Polypropylene fibers and fabrics

• US 20040028903A1
• Filed: 07/02/2003
• Published: 02/12/2004
• Est. Priority Date: 08/22/2000
• Status: Active Grant

• Current Assignee: ExxonMobil Chemical Patents Inc. (Exxon Mobil Corporation)
• Original Assignee: ExxonMobil Chemical Patents Inc. (Exxon Mobil Corporation)
• Inventors: Richeson, Galen Charles
• Granted Patent: US 7,081,299 B2
• Time in Patent Office: Days
• US Class Current: 428/401
• CPC Class Codes: C08F 110/06 Propene
• CPC Class Codes: C08F 2/001 Multistage polymerisation processes characterised by a change in reactor conditions without deactivating the intermediate polymer C08F295/00, C08F297/00 take precedence
• CPC Class Codes: C08F 210/06 Propene
• CPC Class Codes: C08F 210/16 Copolymers of ethene with alpha-alkenes, e.g. EP rubbers
• CPC Class Codes: C08F 2500/03 Narrow molecular weight distribution, i.e. Mw/Mn < 3
• CPC Class Codes: C08F 2500/06 Comonomer distribution, e.g. normal, reverse or narrow
• CPC Class Codes: C08F 2500/12 Melt flow index or melt flow ratio
• CPC Class Codes: C08F 2500/15 Isotactic
• CPC Class Codes: C08F 2500/26 Use as polymer for film forming
• CPC Class Codes: C08F 4/65908 in combination with an ionising compound other than alumoxane, e.g. (C6F5)4B-X+
• CPC Class Codes: C08F 4/65916 supported on a carrier, e.g. silica, MgCl2, polymer
• CPC Class Codes: C08F 4/65927 two cyclopentadienyl rings being mutually bridged
• CPC Class Codes: C08J 2323/12 Polypropene
• CPC Class Codes: C08J 5/18 Manufacture of films or sheets
• CPC Class Codes: D01D 5/0985 by means of a flowing gas (e.g. melt-blowing)
• CPC Class Codes: D01F 6/06 from polypropylene
• CPC Class Codes: H01G 4/18 of synthetic material, e.g. derivatives of cellulose H01G4/16 takes precedence
• CPC Class Codes: Y10T 428/2967 Synthetic resin or polymer
• CPC Class Codes: Y10T 428/2969 Polyamide, polyimide or polyester
• CPC Class Codes: Y10T 428/298 Physical dimension
• CPC Class Codes: Y10T 442/3065 : Including strand which is of specific structural definition
• CPC Class Codes: Y10T 442/3976 : Including strand which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous composition, water solubility, heat shrinkability, etc.]

Abstract

The present invention is a meltblown fiber and a fabric manufactured from the fiber comprising reactor grade polypropylene having a melt flow rate of from 100 to 5000 and having less than 50 stereo defects per 1000 units. Further, the polypropylene is typically produced from a metallocene catalyzed process, the metallocene being at least one bridged 2,4 di-substituted indenyl metallocene in one embodiment, and a bridged 4-phenyl indenyl metallocene in another embodiment. The metallocene is part of a system that can include a fluorided support and a non-coordinating anion activator.

Claims

1. A fiber comprising reactor grade polypropylene having a crystallization half time of from 2.5 to 6.5 min and having less than 50 stereo defects per 1000 units.

2. The fiber of claim 1, wherein the polypropylene is produced from a catalyst system comprising at least one bridged 2,4 di-substituted indenyl metallocene.

3. The fiber of claim 1, wherein the melt flow rate of the polypropylene is greater than 1000 dg/min.

4. The fiber of claim 1, wherein the melt flow rate of the polypropylene is from 500 dg/min to 3000 dg/min.

5. The fiber of claim 1, wherein the polypropylene has a MWD in the range from 2 to 4.

6. The fiber of claim 2, wherein the catalyst system also comprises at least one activator selected from trisperfluorophenylboron, tris(3,5-di(trifluoromethyl)phenyl)boron, tris(di-t-butylmethylsilyl)perfluorophenylboron, triethylammonium tetraphenylborate;

tripropylammonium tetraphenylborate;

tri(n-butyl)ammonium tetraphenylborate;

trimethylammonium tetrakis(p-tolyl)borate;

trimethylammonium tetrakis(o-tolyl)borate;

tributylammonium tetrakis(pentafluorophenyl)borate;

tripropylammonium tetrakis(o,p-dimethylphenyl)borate;

tributylammonium tetrakis(m,m-dimethylphenyl)borate;

tributylammonium tetrakis(p-trifluoromethylphenyl)borate;

tributylammonium tetrakis(pentafluorophenyl)borate;

tri(n-butyl)ammonium tetrakis(o-tolyl)borate;

