# US 2014/0194577 A1 · Propylene impact copolymers having good optical properties

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- Number: US 2014/0194577 A1
- Document ID: US20140194577A1
- Status: Published application
- Kind: A1
- Application number: 13/737,684
- Filed: 2013-01-09
- Published: 2014-07-10
- Earliest claimed: 2013-01-09
- Assignees: Braskem America, Inc.
- Applicants: Braskem America, Inc.
- Inventors: Peter S. Dias; Jonathan D. Kersey; Peter S. Martin; Thomas R. Cuthbert
- Web page: https://patentgrep.com/patent/US20140194577A1

## CPC

- C08L 19/00: Compositions of rubbers not provided for in groups C08L7/00 - C08L17/00
- B29C 45/0001: {characterised by the choice of material}
- B29C 49/0005: {characterised by the material}
- B29C 51/002: {characterised by the choice of material}
- C08L 23/12: Polypropene
- B29K 2023/12: {PP, i.e. polypropylene}
- 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
- C08L 2308/00: Chemical blending or stepwise polymerisation process with the same catalyst
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- 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)
- 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

## Abstract

Propylene impact copolymers (ICPs) are provided which comprise: (a) a matrix phase which comprises from 60 to 95 weight % of a polypropylene polymer containing from 0 to 6 mole % of units derived from one or more alpha-olefins other than propylene, and (b) a dispersed phase which comprises from 5 to 40 weight % of a copolymer derived from a first comonomer which can be either propylene or ethylene together with a second alpha-olefin comonomer. The ICP is further characterized by having a beta/alpha ratio less than or equal to 1.1. The ICPs of the present invention are particularly well suited for applications requiring clear, tough polymers such as thin walled injection molded articles for frozen food packaging applications.

## Claims

### Claim 1

A composition comprising:
a matrix phase comprising 50 to 95 weight % of a polypropylene polymer comprising from 0 to 6 mole % of units derived from one or more alpha-olefins selected from the group consisting of ethylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, 1-undecene and 1-dodecene; and
a dispersed copolymer phase comprising from 5 to 50 weight % of the total composition, the dispersed copolymer phase comprising:
from 40 to 90 weight % of a first copolymer comprising 35 to 85 weight % of ethylene and 15 to 65 weight % of a first rubber comonomer comprising one or more C3-C12 α-olefin, and
from 10 to 60 weight % of a second copolymer comprising 65 to 95 weight % of ethylene and 5 to 35 weight % of a second rubber comonomer comprising one or more C3-C12 α-olefin,
wherein the weight percent of ethylene in the second copolymer is greater than the weight percent of ethylene in the first copolymer.

### Claim 2 (depends on 1)

The composition of claim 1, wherein the composition has a beta/alpha ratio of less than or equal to about 1.1.

### Claim 3 (depends on 1)

The composition of claim 1, wherein the first copolymer and the second copolymer contain amounts of ethylene such that the composition is non-blooming.

### Claim 4 (depends on 3)

The composition of claim 3, wherein the composition has a haze value less than about 25% on a 20 mil plaque as measured in accordance with ASTM D 1003.

### Claim 5 (depends on 3)

The composition of claim 3, wherein the composition has a clarity value greater than about 95% on a 20 mil plaque as measured in accordance with ASTM D 1003.

### Claim 6 (depends on 1)

The composition of claim 1, wherein the composition has a Gardner impact value greater than about 100 in-lbs at −40° C.

### Claim 7 (depends on 1)

The composition of claim 1, wherein at least one of the first rubber comonomer and the second rubber comonomer is propylene.

### Claim 8

A fabricated article comprising:
a propylene impact copolymer composition comprising:
a matrix phase comprising 50 to 95 weight % of a polypropylene polymer comprising from 0 to 6 mole % of units derived from one or more alpha-olefins selected from the group consisting of ethylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, 1-undecene and 1-dodecene; and
a dispersed copolymer phase comprising from 5 to 50 weight % of the total composition, the dispersed copolymer phase comprising:
from 40 to 90 weight % of a first copolymer comprising 35 to 85 weight % of ethylene and 15 to 65 weight % of a first rubber comonomer comprising one or more C3-C12 α-olefin, and
from 10 to 60 weight % of a second copolymer comprising 65 to 95 weight % of ethylene and 5 to 35 weight % of a second rubber comonomer comprising one or more C3-C12 α-olefin,
wherein the weight percent of ethylene in the second copolymer is greater than the weight percent of ethylene in the first copolymer.

### Claim 9 (depends on 8)

The fabricated article of claim 8, wherein the propylene impact copolymer composition has a beta/alpha ratio of less than or equal to about 1.1.

### Claim 10 (depends on 8)

The fabricated article of claim 8, wherein the first copolymer and the second copolymer contain amounts of ethylene such that the composition is non-blooming.

### Claim 11 (depends on 10)

The fabricated article of claim 10, wherein the propylene impact copolymer composition in the fabricated article has a haze value less than about 25% on a 20 mil plaque as measured in accordance with ASTM D1003.

### Claim 12 (depends on 10)

The fabricated article of claim 10, wherein the propylene impact copolymer composition in the fabricated article has a clarity value greater than about 95% on a 20 mil plaque as measured in accordance with ASTM D1003.

