# US 11,027,473 B2 · Multilayered article comprising polypropylene impact copolymers, and method of making same

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- Number: US 11,027,473 B2
- Document ID: US11027473B2
- Status: Granted
- Kind: B2
- Application number: 16/210,164
- Filed: 2018-12-05
- Published: 2019-04-11
- Granted: 2021-06-08
- Earliest claimed: 2013-03-14
- Assignees: Braskem America, Inc.
- Applicants: Braskem America, Inc.
- Inventors: Peter Simon Dias; Debra R. Wilson
- Web page: https://patentgrep.com/patent/US11027473B2

## CPC

- B29C 48/21: the layers being joined at their surfaces
- B29C 49/0691: {using sheet like material, e.g. sheet blow-moulding from joined sheets}
- B29C 49/22: using multilayered preforms or parisons
- B32B 1/00: Layered products having a non-planar shape
- B32B 27/08: of synthetic resin
- B32B 27/30: comprising vinyl {(co)polymers; comprising acrylic (co)polymers}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- C08F 210/06: Propene
- C08J 5/00: Manufacture of articles or shaped materials containing macromolecular substances (manufacture of semi-permeable membranes B01D67/00 - B01D71/00)
- C08J 5/18: Manufacture of films or sheets
- C08L 23/12: Polypropene
- C08L 23/14: Copolymers of propene (C08L23/16 takes precedence)
- C08L 23/142: {at least partially crystalline copolymers of propene with other olefins}
- B29C 49/0685: {Compression blow-moulding}
- B29K 2023/12: {PP, i.e. polypropylene}
- B29K 2105/258: {Tubular}
- B29K 2995/0026: Transparent
- B32B 2250/03: 3 layers
- B32B 2250/242: All polymers belonging to those covered by group B32B27/32
- B32B 2270/00: Resin or rubber layer containing a blend of at least two different polymers
- B32B 2307/412: Transparent
- B32B 2307/558: Impact strength, toughness
- B32B 2439/02: Open containers
- C08J 2323/12: Polypropene
- C08J 2323/14: Copolymers of propene (C08J2323/16 takes precedence)
- C08J 2423/08: Copolymers of ethene (C08J2423/16 takes precedence)
- C08L 2203/10: used for bottles
- C08L 2205/025: containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
- C08L 2207/02: Heterophasic composition
- Y10T 428/13: Hollow or container type article [e.g., tube, vase, etc.]
- Y10T 428/1352: Polymer or resin containing [i.e., natural or synthetic]
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C08F: MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A polymer sheet includes a core layer containing a propylene impact copolymer (ICP), and a first additional layer comprising a first polymer composition. The propylene impact copolymer (ICP) in the core layer includes a matrix and a dispersed phase. The matrix comprises a polypropylene homopolymer or a propylene/alpha-olefin random copolymer which includes greater than 50 wt. % of units derived from propylene monomer. The dispersed phase includes a copolymer of ethylene and a C3-C8 α-olefin. The ICP has a first melting point being greater than 100° C. (e.g., in the range of from 100° C. to 130° C.) and a second melting point. The polymer sheet can also include a second additional layer containing a second polymer composition.

## Claims

### Claim 1

A polymer sheet, comprising:
a core layer comprising a propylene impact copolymer (ICP), the propylene ICP comprising:
(a) a matrix comprising a polypropylene homopolymer or a propylene/alpha-olefin random copolymer which comprises greater than 50 wt. % of units derived from propylene monomer, and
(b) a dispersed copolymer which comprises ethylene and a C3-C8 α-olefin,
wherein the ICP has a first melting point between 100° C. and 130° C. and a second melting point between 106° C. and 180° C.; and
a first additional layer comprising a first polymer composition,
wherein the molar ratio of ethylene monomer in the dispersed phase is greater than 0.82.

### Claim 2 (depends on 1)

The polymer sheet of claim 1, wherein
the first polymer composition in the first additional layer comprises at least one of a polypropylene homopolymer, a random copolymer of propylene comprising from 0.01 molar percent (mol. %) to 5 mol. % of ethylene, the propylene ICP and blends thereof.

### Claim 3 (depends on 1)

The polymer sheet of claim 1, further comprising:
a second additional layer comprising a second polymer composition,
wherein the first additional layer and the second additional layer are in direct contact with the core layer.

