Polypropylene peroxide master batch

Abstract

Polymer blends, and methods of making and using the polymer blends are disclosed. The polymer blend includes 75 to 99 wt% of a first polypropylene composition comprising polypropylene and having a melt flow rate (MFR) of A g / 10 minutes as measured by ASTM D1238 (230 DEG C / 2.16 kg), and 1 to 25 wt% of a second polypropylene composition as measured by ASTM D1238 (230 DEG C / 2.16 kg). Wherein the first polypropylene composition has been pre-extruded prior to forming the blend, and the second polypropylene composition comprises polypropylene and an organic peroxide, and has an MFR of B g / 10 minutes, measured by ASTM D1238 (230 DEG C / 2.16 kg), and wherein the second polypropylene composition has been pre-extruded prior to forming the blend, measured by ASTM D1238 (230 DEG C / 2.16 kg), and measured by ASTM D1238 (230 DEG C / 2.16 kg). Wherein the MFR of the polymer blend is C g / 10 minutes, measured by ASTM D1238 (230 DEG C / 2.16 kg), and wherein C is greater than A.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 412,105, filed on September 30, 2022, which is incorporated herein by reference in its entirety. Background of the Invention A. Technical field

[0004] The present invention generally relates to polyolefin blends (e.g., polypropylene blends). In some aspects, the melt flow rate of a pre-extruded polyolefin composition (e.g., a first polypropylene composition) can be changed (e.g., reduced) by blending the pre-extruded polyolefin composition with another pre-extruded polyolefin composition (e.g., a second polypropylene composition) comprising an organic peroxide. In some aspects, the second pre-extruded polyolefin composition having an organic peroxide can be used as an organic peroxide masterbatch melt flow rate modifier for the first polyolefin composition. B. Background Technology

[0005] Polyolefins, such as propylene polymers, are widely used in today's society (e.g., agriculture, construction, fibers, spun-bound nonwovens, healthcare, packaging, and other industries). Typical propylene polymers include: polypropylene homopolymers, random and heterophasic polypropylene copolymers, impact copolymers, or combinations thereof.

[0006] Polypropylene is usually manufactured in large-scale reactors. Depending on the intended application, a given polypropylene is manufactured into different grades, depending on the desired process conditions. For example, polypropylene with a relatively low melt flow rate usually has a high average molecular weight and a wide molecular weight distribution. When manufacturing fibers, or when using an injection molding process, this low melt flow rate polypropylene may be difficult to handle. In order to overcome these processing limitations, polypropylene can be manufactured into a relatively high melt flow rate, wherein compared with a low melt flow rate polymer, the polymer average molecular weight is relatively low and the molecular weight distribution is narrower.

[0007] Typically, peroxides (e.g., peroxide masterbatches) are used as additives to change the melt flow rate of a polypropylene composition. Peroxides can act as visbreaking agents and can reduce viscosity; thereby increasing the melt flow rate of a given polypropylene composition or its blend. This typically occurs through polymer chain scission. Specifically, peroxides can act as free radical initiators, which can cause polypropylene chain scission. Peroxides used as visbreaking agents can be in both liquid and solid forms, both of which are typically added during the extrusion process to change the melt flow rate of a given polymer composition.

[0008] It is generally believed that processing conditions and / or chemical reactions during the extrusion process decompose the peroxide to the extent that it cannot keep the visbreaking agent active, and / or cannot be used again. This is problematic because peroxides can be expensive. Further, it may be difficult to store and handle peroxides, especially liquid-based peroxides. Even further, there is a continuing need for peroxide-based chemicals, whether in liquid or solid form, resulting in more chemicals being present in today's society. Summary of the invention

[0009] The present invention has made discovery, provides one or more schemes for the above-mentioned problem relevant to the melt flow rate of the polypropylene composition (for example the first extruded polypropylene composition) that changes and has been extruded.In one aspect, find: the pre-extruded polypropylene composition (for example the second extruded polypropylene composition) with peroxide can be used as the melt flow rate modifier of the first polypropylene composition by itself.Specifically, in one aspect, the second extruded polypropylene composition with the peroxide can be used as a peroxide masterbatch, so as to reduce the melt flow rate of the first extruded polypropylene composition.It is not expected to be subject to theory, it is believed that, although the second composition has been subjected to common extrusion conditions in advance, at least a portion from the peroxide of the second extruded polypropylene composition remains active (for example, can serve as a visbreaking agent). This may be advantageous for one or more of the following reasons: (1) a pellet to pellet polypropylene blend may be used without the need for an additional peroxide masterbatch formulation; (2) the peroxide in the second extruded polypropylene composition has been previously used to modify the melt flow rate of the second composition and may be reused / recycled as a melt flow rate modifier for the first composition - the peroxide is used more than once as a melt flow rate modifier, reducing the need to purchase or manufacture additional peroxide, which may be beneficial from a cost and / or social perspective by limiting the need to produce additional peroxide; and / or (3) given the presence of the extruded polypropylene, the second extruded polypropylene composition may be safely used as a peroxide masterbatch for the first composition (e.g., because of the similarities between the first and second pre-extruded compositions, the melt flow rate of the first composition may be modified as desired while other properties of the first composition may be maintained).

[0010] In one aspect of the present invention, the following polymer blend is disclosed, the polymer blend includes 75 wt% to 99 wt% of a first polypropylene composition, the first polypropylene composition including polypropylene. The melt flow rate (MFR) of the first composition may be A g / 10 minutes, which is measured by ASTM D1238 (230°C / 2.16kg). In some aspects, the first polypropylene composition has been pre-extruded before forming the blend. In other aspects, the first polypropylene composition is not pre-extruded before forming the blend. In one aspect, the first polypropylene composition includes an organic peroxide compound before forming the blend. In another aspect, the first polypropylene composition does not include an organic peroxide compound before forming the blend. The blend may also include 1 wt% to 25 wt% of a second polypropylene composition, the second polypropylene composition including polypropylene and an organic peroxide. The MFR of the second composition may be B g / 10 minutes, which is measured by ASTM D1238 (230°C / 2.16kg). In some aspects, the second polypropylene composition has been pre-extruded before forming the blend. The MFR value of the blend of the first and second compositions may be C g / 10 minutes, which is measured by ASTM D1238 (230°C / 2.16kg). In certain aspects, C is greater than A. In some aspects, the polymer blend does not include any other organic peroxide than the organic peroxide present in the second polypropylene composition. The second polypropylene composition may serve as a peroxide masterbatch, such that C is greater than A. In a preferred aspect, the second polypropylene composition may satisfy any one, any combination, or all of the following: a density specific gravity of 0.89 g / cc to 0.92 g / cc, preferably about 0.905 g / cc, measured according to ASTM D1505; a melting point of 145° C. to 175° C., preferably about 165° C., measured using differential scanning calorimetry (DSC); and / or an MFR value of 500 to 2000 g / 10 min, preferably 1250 to 1350 g / 10 min, or more preferably about 1300 g / 10 min, measured by ASTM D1238 (230° C. / 2.16 kg). The second polypropylene composition may also include other additives commonly used in polypropylene resins (e.g., antioxidants, neutralizers, etc.) - the reason for which is based on the discovery that a pre-extruded polypropylene composition including a peroxide masterbatch (e.g., a liquid masterbatch) can itself act as a peroxide masterbatch. In this case, the second polymer composition may be extruded and in the form of a solid / non-liquid peroxide masterbatch capable of modifying (eg increasing) the MFR of the further polymer composition.Still further, both the first and second polypropylene compositions can be made from various catalysts (e.g., Zeigler-Natta or metallocene catalysts, with Zeigler-Natta catalysts being preferred). In some aspects, the polypropylene in the first and / or second polypropylene composition can be a polypropylene homopolymer, a random copolymer, or an impact copolymer, or any combination thereof. In some aspects, the second polypropylene composition can include at least 99 wt % of the polypropylene, and less than 1 wt % of the organic peroxide, based on the total weight of the second polypropylene composition. In some specific aspects, the organic peroxide is 3,6,9-triethyl-3,6,9-trimethyl-1,4,7-triperoxonane. However, it is contemplated that other peroxides may be used, such as those used with polypropylene compositions (e.g., 2,5-dimethyl-2,5-di(tert-butylperoxy)hexane, 3,6,9-triethyl-3,6,9-trimethyl-1,4,7-triperoxynonane, or (1,2,4,5,7,8-hexaoxonane, 3,6,9-trimethyl-3,6,9-tri(ethyl and propyl) derivatives, or any combination thereof. In certain aspects, A in the first composition may be from 0.5 g / 10 min to 150 g / 10 min, or any range or value therein (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, 146, 147, 148, 149, etc.). In some aspects, the first polymer composition may include at least 80 wt% polypropylene, preferably at least 90 to 95 wt% polypropylene, based on the total weight of the first composition. In some aspects, the polypropylene in the first polypropylene composition may be a polypropylene homopolymer.

