Blow molded article with good mechanical and optical properties
09587097 ยท 2017-03-07
Assignee
Inventors
Cpc classification
C08F4/65927
CHEMISTRY; METALLURGY
C08F2/001
CHEMISTRY; METALLURGY
C08F210/16
CHEMISTRY; METALLURGY
C08F210/16
CHEMISTRY; METALLURGY
B29C49/0005
PERFORMING OPERATIONS; TRANSPORTING
B29C49/04114
PERFORMING OPERATIONS; TRANSPORTING
C08L23/142
CHEMISTRY; METALLURGY
C08F2/001
CHEMISTRY; METALLURGY
C08F4/65927
CHEMISTRY; METALLURGY
C08L2205/025
CHEMISTRY; METALLURGY
C08F210/14
CHEMISTRY; METALLURGY
C08L23/142
CHEMISTRY; METALLURGY
C08F210/14
CHEMISTRY; METALLURGY
B29K2105/0094
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
Blow molded article comprising a propylene copolymer having a MFR.sub.2 (230 C.) in the range of more than 2.0 to 12.0 g/10 min, a comonomer content in the range of 4.0 to below 4.0 mol.-%, a melting temperature in the range of 125 to below 143 C., and a xylene cold soluble fraction (XCS) in the range of above 15.0 to 40.0 wt.-%.
Claims
1. Blow molded article comprising at least 75.0 wt. % based on the total weight of the blow molded article, of a propylene copolymer (R-PP), wherein the blow molded article and/or the propylene copolymer (R-PP) has/have: (a) a melt flow rate MFR.sub.2 (230 C.) measured according to ISO 1133 in the range of more than 2.0 to 12.0 g/10 min, (b) a comonomer content in the range of 4.0 to below 14.0 mol. %, (c) a melting temperature in the range of 125 to below 143 C., and (d) a xylene cold soluble fraction (XCS) in the range of above 15.0 to 40.0 wt. %.
2. Blow molded article according to claim 1, wherein the comonomer of the propylene copolymer (R-PP) is selected from ethylene, C.sub.4 to C.sub.12 -olefin, and mixtures thereof.
3. Blow molded article according to claim 1, wherein said propylene copolymer (R-PP) has: (a) a glass transition temperature in the range of 12 C. to +2 C.; and/or (b) no glass transition temperature below 20 C.
4. Blow molded article according to claim 1, wherein said propylene copolymer (R-PP) has: (a) a molecular weight distribution (Mw/Mn) of at least 2.7; and/or (b) a polydispersity index (PI) of at least 2.3.
5. Blow molded article according claim 1, wherein said propylene copolymer (R-PP): (a) has 2,1 regio-defects of at least 0.2% determined by .sup.13C-NMR spectroscopy; and/or (b) is monophasic.
6. Blow molded article according to claim 1, wherein the blow molded article comprises said propylene copolymer (R-PP) in an amount of at least 80.0 wt. %, based on the total weight of the blow molded article.
7. Blow molded article according to claim 1, wherein the blow molded article has a bottle appearance factor (BAF) before sterilization of in-equation (I):
BAF>180(I), wherein: BAF is defined as:
8. Blow molded article according to claim 1, wherein said propylene copolymer (R-PP) comprises two fractions, a first propylene copolymer fraction (R-PP1) and a second propylene copolymer fraction (R-PP2), said first propylene copolymer fraction (R-PP1) differs from said second propylene copolymer fraction (R-PP2) in the melt flow rate MFR.sub.2 (230 C.) and/or in the comonomer content.
9. Blow molded article according to claim 8, wherein (a) the weight ratio between the first propylene copolymer fraction (R-PP1) and the second propylene copolymer fraction (R-PP2) [(R-PP1):(R-PP2)] is 70:30 to 30:70; and/or (b) the comonomers for the first propylene copolymer fraction (R-PP1) and the second propylene copolymer fraction (R-PP2) are selected from ethylene, C.sub.4 to C.sub.12 -olefin, and mixtures thereof.