### Claim 4 (depends on 3)

The polymer sheet of claim 3, wherein
the second polymer composition in the second additional layer comprises at least one of a polypropylene homopolymer, a random copolymer of propylene comprising from 0.01 molar percent (mol. %) to 5 mol. % of ethylene, the propylene ICP and blends thereof.

### Claim 5 (depends on 3)

The polymer sheet of claim 3, wherein
the first additional layer and the second additional layer comprise the same composition.

### Claim 6 (depends on 4)

The polymer sheet of claim 4, wherein
the thickness of the core layer is in the range of from 60% to 99% of the total thickness of the polymer sheet; and
the thickness of the first and the second additional layers is in the range of from 2.5% to 40% of the total thickness of the polymer sheet.

### Claim 7 (depends on 3)

The polymer sheet of claim 3, wherein
the first additional layer or the second additional layer include a propylene ICP which comprises a blend comprising about 20% of the propylene ICP and about 80% of polypropylene homopolymer or a random copolymer of propylene comprising ethylene in the range from 0.2 molar percent (mol. %) to 1 mol. %.

### Claim 8 (depends on 1)

The polymer sheet of claim 1, wherein haze is less than 20%.

### Claim 9 (depends on 1)

The polymer sheet of claim 1, wherein clarity is greater than 80%.

### Claim 10

A fabricated article, comprising:
a core layer comprising a propylene impact copolymer (ICP), the propylene ICP comprising:
(a) a matrix comprising a polypropylene homopolymer or a propylene/alpha-olefin random copolymer which comprises greater than 50 wt. % of units derived from propylene monomer, and
(b) a dispersed copolymer which comprises ethylene and a C3-C8 α-olefin,
wherein the ICP has a first melting point between 100° C. and 130° C. and a second melting point between 106° C. and 180° C.; and
a first additional layer comprising a first polymer composition,
wherein the molar ratio of ethylene monomer in the dispersed phase is greater than 0.82.

### Claim 11 (depends on 10)

The fabricated article of claim 10, wherein
the first polymer composition in the first additional layer comprises at least one of a polypropylene homopolymer, a random copolymer of propylene comprising from 0.01 molar percent (mol. %) to 5 mol. % of ethylene, the propylene ICP and blends thereof.

### Claim 12 (depends on 10)

The fabricated article of claim 10, further comprising:
a second additional layer comprising a second polymer composition,
wherein the first additional layer and the second additional layer are in direct contact with the core layer.

### Claim 13 (depends on 12)

The fabricated article of claim 12, wherein
the first additional layer and the second additional layer comprise the same composition.

### Claim 14 (depends on 12)

The fabricated article of claim 12, wherein
the thickness of the core layer is in the range of from 60% to 99% of the total thickness of the polymer sheet; and
the thickness of the first and the second additional layers is in the range of from 2.5% to 40% of the total thickness of the polymer sheet.

### Claim 15 (depends on 10)

The fabricated article of claim 10, wherein the fabricated article is a container.

### Claim 16 (depends on 10)

The fabricated article of claim 10, wherein the fabricated article is a cup.

### Claim 17 (depends on 1)

A method of making the polymer sheet of claim 1, comprising a step of co-extruding the core layer and the first additional layer.

### Claim 18 (depends on 17)

The method of claim 17, wherein
the core layer, the first additional layer and a second additional layer are co-extruded together in a single coextrusion step; and
the first and the second additional layers are in direct contact with the core layer.

### Claim 19 (depends on 17)

The method of claim 17, wherein
the core layer is formed using a first polymer compound comprising the propylene ICP; and the first additional layer and a second additional layer are formed using a second polymer compound, the second polymer compound comprising at least one of a polypropylene homopolymer, a random copolymer of propylene comprising from 0.01 molar percent (mol. %) to 5 mol. % of ethylene, the propylene ICP and blends thereof.

### Claim 20 (depends on 17)

The method of claim 17, wherein
the thickness of the core layer is in the range of from 60% to 99% of the total thickness of the polymer sheet; and
the thickness of a first and the second additional layer are in the range of from 1.0% to 40% of the total thickness of the polymer sheet.

### Claim 21 (depends on 10)

The fabricated article of claim 10, wherein haze is less than 20%.

### Claim 22 (depends on 10)

The fabricated article of claim 10, wherein clarity is greater than 80%.