N,N-dimethylanilinium tetrakis(pentafluorophenyl)borate;

N,N-dimethylaniliniumtetrakis(heptafluoronaphthyl)borate;

N,N-dimethylanilinium tetrakis(perfluoro-4-biphenyl)borate;

N,N-dimethylanilinium tetraphenylborate;

N,N-diethylanilinium tetraphenylborate;

N,N-2,4,6-pentamethylanilinium tetraphenylborate, and other highly fluorinated trisarylboron compounds and their ionic analogs.

7. The fiber of claim 6, wherein the catalyst system also comprises a fluorided silica support.

8. The fiber of claim 1, wherein the polypropylene is a homopolymer.

9. The fiber of claim 1, wherein a fabric formed from the fiber has a shot rating of from 0.5 to 1.5 at 0.4 ghm, 8 inch DCD, and a MFR of from 1200 to 3000.

10. The fiber of claim 1, wherein a fabric formed from the fiber has a shot rating of from 0.5 to 4 at 0.8 ghm, 8 inch DCD, and a MFR of from 1200 to 3000.

11. The fiber of claim 1, wherein a fabric formed from the fiber has a hydrohead value of from greater than 20 inches at 0.4 ghm, 8 inch DCD, and a MFR of from 1200 to 3000.

12. The fiber of claim 1, wherein a fabric formed from the fiber has a hydrohead value of greater than 15 inches at 0.8 ghm, 8 inch DCD, and an MFR of from 1200 to 3000.

13. The fiber of claim 1, wherein the fiber is meltblown.

14. A meltblown fiber comprising reactor grade propylene homopolymer having a melt flow rate of from 100 dg/min to 5000 dg/min and having less than 50 stereo defects per 1000 units, the polypropylene produced from a catalyst system comprising at least one metallocene catalyst.

15. The fiber of claim 14, wherein the at least one metallocene catalyst is a bridged 2,4 di-substituted metallocene.

16. The fiber of claim 14, wherein the melt flow rate of the polypropylene is greater than 1000 dg/min.

17. The fiber of claim 14, wherein the melt flow rate of the polypropylene is from 500 dg/min to 3000 dg/min.

18. The fiber of claim 14, wherein the polypropylene has a MWD in the range from 2 to 4.

19. The fiber of claim 14, wherein the catalyst system also comprises at least one activator selected from trisperfluorophenylboron, tris(3,5-di(trifluoromethyl)phenyl)boron, tris(di-t-butylmethylsilyl)perfluorophenylboron, triethylammonium tetraphenylborate;

tripropylammonium tetraphenylborate;

tri(n-butyl)ammonium tetraphenylborate;

trimethylammonium tetrakis(p-tolyl)borate;

trimethylammonium tetrakis(o-tolyl)borate;

tributylammonium tetrakis(pentafluorophenyl)borate;

tripropylammonium tetrakis(o,p-dimethylphenyl)borate;

tributylammonium tetrakis(m,m-dimethylphenyl)borate;

tributylammonium tetrakis(p-trifluoromethylphenyl)borate;

tributylammonium tetrakis(pentafluorophenyl)borate;

tri(n-butyl)ammonium tetrakis(o-tolyl)borate;

N,N-dimethylanilinium tetrakis(pentafluorophenyl)borate;

N,N-dimethylaniliniumtetrakis(heptafluoronaphthyl)borate;

N,N-dimethylanilinium tetrakis(perfluoro-4-biphenyl)borate;

N,N-dimethylanilinium tetraphenylborate;

N,N-diethylanilinium tetraphenylborate;

N,N-2,4,6-pentamethylanilinium tetraphenylborate, and other highly fluorinated trisarylboron compounds and their ionic analogs.