10. Blow molded article according to claim 8, wherein: (a) the first propylene copolymer fraction (R-PP1) is the comonomer lean fraction and the second propylene copolymer fraction (R-PP2) is the comonomer rich fraction; and/or, (b) the first propylene copolymer fraction (R-PP1) has a lower melt flow rate MFR.sub.2 (230 C.) than the second propylene copolymer fraction (R-PP2).
11. Blow molded article according to claims 8, wherein: (a) the first propylene copolymer fraction (R-PP1) has a lower comonomer content than the propylene copolymer (R-PP); and/or, (b) the first propylene copolymer fraction (R-PP1) has a lower melt flow rate MFR.sub.2 (230 C.) than the propylene copolymer (R-PP).
12. Blow molded article according to claim 8, wherein (a) the first propylene copolymer fraction (R-PP1) has a comonomer content in the range of 0.5 to 8.0 mol % based on the first propylene copolymer fraction (R-PP1); and/or, (b) the second propylene copolymer fraction (R-PP2) has a comonomer content in the range of more than 8.0 to 20.0 mol % based on the second propylene copolymer fraction (R-PP2).
13. Blow molded article according to claim 8, wherein: (a) the first propylene copolymer fraction (R-PP1) has a melt flow rate MFR.sub.2 (230 C.) in the range of 1.5 to 8.0 g/10 min; and/or, (b) the second propylene copolymer fraction (R-PP2) has a melt flow rate MFR.sub.2 (230 C.) in the range of more than 2.0 to 20.0 g/10 min.
14. Blow molded article according to claim 8, wherein: (a) the first random propylene copolymer fraction (R-PP1) and the second random propylene copolymer fraction (R-PP2) fulfill together the inequation (IV):
15. Blow molded article according to claim 8, wherein: (a) the first random propylene copolymer fraction (R-PP1) and the second random propylene copolymer fraction (R-PP2) fulfill together the inequation (III):
16. Blow molded article according to claim 1, wherein the blow molded article is an extrusion blow molded article.
17. Extrusion blow molded article according to claim 16, wherein the extrusion blow molded article is a bottle or a container.
Description
EXAMPLES
(1) A. Measuring Methods
(2) The following definitions of terms and determination methods apply for the above general description of the invention as well as to the below examples unless otherwise defined.
(3) Quantification of Microstructure by NMR Spectroscopy
(4) Quantitative nuclear-magnetic resonance (NMR) spectroscopy was used to quantify the comonomer content of the polymers.
(5) Quantitative .sup.13C {.sup.1H} NMR spectra were recorded in the solution-state using a Bruker Advance III 400 NMR spectrometer operating at 400.15 and 100.62 MHz for .sup.1H and .sup.13C respectively. All spectra were recorded using a .sup.13C optimised 10 mm extended temperature probehead at 125 C. using nitrogen gas for all pneumatics. Approximately 200 mg of material was dissolved in 3 ml of 1,2-tetrachloroethane-d.sub.2 (TCE-d.sub.2) along with chromium-(III)-acetylacetonate (Cr(acac).sub.3) resulting in a 65 mM solution of relaxation agent in solvent as described in G. Singh, A. Kothari, V. Gupta, Polymer Testing 2009, 28(5), 475.
(6) To ensure a homogenous solution, after initial sample preparation in a heat block, the NMR tube was further heated in a rotatory oven for at least 1 hour. Upon insertion into the magnet the tube was spun at 10 Hz. This setup was chosen primarily for the high resolution and quantitatively needed for accurate ethylene content quantification. Standard single-pulse excitation was employed without NOE, using an optimised tip angle, 1 s recycle delay and a bi-level WALTZ16 decoupling scheme as described in Z. Zhou, R. Kuemmerle, X. Qiu, D. Redwine, R. Cong, A. Taha, D. Baugh, B. Winniford, J. Mag. Reson. 187 (2007) 225 and V. Busico, P. Carbonniere, R. Cipullo, C. Pellecchia, J. Severn, G. Talarico, Macromol. Rapid Commun. 2007, 28, 1128. A total of 6144 (6k) transients were acquired per spectra. Quantitative .sup.13C {.sup.1H} NMR spectra were processed, integrated and relevant quantitative properties determined from the integrals. All chemical shifts were indirectly referenced to the central methylene group of the ethylene block (EEE) at 30.00 ppm using the chemical shift of the solvent. This approach allowed comparable referencing even when this structural unit was not present.
