Modified polypropylene and polymer blends thereof

Abstract

A propylene-based polymer composition is characterized by a melt strength at 190 C. of at least 20 cN, a melt drawability at 190 C. of at least 100 mm/s, and a flexural modulus at room temperature of at least 240,000 psi. The propylene-based polymer composition includes a propylene-based polymer resin having a crystallinity of at least 50% coupled with a poly(sulfonyl azide).

Claims

1. A propylene-based polymer composition comprising: a propylene-based polymer resin having a crystallinity of at least 50%; a poly(sulfonyl azide); and a first uncoupled polypropylene homopolymer resin; wherein the propylene-based polymer composition has a melt strength at 190 C. of at least 20 cN, a melt drawability at 190 C. of at least 100 mm/s, a melt flow rate of at least 1.8 g/10min, and a flexural modulus at room temperature of at least 240,000 psi.

2. The propylene-based polymer composition of claim 1, wherein the propylene-based polymer resin is a polypropylene homopolymer.

3. The propylene-based polymer composition of claim 1, wherein the composition comprises 500 ppm to 3000 ppm of the poly(sulfonyl azide), based on the total weight of the composition.

4. The propylene-based polymer composition of claim 1, wherein the composition comprises 1,000 ppm to 2,000 ppm of the poly(sulfonyl azide), based on the total weight of the composition.

5. The propylene-based polymer composition of claim 1, wherein the propylene-based polymer resin has a crystallinity in the range of from 60% to 90%.

6. The propylene-based polymer composition of claim 1, wherein the propylene-based polymer resin has a crystallinity in the range of from 70% to 80%.

7. The propylene-based polymer composition of claim 1, wherein the composition has a melt strength at 190 C. in the range of from 25 cN to 100 cN.

8. The propylene-based polymer composition of claim 1, wherein the composition has a heat distortion temperature under a load of 66 psi that is greater than 101 C.

9. The propylene-based polymer composition of claim 1, wherein the composition has a melting temperature in the range of from 160 C. to 170 C.

10. The propylene-based polymer composition of claim 1, wherein the composition has a ratio of melt strength to melt flow rate (MS/MFR) that is less than 10.

11. The propylene-based polymer composition of claim 1, wherein the composition has a ratio of melt strength to melt flow rate (MS/MFR) that is greater than 18.

12. The propylene-based polymer composition of claim 1, further comprising a second uncoupled polyolefin resin, wherein the second uncoupled polyolefin comprises a polypropylene homopolymer resin or a resin comprising a copolymer of ethylene and at least one C.sub.3-C.sub.12 -olefin comonomer.

13. The propylene-based polymer composition of claim 12, further comprising a third uncoupled polyolefin resin, wherein the third uncoupled polyolefin resin comprises a polypropylene homopolymer resin or a resin comprising a copolymer of ethylene and at least one C.sub.3-C.sub.12 -olefin comonomer.

14. The propylene-based polymer composition of claim 1, further comprising an additive.

15. The propylene-based polymer composition of claim 1, further comprising a mineral filler.

16. The propylene-based polymer composition of claim 1, wherein the composition exhibits an Izod impact resistance at room temperature, measured according to ASTM D256-10e1, of greater than or equal to 1.20 ft-lb/in.

17. The propylene-based polymer composition of claim 1, wherein the composition exhibits a melt strength at 190 C. of greater than or equal to 30 cN.

18. The propylene-based polymer composition of claim 1, wherein the composition exhibits a melt drawbility at 190 C. of greater than or equal to 145 mm/s.

19. The propylene-based polymer composition of claim 1, wherein the composition comprises 20-80% of the poly(sulfonyl azide) and the propylene-based polymer resin by total weight of the composition.

20. The propylene-based polymer composition of claim 1, further comprising an uncoupled copolymer resin comprising a copolymer of ethylene and propylene.

21. The propylene-based polymer composition of claim 1, further comprising a coupled copolymer resin comprising a copolymer of ethylene and propylene.