20. The fiber of claim 14, wherein the catalyst system comprises a support component, the support component being fluorided silica.

21. The fiber of claim 14, wherein a fabric formed from the fiber has a shot rating of from 0.5 to 1.5 at 0.4 ghm, 8 inch DCD, and a MFR of from 1200 to 3000.

22. The fiber of claim 14, wherein a fabric formed from the fiber has a shot rating of from 0.5 to 4 at 0.8 ghm, 8 inch DCD, and a MFR of from 1200 to 3000.

23. The fiber of claim 14, wherein a fabric formed from the fiber has a hydrohead value of from greater than inches at 0.4 ghm, 8 inch DCD, and a MFR of from 1200 to 3000.

24. The fiber of claim 14, wherein a fabric formed from the fiber has a hydrohead value of from greater than 15 inches at 0.8 ghm, 8 inch DCD, and an MFR of from 1200 to 3000.

25. A fabric produced from a polypropylene fiber, the polypropylene being reactor grade and having a melt flow rate of from 100 dg/min to 5000 dg/min and having less than 50 stereo defects per 1000 units.

26. The fabric of claim 25, wherein the melt flow rate of the polypropylene is greater than 1000 dg/min.

27. The fabric of claim 25, wherein the melt flow rate of the polypropylene is from 500 dg/min to 3000 dg/min.

28. The fabric of claim 25, wherein the polypropylene has a MWD in the range from 2 to 4.

29. The fabric of claim 25, wherein the polypropylene is produced from a catalyst system comprising a bridged 2,4 di-substituted indenyl metallocene.

30. The fabric of claim 25, wherein the polypropylene is produced from a catalyst system comprising a bridged 4-phenyl indenyl metallocene.

31. The fabric of claim 25, wherein the polypropylene is a homopolymer.

32. The fabric of claim 25, wherein the fabric is formed by a meltblown process.

33. The fabric of claim 25, wherein the catalyst system also comprises at least one activator selected from trisperfluorophenylboron, tris(3,5-di(trifluoromethyl)phenyl)boron, tris(di-t-butylmethylsilyl)perfluorophenylboron, triethylammonium tetraphenylborate;

tripropylammonium tetraphenylborate;

tri(n-butyl)ammonium tetraphenylborate;

trimethylammonium tetrakis(p-tolyl)borate;

trimethylammonium tetrakis(o-tolyl)borate;

tributylammonium tetrakis(pentafluorophenyl)borate;

tripropylammonium tetrakis(o,p-dimethylphenyl)borate;

tributylammonium tetrakis(m,m-dimethylphenyl)borate;

tributylammonium tetrakis(p-trifluoromethylphenyl)borate;

tributylammonium tetrakis(pentafluorophenyl)borate;

tri(n-butyl)ammonium tetrakis(o-tolyl)borate;

N,N-dimethylanilinium tetrakis(pentafluorophenyl)borate;

N,N-dimethylaniliniumtetrakis(heptafluoronaphthyl)borate;

N,N-dimethylanilinium tetrakis(perfluoro-4-biphenyl)borate;

N,N-dimethylanilinium tetraphenylborate;

N,N-diethylanilinium tetraphenylborate;

N,N-2,4,6-pentamethylanilinium tetraphenylborate, and other highly fluorinated trisarylboron compounds and their ionic analogs.

34. The fabric of claim 25, wherein the catalyst system also comprises a silica support.

35. The fabric of claim 25, wherein the catalyst system is the product of contacting the metallocene, the activator, and the silica support.

36. The fabric of claim 25, wherein the polypropylene is a homopolymer.

37. The fabric of claim 25, wherein the fabric has a shot rating of from 0.5 to 1.5 at 0.4 ghm, 8 inch DCD, and a MFR of from 1200 to 3000.

38. The fabric of claim 25, wherein the fabric has a shot rating of from 0.5 to 4 at 0.8 ghm, 8 inch DCD, and a MFR of from 1200 to 3000.