(7) With characteristic signals corresponding to 2,1 erythro regio defects observed (as described in L. Resconi, L. Cavallo, A. Fait, F. Piemontesi, Chem. Rev. 2000, 100 (4), 1253, in Cheng, H. N., Macromolecules 1984, 17, 1950, and in W-J. Wang and S. Zhu, Macromolecules 2000, 33 1157) the correction for the influence of the regio defects on determined properties was required. Characteristic signals corresponding to other types of regio defects were not observed.
(8) Characteristic signals corresponding to the incorporation of ethylene were observed (as described in Cheng, H. N., Macromolecules 1984, 17, 1950) and the comonomer fraction calculated as the fraction of ethylene in the polymer with respect to all monomer in the polymer.
(9) The comonomer fraction was quantified using the method of W-J. Wang and S. Zhu, Macromolecules 2000, 33 1157, through integration of multiple signals across the whole spectral region in the .sup.13C {.sup.1H} spectra. This method was chosen for its robust nature and ability to account for the presence of regio-defects when needed. Integral regions were slightly adjusted to increase applicability across the whole range of encountered comonomer contents.
(10) The mole percent comonomer incorporation was calculated from the mole fraction. The weight percent comonomer incorporation was calculated from the mole fraction. Calculation of comonomer content of the second propylene copolymer fraction (R-PP2):
(11)
wherein w(PP1) is the weight fraction [in wt.-%] of the first propylene copolymer fraction (R-PP1), w(PP2) is the weight fraction [in wt.-%] of second propylene copolymer fraction (R-PP2), C(PP1) is the comonomer content [in mol-%] of the first random propylene copolymer fraction (R-PP1), C(PP) is the comonomer content [in mol-%] of the random propylene copolymer (R-PP), C(PP2) is the calculated comonomer content [in mol-%] of the second random propylene copolymer fraction (R-PP2).
Melt Flow Rate (MFR)
(12) The melt flow rates are measured with a load of 2.16 kg (MFR.sub.2) at 230 C. The melt flow rate is that quantity of polymer in grams which the test apparatus standardised to ISO 1133 extrudes within 10 minutes at a temperature of 230 C. under a load of 2.16 kg.
(13) Calculation of melt flow rate MFR.sub.2 (230 C.) of the second propylene copolymer fraction (R-PP2):
(14)
wherein w(PP1) is the weight fraction [in wt.-%] of the first propylene copolymer fraction (R-PP1), w(PP2) is the weight fraction [in wt.-%] of second propylene copolymer fraction (R-PP2), MFR(PP1) is the melt flow rate MFR.sub.2 (230 C.) [in g/10 min] of the first propylene copolymer fraction (R-PP1), MFR(PP) is the melt flow rate MFR.sub.2 (230 C.) [in g/10 min] of the propylene copolymer (R-PP), MFR(PP2) is the calculated melt flow rate MFR.sub.2 (230 C.) [in g/10 min] of the second propylene copolymer fraction (R-PP2).
(15) The xylene solubles (XCS, wt.-%): Content of xylene cold solubles (XCS) is determined at 25 C. according ISO 16152; first edition; 2005-07-01
(16) Calculation of the xylene cold soluble (XCS) content of the second propylene copolymer fraction (R-PP2):
(17)
wherein w(PP1) is the weight fraction [in wt.-%] of the first propylene copolymer fraction (R-PP1), w(PP2) is the weight fraction [in wt.-%] of the second propylene copolymer fraction (R-PP2), XS(PP1) is the xylene cold soluble (XCS) content [in wt.-%] of the first propylene copolymer fraction (R-PP1), XS(PP) is the xylene cold soluble (XCS) content [in wt.-%] of the propylene copolymer (R-PP), XS(PP2) is the calculated xylene cold soluble (XCS) content [in wt.-%] of the second propylene copolymer fraction (R-PP2).
