EXTRUSION COATED SUBSTRATE

• US 20090169907A1
• Filed: 02/09/2009
• Published: 07/02/2009
• Est. Priority Date: 08/25/2006
• Status: Active Grant

• Current Assignee: Borealis Technology Oy (IPIC Holdings GmbH)
• Original Assignee: Borealis Technology Oy (IPIC Holdings GmbH)
• Inventors: Manfred, Kirchberger, Ernst, Eberhard, Stadlbauer, Manfred
• Granted Patent: US 8,142,902 B2
• Time in Patent Office: Days
• US Class Current: 428/523
• CPC Class Codes: B29C 48/08 flexible, e.g. films
• CPC Class Codes: B29C 48/155 Partial coating thereof
• CPC Class Codes: B29K 2023/0641 MDPE, i.e. medium density polyethylene
• CPC Class Codes: B29K 2023/083 EVA, i.e. ethylene vinyl acetate copolymer
• CPC Class Codes: B29K 2023/12 PP, i.e. polypropylene
• CPC Class Codes: C08F 10/06 Propene
• CPC Class Codes: C08F 110/06 Propene
• 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 2500/11 Melt tension or melt strength
• CPC Class Codes: C08F 2500/12 Melt flow index or melt flow ratio
• CPC Class Codes: C08F 2500/20 Activation energy or enthalpy
• CPC Class Codes: C08F 2500/26 Use as polymer for film forming
• CPC Class Codes: C08F 2500/27 Amount of comonomer in wt% or mol%
• CPC Class Codes: C08F 2500/32 Glass transition temperature [Tg]
• CPC Class Codes: C08F 2500/33 Crystallisation temperature [Tc]
• CPC Class Codes: C08F 2500/34 Melting point [Tm]
• CPC Class Codes: C08F 2500/35 Crystallinity, e.g. soluble or insoluble content as determined by the extraction of the polymer with a solvent
• CPC Class Codes: C08F 2500/38 Branching index [gvis], i.e. ratio of the intrinsic viscosity of the branched polymer to the intrinsic viscosity of a linear polymer of equal molecular weight and same composition
• CPC Class Codes: C08F 4/65927 : two cyclopentadienyl rings being mutually bridged
• CPC Class Codes: C08L 2314/06 : Metallocene or single site catalysts
• CPC Class Codes: C09D 123/10 : Homopolymers or copolymers of propene
• CPC Class Codes: Y10T 428/31692 : Next to addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31855 : Of addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31895 : Paper or wood
• CPC Class Codes: Y10T 428/31902 : Monoethylenically unsaturated
• CPC Class Codes: Y10T 428/31938 : Polymer of monoethylenically unsaturated hydrocarbon

Abstract

Certain embodiments provide an article comprising a substrate, wherein the substrate is extrusion coated with a composition comprising a multi-branched polypropylene having a g′ of less than 1.00. In certain embodiments, the substrate is extrusion coated with a composition comprising a polypropylene material. Either the composition and/or the polypropylene material are represented by the equation:

Vicat B [° C.]>−3.96·C_x [mol %]+86.85;

wherein Vicat B is the heat resistance, according to ISO 306 (50 N), of the composition and/or the polypropylene material; and C_x is the comonomer content the composition and/or the polypropylene material.

Claims

1. An article comprising a substrate, said substrate extrusion coated with a composition comprising a polypropylene material, wherein at least one of the composition and the polypropylene material satisfy the equation:

Vicat B [°

C.]>

−

3.96·

C_x [mol %]+86.85;

wherein;

a) Vicat B is the heat resistance, according to ISO 306 (50 N), of at least one of the composition and the polypropylene material; and

b) C_x is the comonomer content in at least one of said composition and said polypropylene material.

2. The article of claim 1, wherein at least one of said composition and said polypropylene material have xylene solubles of less than 2.0 percent by weight.

3. The article of claim 2, wherein said composition comprises a propylene homopolymer, and wherein at least one of said composition and said homopolymer have a heat resistance measured according to Vicat B of at least 90°

C.

4. The article of claim 2, wherein said composition comprises a propylene copolymer, and wherein at least one of said composition and said copolymer have a heat resistance measured according to Vicat B of at least 73°

C.