39. The fabric of claim 25, wherein the fabric has a hydrohead value of from greater than 20 inches at 0.4 ghm, 8 inch DCD, and a MFR of from 1200 to 3000.

40. The fabric of claim 25, wherein the fabric has a hydrohead value of from greater than 15 inches at 0.8 ghm, 8 inch DCD, and an MFR of from 1200 to 3000.

41. The fabric of claim 25, wherein a nucleating agent is added to the polypropylene prior to forming the fiber.

42. A filter formed from the fabric of claim 25.

43. An a composite of the fabric of claim 25.

44. A fabric manufactured from a meltblown fiber comprising reactor grade propylene homopolymer having a melt flow rate of from 100 dg/min to 5000 dg/min and having less than 50 stereo defects per 1000 units, the polypropylene produced from a catalyst system comprising at least one metallocene catalyst.

45. The fabric of claim 44, wherein the melt flow rate of the polypropylene is greater than 1000 dg/min.

46. The fabric of claim 44, wherein the melt flow rate of the polypropylene is from 500 dg/min to 3000 dg/min.

47. The fabric of claim 44, wherein the polypropylene has a MWD in the range from 2 to 4.

48. The fabric of claim 44, wherein the catalyst system also comprises at least one activator selected from trisperfluorophenylboron, tris(3,5-di(trifluoromethyl)phenyl)boron, tris(di-t-butylmethylsilyl)perfluorophenylboron, triethylammonium tetraphenylborate;

tripropylammonium tetraphenylborate;

tri(n-butyl)ammonium tetraphenylborate;

trimethylammonium tetrakis(p-tolyl)borate;

trimethylammonium tetrakis(o-tolyl)borate;

tributylammonium tetrakis(pentafluorophenyl)borate;

tripropylammonium tetrakis(o,p-dimethylphenyl)borate;

tributylammonium tetrakis(m,m-dimethylphenyl)borate;

tributylammonium tetrakis(p-trifluoromethylphenyl)borate;

tributylammonium tetrakis(pentafluorophenyl)borate;

tri(n-butyl)ammonium tetrakis(o-tolyl)borate;

N,N-dimethylanilinium tetrakis(pentafluorophenyl)borate;

N,N-dimethylaniliniumtetrakis(heptafluoronaphthyl)borate;

N,N-dimethylanilinium tetrakis(perfluoro-4-biphenyl)borate;

N,N-dimethylanilinium tetraphenylborate;

N,N-diethylanilinium tetraphenylborate;

N,N-2,4,6-pentamethylanilinium tetraphenylborate. and other highly fluorinated trisarylboron compounds and their ionic analogs.

49. The fabric of claim 44, wherein the catalyst system also includes a support component, the support being fluorided silica.

50. The fabric of claim 44, wherein the fabric has a shot rating of from 0.5 to 1.5 at 0.4 ghm, 8 inch DCD, and a MFR of from 1200 to 3000.

51. The fabric of claim 44, wherein the fabric has a shot rating of from 0.5 to 4 at 0.8 ghm, 8 inch DCD, and a MFR of from 1200 to 3000.

52. The fabric of claim 44, wherein the fabric has a hydrohead value of from greater than 20 inches at 0.4 ghm, 8 inch DCD, and a MFR of from 1200 to 3000.

53. The fabric of claim 44, wherein the fabric has a hydrohead value of from greater than 15 inches at 0.8 ghm, 8 inch DCD, and an MFR of from 1200 to 3000.

54. The fabric of claim 44, wherein the metallocene is a bridged 2,4 di-substituted indenyl metallocene.

55. A composite of the fabric in claim 44.

63. The method of claim 52, wherein the catalyst system also comprises a silica support.

64. The method of claim 53, wherein the catalyst system is the product of contacting the metallocene, the activator, and the silica support.

56. A method for making a meltblown fiber comprising:

(a) forming a molten reactor grade isotactic polypropylene, the polypropylene produced by contacting propylene monomers with a catalyst system comprising at least one bridged 2,4 di-substituted indenyl metallocene and at least one non-coordinating anion activator;

(b) creating a fiber from the polypropylene.

