PROCESSING AID AND BLEND EMPLOYING THE PROCESSING AID FOR ACHIEVING EFFECTIVE ORIENTATION OF AN EXTRUDED FILM LAYER AND A BIAXIALLY ORIENTED FILM INCLUDING SUCH FILM LAYER

Abstract

Processing aid for aiding in orienting an extruded film layer including a preponderance, by weight, of a high crystal-line polypropylene is a crystalline polypropylene wax. An oriented film layer including a blend of crystalline polypropylene wax and high crystallinity polypropylene homopolymer is part of the invention. The invention includes a method of forming an oriented film layer including a preponderance by weight of a high crystallinity polypropylene and includes the steps of blending a high crystallinity polypropylene with a crystalline polypropylene wax, directing the blend through an extruder to form a film layer and then orienting the film layer. The invention includes a biaxially oriented, multi-layer film including a base layer and at least one skin layer. The base layer includes a blend of crystalline metallocene catalyzed polypropylene wax and a high crystallinity polypropylene.

Claims

1. A processing aid for aiding in orienting an extruded film layer including a preponderance, by weight, of high crystalline polypropylene, said processing aid being a crystalline polypropylene wax.

2. The processing aid of claim 1, said crystalline polypropylene wax being a crystalline, metallocene catalyzed wax.

3. A processing aid for aiding in orienting a multilayer film including a core layer, optionally one or more intermediate layers, and at least one skin layer, said processing aid including a crystalline polypropylene wax in said core layer and/or one or more of the optional intermediate layers.

4. The processing aid of claim 3, wherein said multilayer film includes only said core layer and at least one skin layer, said processing aid being a crystalline polypropylene wax located only is said core layer.

5. The processing aid of claim 3, said crystalline polypropylene wax being a crystalline, metallocene catalyzed wax.

6. An oriented film layer including a blend of a crystalline polypropylene wax and a high crystallinity polypropylene homopolymer.

7. The oriented film layer of claim 6, said crystalline polypropylene wax being a crystalline metallocene catalyzed polypropylene wax.

8. The oriented film layer of claim 6, including less than 10%, by weight, of the crystalline polypropylene wax.

9. The oriented film layer of claim 7, wherein said crystalline polypropylene wax is a crystalline metallocene catalyzed polypropylene wax.

10. The oriented film layer of claim 6, including less than 10%, by weight, of the crystalline polypropylene wax and over 90% of the high crystallinity polypropylene homopolymer.

11. The oriented film layer of claim 10, said crystalline polypropylene wax being a crystalline metallocene catalyzed polypropylene wax.

12. A method of orienting an extruded film layer including a preponderance by weight of a high crystallinity polypropylene homopolymer, said method including the steps of blending the high crystallinity polypropylene homopolymer with a crystalline polypropylene wax, extruding said blend to form the film layer and thereafter orienting said extruded film layer.

13. The method of claim 12, wherein said blend includes less than 10%, by weight, of the crystalline polypropylene wax and over 90% by weight of the high crystallinity polypropylene homopolymer.

14. The method of claim 12, wherein said step of extruding the blend to form said film layer is part of a co-extrusion process for forming a multi-layer film including a base layer, optionally one or more intermediate layers, and at least one skin layer, with said film layer being one or more of said base layer and one or more of said intermediate layers of said multi-layer film.

15. The method of claim 12 wherein said step of extruding the blend to form said film layer is part of a co-extrusion process for forming a multi-layer film with said film layer being the base layer of said multi-layer film and wherein the step of orienting the film layer is carried out by biaxially orienting said multi-layer film.

16. A method of forming an oriented, multilayer, coextruded film including a base layer, optionally one or more intermediate layers and at least one skin layer, said method including the steps of blending a high crystallinity polypropylene homopolymer with a crystalline polypropylene wax, coextruding said blend with at least one skin layer to form the base layer and/or one or more of said optional intermediate layers from said blend and orienting said multilayer, coextruded film.

17. The method of claim 16, wherein the step of orienting the film is carried out by biaxially orienting the coextruded film.

18. A biaxially oriented, multi-layer film including a base layer and at least one intermediate layers on one side of said base layer and at least one skin layer adjacent said at least one intermediate layer, said base layer and/or at least one intermediate layer including a blend of crystalline polypropylene wax and a high crystallinity polypropylene homopolymer.