[0011] In a specific aspect, the polymer blend of the present invention may include 94 wt% to 96 wt% of the first polypropylene composition and 4 wt% to 6 wt% of the second polypropylene composition, based on the total weight of the blend, and wherein the ratio of C:A is 2 to 3. In certain aspects, A may be 3 to 5 g / 10 minutes, and C may be 8 to 12 g / 10 minutes. In another aspect, the polymer blend may include 89 wt% to 91 wt% of the first polypropylene composition and 9 wt% to 11 wt% of the second polypropylene composition, based on the total weight of the blend, and wherein the ratio of C to A is 4 to 5. In certain aspects, A may be 3 to 5 g / 10 minutes, and C may be 16 to 20 g / 10 minutes. In one aspect, the first polypropylene composition may meet any one, any combination, or all of the following: a density specific gravity of 0.89 g / cc to 0.92 g / cc, preferably about 0.905 g / cc, measured according to ASTM D1505; a melting point of 160° C. to 170° C., preferably about 165° C., measured using differential scanning calorimetry (DSC); and an MFR of 3 to 5 g / 10 min, preferably about 4.1 g / 10 min, measured by ASTM D1238 (230° C. / 2.16 kg).

[0012] In another aspect, the polymer blends of the present invention may meet any one, any combination, or all of the following: a density specific gravity of 0.89 g / cc to 0.92 g / cc, preferably about 0.905 g / cc, as measured according to ASTM D1505; a melting point of 145° C. to 160° C., preferably about 152° C., as measured using differential scanning calorimetry (DSC); and a MFR of 10 to 20 g / 10 minutes, preferably about 14 g / 10 minutes, as measured by ASTM D1238 (230° C. / 2.16 kg).

[0013] In yet another aspect, the first polypropylene composition may satisfy any one, any combination, or all of the following: a density specific gravity of 0.89 g / cc to 0.92 g / cc, preferably about 0.90 g / cc, measured according to ASTM D1505; a melting point of 145°C to 160°C, preferably about 151°C, measured using differential scanning calorimetry (DSC); and a MFR of 20 to 30 g / 10 min, preferably about 24.7 g / 10 min, measured by ASTM D1238 (230°C / 2.16 kg).

[0014] In yet another aspect, the first polypropylene composition may meet any one, any combination, or all of the following: a density specific gravity of 0.89 g / cc to 0.92 g / cc, preferably about 0.905 g / cc, measured according to ASTM D1505; a melting point of 160° C. to 170° C., preferably about 165° C., measured using differential scanning calorimetry (DSC); and a MFR of 25 to 35 g / 10 min, preferably about 30 g / 10 min, measured by ASTM D1238 (230° C. / 2.16 kg).

[0015] In another aspect, the first polypropylene composition may satisfy any one, any combination, or all of the following: a density specific gravity of 0.89 g / cc to 0.92 g / cc, preferably about 0.905 g / cc, as measured according to ASTM D1505; a melting point of 160° C. to 170° C., preferably about 165° C., as measured using differential scanning calorimetry (DSC); and a MFR of 90 to 110 g / 10 min, preferably about 100 g / 10 min, as measured by ASTM D1238 (230° C. / 2.16 kg).

[0016] In some aspects, the polymer blend is in the form of a fiber and / or nonwoven material, or can be formed into a fiber and / or nonwoven material. In some cases, a plurality of the fibers are included in a fully oriented yarn (FOY), wherein the FOY has a denier of 300 and 400 at a 2:1 draft ratio, a maximum tenacity of 2 to 3, and a maximum elongation of 150 to 250. In some cases, a plurality of the fibers are included in a partially oriented yarn (POY), wherein the POY has a denier of 100 to 150 at a spinning rate of 4000 m / min, a maximum tenacity of 1.85 to 2.50, and a maximum elongation of 150 to 200.

[0017] The present invention also discloses a manufactured article comprising the polymer blend of the present invention. Non-limiting examples of manufactured articles include: extruded, blow molded, injection molded, rotationally molded, compression molded, 3-D printed, or thermoformed compositions or fibers.

[0018] Also disclosed is a method for making a fiber, the fiber comprising any one of the polymer blends described in the present invention. The method may include: blending the second polypropylene composition with the first polypropylene composition to form a polymer blend; and forming a fiber from the polymer blend. In some aspects, forming the fiber may include: melting the polymer blend at a melting temperature of 250°C or less to form a molten composition, extruding the molten composition through a spinneret to form extruded fiber filaments, and drawing the extruded fiber filaments. In some aspects, the molten composition is extruded through the spinneret at a speed of 1500 meters per minute to 4500 meters per minute. In some aspects, the drawing ratio of the drawing process is 1.5:1 to 4.5:1.

[0019] In another aspect of the present invention, the melt flow rate (MFR) of the first polypropylene composition comprising polypropylene is increased. The method may include: blending the first polypropylene polymer composition with a second polypropylene composition comprising polypropylene and an organic peroxide to form a polymer blend. In the polymer blend, the second polypropylene composition has been pre-extruded before forming the blend, and the MFR of the polymer blend is greater than the first polypropylene composition. In some aspects, the polymer blend does not include any other organic peroxides different from the organic peroxide present in the second polypropylene composition. In some cases, the second polypropylene composition has a density specific gravity of 0.89 g / cc to 0.92 g / cc, preferably about 0.905 g / cc, measured according to ASTM D1505, a melting point of 145° C. to 170° C., preferably about 165° C., measured using differential scanning calorimetry (DSC), and an MFR of 500 to 2000 g / 10 min, preferably 1250 to 1350 g / 10 min, or even more preferably about 1300 g / 10 min, measured by ASTM D1238 (230° C. / 2.16 kg). In some aspects, the polypropylene in the second polypropylene composition is a polypropylene homopolymer.