57. The method of claim 56, wherein the melt flow rate of the polypropylene is from 100 dg/min to 5000 dg/min.

58. The method of claim 56, wherein the melt flow rate of the polypropylene is greater than 1000 dg/min.

59. The method of claim 56, wherein the melt flow rate of the polypropylene is from 500 dg/min to 3000 dg/min.

60. The method of claim 56, wherein the polypropylene has fewer than 50 stereo defects per 1000 units.

61. The method of claim 56, wherein the polypropylene has a MWD in the range from 2 to 4.

62. The method of claim 56, wherein the at least one activator is selected from trisperfluorophenylboron, tris(3,5-di(trifluoromethyl)phenyl)boron, tris(di-t-butylmethylsilyl)perfluorophenylboron, triethylammonium tetraphenylborate;

tripropylammonium tetraphenylborate;

tri(n-butyl)ammonium tetraphenylborate;

trimethylammonium tetrakis(p-tolyl)borate;

trimethylammonium tetrakis(o-tolyl)borate;

tributylammonium tetrakis(pentafluorophenyl)borate;

tripropylammonium tetrakis(o,p-dimethylphenyl)borate;

tributylammonium tetrakis(m,m-dimethylphenyl)borate;

tributylammonium tetrakis(p-trifluoromethylphenyl)borate;

tributylammonium tetrakis(pentafluorophenyl)borate;

tri(n-butyl)ammonium tetrakis(o-tolyl)borate;

N,N-dimethylanilinium tetrakis(pentafluorophenyl)borate;

N,N-dimethylaniliniumtetrakis(heptafluoronaphthyl)borate;

N,N-dimethylanilinium tetrakis(perfluoro-4-biphenyl)borate;

N,N-dimethylanilinium tetraphenylborate;

N,N-diethylanilinium tetraphenylborate;

N,N-2,4,6-pentamethylanilinium tetraphenylborate, and other highly fluorinated trisarylboron compounds and their ionic analogs.

65. The method of claim 56, wherein the polypropylene is a homopolymer.

66. The method of claim 56, wherein a fabric formed from the fiber has a shot rating of from 0.5 to 1.5 at 0.4 ghm, 8 inch DCD, and a MFR of from 1200 to 3000.

67. The method of claim 56, wherein a fabric formed from the fiber has a shot rating of from 0.5 to 4 at 0.8 ghm, 8 inch DCD, and a MFR of from 1200 to 3000.

68. The method of claim 56, wherein a fabric formed from the fiber has a hydrohead value of from greater than 20 inches at 0.4 ghm, 8 inch DCD, and a MFR of from 1200 to 3000.

69. The method of claim 56, wherein a fabric formed from the fiber has a hydrohead value of from greater than 15 inches at 0.8 ghm, 8 inch DCD, and an MFR of from 1200 to 3000.

70. A method for making a meltblown fiber comprising:

(a) forming a molten reactor grade isotactic polypropylene at a temperature of from 150 to 200°

C. having a melt flow rate of from 1000 to 5000 dg/min;

(b) creating a fiber from the polypropylene.

71. The method of claim 70, wherein the polypropylene has fewer than 50 stereo defects per 1000 units.

72. The method of claim 70, wherein the polypropylene has a MWD in the range from 2 to 4.

73. The method of claim 70, wherein the polypropylene is produced from a catalyst system comprising a 4-phenyl substituted indenyl metallocene.

74. The method of claim 70, wherein catalyst system also comprises at least one activator, the activator is selected from trisperfluorophenylboron, tris(3,5-di(trifluoromethyl)phenyl)boron, tris(di-t-butylmethylsilyl)perfluorophenylboron, triethylammonium tetraphenylborate;

tripropylammonium tetraphenylborate;

tri(n-butyl)ammonium tetraphenylborate;

trimethylammonium tetrakis(p-tolyl)borate;

trimethylammonium tetrakis(o-tolyl)borate;

tributylammonium tetrakis(pentafluorophenyl)borate;

tripropylammonium tetrakis(o,p-dimethylphenyl)borate;

tributylammonium tetrakis(m,m-dimethylphenyl)borate;

tributylammonium tetrakis(p-trifluoromethylphenyl)borate;

tributylammonium tetrakis(pentafluorophenyl)borate;

tri(n-butyl)ammonium tetrakis(o-tolyl)borate;