22. A sheet or film comprising the propylene-based polymer composition of claim 1.

23. A thermoformed sheet or film comprising the propylene-based polymer composition of claim 1.

24. A rigid packaging substrate comprising the propylene-based polymer composition of claim 1.

25. A propylene-based polymer composition comprising: 1-99% (by total weight of the composition) of a poly(sulfonyl azide)-coupled propylene-based polymer resin, the poly(sulfonyl azide)-coupled propylene-based polymer resin comprising: 90-99% (by total weight of the poly(sulfonyl azide)-coupled propylene-based polymer resin) of a homopolymer propylene resin having a crystallinity of at least 50%; 1-10% (by total weight of the poly(sulfonyl azide)-coupled propylene-based polymer resin) of a copolymer resin comprising a copolymer of ethylene and propylene; and 1000-2000 ppm (by total weight of the poly(sulfonyl azide)-coupled propylene-based polymer resin) of a poly(sulfonyl azide); and 1-99% (by total weight of the composition) of an uncoupled homopolymer polypropylene resin; wherein the propylene-based polymer composition has a melt strength at 190 C. of at least 20 cN, a melt drawability at 190 C. of at least 145 mm/s, an Izod impact resistance at room temperature (measured according to ASTM D256-10e1) of greater than or equal to 1.20 ft-lb/in, a melt flow rate of at least 1.8 g/10 min, and a flexural modulus at room temperature of at least 240,000 psi.

26. The propylene-based polymer composition of claim 25, wherein the composition comprises 20-80% (by total weight of the composition) of the poly(sulfonyl azide)-coupled propylene-based polymer resin, and 20-80% (by total weight of the composition) of the uncoupled homopolymer polypropylene resin.

27. The propylene-based polymer composition of claim 1, wherein the melt flow rate of the propylene-based polymer composition is at least 2.1 g/10 min.

Description

EXAMPLES

(1) In the following examples, differential scanning calorimetry was performed by conducting non-isothermal DSC sweeps using a TA Instruments 200 Differential Scanning calorimeter. The specimens were equilibrated at 200 C. for 5 minutes to ensure complete melting. The melt was then cooled to 50 C. at a rate of 10 C./min. The peak temperature of the melt crystallization exotherm was recorded as the crystallization temperature (T.sub.mc). The specimens were then heated back to 200 C. at a rate of 10 C./min and the peak of the melting endotherm was recorded as the melting point temperature (T.sub.m). The reported tensile properties were measured according to ASTM D638-14: Standard Test Method for Tensile Properties of Plastics. Other properties were determined as described above.

Examples 1-6

Propylene-based Polymer Compositions Comprising Poly(Sulfonyl Azide)-coupled Propylene-based Polymer Resins

(2) Propylene-based polymer compositions comprising poly(sulfonyl azide)-coupled propylene-based polymer resins were produced by twin screw extrusion of the following components: a polypropylene homopolymer resin having a melt index of 18 g/10 min. produced using a Ziegler-Natta catalyst; a molecular melt containing 4,4-diphenyl oxide bis(sulfonyl azide) (DPOBSA) phlegmatized in IRGANOX1010 antioxidant; IRGANOX B225 antioxidant; IRGAFOS 168 antioxidant; and calcium stearate.
IRGANOX 1010 is pentaerythritol tetrakis(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate). IRGAFOS 168 is tris(2,4-di-tert-butylphenyl)phosphite. IRGANOX B225 is a 50/50 weight percent blend of pentaerythritol tetrakis(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate) (IRGANOX 1010) and tris(2,4-di-tert-butylphenyl)phosphite (IRGAFOS 168).

(3) The formulations of Examples 1-6 are shown in Table 1 below. In the table, the row labeled extruder type specifies the screw size of the twin-screw extruder (TSE) used to mix the components. Melt temperature refers the measured temperature recorded by a thermocouple inserted into the extruder barrel near the die. Residence time is estimated as the amount of time the poly(sulfonyl azide) and polypropylene resin were in contact during melt-mixing. The measured properties of Examples 1-6 are shown in Table 2, below, and are compared to the properties of commercially available polypropylene resins identified as comparative Examples CE1-CE6 and shown in Table 3.