Hexane Solubles
FDA section 177.1520
(18) 1 g of a polymer film of 100 m thickness is added to 400 ml hexane at 50 C. for 2 hours while stirring with a reflux cooler.
(19) After 2 hours the mixture is immediately filtered on a filter paper No 41.
(20) The precipitate is collected in an aluminium recipient and the residual hexane is evaporated on a steam bath under N.sub.2 flow.
(21) The amount of hexane solubles is determined by the formula
((wt. sample+wt. crucible)(wt. crucible))/(wt. sample).Math.100.
(22) Melting temperature (T.sub.m) and heat of fusion (H.sub.f), crystallization temperature (T.sub.c) and heat of crystallization (H.sub.e): measured with Mettler TA820 differential scanning calorimetry (DSC) on 5 to 10 mg samples. DSC is run according to ISO 3146/part 3/method C2 in a heat/cool/heat cycle with a scan rate of 10 C./min in the temperature range of +23 to +210 C. Crystallization temperature and heat of crystallization (H.sub.e) are determined from the cooling step, while melting temperature and heat of fusion (H.sub.f) are determined from the second heating step
(23) The glass transition temperature Tg is determined by dynamic mechanical analysis according to ISO 6721-7. The measurements are done in torsion mode on compression moulded samples (40101 mm.sup.3) between 100 C. and +150 C. with a heating rate of 2 C./min and a frequency of 1 Hz.
(24) Number average molecular weight (M.sub.n), weight average molecular weight (M.sub.w) and polydispersity (Mw/Mn)
(25) are determined by Gel Permeation Chromatography (GPC) according to the following method:
(26) The weight average molecular weight Mw and the polydispersity (Mw/Mn), wherein Mn is the number average molecular weight and Mw is the weight average molecular weight) is measured by a method based on ISO 16014-1:2003 and ISO 16014-4:2003. A Waters Alliance GPCV 2000 instrument, equipped with refractive index detector and online viscosimeter was used with 3TSK-gel columns (GMHXL-HT) from TosoHaas and 1,2,4-trichlorobenzene (TCB, stabilized with 200 mg/L 2,6-Di tert butyl-4-methyl-phenol) as solvent at 145 C. and at a constant flow rate of 1 mL/min. 216.5 L of sample solution were injected per analysis. The column set was calibrated using relative calibration with 19 narrow MWD polystyrene (PS) standards in the range of 0.5 kg/mol to 11 500 kg/mol and a set of well characterized broad polypropylene standards. All samples were prepared by dissolving 5-10 mg of polymer in 10 mL (at 160 C.) of stabilized TCB (same as mobile phase) and keeping for 3 hours with continuous shaking prior sampling in into the GPC instrument.
(27) Rheology: Dynamic rheological measurements were carried out with Rheometrics RDA-II QC on compression moulded samples under nitrogen atmosphere at 200 C. using 25 mmdiameter plate and plate geometry. The oscillatory shear experiments were done within the linear viscoelastic range of strain at frequencies from 0.01 to 500 rad/s. (ISO 6721-10)
(28) The values of storage modulus (G), loss modulus (G), complex modulus (G*) and complex viscosity (*) were obtained as a function of frequency ().
(29) The Zero shear viscosity (.sub.0) was calculated using complex fluidity defined as the reciprocal of complex viscosity. Its real and imaginary part are thus defined by
f()=()/[().sup.2+().sup.2] and
f()=()/[().sup.2+().sup.2]
(30) From the following equations
=G/ and =G/
f()=G().Math./[G().sup.2+G().sup.2]
f()=G().Math./[G().sup.2+G().sup.2]
(31) The polydispersity index, PI,
(32) PI=10.sup.5/G.sub.c, is calculated from the cross-over point of G() and G(), for which G(.sub.c)=G(.sub.c)=G.sub.c holds.