N,N-dimethylanilinium tetrakis(pentafluorophenyl)borate;

N,N-dimethylaniliniumtetrakis(heptafluoronaphthyl)borate;

N,N-dimethylanilinium tetrakis(perfluoro-4-biphenyl)borate;

N,N-dimethylanilinium tetraphenylborate;

N,N-diethylanilinium tetraphenylborate;

N,N-2,4,6-pentamethylanilinium tetraphenylborate, and other highly fluorinated trisarylboron compounds and their ionic analogs.

75. The method of claim 70, wherein the catalyst system also comprises a silica support.

76. The method of claim 70, wherein a fabric formed from the fiber has a shot rating of from 0.5 to 1.5 at 0.4 ghm, 8 inch DCD, and a MFR of from 1200 to 3000.

77. The method of claim 70, wherein a fabric formed from the fiber has a shot rating of from 0.5 to 4 at 0.8 ghm, 8 inch DCD, and a MFR of from 1200 to 3000.

78. The method of claim 70, wherein a fabric formed from the fiber has a hydrohead value of from greater than 20 inches at 0.4 ghm, 8 inch DCD, and a MFR of from 1200 to 3000.

79. The method of claim 70, wherein a fabric formed from the fiber has a hydrohead value of from greater than inches at 0.8 ghm, 8 inch DCD, and an MFR of from 1200 to 3000.

80. A method for making a fabric from polypropylene fibers comprising:

(a) forming at least one meltblown fiber from a molten reactor grade isotactic polypropylene, the polypropylene produced by contacting propylene monomers with a catalyst system comprising at least one bridged 2,4 di-substituted indenyl metallocene and at least one non-coordinating anion activator; and

(b) contacting the fibers with one another to form at least one layer of a fabric.

81. The method of claim 80, wherein the melt flow rate of the polypropylene is greater than 1000 dg/min.

82. The method of claim 80, wherein the melt flow rate of the polypropylene is from 500 dg/min to 3000 dg/min.

83. The method claim 80, wherein the polypropylene has a MWD in the range from 2 to 4.

84. The method of claim 80, wherein the fabric is formed by a meltblown process.

85. The method of claim 80, wherein the at least one activator is selected from trisperfluorophenylboron, tris(3.5-di(trifluoromethyl)phenyl)boron, tris(di-t-butylmethylsilyl)perfluorophenylboron, triethylammonium tetraphenylborate;

tripropylammonium tetraphenylborate;

tri(n-butyl)ammonium tetraphenylborate;

trimethylammonium tetrakis(p-tolyl)borate;

trimethylammonium tetrakis(o-tolyl)borate;

tributylammonium tetrakis(pentafluorophenyl)borate;

tripropylammonium tetrakis(o,p-dimethylphenyl)borate;

tributylammonium tetrakis(m,m-dimethylphenyl)borate;

tributylammonium tetrakis(p-trifluoromethylphenyl)borate;

tributylammonium tetrakis(pentafluorophenyl)borate;

tri(n-butyl)ammonium tetrakis(o-tolyl)borate;

N,N-dimethylanilinium tetrakis(pentafluorophenyl)borate;

N,N-dimethylaniliniumtetrakis(heptafluoronaphthyl)borate;

N,N-dimethylanilinium tetrakis(perfluoro-4-biphenyl)borate;

N,N-dimethylanilinium tetraphenylborate;

N,N-diethylanilinium tetraphenylborate;

N,N-2,4,6-pentamethylanilinium tetraphenylborate, and other highly fluorinated trisarylboron compounds and their ionic analogs.

86. The method of claim 80, wherein the catalyst system also comprises a silica support.

87. The method of claim 80, wherein the catalyst system is the product of contacting the metallocene, the activator, and the silica support.

88. The method of claim 80, wherein the polypropylene is a homopolymer.

89. The method of claim 80, wherein the polypropylene is molten at an operating temperature of from 150°

C. to 200°

C.

90. The method of claim 80, wherein the fabric has a shot rating of from 0.5 to 1.5 at 0.4 ghm, 8 inch DCD, and a MFR of from 1200 to 3000.