(4) Comparative Example 1 (CE-1) is DAPLOY WB140 (available from Borealis AG), which is a structurally isomeric modified polypropylene homopolymer having high melt strength, but low stiffness and low temperature resistance. Comparative Example 2 (CE-2) is INSPIRE 6025N (available from Braskem America, Inc.), which is a commercial grade of polypropylene homopolymer that contains an external crystal nucleating agent. Comparative Examples 3 and 4 (CE-3 and CE-4) are linear grades of polypropylene homopolymer with high melt strength and very low melt flow rate. Comparative Example 5 (CE-5) is INSPIRE 114 (available from Braskem America, Inc.), a commercial grade of impact copolymer polypropylene (ICP). Comparative Example 6 (CE-6) is a high crystalline polypropylene homopolymer.

(5) Examples 1-6 demonstrate that the inventive propylene-based polymer compositions have higher crystallinity and flexural modulus than commercially available high melt strength polypropylene resin (e.g., DAPLOY WB140 (CE-1)). Moreover, Examples 1-5 show that the inventive propylene-based polymer compositions also exhibit significantly higher melt drawability and high melt strength compared to conventional polypropylene resins (e.g., CE-2, CE-3, and CE-4). High stiffness is also shown by the delta H values, flexural modulus, and heat distortion temperature (distortion temperature under load) of the inventive examples.

(6) TABLE-US-00001 TABLE 1 Inventive polymer compositions and extrusion parameters Examples Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. 5 Ex. 6 polypropylene resin 99.15 99.15 99.18 99.33 99.33 94.34 (MFR 35) (MFI 18) VISTAMAXX 0 0 0 0 0 5.0 7010FL* DPOBSA 0.65 0.65 0.65 0.55 0.55 0.55 phlegmatized in IRGANOX 1010 B225 0.15 0.15 0 0 0 0 IRGAFOS 168 0 0 0.12 0.07 0.07 0.07 Calcium stearate 0.05 0.05 0.05 0.05 0.05 0.05 Poly(sulfonyl 1560 1560 1560 1320 1320 1320 azide), ppm Extruder type 45 mm 45 mm 50 mm 50 mm 50 mm 50 mm TSE TSE TSE TSE TSE TSE Feed location main side side side side side hopper feeder feeder feeder feeder feeder Melt temperature, F. 405 470 490 490 490 490 Residence time, sec 28 28 19 18 18 18 *VISTAMAXX 7010FL, available from Exxon Mobile Chemical Company

(7) TABLE-US-00002 TABLE 2 Properties of inventive polymer compositions Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. 5 Ex. 6 (BRASKEM Inventive Inventive Inventive Inventive Inventive Inventive Polymer) HMS-PP HMS-PP HMS-PP HMS-PP HMS-PP HMS-PP MFR, dg/min 1.7 1.2 0.8 1.4 2.1 3.2 Melt strength, cN 34 40.3 52.4 55.3 43.6 45.0 Melt drawability, 146 153 147.7 172 157.2 170.0 mm/s Tc ( C.) 133.8 133.8 131.2 131.4 131.4 131.3 Tm ( C.) 163.8 162.9 163.9 163.4 163.6 164.0 delta Hm 107.8 112.4 105.1 111.2 110 112 (Joules/g) Flexural Modulus, 279,803 280,910 297,132 294,786 276,090 sec (psi) DTUL@ 66 psi, C. 111 114 119 117 108.33 Melt strength 20 34 66 40 21 14 (cN)/MFR/(dg/min) Melt strength/melt 0.2 0.3 0.4 0.3 0.3 0.3 drawability(mm/s)