[0020] In the present invention, aspects 1 to 31 are also disclosed. Aspect 1 is a polymer blend comprising: 75 wt% to 99 wt% of a first polypropylene composition and 1 wt% to 25 wt% of a second polypropylene composition, wherein the first polypropylene composition comprises polypropylene and has a melt flow rate (MFR) of A g / 10 min as measured by ASTM D1238 (230°C / 2.16 kg), wherein the first polypropylene composition has been pre-extruded before forming the blend; and the second polypropylene composition comprises polypropylene and an organic peroxide and has an MFR of B g / 10 min as measured by ASTM D1238 (230°C / 2.16 kg), wherein the second polypropylene composition has been pre-extruded before forming the blend, wherein the MFR of the polymer blend is C g / 10 min as measured by ASTM D1238 (230°C / 2.16 kg), and wherein C is greater than A. Aspect 2 is a polymer blend as described in aspect 1, wherein the polymer blend does not include any other organic peroxide than the organic peroxide present in the second polypropylene composition. Aspect 3 is a polymer blend as described in any one of aspects 1 to 2, wherein the second polypropylene composition has a density specific gravity of 0.89 g / cc to 0.92 g / cc, preferably about 0.905 g / cc, as measured according to ASTM D1505; a melting point of 145° C. to 175° C., preferably about 165° C., as measured using differential scanning calorimetry (DSC); and an MFR B of 500 to 2000 g / 10 minutes, preferably 1250 to 1350 g / 10 minutes, or more preferably about 1300 g / 10 minutes, as measured by ASTM D1238 (230° C. / 2.16 kg). Aspect 4 is a polymer blend as described in any one of aspects 1 to 3, wherein the polypropylene in the second polypropylene composition is a polypropylene homopolymer, a random copolymer, or an impact copolymer, or any combination thereof. Aspect 5 is a polymer blend as described in any one of aspects 1 to 4, wherein the second polypropylene composition comprises at least 99 wt% of the polypropylene and less than 1 wt% of the organic peroxide, based on the total weight of the second polypropylene composition. Aspect 6 is a polymer blend as described in any one of aspects 1 to 5, wherein the organic peroxide is 3,6,9-triethyl-3,6,9-trimethyl-1,4,7-triperoxynonane. Aspect 7 is a polymer blend as described in any one of aspects 1 to 6, wherein the MFR A is from 0.5 g / 10 min to 150 g / 10 min. Aspect 8 is a polymer blend as described in any one of aspects 1 to 7, wherein the first polymer composition comprises at least 80 wt% polypropylene, preferably at least 90 to 95 wt% polypropylene, based on the total weight of the first composition.Aspect 9 is a polymer blend as described in any one of aspects 1 to 8, wherein the polypropylene in the first polypropylene composition is a polypropylene homopolymer. Aspect 10 is a polymer blend as described in any one of aspects 1 to 9, wherein the blend comprises 94 wt% to 96 wt% of the first polypropylene composition and 4 wt% to 6 wt% of the second polypropylene composition, based on the total weight of the blend, and wherein the MFR ratio of C:A is 2 to 3. Aspect 11 is a polymer blend as described in aspect 10, wherein A is 3 to 5 g / 10 min and C is 8 to 12 g / 10 min. Aspect 12 is a polymer blend as described in any one of aspects 1 to 9, wherein the blend comprises 89 wt% to 91 wt% of the first polypropylene composition and 9 wt% to 11 wt% of the second polypropylene composition, based on the total weight of the blend, and wherein the MFR ratio of C:A is 4 to 5. Aspect 13 is a polymer blend as described in aspect 12, wherein A is 3 to 5 g / 10 minutes, and C is 16 to 20 g / 10 minutes. Aspect 14 is a polymer blend as described in any one of aspects 9 to 13, wherein the first polypropylene composition has a density specific gravity of 0.89 g / cc to 0.92 g / cc, preferably about 0.905 g / cc, as measured according to ASTM D1505; a melting point of 160° C. to 170° C., preferably about 165° C., as measured using differential scanning calorimetry (DSC); and an MFR A of 3 to 5 g / 10 minutes, preferably about 4.1 g / 10 minutes, as measured by ASTM D1238 (230° C. / 2.16 kg). Aspect 15 is a polymer blend as described in any one of Aspects 1 to 9, wherein the first polypropylene composition has: a density specific gravity of 0.89 g / cc to 0.92 g / cc, preferably about 0.905 g / cc, as measured according to ASTM D1505; a melting point of 145° C. to 160° C., preferably about 152° C., as measured using differential scanning calorimetry (DSC); and an MFR A of 10 to 20 g / 10 min, preferably about 14 g / 10 min, as measured by ASTM D1238 (230° C. / 2.16 kg). Aspect 16 is a polymer blend as described in any one of Aspects 1 to 9, wherein the first polypropylene composition has: a density specific gravity of 0.89 g / cc to 0.92 g / cc, preferably about 0.90 g / cc, as measured according to ASTM D1505; a melting point of 145° C. to 160° C., preferably about 151° C., as measured using differential scanning calorimetry (DSC); and an MFR A of 20 to 30 g / 10 min, preferably about 24.7 g / 10 min, as measured by ASTM D1238 (230° C. / 2.16 kg).Aspect 17 is a polymer blend as described in any one of Aspects 1 to 9, wherein the first polypropylene composition has: a density specific gravity of 0.89 g / cc to 0.92 g / cc, preferably about 0.905 g / cc, as measured according to ASTM D1505; a melting point of 160° C. to 170° C., preferably about 165° C., as measured using differential scanning calorimetry (DSC); and an MFR A of 25 to 35 g / 10 min, preferably about 30 g / 10 min, as measured by ASTM D1238 (230° C. / 2.16 kg). Aspect 18 is a polymer blend as described in any one of aspects 1 to 9, wherein the first polypropylene composition has a density specific gravity of 0.89 g / cc to 0.92 g / cc, preferably about 0.905 g / cc, as measured according to ASTM D1505; a melting point of 160° C. to 170° C., preferably about 165° C., as measured using differential scanning calorimetry (DSC); and an MFR A of 90 to 110 g / 10 min, preferably about 100 g / 10 min, as measured by ASTM D1238 (230° C. / 2.16 kg). Aspect 19 is a polymer blend as described in any one of aspects 1 to 18, wherein the blend is in the form of a fiber. Aspect 20 is a polymer blend as described in aspect 19, wherein a plurality of the fibers are contained in fully oriented yarns (FOY), wherein the FOY has a denier of 300 and 400 at a 2:1 draw ratio, a maximum tenacity of 2 to 3, and a maximum elongation of 150 to 250. Aspect 21 is a polymer blend as described in aspect 19, wherein a plurality of the fibers are contained in a partially oriented yarn (POY), wherein the POY has a denier of 100 to 150, a maximum tenacity of 1.85 to 2.50, and a maximum elongation of 150 to 200 at a spinning rate of 4000 m / min.