19. The biaxially oriented, multi-layer film of claim 18, wherein said wax is a crystalline metallocene catalyzed polypropylene wax.

20. The biaxially oriented, multi-layer film of claim 18, wherein said crystalline polypropylene wax is less than 10% by weight of the blend and the machine direction and cross-direction tensile strength (psi) and the machine direction and cross direction tensile modulus (psi) of the multi-layer film are at least 90% of the machine direction and cross-direction tensile strength (psi) and the machine direction and cross direction tensile modulus (psi) of the same multi-layer film but excluding the crystalline polypropylene in the base layer.

21. The biaxially oriented, multi-layer film of claim 20, wherein said crystalline polypropylene wax is a crystalline metallocene catalyzed polypropylene wax.

22. The biaxially oriented, multi-layer film of claim 20, wherein said crystalline polypropylene wax is in the range of 3.0-7.5% by weight of the blend.

23. The biaxially oriented, multi-layer film of claim 21, wherein said crystalline polypropylene wax is in the range of 3.0-7.5% of the blend.

Description

DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

[0043] In accordance with this invention processing aids for forming a biaxially oriented film layer including a preponderance, by weight, (preferably 90% of the polymer weight in the film) of a high crystalline polypropylene, or for forming a multilayer, biaxially oriented extruded film employing such a film layer, are crystalline polypropylene waxes introduced at low to moderate levels into a high crystalline polypropylene homopolymer employed to form the film layer. Applicant has discovered, quite surprisingly, that crystalline metallocene catalyzed polypropylene waxes employed in this invention achieve the processability benefits of the prior art processing aids while having either only a minimal adverse impact on the modulus and strength of the film layer or actually achieving an improvement in the modulus and strength of the film. This is far superior to prior art processing aids, such as the prior art copolymers discussed earlier herein.

[0044] The preferred embodiments of this invention include crystalline metallocene catalyzed polypropylene waxes as the processing aid and the following description will be limited to such waxes as the processing aid. However, as noted earlier, in accordance with the broadest aspects of this invention the crystalline polypropylene waxes need not be metallocene catalyzed. However, whether the crystalline waxes are metallocene catalyzed or not they should have the properties of crystalline polypropylene waxes set forth earlier in this application. Moreover, the weight percentages of the crystalline polypropylene waxes employed in this invention are the weight percentages of the crystalline metallocene waxes described herein.

[0045] A representative embodiment of a coextruded, biaxially oriented, multi-layer film of this invention includes a base layer and opposed skin layers. In one preferred embodiment the multilayer film is a three-layer structure including a base layer and opposed skin layers. However, in accordance with the broadest aspects of this invention the multi-layer film can include more than three layers, e.g., 5 layers, 7 layers, etc.

[0046] In a three layer structure a blend of the crystalline metallocene catalyzed polypropylene wax and the high crystalline polypropylene homopolymer is in the base layer. When the structure is more than three layers, e.g., a five layer structure including a base layer, intermediate layers on opposed sides of the base layer and skin layers on opposed sides of the intermediate layers, the blend of a crystalline metallocene catalyzed polypropylene wax and the high crystalline polypropylene homopolymer can be in the base layer and/or in one or more of the intermediate layers. However, regardless how the blend is distributed in the base layer and/or intermediate layers, in the preferred embodiment the total weight percent of the high crystalline polypropylene homopolymer and the crystalline metallocene catalyzed polypropylene wax in the blend or blends should be the same. In other words, the weight percentage of the crystalline polypropylene wax and high crystalline polypropylene homopolymer blend will be the same whether the blend only is in the base layer, is in one or more of the intermediate layers, or is in one or more of the intermediate layers and the base layer.

[0047] The thickness of multilayer structures including more than three layers generally is the same as a three layer structure and the skin layers are essentially of the same thickness as in a three layer structure. The total thickness of the intermediate layers and base layer of multilayer structures including more than three layers essentially is the same as the thickness of the core layer in a three layer structure. Therefore, the combination of the base layer and intermediate layers in a structure including more than three layers can essentially be viewed as the core component equivalent to the core layer of a three layer structure, and the blend of the crystalline polypropylene wax and crystalline polypropylene homopolymer can be distributed throughout the base layer and intermediate layers, as desired.