(8) TABLE-US-00003 TABLE 3 Properties of comparative polypropylene compositions CE-1 CE-2 CE-3 CE-4 CE-5 CE-6 Description HMS- 2-MFR Fractional Fractional HMS- 2-MFR high PP homopolymer MFR MFR PP crystalline homopolymer homopolymer homopolymer (contains <1 wt (containing % ethylene) no ethylene) MFR 2.5 2.0 0.6 0.6 0.3 2.0 (dg/min.) Melt 45.0 10.0 63.2 72.6 53.0 10.0 strength (cN) Melt 172.2 100.0 97.3 89.8 119.0 100.0 extension (mm/s) Tc ( C.) 128.1 133.5 116.4 124.2 Tm ( C.) 158.3 162.9 158.1 162.3 delta Hm 97.2 112.3 90.4 100.9 (Joules/gram) Flexural 239,632 Modulus, sec (psi) DTUL@ 101 66 psi ( C.) Melt 18 5 105 121 177 5.0 strength/MFR (cN/(dg/min)) Melt 0.3 0.1 0.6 0.8 0.4 0.1 strength/melt extension (mm/s)

Examples 7-19

Propylene-based Polymer Compositions Comprising Blends of Poly(Sulfonyl Azide)-coupled Propylene-based Polymer Resins and Uncoupled Homopolymer Polypropylene Resin

(9) Propylene-based polymer compositions were produced by blending a poly(sulfonyl azide)-coupled propylene-based polymer resin and an uncoupled homopolymer polypropylene resin. The poly(sulfonyl azide)-coupled propylene-based polymer resin was produced by melt blending the following components (in percent by total weight): 94.34% of a polypropylene homopolymer resin having a melt index of 35 g/10 min. produced using a Ziegler-Natta catalyst; 5.0% of VISTAMAXX 7010FL (a metallocene-catalyzed isotactic random copolymer of propylene and ethylene, available from the Exxon Mobile Chemical Company); 0.55% of a molecular melt containing 726 ppm (by total weight of the molecular melt) of 4,4-diphenyl oxide bis(sulfonyl azide) (DPOBSA) phlegmatized in IRGANOX 1010 antioxidant (1320 ppm DPOBSA by total weight of the poly(sulfonyl azide)-coupled propylene-based polymer resin); 0.06% of IRGAFOS 168 antioxidant; and 0.05% of calcium stearate.

(10) The poly(sulfonyl azide)-coupled propylene-based polymer resin was blended with a homopolymer polypropylene resin having a nominal melt flow rate of 2.5 g/10 min. (INSPIRE 6025N, available from Braskem America, Inc.) in various proportions, as shown below in Table 4. The poly(sulfonyl azide)-coupled propylene-based polymer resin was blended with an impact copolymer polypropylene resin having a nominal melt flow rate of 0.5 g/10 min. (INSPIRE 114, available from Braskem America, Inc.) in various proportions, as shown below in Table 4. The blend components were ground to a fine powder in a Wiley mill and dry blended for 15 minutes in a Patterson-Kelly V-blender.

(11) TABLE-US-00004 TABLE 4 Poly(sulfonyl azide)- coupled propylene- INSPIRE 6025N INSPIRE 114 based polymer resin (percent by total (percent by total Example (percent by total weight of weight of No. weight of the blend) the blend) the blend) 7 100 8 100 9 100 10 1 99 11 5 95 12 10 90 13 20 80 14 40 60 15 60 40 16 80 20 17 25 75 18 50 50 19 75 25

(12) The following material properties were measured for the blends and blend components: deflection temperature under load (DTUL)ASTM D648-07: Standard Test Method for Deflection Temperature of Plastics Under Flexural Load in the Edgewise Position; tensile tangent modulus at room temperatureASTM D638-14: Standard Test Method for Tensile Properties of Plastics; flexural modulus (1% secant) at room temperatureASTM D790-10: Standard Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials; Izod impact resistance at room temperatureASTM D256-10e1: Standard Test Methods for Determining the Izod Pendulum Impact Resistance of Plastics; and high speed multiaxial impact energy absorption at room temperature (3.2 mm thick specimens)ASTM D3763-15: Standard Test Method for High Speed Puncture Properties of Plastics Using Load and Displacement Sensors. The material properties are reported below in Tables 5 and 6.