[0021] Aspect 22 is a manufactured article comprising the polymer blend described in any one of aspects 1 to 21. Aspect 23 is a manufactured article as described in aspect 22, wherein the manufactured article is a composition that has been extruded, blow molded, injection molded, rotationally molded, compression molded, 3-D printed, or thermoformed.

[0022] Aspect 24 is a method for manufacturing a fiber, the fiber comprising any one of the polymer blends of aspects 1 to 21, the method comprising: blending the second polypropylene composition with the first polypropylene composition to form the polymer blend; and forming a fiber from the polymer blend. Aspect 25 is the method of aspect 24, wherein forming the fiber comprises: melting the polymer blend at a melt temperature of 250° C. or less to form a molten composition; extruding the molten composition through a spinneret to form extruded fiber filaments; and drawing the extruded fiber filaments. Aspect 26 is the method of aspect 25, wherein the molten composition is extruded through the spinneret at a speed of 1500 m / min to 4500 m / min. Aspect 27 is the method of aspect 25 or 26, wherein the drawing ratio of the drawing process is 1.5:1 to 4.5:1.

[0023] Aspect 28 is a method of increasing the melt flow rate (MFR) of a first polypropylene composition comprising polypropylene, the method comprising: blending the first polypropylene polymer composition with a second polypropylene composition comprising polypropylene and an organic peroxide to form a polymer blend, wherein the second polypropylene composition has been pre-extruded prior to forming the blend, wherein the polymer blend has an MFR greater than the first polypropylene composition. Aspect 29 is a method as described in aspect 28, wherein the polymer blend does not include any other organic peroxide than the organic peroxide present in the second polypropylene composition. Aspect 30 is a polymer blend as described in any one of aspects 28 to 29, wherein the second polypropylene composition has: a density specific gravity of 0.89 g / cc to 0.92 g / cc, preferably about 0.905 g / cc, as measured according to ASTM D1505; a melting point of 145° C. to 170° C., preferably about 165° C., as measured using differential scanning calorimetry (DSC); and an MFR of 500 to 2000 g / 10 min, preferably 1250 to 1350 g / 10 min, or even more preferably about 1300 g / 10 min, as measured by ASTM D1238 (230° C. / 2.16 kg). Aspect 31 is a method as described in any one of aspects 28 to 30, wherein the polypropylene in the second polypropylene composition is a polypropylene homopolymer.

[0024] Other aspects or embodiments of the present invention are also discussed in this application. Any aspect or embodiment discussed with respect to one aspect of the present invention is also applicable to other aspects or embodiments of the present invention, and vice versa. Each aspect or embodiment described herein is understood to be applicable to aspects or embodiments of the present invention of other aspects of the present invention. It is contemplated that any aspect or embodiment discussed herein can be combined with other aspects or embodiments discussed herein and / or implemented with any method or composition of the present invention, and vice versa. In addition, compositions and systems of the present invention can be used to implement methods of the present invention.

[0025] Included below are definitions of various terms and phrases used throughout this specification.

[0026] The term "about" or "approximately" is defined as close to the understanding of those skilled in the art. In a non-limiting embodiment, the term is defined as within 10% or within 5% or within 1% or within 0.5%.

[0027] The terms "weight %", "volume %" or "mole %" refer to the weight percentage, volume percentage or mole percentage of a component, respectively, based on the total weight, total volume or total number of moles of the material containing the component. In a non-limiting example, 10 grams of a component in 100 grams of a material is 10 weight % of the component. The term "ppm" refers to one millionth by weight based on the total weight including the component.

[0028] The term "substantially" and variations thereof are defined to include ranges within 10%, within 5%, within 1%, or within 0.5%.

[0029] When used in the claims and / or specification, the terms "inhibit" or "reduce" or "prevent" or "avoid" or any variation of these terms includes any measurable reduction or complete inhibition to achieve the desired result.

[0030] The term "effective," as used in the specification and / or claims, means sufficient to accomplish a desired, intended, or anticipated result.

[0031] When "a" or "an" is used with any of the terms "comprising," "including," "containing," or "having" in the claims or the specification, it may mean "one," but is also consistent with the meaning of "one or more," "at least one," and "one or more than one."

[0032] The expression "and / or" may include "and" or "or". To illustrate, X, Y and / or Z may include: X alone, Y alone, Z alone, a combination of X and Y, a combination of X and Z, a combination of Y and Z, or a combination of X, Y, Z.

[0033] The words "comprise" (and any forms of inclusion, such as "comprising" and "containing"), "have" (and any forms of having, such as "having" and "having"), "include" (and any forms of inclusion, such as "including" and "comprising"), or "contain" (and any forms of containing, such as "including" and "including") are inclusive or open-ended and do not exclude additional unrecited elements or method steps.

[0034] The methods and systems of the present invention may "comprise," "consist essentially of," or "consist of specific ingredients, components, compositions, steps, etc. disclosed throughout the specification." With respect to the transitional expression "consisting essentially of," in one non-limiting aspect, the basic and novel features of the compositions and processes of the present invention include the use of a second pre-extruded polymer (e.g., polypropylene) composition having an organic peroxide as a masterbatch melt flow rate modifier for a first polymer (e.g., polypropylene) composition. The second pre-extruded polymer composition may be capable of visbreaking the polymer in the first composition, thereby reducing the average molecular weight of the polymer and increasing the melt flow rate of the first polymer composition.

[0035] Other objects, features and advantages of the present invention will be apparent from the following drawings, detailed descriptions and examples. However, it should be understood that although these figures, detailed descriptions and examples show specific embodiments of the present invention, they are only given in an illustrative manner and are not meant to be restrictive. In addition, it is conceivable that changes and modifications within the spirit and scope of the present invention will be apparent to those skilled in the art through detailed descriptions. In other embodiments, the features of a specific embodiment may be combined with the features of other embodiments. For example, features from one embodiment may be combined with features from any other embodiment. In other embodiments, additional features may be added to the specific embodiments described herein. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Advantages of the present invention will become apparent to those skilled in the art from the following detailed description with reference to the accompanying drawings.

[0037] Figure 1 is a schematic representation of an embodiment for preparing the second polypropylene composition of the present invention.

[0038] Figure 2 is a graphical representation of the melt flow rate (MFR) of a blend comprising a first polypropylene composition having an MFR of about 14 g / 10 min, and a second polypropylene composition having an MFR of 1300 g / 10 min.

[0039] Figure 3is a graphical representation of the melt flow rate (MFR) of a blend comprising a first polypropylene composition having an MFR of about 24.7 g / 10 min, and a second polypropylene composition having an MFR of 1300 g / 10 min.