(33) Porosity (of the catalyst): BET with N.sub.2 gas, ASTM 4641, apparatus Micromeritics Tristar 3000;
(34) sample preparation: at a temperature of 50 C., 6 hours in vacuum.
(35) Surface area (of the catalyst): BET with N.sub.2 gas ASTM D 3663, apparatus Micromeritics Tristar 3000: sample preparation at a temperature of 50 C., 6 hours in vacuum.
(36) Flexural Modulus: The flexural modulus was determined in 3-point-bending at 23 C. according to ISO 178 on 80104 mm.sup.3 test bars injection moulded in line with EN ISO 1873-2
(37) Description/Dimension and Production of the Bottles:
(38) 1 l bottles, having an outer diameter of 90 mm, a wall thickness of 0.3 or 0.6 mm, an overall-height of 204 mm and a height of the cylindrical mantle of 185 mm were produced by extrusion blow molding on a B&W machine with a single screw extruder using a melt temperature of 210 C. and a mold temperature of 15 C., if not otherwise indicated.
(39) Transparency, Clarity, and Haze Measurement on Bottles:
(40) Instrument: Haze-gard plus from BYK-Gardner Testing: according to ASTM D1003 (as for injection molded plates) Method: The measurement is done on the outer wall of the bottles. The top and bottom of the bottles are cut off. The resulting round wall is then split in two, horizontally. Then from this wall six equal samples of app. 6060 mm are cut from close to the middle. The specimens are placed into the instrument with their convex side facing the haze port. Then the transparency, haze and clarity are measured for each of the six samples and the haze value is reported as the average of these six parallels.
Gloss Measurement on Bottles: Instrument: Screen TRI-MICROGLOSS 20-60-80 from BYK-Gardner 20 Testing: ASTM D 2457 (as for injection molded plates) The bottles: It is measured on the wall of the bottles. The top and bottom of the bottles is cut off. This round wall is then split in two, horizontally. Then this wall is cut into six equal 25 samples of app. 9090 mm, just to fit into a special light trap made for testing on injection molded parts. Then the gloss at 20 is measured on these six samples, and the average value is reported as gloss at 20.
Drop Test on Bottles
(41) The drop test is performed on the extrusion blow molded 1 l bottles as described before according to ASTM D2463-10b, procedure B The bottles are filled up to their shoulder with water.
(42) During a pre-test the estimated falling height is determined on 10 bottles.
(43) The final test is to be performed on 20 bottles, starting at the pre-determined falling height.
(44) For each run 2 bottles are dropped.
(45) Depending on 2 breaks or 1 break/1 no-break (=neutral) or 2 no-breaks, the next dropping height is chosen to be lower/same/higher for the next round.
(46) The increase or decrease in height is 0.25 m, only at dropping heights <1.5 m the increase or decrease is 0.1 m.
(47) The final drop height is determined depending on the falling heights of the containers after the first change in trend or after the first neutral result according following formula:
he=(ni.Math.hi)/ng
wherein he=50% drop height hi=drop height ni=number of containers dropped at the respective height ng=total number of dropped containers
B. Examples
(48) The catalyst used for inventive example IE1 is described in example 10 of WO 2010/052263 A1. The catalyst used in the polymerization process for comparative example CE1 is described in example 1 of EP 1 741 725 A1.