[0048] The remaining description, unless stated otherwise, will be directed to a three layer structure including a base layer and opposed skin layers. However, it is understood that multi-layer structures including more than three layers are within the scope of this invention, e.g., 5 layers, 7 layers, etc. Also in accordance with the broadest scope of this invention, when the multi-layer structure is more than 3 layers the percentages of the crystalline polypropylene wax and high crystalline homopolymer of the blend in the core layer of a three layer structure can be distributed in one or more of the core layer and/or intermediate layers.

[0049] The base or core layer of a representative embodiment of this invention includes a blend of a crystalline metallocene catalyzed polypropylene wax in a weight percent of 3-7.5% and over 90% high crystalline polypropylene homopolymer. Other well-known additives can be included in the base layer, as desired.

[0050] One of the skin layers can include one or more polypropylene random copolymer(s) and is intended to receive a metallized layer thereon. For example, and not by way of limitation, the copolymers can be a propylene/ethylene and/or propylene/butene copolymer. However, in accordance with the broadest aspects of this invention the composition of the skin layers can be varied and the films are not required to include a metallized layer.

[0051] The opposed skin layer can include a number of different polymers; including homopolymers, copolymers and terpolymer, as is well known in the art.

[0052] It should be understood that the invention is not limited to a three layer structure of the above construction or composition. For example, the skin layers can include a variety of different polymer compositions and additives depending upon the required properties of the skin layers, as are well known in the art.

[0053] Although the composition of the base layer also can be different than described above, in accordance with preferred aspects of this invention the base layer includes over 90% by weight high crystalline polypropylene homopolymer and less than 10% by weight of a crystalline metallocene catalyzed polypropylene wax; based on the total weight of the base layer. In accordance with a preferred embodiment of this invention the base layer of the three layer structure is the thickest component; constituting over 85% of the thickness of the multilayer film.

[0054] A representative, biaxially oriented, multi-layer film of this invention and made in accordance with the coextrusion method of this invention is a three-layer film including opposed skin layers and a core layer. The skin layers can be of any desired composition; depending upon the desired properties. The compositions of the skin layers do not constitute a limitation on the present invention.

[0055] In a representative embodiment of the invention the core layer includes 95% of a high crystalline polypropylene homopolymer designated Total 3270 and provided by Total Petrochemicals & Refining USA, located in La Porte, Tex. and 5% of a crystalline, metallocene catalyzed polypropylene wax sold under the designation Clariant Licocene PP 6502 by Clariant International LTD and located in Frankfurt Germany.

[0056] Referring to Table 1 below, comparative results of product made on a pilot line are reported for Example 1, made in accordance with this invention, Control Example 1, which is devoid of any processing aid and Comparative Example 1, which includes a prior art processing aid in the form of a copolymer.

[0057] Example 1 employed a crystalline metallocene catalyzed polypropylene wax, (Clariant Licocene PP 7502 provided by Clariant International LTD and located in Frankfurt Germany). Table 1 shows that the use of a crystalline metallocene catalyzed polypropylene wax in relatively small quantities as a processing aid for extruding a film including predominately Total 3270, a high crystalline polypropylene homopolymer, substantially improves processability relative to forming the film with the Total 3270 but without any processing aid (Control Example 1). Total 3270 is provided by Total Petrochemicals & Refining USA, located in La Porte, Tex. This improved processability was achieved while maintaining good modulus and strength retention when the crystalline, metallocene polypropylene wax was incorporated into the high crystalline polypropylene homopolymer in an amount of approximately 3%. In fact, the machine direction (MD) properties of the film made with the use of the crystalline metallocene catalyzed polypropylene wax as a processing aid actually slightly improved over the machine direction properties of the film formed of Total 3270, but without any processing aid.

[0058] In comparison with the use of a prior art, copolymer processing aid, e.g., the Braskem DS6D21 blend, with Total 3270 (i.e., a high crystalline polypropylene homopolymer) (Comparative Example 1), the use of a crystalline metallocene catalyzed polypropylene wax of this invention as the processing aid provided a noticeable incremental improvement in processability with a substantially improved balance of properties.