[0040] Figure 4 is a graphical representation of the melt flow rate (MFR) of a blend comprising a first polypropylene composition having an MFR of about 30 g / 10 min, and a second polypropylene composition having an MFR of 1300 g / 10 min. DETAILED DESCRIPTION

[0041] One aspect of the present invention is based on the discovery that a pre-extruded polymer (e.g., polypropylene) composition (second polymer composition) comprising an organic peroxide masterbatch melt flow rate modifier can itself be used as a masterbatch melt flow rate modifier for another polymer (e.g., polypropylene) composition (first polymer composition). In some aspects, and without wishing to be bound by theory, it is believed that at least a portion of the organic peroxide in the pre-extruded second polymer composition remains active because it is able to visbreak the polymer in the first polymer composition, thereby reducing the average molecular weight of the polymer and increasing the melt flow rate of the first polymer composition. The non-limiting data in the Examples section confirm this discovery. Advantages of this discovery over existing organic peroxide masterbatches for melt flow rate modifiers include, but are not limited to: (1) a pellet to pellet polypropylene blend can be used for co-extrusion without the need for additional organic peroxide masterbatch melt flow rate modifiers (e.g., without the need for additional liquid-based or solid-based peroxide masterbatch formulations); (2) the organic peroxide in the second extruded polypropylene composition has been previously used to modify the melt flow rate of the second composition and can be reused as a melt flow rate modifier in the first composition - the peroxide is used more than once as a melt flow rate modifier, reducing the need to purchase or manufacture additional peroxide, which can be beneficial from a cost and / or social perspective by limiting the need to produce additional peroxide; and / or (3) given the presence of polypropylene, the second extruded polypropylene composition can be safely used as a peroxide masterbatch for the first composition (e.g., because the first and second compositions are similar, the melt flow rate of the first composition can be modified as desired while other properties of the first composition can be maintained).

[0042] These and other non-limiting aspects of the present invention are discussed in further detail in the following sections.

[0043] A. Polymer Blends

[0044] The polymer blend of the present invention may contain a first polypropylene composition and a second polypropylene composition. In some aspects, the polymer blend may contain: i) 75 wt% to 99 wt% of the first polypropylene composition, or an amount equal to any one of the following, at least any one of the following, at most any one of the following, or between any two of the following: 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, and 99 wt%. % of the first polypropylene composition, and ii) 1 wt % to 25 wt % of the second polypropylene composition, or an amount equal to any one of the following, at least any one of the following, at most any one of the following, or between any two of the following: 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, and 25 wt % of the second polypropylene composition. In some aspects, the polymer blend contains less than 0.5 wt %, such as less than 0.3 wt %, such as less than 0.1 wt %, such as less than 0.05 wt %, such as less than 0.01 wt %, such as less than 0.001 wt % of any other organic peroxide different from the organic peroxide present in the second polypropylene composition, or is substantially free of, or free of, any other organic peroxide different from the organic peroxide present in the second polypropylene composition. In some aspects, the MFR of the polymer blend (e.g., C) can be from 5 g / 10 min to 2000 g / 10 min, or equal to any of the following, at least any of the following, at most any of the following, or between any two of the following: 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 110, 150, 1500, 1600, 1650, 1700, 1750, 1800, 1850, 1900, 1950, and 2000 g / 10 min as measured according to ASTM D1238 (230°C / 2.16 kg). In some non-limiting aspects, the MFR ratio of the polymer blend to the first polypropylene composition may be 2 to 3, or 4 to 5.

[0045] 1. Polypropylene

[0046] The polymers used in the polymer blends may include polypropylene homopolymers (e.g., isotactic, syndiotactic, atactic polypropylene), copolymers of propylene and other olefins, and terpolymers of propylene, ethylene, and / or dienes. In some cases, controlled rheology grade polypropylene (CRPP) may be used. CRPP is a polypropylene polymer that has been further processed (e.g., by a degradation process) to produce a higher melt flow index (MFI), lower molecular weight, and / or narrower molecular weight distribution than the starting polypropylene.

[0047] Polypropylene can be prepared by any commercially used polymerization process (such as a "high pressure" process, a slurry process, a solution process and / or a gas phase process) and using any known catalyst (such as a Ziegler-Natta catalyst, a chromium or Phillips catalyst, a single site catalyst, a metallocene catalyst, etc.). Polypropylene can be prepared using the methods described in U.S. Pat. Nos. 8,957,159, 8,088,867, 8,071,687, 7,056,991 and 6,653,254. The polypropylene can also be purchased from commercial sources such as Total Energies (USA), Total SA, Lyondell Bassel Industries, Reliance Industries Ltd, Sinopec and ExxonMobil Chemical Co. The polypropylene can be in pre-extruded form and / or solid form, such as pellets.

[0048] 2. First Polypropylene Composition

[0049] The first polypropylene composition can contain at least 95 wt%, such as 95 wt% to 100 wt% polypropylene, or an amount equal to any one of the following, at least any one of the following, at most any one of the following, or between any two of the following: 95, 96, 97, 98, 99, 99.1, 99.2, 99.3, 99.4, 99.5, 99.6, 99.7, 99.8 and 99.9, 99.95 and 100 wt% of the polypropylene, based on the total weight of the first composition. In some aspects, the polypropylene in the first polypropylene composition can be a polypropylene homopolymer. In certain aspects, the first polypropylene composition can meet any one of the following, any combination thereof, or all of the following: i) MFR is (for example, A can be) 0.5 g / 10 min to 150 g / 10 min, or is equal to any one of the following, at least any one of the following, at most any one of the following, or between any two of the following: 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 110, 120, 130, 140, and 150 g / 10 min, which is according to ASTM D1238 (230°C / 2.16 kg), ii) a specific gravity or density of 0.85 g / cc to 0.95 g / cc, or equal to any of the following, at least any of the following, at most any of the following, or between any two of the following: 0.85, 0.86, 0.87, 0.88, 0.89, 0.9, 0.91, 0.92, 0.93, 0.94, and 0.95 g / cc, which is measured according to ASTM 164, 165, 166, 167, 168, 169, 170, 171, 172, 173, 174, 175, 176, 177, 178, 179, and 180°C as measured using Differential Scanning Calorimetry (DSC). In some aspects, the first polypropylene composition has been pre-extruded prior to forming the blend.

[0050] A non-limiting example of the first polypropylene composition of the present invention includes Polypropylene 3860X, which is commercially available from Total Energies Petrochemicals & Refining USA, Inc. (Houston, Texas). Polypropylene 3860X is a polypropylene resin composition including homopolymer propylene and additives. Table 1 provides the properties of Polypropylene 3860X.

[0051] Table 1

[0052]

[0053]

[0054] (1) Data were obtained under laboratory conditions.

[0055] (2) MP was determined by DSC-2 differential scanning calorimeter.

[0056] A non-limiting example of the first polypropylene composition of the present invention includes Polypropylene M3661, which is commercially available from Total Energy Petrochemicals & Refining (Houston, Texas). Polypropylene M3661 is a polypropylene resin composition comprising metallocene homopolymer propylene and additives. It is a homopolymer polypropylene in isotactic form. Table 2 provides the properties of Polypropylene M3661.

[0057] Table 2

[0058] method unit Typical values Rheological properties Melt Flow D-1238 g / 10 minutes 14 <![CDATA[Physical properties (1) > Tensile strength at break D-882,A psi(MD / TD) 5,800 / 5,500 Elongation at break D-882,A %(MD / TD) 720 / 810 1% secant modulus D-882,A kpsi(MD / TD) 81 / 82 Haze D-1003 ％ 0.4 Gloss, 45° D-2457 - 81 <![CDATA[Thermal properties (2)(3) > Melting point DSC °F(℃) 302(150) Other physical properties density D-1505 g / cc 0.9

[0059] (1) Non-oriented film - 2 mil (50 microns)

[0060] (2) Data were obtained under laboratory conditions.