(49) TABLE-US-00001 TABLE 1 Preparation of the example IE1 and CE1 IE1 CE1 Catalyst Temperature ( C.) 20 20.8 Residence time (h) 0.33 0.31 Loop Temperature ( C.) 70 65 H2/C3 ratio [mol/kmol] 0.1 0.01 C6/C3 ratio [mol/kmol] 9.1 C2/C3 ratio [mol/kmol] 10.6 MFR.sub.2 [g/10 min] 4.5 0.7 C6 [mol-%] 0.7 C2 [mol-%] 2.2 XCS [wt.-%] 1.4 2.5 GPR Temperature ( C.) 75 85 H2/C3 ratio [mol/kmol] 0.3 0.5 C6/C3 ratio [mol/kmol] 0.4 C2/C3 ratio [mol/kmol] 282 MFR.sub.2 of copo B [g/10 min] 5.8 5.8 C6 of copo B [mol-%] 2.6 C2 of copo B [mol-%] 12.8 XCS of copo B [wt.-%] 51 1.1 Split Loop/GPR [%] 51/49 46/54 Loop defines the first propylene copolymer fraction (R-PP1) GPR defines the second propylene copolymer fraction (R-PP2)
(50) CE2 is the commercial grade LE6609-PH available from Borealis AG, Austria and is a low density polyethylene having a density of 930 kg/m.sup.3 and a MFR.sub.2 (190 C./2.16 kg) of 0.3 g/10 min.
(51) CE3 is the commercial grade Purell SM170G available from LyondellBasell Industries Holdings B.V. and is a SSC propylene-ethylene random copolymer having a density of 900 kg/m.sup.3 and a MFR.sub.2 (230 C.) of 1.5 g/10 min.
(52) CE4 is the commercial grade RB801CF-01 available from Borealis AG, Austria and is a ZN propylene-ethylene random copolymer having a melting temperature of 140 C. and a MFR.sub.2 (230 C.) of 1.9 g/10 min.
(53) CE5 is the commercial grade RB206MO available from Borealis AG, Austria and is a ZN propylene-ethylene random copolymer having a melting temperature of 148 C. and a MFR.sub.2 (230 C.) of 1.9 g/10 min.
(54) TABLE-US-00002 TABLE 2 Properties of the example IE1 and the comperative examples CE1 to CE5 IE1 CE1 CE2 CE3 CE4 CE5 Nucleation [] No no no no no No Comonomer [mol-%] 7.4 1.7 7.0 7.0 4.4 content Comonomer [] (C2) (C6) (C2) (C2) (C2) type MFR.sub.2 [g/10 5.1 2.2 0.3** 1.5 1.9 1.9 min] C6 solubles [wt.-%] 3.7 1.5 <5 0.8 1.5 XCS [wt.-%] 26 1.7 Mw kg/mol 216 265 MWD [] 2.9 2.8 Tm [ C.] 136.2 137.3 140 148 Tc [ C.] 100.6 95.6 Tg [ C.] 7 2,1 [%] 0.6 0.6 Tensile [MPa] 557 774* 420 605 791 1150 modulus *Flexural modulus **MFR.sub.2 measured at 190 C.
(55) The examples IE1 and CE1 to CE5 were used in an EBM process.
(56) Table 3 shows the EBM bottle production data and the performance of the produced bottles.
(57) TABLE-US-00003 TABLE 3 EBM bottle production data and properties IE 1 CE1 CE2 CE4 CE5 EBM bottle [mm] 0.6 0.6 0.6 0.6 0.6 wall thickness Melt [ C.] 177 178 198 197 197 temperature Screw speed [1/min] 15.6 15.0 16.0 13.2 15.8 Die pressure [bar] 60 81 73 72 73 Drop height [m] 2.53 4.55 5.50 3.48 1.11 Gloss [%] 21 17 na na 19.7 Clarity [%] 71 67 89 67 79.2 Haze [%] 25 36 34 47 26 BAF [] 58 31 na na 60 EBM bottle [mm] 0.3 0.3 0.3 0.3 0.3 wall thickness Melt [ C.] 176 177 196 196 197 temperature Screw speed [1/min] 9.9 10.7 11.1 9.9 10.0 Die pressure [bar] 66 83 91 71 83 Gloss [%] 59.0 33.7 30.3 32.5 18.5 Clarity [%] 89.5 77.8 88.9 89.2 73.3 Haze [%] 14.5 21.7 23.7 17.9 17.6 BAF [] 364 121 114 162 77 BAF Bottle Appearance Factor (BAF = Gloss * Clarity/Haze)