[0059] As is shown in Table 1, in accordance with this invention (Example 1) the machine direction and cross-direction tensile strength (psi) and the machine direction and cross direction tensile modulus (psi) of the multi-layer film are at least 90% of the machine direction and cross-direction tensile strength (psi) and the machine direction and cross direction tensile modulus (psi) of the same multi-layer film but excluding the metallocene catalyzed polypropylene in the base layer. In fact, the machine direction tensile strength and the machine direction modulus actually were higher in the film of this invention (Example 1), as compared to a prior art film that did not include any processing aid. (Control Example 1)

TABLE-US-00001 TABLE 1 Control Example 1 Comparative Example 1 Example 1 Core Resin Total 3270 Total 3270 Total 3270 Modifier Type None Braskem DS6D21 Licocene PP 7502 Weight % Modifier     0      15     3 Modifier MP (° C.) na      142    151 Modifier % Crystallinity na      24.3    45.0 (by DSC) Modifier Viscosity na —  1,800 @ 170° C. (mPa .Math. s) Weight Average 352,000 .sup.2 ~287,000 .sup.2  19,300 .sup.2 Molecular Weight Gauge    68      76    63 MDO Temp (° C.)    132      130    130 TDO Temp (° C.)    177      176    176 % Haze     1.1       3.1     2.2 45° Gloss    88.7      84.9    88.3 Tensile Strength (Psi) % Change % Change MD  29,095 25,947 −10.8 29,361 +0.9 TD  51,697 40,914 −20.9 46,826 −9.4 Elongation (%) MD    171 168 164 TD    51 58 59 Tensile Modulus (Psi) MD 380,372 317,939 −16.4 386,685 +1.7 TD 744,398 571,590 −23.2 696,295 −6.5 Processability Rating (1-5)     1       3     4 1 = poor 5 = excellent .sup.1 Mw of Core Resin .sup.2 Mw of Modifier

[0060] The test results reported in Table 2 below were obtained by evaluating a series of four Licocene PP crystalline, metallocene catalyzed waxes (all at 7.5%, by weight, of the film layer) in Total 3270 high crystalline, polypropylene homopolymer on applicant's pilot line. The waxes differed in melting point and/or viscosity at 170° C. but are all considered to be within the broad scope of this invention. As will be discussed in greater detail hereinafter, the use of Licocene PP 6502, 7502 and 2602 are considered more preferred that Licocene 6102.

[0061] Before discussing the results reported in Table 2 it should be noted that three important parameters of the metallocene catalyzed waxes employed in this invention are viscosity, crystallinity and melting point. If the viscosity is too low processability of the film can be adversely effected. If the crystallinity and melting point are two low physical properties of the film can be adversely affected.

[0062] Turning to Table 2, results are reported for Examples 2-5, which are within the scope of this invention, and the results for these latter four Examples are compared to Control Example 1, which had no processing aid, and Comparative Example 1, which had a prior art copolymer processing aid.

TABLE-US-00002 TABLE 2 Control Comparative Example 1 Example 1 Example 2 Example 3 Example 4 Example 5 Core Resin Total 3270 Total 3270 Total 3270 Total 3270 Total 3270 Total 3270 Modifier Type None Braskem Licocene Licocene Licocene Licocene DS6D21 PP 7502 PP 6502 PP 6102 PP 2602 Weight % Modifier     0      15    7.5    7.5    7.5    7.5 Modifier MP (° C.) na      142   151   137   132    86 Modifier % Crystallinity na      24.3    45.0    32.7   23.5    6.8 (by DSC) Modifier Viscosity na —  1,800  1,700   60  6,300 @ 170° C. (mPa .Math. s) Weight Average 352,000 .sup.1 ~287,000 .sup.2 19,300 .sup.2 18,500 .sup.2 3,800 .sup.2 27,700 .sup.2 Molecular Weight Gauge    68      69    66    58   58    67 MDO Temp (° C.)    132      137   135   135   138   138 TDO Temp (° C.)    177      174   175   172   174   178 % Haze     1.1 —    2.7    1.2    1.4    0.9 45° Gloss    88.7 —    85.1    88.6   89.1    89.0 % % % % % Tensile Strength (Psi) Change Change Change Change Change MD  29,095 25,739 −11.5 33,594 +15.5 31,917 +9.7 32,785 +12.7 32,095 +10.3 TD  51,697 43,528 −15.8 47,425 −8.3 47,475 −8.2 51,093 −1.2 46,595 −9.9 Elongation (5) MD    171 152 140 147 148 148 TD    51 62 66 63 59 58 Tensile Modulus (Psi) MD 380,372 319,477 −16.0 379,123 −0.3 361,833 −4.9 362,294 −4.8 320,824 −15.7 TD 744,398 589,974 −20.7 671,743 −9.8 673,411 −9.5 685,169 −7.9 612,751 −17.7 Processability Rating     1       3    4    4    2    5 (1-5) 1 = poor 5 = excellent .sup.1 Mw of Core Resin .sup.2 Mw of Modifier