[0061] (3) MP was determined by DSC-2 differential scanning calorimeter.

[0062] Another non-limiting example of the first polypropylene composition of the present invention includes Polypropylene M3766, which is commercially available from Total Energy Petrochemicals & Refining (Houston, Texas). Polypropylene M3766 is a polypropylene resin composition including metallocene homopolymer propylene and additives. It is a homopolymer polypropylene in isotactic form. Table 3 provides the properties of Polypropylene M3766.

[0063] Table 3

[0064]

[0065]

[0066] (1) Data were obtained under laboratory conditions.

[0067] (2) MP was determined by DSC-2 differential scanning calorimeter.

[0068] Another non-limiting example of the first polypropylene composition of the present invention includes Polypropylene 3825, which is commercially available from Total Energy Petrochemicals & Refining (Houston, Texas). Polypropylene 3825 is a polypropylene resin composition including homopolymer propylene and additives. Table 4 provides the properties of Polypropylene 3825.

[0069] Table 4

[0070]

[0071] (1) Data were obtained under laboratory conditions.

[0072] (2) MP was determined by DSC-2 differential scanning calorimeter.

[0073] Further non-limiting examples of the first polypropylene composition of the present invention include Polypropylene 3462, which is commercially available from Total Energy Petrochemicals & Refining (Houston, Texas). Polypropylene 3462 is a polypropylene resin composition including homopolymer propylene and additives. Table 5 provides the properties of Polypropylene 3462.

[0074] Table 5

[0075]

[0076] (1) Data were obtained under laboratory conditions.

[0077] (2) MP was determined by DSC-2 differential scanning calorimeter.

[0078] (3) Samples were processed at a 6:1 draw ratio and a melt temperature of 450°F (232°C).

[0079] 3. Second polypropylene composition

[0080] The second polypropylene composition comprises: at least 99 wt% (such as 99 wt% to 99.95 wt%, or an amount equal to any one of the following, at least any one of the following, or between any two of the following: 99, 99.1, 99.2, 99.3, 99.4, 99.5, 99.6, 99.7, 99.8 and 99.9, 99.91, 99.92, 99.93, 99.94 and 99.5 wt%) of the polypropylene; propylene, and less than 1 wt % (such as 0.05 wt % to 1 wt %, or an amount equal to any one of the following, at least any one of the following, or between any two of the following: 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, and 1 wt %) of the organic peroxide, based on the total weight of the second polypropylene composition.

[0081] In some aspects, the polypropylene in the second polypropylene composition may be a polypropylene homopolymer. In certain aspects, the second polypropylene composition satisfies any one, any combination, or all of the following: i) MFR is (for example, B may be) 500 g / 10 min to 2000 g / 10 min, preferably 1000 g / 10 min to 1500 g / 10 min, or more preferably 1250 g / 10 min to 1350 g / 10 min, or is equal to any one of the following, at least any one of the following, at most any one of the following, or between any two of the following: 500, 60 0, 700, 800, 900, 1000, 1050, 1100, 1150, 1200, 1250, 1260, 1270, 1280, 1290, 1300, 1310, 1320, 1330, 1340, 1350, 1400, 1450, 1500, 1550, 1600, 1650, 1700, 1750, 1800, 1850, 1900, 1950, and 2000 g / 10 minutes according to ASTM D1238 (230°C / 2.16kg), ii) a specific gravity or density of 0.85 g / cc to 0.95 g / cc, or equal to any one of the following, at least any one of the following, at most any one of the following, or between any two of the following: 0.85, 0.86, 0.87, 0.88, 0.89, 0.9, 0.91, 0.92, 0.93, 0.94, and 0.95 g / cc, as measured according to ASTM D1505, and iii) a melting point of 160°C to 170°C, or equal to any one of the following, at least any one of the following, at most any one of the following, or between any two of the following: 160, 161, 162, 163, 164, 165, 166, 167, 168, 169, and 170°C, as measured using differential scanning calorimetry (DSC). In some aspects, the second polypropylene composition has been pre-extruded prior to forming the blend.

[0082] Examples of organic peroxides include: 3,6,9-triethyl-3,6,9-trimethyl-1,4,7-triperoxynonane; dicetyl peroxydicarbonate; 2,5-bis(tert-butylperoxy)-2,5-dimethyl-3-hexane; 2,5-dimethyl-2,5-bis-(tert-butylperoxy)-hexyne; 3,4-methyl-4-tert-butylperoxy-2-pentanone; 3,6,6,9,9-pentamethyl-3-(ethyl acetate)-1,2,4,5-tetraoxycyclononane; α,α′-bis-(tert-butylperoxy)diisopropylbenzene; 1,2,4,5,7,8-hexaoxynonane 3,6,9-trimethyl-3,6,9- Tri(ethyl and propyl) derivatives, 3,6,6,9,9-pentamethyl-3-(ethyl acetate)-1,2,4,5-tetraoxycyclononane; bis-2-ethylhexyl peroxydicarbonate; 3,3-bis(2-methylbutan-2-ylperoxy)butyrate; 2,2-bis(tert-butylperoxy)butane; 1,1-bis(tert-butylperoxycyclohexane); n-butyl, 4,4-bis(tert-butylperoxyvalerate; 2,2-bis(4,4-di-tert-butylperoxycyclohexyl)propane; tert-butyl hydroperoxide; cumene hydroperoxide, diisopropylbenzene hydroperoxide; p-menthane hydroperoxide; 1,1,3,3-tetramethylbutyl hydroperoxide peroxide; tert-butyl cumyl peroxide, di-tert-butyl peroxide; dicumyl peroxide; isobutyryl peroxide; lauroyl peroxide; succinic acid peroxide; 3,5,5-trimethylhexanoyl peroxide; bis-2-ethoxyethyl peroxydicarbonate; diisopropyl peroxycarbonate; dimethoxybutyl peroxydicarbonate; butyl peroxyisopropyl monocarbonate; tert-butyl peroxymaleic acid; tert-butyl peroxyisobutyrate; tert-butyl peroxyacetate; tert-butyl peroxy-2-ethylhexyl monocarbonate; tert-butyl peroxyneodecanoate; tert-butyl peroxy 2-ethylhexanoate, tert-butyl peroxypivalate; tert-butyl peroxybenzoate; tert-butyl peroxy 3,5,5-trimethylhexanoate; α,α'-bis(neodecanoylperoxy)diisopropylbenzene; cumylperoxyneodecanoate; 2,5-dimethyl-2,5-bis(m-toluoylperoxy)hexane; tert-hexylperoxypivalate; 1,1,3,3-tetramethylbutylperoxyneodecanoate; 1,1,3,3-tetramethylbutylperoxy2-ethylhexanoate; tert-amylperoxypivalate; tert-amylperoxy2-ethylhexanoate; tert-amylperoxy2-ethylhexyl monocarbonate; tert-amylperoxyneodecanoate; and mixtures thereof. Commercially available organic peroxides are available, for example, from Arkema (France) under the trade name AkzoNobel, with its trademark and Chemmex (China). In some specific aspects, the organic peroxide may be 3,6,9-triethyl-3,6,9-trimethyl-1,4,7-triperoxynonane.

