motor biking, blankets,
covers, bags,
items of furniture, and the like. Having regard to the specific advantages of
the
polymers used for the articles of the present invention, it will be readily
apparent
to the skilled practitioner to apply and to optionally modify the fibrous web
materials according to the present invention in the above and similar
articles.
The fibrous web material according to the present invention may also be used
as
a construction element in an article. Thereby, the functionalities of the
fibrous
web material includes but is not limited to supporting, carrying, fixing,
protecting
other elements of the article and the like. Such articles include but are not
limited
to adhesive tapes, protective wraps, complex constructions such as buildings
(floor coverings, house wraps, and the like), cars, household appliances,
horticultural and agricultural constructions (geotextiles), and the like.
Having
regard to the specific advantages of the polymers used for the articles of the
present invention, it will be readily apparent to the skilled practitioner to
apply and
to optionally modify the fibrous web materials according to the present
invention
as construction elements in the above and similar articles.
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The article of the present invention may further a membrane such as in
filters, car
batteries, and the like. Having regard to the specific advantages of the
polymers
used for the articles of the present invention, it will be readily apparent to
the
skilled practitioner to apply and to optionally modify the fibrous web
materials
according to the present invention in the above and similar articles.
The present invention provides a coating composition for covering at least a
portion of the surface of an element with a polymeric coating according to the
present invention. The present invention further provides an article
comprising an
element and the aforementioned polymeric coating material covering at least
portion of the- surface of said element. The present invention further
provides a
method for coating an element with the aforementioned polymeric coating
material comprising a step selected from the group of dip coating, spray
coating,
emulsion coating, and combinations thereof.
It has been found that the coating of the present invention can be applied at
relatively low basis weights. Preferably, the basis weight of the coating of
the
present invention is less than 50 grams per square meter, more preferably less
than 40 g/m2, yet more preferably less than 30 g/m2, yet more preferably less
than 20 g/m2, most preferably less than 10 g/m2.
It is a further aspect of the present invention to provide an article
comprising an
element, at least a portion of the surface the element being covered with the
coating material according to the present invention.
In the prior art, a wide variety of suitable techniques to manufacture coating
articles are known including but not being limited to dip coating, spray
coating,
emulsion coating, and combinations thereof. The coating of the present
invention
is not limited to a specific substrate as long as the polymer of the coating
is
capable of sufficiently adhering to the substrate material. Suitable
substrates
include but are not limited to bodies of various material such as metal,
polymer,
. wood, and the like, woven and nonwoven web materials, films, and the like.
The
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aforementioned methods for manufacturing coating articles all have' specific
advantages which are known to the skilled person. Hence, the skilled person
will
be able to select a suitable. method for manufacturing the coating material of
the
present invention depending on the specific requirement of the respective
application of the coating material.
In order to render the coating of the present invention breathable, the
polymer
may be mixed with a particulate filler material such as calcium carbonate
prior to
manufacturing the coating and be stretched subsequently (before or after
contacting the substrate) in order to create micro pores at the location of
the
included filler material by stretching the coating material. Preferably, the
breathable film material of the present invention has a moisture vapour
transmission rate (MVTR) of at least 1000 g per 24 hours per square meter,
more preferably at least 2000 g/24hours/m2, yet more preferably at least 3000
g/24h/m2, most preferably at least 4000 g/24h/m2. The method of determining
MVTR is well known in the art and should be applied accordingly.
The coated article of the present invention could be a hygienic article. The
coating material according to the present invention may also be used as a
construction element in an article. Thereby, the functionalities of the
coating
material includes but is not limited to heat insulation, electric insulation,
shock
absorption, cushioning, acoustic wave damping, protecting other elements of
the
article, corrosion protection, allowance for relative movement of other
elements,
slip reduction, and the like. Such articles include but are not limited to
toys,
furniture, clothing, shoes, sport equipment, grips, complex constructions such
as
buildings (floor coverings, caulking, sealants, ridge/crack filler, and the
like), cars,
household appliances, and the like. Having regard to the specific advantages
of
the polymers used for the arfiicles of the present invention, it will be
readily
apparent to the skilled practitioner to apply and to optionally modify the
coating
materials according to the present invention as construction elements in the
above and similar articles.
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The present invention provides a polymeric foam material. The foam material
comprises the polymer of the present invention. The present invention further
provides a method for manufacturing the polymeric foam material of the present
invention comprising a step of processing the polymeric material, said step of
processing selected from the group of inert gas expansion, evaporated solvent
expansion, reactive reagent gas expansion, high internal phase emulsion, bead
expansion, and combinations thereof.
In the prior art, a wide variety of suitable techniques to manufacture foam
materials are known including but not being limited to inert gas expansion,
evaporated solvent expansion, reactive reagent gas expansion, high internal
phase emulsion, bead expansion, and combinations thereof. The aforementioned
methods for manufacturing foam materials all have specific advantages which
are
known to the skilled person. Hence, the skilled person will be able to select
a
suitable method for manufacturing the foam material of the present invention
depending on the specific requirement of the respective application of the
foam
material. Suitable gases or evaporated solvents for expanding the foams of the
present invention include but are not limited to C02, N~, propene, pentane,
and
the like. It has been found that due to the low fiacticity of the polymer, the
processability of the polymer during manufacture of the foam has been greatly
improved.
The foam material according to the present invention may also be used as a
construction element in an article. Thereby, the functionalities of the foam
material include but is not limited to heat insulation, electric insulation,
shock
absorption, cushioning, acoustic wave damping, protecting other elements of
the
article, sealing, packaging, storing, providing buoyancy, and the like. Such
articles include but are not limited to toys, furniture, mattresses, carpets,
clothing,
shoes, sport equipment, complex constructions such as buildings (floor
coverings, house wraps, and the like), cars, household appliances, and the
like.
Having regard to the specific advantages of the polymers used for the articles
of
the present invention, it will be readily apparent to the skilled practitioner
to apply
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24
and to optionally modify the foam materials according to the present invention
as
construction elements in the above and similar articles. It is particularly
preferred
to combine the foam material with a conventional polypropylene material to
form
the article. In this case, recycling of the material does not require
separation of
the different materials.
The foam material of the present invention may be oil absorbent and may be
rendered water absorbent by suitable surface energy modifiers. Suitable
surface
energy modifiers are well known in the art. In case the foam material of the
present invention is absorbent, the foam material may used in instances
including
but not being limited to oil absorption, solvent absorption, spill absorption,
liquid
distribution, liquid transportation, and the like. To improve the absorbency
of the
foam of the present invention, various additives such as those known in the
art
may be added to the external and internal surfaces of the foam of the present
invention. The foam material of the present invention may further be used to
deliver absorbed liquids such as for example adhesive, shoe polish, ink,
lubricants and the like upon compression of the foam material.