[0063] It should be noted that a substantially greater fall off in tensile strength and tensile modulus (both MD and TD) occurred with the conventional prior art copolymer processing aid (Comparative Example 1), as compared to the use of the crystalline metallocene catalyzed polypropylene waxes of this invention as the processing aid. (Examples 2-5).

[0064] Although the TD tensile strength of the Control Example 1 (no processing aid) was slightly better that the TD tensile strength of the examples in accordance with this invention (Examples 2-5) the processability of the Control was woefully inadequate; resulting in non-uniform orientation; particularly in the TD and also in an unacceptable number of film breakages during TD stretching. All of the Examples within the scope of this invention were superior to Control Example 1.

[0065] Example 4 of this invention, which employed Licocene PP 6102, was the least preferred of the waxes utilized in this invention because its low viscosity adversely affected the processability of the film layer. However, the crystallinity and melting point of the Licocene PP 6102 were at an acceptable level to maintain desired physical properties, such as tensile strength and tensile modulus.

[0066] The most preferred waxes tested by applicant were Licocene PP 6502, 7502 and 2602. All three of these latter processing aids were superior in all respects to the Comparative Example 1 employing the prior art copolymer processing aid. Specifically, both the 6502 and 7502 waxes provided excellent processability properties; being rated 4 out of 5 and 2602 was given the highest possible rating of 5. However, the processability of Comparative Example 1 was rated only 3. Moreover, the 6502, 7502 and 2602 waxes provided excellent physical properties; being better than the physical properties achieved with the prior art copolymer processing aid employed in Comparative Example 1.

[0067] The results from the two sets of experiments reported above in Tables 1 and 2 also were useful in helping to establish, identify or determine a number of acceptable parameters of the invention, as follows: (1) a preferred level of incorporation, or range, of the crystalline metallocene catalyzed polypropylene waxes of this invention in the high crystalline polypropylene homopolymer to achieve desirable benefits of this invention (considered to be 3-7.5%, by weight, of the film layer including the wax); (2) the sensitivity to the additive of the melting point/drop point (results show that 132-151 C is preferred and that 86 C was less preferred because it was more detrimental to modulus retention than the other waxes that were employed in the tests; (3) a viscosity range for the additive (1700-6300 mPa was determined to be good to excellent for processability but 60 mPa was determined not to be as good).

[0068] The effect of the percent wax addition of several grades of crystalline metallocene catalyzed polypropylene wax on the degree of difficulty in stretching the polymer was measured or tested and the results are graphically represented below in Table 3. The test was carried out by simultaneously biaxially orienting a 2 inch by 2 inch by 23 mil polymer and then determining the stretching temperature at which the yield stress of the sample was equal to 350 psi (referred to as T350). This provides a comparative measure, among the series of polymers tested, of the degree of difficulty of stretching the polymer. The response to different weight percentages of the processing aids of this invention being employed in a high crystalline, polypropylene homopolymer appears to be equivalent to or somewhat sharper (steeper) than the response to the prior art Braskem DS6D21 copolymer addition. A sharper response is indicative of superior performance.

[0069] While the invention has been described in detail and with reference to specific examples thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. For example, the core layer and/or intermediate layers can be provided in any desired additives, including organic and inorganic voiding agents, e.g., calcium carbonate, polybutylene terephthalate, etc., pigments, antiblock agents, slip additives, hard resins, etc.