[0083] The second polypropylene composition can be obtained by adding an effective amount of organic peroxide to a polypropylene polymer to produce the second polypropylene composition. The organic peroxide can be added in an amount and condition that results in the presence of unreacted organic peroxide in the second polypropylene composition. Known equipment (e.g., mixer, kneader, and extruder) can be used and melt blended at the following melt temperature: 160°C to 180°C, or equal to any one of the following, at least any one of the following, at most any one of the following, or between any two of the following: 160°C, 165°C, 170°C, 175°C, and 180°C. In some embodiments, additional organic peroxide is added to the second polypropylene containing a small amount of organic peroxide from previous processing. In some embodiments, the second polypropylene composition is derived from a commercial source. In certain embodiments, the second polypropylene composition is used as a masterbatch. The second polypropylene composition is suitable for use as a masterbatch. Non-limiting examples of the second polypropylene composition of the present invention include Polypropylene 3962, which is commercially available from Total Energy Petrochemicals & Refining (Houston, Texas). Polypropylene 3962 includes about 99 weight percent homopolymer propylene, about 0.36 weight percent 3,6,9-triethyl-3,6,9-trimethyl-1,4,7-triperoxynonane, and other additives. Table 6 provides the characteristics of Polypropylene 3962.

[0084] Table 6

[0085]

[0086]

[0087] (1) Data were obtained under laboratory conditions.

[0088] (2) MP was determined by DSC-2 differential scanning calorimeter.

[0089] 4. Optional additives

[0090] The first and second polypropylene compositions of the present invention may include various additives. Non-limiting examples of additives include: anti-caking agents, antistatic agents, antioxidants, neutralizers, foaming agents, crystallization aids, dyes, flame retardants, fillers, impact modifiers, release agents, oils, additional polymers, colorants, processing agents, reinforcing agents, nucleating agents, clarifying agents, slip agents, flow modifiers, stabilizers, UV inhibitors, and combinations thereof. Additives can be obtained from various commercial suppliers. Non-limiting examples of commercial additive suppliers include: BASF (Germany), Dover Chemical Corporation (USA), AkzoNobel (Netherlands), (Sigma-Aldrich, USA), Atofina Chemicals, etc. In the first polypropylene composition, the second polypropylene composition, or the polymer blend, the amount of the optional additive can range from 0.01 wt% to 5 wt% (e.g., 0.01 wt%, 0.05 wt%, 0.1 wt%, 0.2 wt%, 0.3 wt%, 0.4 wt%, 0.5 wt%, 0.6 wt%, 0.7 wt%, 0.8 wt%, 0.9 wt%, 1 wt%, 1.5 wt%, 2 wt%, 2.5 wt%, 3 wt%, 3.5 wt%, 4 wt%, 4.5 wt%, 5 wt%, or any value or range therebetween).

[0091] B. Method of making the polymer blend

[0092] The polymer blend of the present invention can be obtained by blending the first and second compositions together. In some aspects, the first and second polypropylene compositions can be in solid form (e.g., pellets), and can be melted and mixed with the optional additive. Suitable blending machines are known to those skilled in the art. Non-limiting examples include mixers, kneaders, and extruders. In some aspects, the process can be carried out in an extruder by introducing the first polypropylene composition, the second polypropylene composition, and optional additives during processing. Non-limiting examples of extruders include: single screw extruders, counter-rotating and co-rotating twin screw extruders, planetary gear extruders, annular extruders, or co-kneaders. The melt blending can be carried out at a melt temperature of 160°C to 260°C, or equal to any one of the following, at most any one of the following, or between any two of the following: 160°C, 165°C, 170°C, 175°C, 180°C, 185°C, 190°C, 195°C, 200°C, 205°C, 210°C, 215°C, 220°C, 225°C, 230°C, 235°C, 240°C, 245°C, and 250°C. During blending, the first polypropylene composition and the second polypropylene composition can experience an elevated temperature for a sufficient time. The blending temperature can be higher than the softening point of the polypropylene composition. The amount of the first polypropylene composition relative to the second polypropylene composition can be adjusted as long as the weight ratio of the first polypropylene composition relative to the second polypropylene composition is greater than 5:1 to 99:1. The ratio of the first polypropylene composition to the second polypropylene composition may be at least, equal to, or between any two of 5:1, 10:1, 15:1, 20:1, 30:1, 40:1, 50:1, 60:1, 70:1, 80:1, 90:1, and 99:1.

[0093] The additives may be premixed, or additives may be added separately to the polymer blend, or the first polypropylene composition, or the second polypropylene composition. For example, the additives may be premixed so that they are added to the polymer blend, the first polypropylene composition, or the second polypropylene composition. Additives may be incorporated into the polymer blend, for example, by mixing the above components using methods common in processing technology. The blending temperature may be higher than the softening point of the polymer. In some aspects, the process may be carried out at a temperature of about 160° C. to 250° C. This "melt mixing" or "melt blending" results in a uniform dispersion of the additives of the present invention in the polymer blend, the first polypropylene composition, the second polypropylene composition, or a combination thereof.

[0094] C. Fibers containing the polymer blend

[0095] The polymer blends of the present invention can be used to make fibers and fiber bundles, and nonwoven materials. In some aspects, the fibers may be included in fully oriented yarns (fully oriented yarn, FOY). In some aspects, the fibers may be included in partially oriented yarns (partially oriented yarn, POY).

[0096] The FOY of the present invention can be drafted at a draft ratio of: 1.5:1 to 4.5:1, or equal to any of the following, at least any of the following, at most any of the following, or between any two of the following: 1.5:1, 2:1, 2.5:1, 3:1, 3.5:1, 4:1, and 4.5:1. In certain aspects, the FOY can meet any one, any combination, or all of the following: i) a denier of 150 to 450, or equal to any one of the following, at least any one of the following, or between any two of the following: 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400, 410, 420, 430, 440, and 450, ii) a maximum tenacity of 1.5 to 4.5, or equal to any one of the following, at least any one of the following, or between any two of the following: 1.5, 1.6, 1 .7, 1.8, 1.9, 2, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4, 4.1, 4.2, 4.3, 4.4, and 4.5, and iii) a maximum elongation of 50% to 300%, or In some aspects, the FOY can be drawn at a draw ratio of 2:1, and the denier can be 300 and 400, the maximum tenacity can be 2 to 4.5, and / or the maximum elongation can be 150% to 250%. In some aspects, the FOY can be drawn at a draw ratio of 3:1, and the denier can be 300 and 400, the maximum tenacity can be 2 to 4.5, and / or the maximum elongation can be 50% to 150%. In some aspects, the FOY can have a denier of 300 and 400, a maximum tenacity of 2.5 to 4.5, and / or a maximum elongation of 50% to 150% at a draw ratio of 3.5:1.