(13) TABLE-US-00005 TABLE 5 Tensile Tangent Average Total Exam- Modulus Flexural Modulus Energy on ple DTUL (pounds (force) (pounds (force) Impact No. ( C.) per square inch) per square inch) (foot-pounds) 7 108.33 342462 276090 0.98 8 106.33 321322 279253 1.56 9 76.53 238658 180852 27.1 10 98.23 334459 277362 1.81 11 96.03 320626 280714 2.51 12 103.33 322424 279853 1.79 13 106.67 321730 279840 1.59 14 108.33 329780 280416 1.51 15 97.53 335171 278165 1.12 16 108.67 330002 267557 1.21 17 87.80 253557 229021 26.8 18 93.90 272671 208704 17 19 103.00 284888 244184 10

(14) TABLE-US-00006 TABLE 6 Izod - Izod - Partial Izod - no Complete Break Break Break on Impact on Impact on Impact Example (foot-pounds- (foot-pounds- (foot-pounds- No. per-inch) per-inch) per-inch) 7 1.07 8 0.637 9 7.228 11.682 (30% of specimens) (70% of specimens) 10 0.701 11 0.808 12 1.028 13 1.27 14 1.413 15 1.307 16 1.261 17 5.504 18 3.51 19 1.859

(15) As the above results indicate, propylene-based polymer compositions comprising a poly(sulfonyl azide)-coupled propylene-based polymer resin and an uncoupled homopolymer polypropylene resin exhibit synergistically increased Izod impact resistance without any attendant decrease in tensile modulus or flexural modulus. For instance, Table 7 below compares the measured Izod impact resistance values for each blend with the expected Izod impact resistance values for each blend, which correspond to the mass-weighted average of the measured Izod impact resistance values for the two blend components.

(16) TABLE-US-00007 TABLE 7 Poly(sulfonyl azide)- coupled propylene- Synergism based polymer resin INSPIRE 6025N (% measured Example (percent by total weight (percent by total Measured Izod Expected Izod greater than No. of the blend) weight of the blend) (ft-lb/in.) (ft-lb/in.) expected) 8 0 100 0.637 10 1 99 0.701 0.641 9.30 11 5 95 0.808 0.659 22.68 12 10 90 1.028 0.680 51.11 13 20 80 1.27 0.724 75.51 14 40 60 1.413 0.810 74.40 15 60 40 1.307 0.897 45.74 16 80 20 1.261 0.983 28.23 7 100 0 1.07

(17) As shown in Table 7, combinations of a poly(sulfonyl azide)-coupled propylene-based polymer resin and an uncoupled homopolymer polypropylene resin exhibit Izod impact resistances that range from about 9% to about 76% greater than the expected Izod impact resistances for the blended resins. Moreover, the increase in the measured Izod impact resistances over the expected Izod impact resistances occurs without any appreciable decrease in stiffness, measured as tensile and flexural moduli, as shown above in Table 5. These results are surprising and unexpected because the improvement in impact toughness is greater than expected under the rule of mixtures, and because stiffness of propylene-based polymer compositions (measured as the materials' moduli) is generally inversely proportional to the impact toughness of propylene-based polymer compositions (measured as the materials' Izod impact resistance).

(18) In addition to the properties described above, the melt strength and melt drawability of Examples 7, 8, and 13-16 were measured using a RHEO-TESTER 2000 high-pressure capillary rheometer equipped with a RHEOTENS 71.97 unit, both available from Gettfert Werkstoff-Prfmaschinen GMBH, Buchen, Germany, operated in accordance with ASTM D3835-08: Standard Test Method for Determination of Properties of Polymeric Materials by Means of a Capillary Rheometer. These properties are reported below in Tables 8 and 9, which also compare the measured values for each blend with the expected values for each blend corresponding to the mass-weighted average of the measured values for the two blend components.