### Claim 13 (depends on 8)

The fabricated article of claim 8, wherein the propylene impact copolymer composition in the fabricated article has a Gardner impact value greater than about 100 in-lbs at −40° C. as measured in accordance with ASTM D5420-10 GE configuration.

### Claim 14 (depends on 8)

The fabricated article of claim 8, wherein the propylene impact copolymer composition in the fabricated article has a flexural modulus/stiffness value of greater than 110 kpsi as measured in accordance with ASTM D790 at 1% secant.

### Claim 15 (depends on 8)

The fabricated article of claim 8, wherein at least one of the first rubber comonomer and the second rubber comonomer is propylene.

### Claim 16 (depends on 8)

The fabricated article of claim 8, wherein the fabricated article is selected from the group consisting of a thermoformed article, an injection molded article, a thin walled injection molded article, a flat plaque, and a blow molded article.

### Claim 17

A fabricated article comprising:
a propylene impact copolymer composition having;
bloom resistance;
a haze value less than about 25% on a 20 mil plaque as measured in accordance with ASTM D1003;
a clarity value greater than about 95% on a 20 mil plaque as measured in accordance with ASTM D1003;
a drop impact resistance value greater than about 100 in-lbs at −40° C. as measured in accordance with ASTM D5420-10 GE configuration; and
a flexural modulus/stiffness value of greater than 110 kpsi as measured in accordance with ASTM D790 at 1% secant.

### Claim 18 (depends on 17)

The fabricated article of claim 17, wherein the fabricated article is conditioned according to ASTM D4332 at −40° C.; and
dropped according to ASTM D5276, wherein the mean failure height is greater than 36 inches with 420 g of fill weight.

### Claim 19 (depends on 17)

The fabricated article of claim 17, wherein the fabricated article is selected from the group consisting of a thermoformed article, an injection molded article, a thin walled injection molded article, a flat plaque, and a blow molded article.

### Claim 20

A process for making a propylene impact copolymer composition comprising a matrix phase and a dispersed phase in a sequential polymerization process, the process comprising:
polymerizing the matrix phase comprising a propylene polymer comprising from 0 to 6 mol % of units derived from monomers selected from the group consisting of ethylene, C4-C12 alpha-olefins and combinations thereof;
polymerizing a first copolymer of the dispersed phase in the presence of the matrix phase, the first copolymer comprising an ethylene content of less than 85% by weight; and
polymerizing a second copolymer of the dispersed phase in the presence of the matrix phase, the second copolymer comprising an ethylene content of greater than 65% by weight,
wherein the ethylene content of the second copolymer is greater than the ethylene content of the first copolymer.

### Claim 21 (depends on 20)

A propylene impact copolymer composition produced by the process of claim 20.

### Claim 22 (depends on 20)

The process of claim 20, further comprising fabricating at least a portion of an article of manufacture from the propylene impact copolymer composition.

### Claim 23 (depends on 22)

The process of claim 22, wherein fabricating at least a portion of an article of manufacture comprises a fabrication step selected from the group consisting of injection molding, thin wall injection molding, thermoforming, and blow molding.

### Claim 24 (depends on 20)

The process of claim 20, wherein the first copolymer of the dispersed phase is polymerized in a first gas phase reactor and the second copolymer of the dispersed phase is polymerized in a second gas phase reactor.

### Claim 25 (depends on 1)

An article of manufacture made from the composition of claim 1, wherein the article is selected from the group consisting of a thin walled article; a thin walled injection molded article; and a thin walled injection molded article for frozen food packaging applications.

### Claim 26 (depends on 25)

The article of manufacture of claim 25, wherein the article has a mean failure height greater than 36 inches with a 420 g of fill weight when dropped according to ASTM D5276 and conditioned according to ASTM D4332 at −40° C.

### Claim 27 (depends on 1)

The composition of claim 1, wherein the dispersed copolymer phase comprises:
from 40 to 90 weight % of a first copolymer comprising 60 to 65 weight % of ethylene and 35 to 40 weight % of a first rubber comonomer comprising one or more C3-C12 α-olefin, and
from 10 to 60 weight % of a second copolymer comprising 85 to 95 weight % of ethylene and 5 to 15 weight % of a second rubber comonomer comprising one or more C3-C12 α-olefin.

### Claim 28 (depends on 8)

The fabricated article of claim 8, wherein the dispersed copolymer phase comprises:
from 40 to 90 weight % of a first copolymer comprising 60 to 65 weight % of ethylene and 35 to 40 weight % of a first rubber comonomer comprising one or more C3-C12 α-olefin, and
from 10 to 60 weight % of a second copolymer comprising 85 to 95 weight % of ethylene and 5 to 15 weight % of a second rubber comonomer comprising one or more C3-C12 α-olefin.

### Claim 29 (depends on 1)

The composition of claim 1, wherein the dispersed copolymer phase does not comprise an ethylene polymer other than the first copolymer and the second copolymer.

### Claim 30 (depends on 8)

The fabricated article of claim 8, wherein the dispersed copolymer phase does not comprise an ethylene polymer other than the first copolymer and the second copolymer.