91. The method of claim 80, wherein the fabric has a shot rating of from 0.5 to 4 at 0.8 ghm, 8 inch DCD, and a MFR of from 1200 to 3000.

92. The method of claim 80, wherein the fabric has a hydrohead value of from greater than 20 inches at 0.4 ghm, 8 inch DCD, and a MFR of from 1200 to 3000.

93. The method of claim 80, wherein the fabric has a hydrohead value of from greater than 15 inches at 0.8 ghm, 8 inch DCD, and an MFR of from 1200 to 3000.

94. A polypropylene fiber, the fiber formed from a polypropylene made by contacting α

-olefin monomers in the presence of at least one metallocene catalyst system comprising at least one bridged 2,4 di-substituted metallocene and at least one non-coordinating anion activator supported on a fluorided support composition.

95. The fiber of claim 94, wherein metallocene is a bridged 4-phenyl indenyl metallocene.

96. The fiber of claim 94, wherein the melt flow rate of the polypropylene is greater than 1000 dg/min.

97. The fiber of claim 94, wherein the melt flow rate of the polypropylene is from 500 dg/min to 3000 dg/min.

98. The fiber of claim 94, wherein the polypropylene has a MWD in the range from 2 to 4.

99. The fiber of claim 94, wherein the at least one activator is selected from trisperfluorophenylboron, tris(3,5-di(trifluoromethyl)phenyl)boron, tris(di-t-butylmethylsilyl)perfluorophenylboron, triethylammonium tetraphenylborate;

tripropylammonium tetraphenylborate;

tri(n-butyl)ammonium tetraphenylborate;

trimethylammonium tetrakis(p-tolyl)borate;

trimethylammonium tetrakis(o-tolyl)borate;

tributylammonium tetrakis(pentafluorophenyl)borate;

tripropylammonium tetrakis(o,p-dimethylphenyl)borate;

tributylammonium tetrakis(m,m-dimethylphenyl)borate;

tributylammonium tetrakis(p-trifluoromethylphenyl)borate;

tributylammonium tetrakis(pentafluorophenyl)borate;

tri(n-butyl)ammonium tetrakis(o-tolyl)borate;

N,N-dimethylanilinium tetrakis(pentafluorophenyl)borate;

N,N-dimethylaniliniumtetrakis(heptafluoronaphthyl)borate;

N,N-dimethylanilinium tetrakis(perfluoro-4-biphenyl)borate;

N,N-dimethylanilinium tetraphenylborate;

N,N-diethylanilinium tetraphenylborate;

N,N-2,4,6-pentamethylanilinium tetraphenylborate, and other highly fluorinated trisarylboron compounds and their ionic analogs.

100. The fiber of claim 94, wherein the catalyst system also comprises a silica support.

101. The fiber of claim 94, wherein the polypropylene is a homopolymer.

102. A fabric comprising the fiber of claim 94.

103. A filter comprising the fiber of claim 94.

104. The fiber of claim 94, wherein a nucleating agent is added to the polypropylene prior to forming the fibers.

105. The fiber of claim 94, wherein the polypropylene is a copolymer of propylene derived units and ethylene or a C₄-C₁₂ derived unit.

106. The fiber of claim 94, wherein a fabric formed from the fiber has a shot rating of from 0.5 to 1.5 at 0.4 ghm, 8 inch DCD, and a MFR of from 1200 to 3000.

107. The fiber of claim 94, wherein a fabric formed from the fiber has a shot rating of from 0.5 to 4 at 0.8 ghm, 8 inch DCD, and a MFR of from 1200 to 3000.

108. The fiber of claim 94, wherein a fabric formed from the fiber has a hydrohead value of from greater than 20 inches at 0.4 ghm, 8 inch DCD, and a MFR of from 1200 to 3000.

109. The fiber of claim 94, wherein a fabric formed from the fiber has a hydrohead value of from greater than 15 inches at 0.8 ghm, 8 inch DCD, and an MFR of from 1200 to 3000.

110. The fiber of claim 94, wherein the polypropylene has a crystallization half time of from 2.5 to 5 min.