5. The article of claim 2, wherein at least one of the composition and the polypropylene material have at least one of the following properties:

a) a branching index g′

of less than 1.00; and

b) a strain hardening index of at least 0.30 measured by a deformation rate of 1.00 s<sup>−

1</sup> at a temperature of 180°

C.;

wherein the strain hardening index is defined as a slope of a logarithm to the basis 10 of the tensile stress growth function as a function of a logarithm to the basis 10 of the Hencky strain in the range of Hencky strains between 1 and 3.

6. The article of claim 3, wherein at least one of the composition and the polypropylene material have at least one of the following properties:

a) a branching index g′

of less than 1.00; and

b) a strain hardening index of at least 0.30 measured by a deformation rate of 1.00 s<sup>−

1</sup> at a temperature of 180°

C.;

wherein the strain hardening index is defined as a slope of a logarithm to the basis 10 of the tensile stress growth function as a function of a logarithm to the basis 10 of the Hencky strain in the range of Hencky strains between 1 and 3.

7. The article of claim 4, wherein at least one of the composition and the polypropylene material have at least one of the following properties:

a) a branching index g′

of less than 1.00; and

b) a strain hardening index of at least 0.30 measured by a deformation rate of 1.00 s<sup>−

1</sup> at a temperature of 180°

C.;

wherein the strain hardening index is defined as a slope of a logarithm to the basis 10 of the tensile stress growth function as a function of a logarithm to the basis 10 of the Hencky strain in the range of Hencky strains between 1 and 3.

8. The article of claim 2, wherein at least one of the composition and the polypropylene material have a multi-branching index of at least 0.15, wherein the multi-branching index is defined as a slope of strain hardening index as a function of the logarithm to the basis 10 of a Hencky strain rate, defined as (log(dε

/dt)), wherein;

a) dε

/dt is the deformation rate,

b) ε

is the Hencky strain, and

c) the strain hardening index is measured at a temperature of 180°

C.,

wherein the strain hardening index is defined as a slope of a logarithm to the basis 10 of the tensile stress growth function as a function of a logarithm to the basis 10 of the Hencky strain in the range of Hencky strains between 1 and 3.

9. The article of claim 3, wherein at least one of the composition and the polypropylene material have a multi-branching index of at least 0.15, wherein the multi-branching index is defined as a slope of strain hardening index as a function of the logarithm to the basis 10 of a Hencky strain rate, defined as (log(dε

/dt)), wherein;

a) dε

/dt is the deformation rate,

b) ε

is the Hencky strain, and

c) the strain hardening index is measured at a temperature of 180°

C.,

wherein the strain hardening index is defined as a slope of a logarithm to the basis 10 of the tensile stress growth function as a function of a logarithm to the basis 10 of the Hencky strain in the range of Hencky strains between 1 and 3.

10. The article of claim 4, wherein at least one of the composition and the polypropylene material have a multi-branching index of at least 0.15, wherein the multi-branching index is defined as a slope of strain hardening index as a function of the logarithm to the basis 10 of a Hencky strain rate, defined as (log(dε

/dt)), wherein;

a) dε

/dt is the deformation rate,

b) ε

is the Hencky strain, and

c) the strain hardening index is measured at a temperature of 180°

C.,

wherein the strain hardening index is defined as a slope of a logarithm to the basis 10 of the tensile stress growth function as a function of a logarithm to the basis 10 of the Hencky strain in the range of Hencky strains between 1 and 3.

11. The article of claim 2, wherein said composition extrusion coated on the substrate comprises gels only having a diameter less than or equal to 500 μ

m, and wherein said gels are not more than 100 gels per square meter.

12. The article of claim 2, wherein the polypropylene material has an mmmm pentad concentration of higher than 90%.

13. The article of claim 2, wherein the polypropylene material has a meso pentad concentration of higher than 90%.

14. The article of claim 2, wherein the polypropylene material has a melting point of at least 125°

C.

15. The article of claim 2, wherein the polypropylene material is multimodal.

16. The article of claim 4, wherein the comonomer of the propylene copolymer is ethylene.

17. The article of claim 16, wherein the total amount of comonomer in the propylene copolymer is up to 10 mol %.

18. The article of claim 2, wherein the article is a packaging material.

19. The article of claim 2, wherein the polypropylene has been produced in the presence of a catalyst system comprising an asymmetric catalyst, and wherein the catalyst system has a porosity of less than 1.40 ml/g.