(19) TABLE-US-00008 TABLE 8 Poly(sulfonyl azide)- coupled propylene- Synergism based polymer resin INSPIRE 6025N Measured Melt Expected Melt (% measured Example (percent by total weight (percent by total Strength Strength greater than No. of the blend) weight of the blend) (cN) (cN) expected) 8 0 100 8.3 13 20 80 20.7 14.8 39.9 14 40 60 30.3 21.2 42.9 15 60 40 35.4 27.7 27.8 16 80 20 37.0 34.1 8.5 7 100 0 40.6

(20) TABLE-US-00009 TABLE 9 Poly(sulfonyl azide)- coupled propylene- Synergism based polymer resin INSPIRE 6025N Measured Melt Expected Melt (% measured Example (percent by total weight (percent by total Drawability Drawability greater than No. of the blend) weight of the blend) (mm/s) (mm/s) expected) 8 0 100 118.5 13 20 80 148.9 130.3 12.5 14 40 60 157.2 142.0 10.7 15 60 40 160.4 153.8 4.3 16 80 20 166.1 165.5 0.4 7 100 0 177.3

(21) Thus, in addition to the surprising and unexpected improvement in impact toughness, combinations of a poly(sulfonyl azide)-coupled propylene-based polymer resin and an uncoupled homopolymer polypropylene resin exhibit melt strengths that range from 8.5% to 39.9% greater than the expected melt strengths for the blended resins, and exhibit melt drawabilities that range from 0.4% to 12.5% greater than the expected melt drawabilities for the blended resins, as shown in Tables 8 and 9. These results indicate that propylene-based polymer compositions comprising a poly(sulfonyl azide)-coupled propylene-based polymer resin and an uncoupled homopolymer polypropylene resin exhibit synergistically increased Izod impact resistance, melt strength, and melt drawability, without y attendant decrease in tensile modulus or flexural modulus.

Aspects of the Invention

(22) Various aspect, features, and characteristics of the invention include, but are not limited to, the following numbered clauses.

(23) 1. A propylene-based polymer composition comprising: a propylene-based polymer resin having a crystallinity of at least 50%; and a poly(sulfonyl azide); wherein the propylene-based polymer composition has a melt strength at 190 C. of at least 20 cN, a melt drawability at 190 C. of at least 100 mm/s, and a flexural modulus at room temperature of at least 240,000 psi.

(24) 2. The propylene-based polymer composition of clause 1, wherein the propylene-based polymer resin is a polypropylene homopolymer.

(25) 3. The propylene-based polymer composition of clause 1 or clause 2, wherein the composition comprises 500 ppm to 3000 ppm of the poly(sulfonyl azide), based on the total weight of the composition.

(26) 4. The propylene-based polymer composition of any one of clauses 1-3, wherein the composition comprises 1,000 ppm to 2,000 ppm of the poly(sulfonyl azide), based on the total weight of the composition.

(27) 5. The propylene-based polymer composition of any one of clauses 1-4, wherein the propylene-based polymer resin has a crystallinity in the range of from 60% to 90%.

(28) 6. The propylene-based polymer composition of any one of clauses 1-5, wherein the propylene-based polymer resin has a crystallinity in the range of from 70% to 80%.

(29) 7. The propylene-based polymer composition of any one of clauses 1-6, wherein the composition has a melt strength at 190 C. in the range of from 25 cN to 100 cN.

(30) 8. The propylene-based polymer composition of any one of clauses 1-7, wherein the composition has a heat distortion temperature under a load of 66 psi that is greater than 101 C.

(31) 9. The propylene-based polymer composition of any one of clauses 1-8, wherein the composition has a melting temperature in the range of from 160 C. to 170 C.

(32) 10. The propylene-based polymer composition of any one of clauses 1-9, wherein the composition has a ratio of melt strength to melt flow rate (MS/MFR) that is less than 10.

(33) 11. The propylene-based polymer composition of any one of clauses 1-9, wherein the composition has a ratio of melt strength to melt flow rate (MS/MFR) that is greater than 18.

(34) 12. The propylene-based polymer composition of any one of clauses 1-11, further comprising a first uncoupled polypropylene homopolymer resin.

(35) 13. The propylene-based polymer composition of clause 12, further comprising a second polyolefin resin, wherein the second polyolefin resin comprises a polypropylene homopolymer resin or a resin comprising a copolymer of ethylene and at least one C.sub.3-C.sub.12 -olefin comonomer.

(36) 14. The propylene-based polymer composition of clause 13, further comprising a third uncoupled polyolefin resin, wherein the third uncoupled polyolefin resin comprises a polypropylene homopolymer resin or a resin comprising a copolymer of ethylene and at least one C.sub.3-C.sub.17 -olefin comonomer.

(37) 15. The propylene-based polymer composition of clause 12, further comprising an additive.

(38) 16. The propylene-based polymer composition of clause 12, further comprising a mineral filler.

(39) 17. The propylene-based polymer composition of clause 12, wherein the composition exhibits an Izod impact resistance at room temperature, measured according to ASTM D256-10e1, of greater than or equal to 1.20 ft-lb/in.

(40) 18. The propylene-based polymer composition of clause 12, wherein the composition exhibits a melt strength at 190 C. of greater than or equal to 30 cN.

(41) 19. The propylene-based polymer composition of clause 12, wherein the composition exhibits a melt drawbility at 190 C. of greater than or equal to 145 mm/s.

(42) 20. The propylene-based polymer composition of clause 12, wherein the composition comprises 20-80% of the poly(sulfonyl azide)-coupled propylene-based polymer resin by total weight of the composition.

(43) 21. The propylene-based polymer composition of any one of clauses 1-12, further comprising an uncoupled copolymer resin comprising a copolymer of ethylene and propylene.

(44) 22. The propylene-based polymer composition of any one of clauses 1-12, further comprising a coupled copolymer resin comprising a copolymer of ethylene and propylene.

(45) 23. A propylene-based polymer composition comprising: 20-80% (by total weight of the composition) of a poly(sulfonyl azide)-coupled propylene-based polymer resin, the poly(sulfonyl azide)-coupled propylene-based polymer resin comprising: 90-99% (by total weight of the poly(sulfonyl azide)-coupled propylene-based polymer resin) of a homopolymer propylene resin having a crystallinity of at least 50%; 1-10% (by total weight of the poly(sulfonyl azide)-coupled propylene-based polymer resin) of a copolymer resin comprising a copolymer of ethylene and propylene; and 1000-2000 ppm (by total weight of the poly(sulfonyl azide)-coupled propylene-based polymer resin) of a poly(sulfonyl azide); and 20-80% (by total weight of the composition) of an uncoupled homopolymer propylene resin; wherein the propylene-based polymer composition has a melt strength at 190 C. of at least 20 cN, a melt drawability at 190 C. of at least 145 mm/s, an Izod impact resistance at room temperature (measured according to ASTM D256-10e1) of greater than or equal to 1.20 ft-lb/in, and a flexural modulus at room temperature of at least 240,000 psi.

(46) 24. The propylene-based polymer composition of clause 23, wherein the composition comprises 20-80% (by total weight of the composition) of the poly(sulfonyl azide)-coupled propylene-based polymer resin, and 20-80% (by total weight of the composition) of the uncoupled homopolymer propylene resin.

(47) 25. A sheet or film comprising the propylene-based polymer composition of any one of clauses 1-24.

(48) 26. A thermoformed sheet or film comprising the propylene-based polymer composition of any one of clauses 1-24.

(49) 27. A rigid packaging substrate comprising the propylene-based polymer composition of any one of clauses 1-24.

(50) 28. A method of producing a propylene-based polymer composition comprising: melting a propylene-based polymer resin having a crystallinity of at least 50%; and mixing, in a single extrusion step, the molten propylene-based polymer resin and a poly(sulfonyl azide); wherein the mixing produces a coupled propylene-based polymer composition having a melt strength at 190 C. of at least 20 cN, a melt drawability at 190 C. of at least 100 mm/s, and a flexural modulus at room temperature of at least 240,000 psi.