20. The article of claim 19, wherein the asymmetric catalyst is dimethylsilyl [(2-methyl-(4′

-tert.butyl)-4-phenyl-indenyl)(2-isopropyl-(4′

-tert.butyl)-4-phenyl-indenyl)]zirconium dichloride.

21. The article of claim 2, wherein the substrate is selected from the group consisting of paper, paperboard, fabrics and metal foils.

22. An article comprising a substrate, said substrate extrusion coated with a composition comprising a polypropylene material, wherein said polypropylene material is produced in the presence of a metallocene catalyst, and wherein at least one of said composition and said polypropylene have:

a) a branching index g′

of less than 1.00; and

b) a strain hardening index of at least 0.30 measured by a deformation rate of 1.00 s<sup>−

1</sup> at a temperature of 180°

C.,

wherein the strain hardening index is defined as a slope of a logarithm to the basis 10 of a tensile stress growth function as a function of a logarithm to the basis 10 of a Hencky strain in the range of Hencky strains between 1 and 3.

23. The article of claim 22, wherein at least one of the composition and the polypropylene material have a multi-branching index of at least 0.15, wherein the multi-branching index is defined as a slope of the strain hardening index as a function of a logarithm to the basis 10 of the Hencky strain rate.

24. The article of claim 22, wherein the polypropylene has been produced in the presence of a catalyst system comprising an asymmetric catalyst, and wherein the catalyst system has a porosity of less than 1.40 ml/g.

25. The article of claim 22, wherein at least one of said composition and said polypropylene material have xylene solubles of less than 2.0 percent by weight, and wherein at least of the composition and the polypropylene material are represented by the equation:

Vicat B [°

C.]>

−

3.96·

C_x [mol %]+86.85;

wherein;

a) Vicat B is the heat resistance, according to ISO 306 (50 N), of at least one of the composition and the polypropylene material; and

b) C_x is the comonomer content in at least one of said composition and said polypropylene material.

26. The article of claim 25, wherein said composition comprises a propylene homopolymer, and wherein at least one of said composition and said homopolymer have a heat resistance measured according to Vicat B of at least 90°

C.

27. The article of claim 25, wherein said composition comprises a propylene copolymer, and wherein at least one of said composition and said copolymer have a heat resistance measured according to Vicat B of at least 73°

C.

28. An article comprising a substrate, said substrate extrusion coated with a composition comprising a polypropylene material, wherein at least one of the composition and the polypropylene material have a multi-branching index of at least 0.15, wherein the multi-branching index is defined as a slope of a strain hardening index as a function of the logarithm to the basis 10 of a Hencky strain rate, defined as (log(dε

/dt)), wherein;

a) dε

/dt is the deformation rate,

b) ε

is the Hencky strain, and

c) the strain hardening index is measured at a temperature of 180°

C.,

wherein the strain hardening index is defined as a slope of a logarithm to the basis 10 of the tensile stress growth function as a function of a logarithm to the basis 10 of the Hencky strain in the range of Hencky strains between 1 and 3.

29. The article of claim 28, wherein at least one of the composition and the polypropylene have at least one of the following properties:

a) a branching index g′

of less than 1.00; and

b) a strain hardening index of at least 0.30 measured by a deformation rate of 1.00 s<sup>−

1</sup> at a temperature of 180°

C.

30. The article of claim 29, wherein the polypropylene has been produced in the presence of a catalyst system comprising an asymmetric catalyst, and wherein the catalyst system has a porosity of less than 1.40 ml/g.

31. A process for manufacturing an article comprising the steps of:

a) providing an article comprising a substrate;

b) extrusion coating the substrate with a composition, said composition comprising a polypropylene material;

wherein at least one of the composition and the polypropylene material used to coat the substrate are represented by the equation;

Vicat B [°

C.]>

−

3.96·

C_x [mol %]+86.85;

wherein;

a) Vicat B is the heat resistance, according to ISO 306 (50 N), of at least one of the composition and the polypropylene material; and

b) C_x is the comonomer content in at least one of said composition and said polypropylene

and wherein at least one of said composition and said polypropylene material have xylene solubles of less than 2.0 percent by weight.

32. The process of claim 31, wherein said substrate is selected from the group consisting of paper, paperboard, fabrics and metal foils.