(51) 29. The method of clause 28, further comprising: solidifying the coupled propylene-based polymer composition; and pelletizing the coupled propylene-based polymer composition.

(52) 30. The method of clause 28 or clause 29, further comprising: melting the coupled propylene-based polymer composition; melting an uncoupled polypropylene homopolymer resin; and blending the molten coupled propylene-based polymer composition and the uncoupled molten polypropylene homopolymer resin.

(53) 31. The method of clause 28 or clause 29, further comprising: melting the coupled propylene-based polymer composition; melting an uncoupled copolymer resin comprising a copolymer of ethylene and at least one C.sub.3-C.sub.12 -olefin comonomer; and blending the molten coupled propylene-based polymer composition and the molten uncoupled copolymer resin.

(54) 33. The method of clause 31, wherein the uncoupled copolymer resin comprises a copolymer of ethylene and propylene.

(55) Various features and characteristics of the invention are described in this specification to provide an overall understanding of the production and properties of the disclosed compositions and products. It is understood that the various features and characteristics described in this specification can be combined in any suitable manner regardless of whether such features and characteristics are expressly described or illustrated in combination in this specification. The Applicant expressly intends such combinations of features and characteristics to be included within the scope of this specification. As such, the claims can be amended to recite, in any combination, any features and characteristics expressly or inherently described in, or otherwise expressly or inherently supported by, this specification. Furthermore, the Applicant reserves the right to amend the claims to affirmatively disclaim features and characteristics that may be present in the prior art, even if those features and characteristics are not expressly described in this specification. Therefore, any such amendments will not add new matter to the specification or claims, and will comply with written description, sufficiency of description, and added matter requirements (e.g., 35 U.S.C. 112(a) and Article 123(2) EPC). The compositions and products described in this specification can comprise, consist of, or consist essentially of the various features and characteristics described in this specification.

(56) Also, any numerical range recited in this specification describes all sub-ranges of the same numerical precision (i.e., having the same number of specified digits) subsumed within the recited range. For example, a recited range of 1.0 to 10.0 describes all sub-ranges between (and including) the recited minimum value of 1.0 and the recited maximum value of 10.0, such as, for example, 2.4 to 7.6, even if the range of 2.4 to 7.6 is not expressly recited in the text of the specification. Accordingly, the Applicant reserves the right to amend this specification, including the claims, to expressly recite any sub-range of the same numerical precision subsumed within the ranges expressly recited in this specification. All such ranges are inherently described in this specification such that amending to expressly recite any such sub-ranges will not add new matter to the specification or claims, and will comply with written description, sufficiency of description, and added matter requirements (e.g., 35 U.S.C. 112(a) and Article 123(2) EPC). Additionally, numerical parameters described in this specification should be construed in light of the number of reported significant digits, the numerical precision of the number, and by applying ordinary rounding techniques. It is also understood that numerical parameters described in this specification will necessarily possess the inherent variability characteristic of the underlying measurement techniques used to determine the numerical value of the parameter.

(57) The grammatical articles one, a, an, and the, as used in this specification, are intended to include at least one or one or more, unless otherwise indicated. Thus, the articles are used in this specification to refer to one or more than one (i.e., to at least one) of the grammatical objects of the article. By way of example, a component means one or more components, and thus, possibly, more than one component is contemplated and can be employed or used in an implementation of the described compositions and products. Further, the use of a singular noun includes the plural, and the use of a plural noun includes the singular, unless the context of the usage requires otherwise.

(58) Any patent, publication, or other disclosure material identified in this specification is incorporated by reference into this specification in its entirety unless otherwise indicated, but only to the extent that the incorporated material does not conflict with existing descriptions, definitions, statements, or other disclosure material expressly set forth in this specification. As such, and to the extent necessary, the express disclosure as set forth in this specification supersedes any conflicting material incorporated by reference. Any material, or portion thereof, that is incorporated by reference into this specification, but which conflicts with existing definitions, statements, or other disclosure material set forth herein, is only incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material. Applicant reserves the right to amend this specification to expressly recite any subject matter, or portion thereof, incorporated by reference.