[0097] The POY of the present invention can be spun at a spinning rate of 1500 to 5000 m / min, or equal to any one of the following, at least any one of the following, at most any one of the following, or between any two of the following: 1500, 2000, 2500, 3000, 3500, 4000, 4500, and 5000 m / min. In certain aspects, the POY may satisfy any one, any combination, or all of the following: i) a denier of 50 to 450, or equal to any one, at least any one, or between any two of the following: 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400, 410, 420, 430, 440, and 450, ii) a maximum tenacity of 1.5 to 4.5, or equal to any one, at least any one, or between any two of the following: Any two of the following: 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4, 4.1, 4.2, 4.3, 4.4, and 4.5, and iii) maximum elongation 50% to 300%, or equal to any one of the following, at least any one of the following, or between any two of the following: 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 260, 270, 280, 290, and 300%. In some aspects, the POY can be spun at a spinning rate of 4000 m / min, the denier can be 50 to 200, the maximum tenacity can be 1.5 to 3, and the maximum elongation can be 100% to 300%. In some aspects, the POY can be spun at a spinning rate of 2,000 m / min, the denier can be 100 to 250, the maximum tenacity can be 1.5 to 3, and the maximum elongation can be 150% to 350%. In some aspects, the POY can be spun at a spinning rate of 4,200 m / min, the denier can be 50 to 200, the maximum tenacity can be 1.5 to 3, and the maximum elongation can be 50% to 300%.

[0098] The fibers of the invention can be produced by generally known production methods, such as those described in Polypropylene Handbook, Nello Pasquini, ed., 2nd edition, Hanser, 2005, pp. 397-403, or F. Fourné, Synthetische Fasern, Carl Hanser Verlag, 1995, chapter 5.2, or BC Goswami et al., Textile Yarns, John Wiley & Sons, 1977, pp. 371-376. In general, the fibers are produced by melting a polymer or a polymer composition in an extruder, optionally passing the molten polymer through a melt pump in order to ensure a constant feed rate, and subsequently extruding the molten polymer or molten polymer composition through the fine capillaries of several spinnerets to form fibers. These still molten fibers are simultaneously cooled and drawn to the final diameter by air and finally collected. Optionally, the fibers thus obtained can be subjected to a further drawing step. In some aspects, the fiber forming process may include any one, any combination, or all of the following: i) melting the polymer blend at a melt temperature of 200°C to 260°C, or equal to any one of the following, up to any one of the following, or between any two of the following: 200°C, 205°C, 210°C, 215°C, 220°C, 225°C, 230°C, 235°C, 240°C, 245°C, 250°C, 255°C, and 260°C, ii) extruding the molten composition through a spinneret to form extruded fiber filaments, and iii) drawing the extruded fiber filaments. In some aspects, the molten polymer blend can be extruded through a spinneret at a speed of 1500 m / min to 5000 m / min, equal to any one of the following, at least any one of the following, at most any one of the following, or between any two of the following: 1500, 2000, 2500, 3000, 3500, 4000, 4500, and 5000 m / min. In some aspects, the draw ratio of the drawing process can be 1.5:1 to 4.5:1, or equal to any one of the following, at least any one of the following, at most any one of the following, or between any two of the following: 1.5:1, 2:1, 2.5:1, 3:1, 3.5:1, 4:1, and 4.5:1.

[0099] D. Articles containing the polymer blend

[0100] The polymer blend of the present invention can be included in the article of manufacture. In some aspects, the article of manufacture can be an article of extrusion, blow molding, transfer molding, injection molding and / or thermoforming. In some aspects, the article of manufacture can be transparent. The non-limiting examples of the article of manufacture can include films, sheets, fibers, yarns, packaging films, molded films, protective packaging, shrink film sleeves, and / or labels, shrink films, twist wraps, sealing films, lids, crates, bottles, jars, funnels, pipette tips, orifice plates, microtiter plates, syringes, sutures, masks, personal protective equipment, medical tools, medical trays, sample bottles, cuvettes, reaction bottles, contact lens molds, cigarette filters, industrial filters, knitted socks, cold-proof warm sportswear, underwear, shoes, ropes, twine, bales, etc. warp), tapes, architectural / industrial fabrics, pipes, non-electrical fuses for detonating explosives, absorbent products (e.g., diapers), expanding foams, carpets, mats, quilts, furniture, toys, luggage, handbags, duffel bags, sports bags, backpacks, fabrics, food containers and covers, deli containers and covers, dairy containers and covers, automotive parts, dashboards, bumpers, cladding, exterior trim, film cushioning, film skins, coverings, automotive interior components. In these and other uses, the resins can be combined with other materials, such as particulate materials, including talc, calcium carbonate, wood, and fibers, such as glass or graphite fibers, to form composite materials. Examples of such composite materials include parts for furniture, automotive parts, and building materials, particularly those used as wood substitutes.

[0101] Example

[0102] The present invention will be described in more detail by specific examples. The examples provided below are only for illustrative purposes and are not intended to limit the present invention in any way. Those skilled in the art will easily recognize various non-critical parameters that can be changed or modified to produce substantially the same result.

[0103] A. Example 1 (Visbreaking using the second polymer composition of the present invention)

[0104] Figure 1is a diagram of two approaches to visbreaking the first polymer composition of the present invention. In one approach, which is a non-limiting embodiment of the present invention, a first melt blend is produced by blending Total Polypropylene 3860X (see Table 1 above, which is a non-limiting example of a first composition of the present invention) with Total Polypropylene 3962 (see Table 6 above, which is a non-limiting example of a second composition of the present invention). As described above, Total Polypropylene 3962 includes about 99 weight percent homopolymer propylene and about 0.36 weight percent 3,6,9-triethyl-3,6,9-trimethyl-1,4,7-triperoxynonane (Triganox Total Polypropylene 3860X is a pre-extruded composition. The first melt blend is produced from a pelletized dry blend, which is extruded on a single screw extruder to produce pellets. The concentration of Trigonox 301 is calculated to increase as follows: 0.072, 0.108, 0.144, 0.18, 0.216, 0.252, 0.288, 0.32 wt%.

[0105] In a second approach as a comparative example of the first melt blend, 3,6,9-triethyl-3,6,9-trimethyl-1,4,7-triperoxynonane (Triganox ) was directly blended with Total Polypropylene 3860X to produce a second comparative melt blend. The second comparative melt blend was produced by blending polypropylene fluff with peroxide and extruding on a single screw extruder to produce pellets. The concentration of peroxide was increased as follows: 0.25, 0.27, 0.29, 0.32, 0.365 wt%.

[0106] like Figure 1 As shown in , the MFR value of the first melt blend is similar to the second comparative melt blend. These MFR data confirm that the inventive preextruded second polypropylene composition can itself be used as a melt flow rate modifier for the inventive first polypropylene composition.

[0107] B. Example 2 (Polymer blend containing polypropylene having an MFR of about 14 g / 10 min)

[0108] Polymer blends containing a first polypropylene composition and Total Polypropylene 3962 as a second polypropylene composition were prepared. The first polypropylene composition contained a polypropylene having an MFR of 13.9 g / 10 min as measured according to ASTM D1238 (230°C / 2.16 kg), a density of 0.905 g / cc as measured according to ASTM D1505, and a melting point of 152°C as measured using differential scanning calorimetry (DSC). The first polypropylene composition was Total Polypropylene M3661 (see Table 2 above). Three (3) polymer blends were prepared having 2 wt%, 5 wt%, and 10 wt% of the second polypropylene composition, respectively, and the remainder being the first polypropylene composition (e.g., 98 wt%, 95 wt%, and 90 wt%, respectively). The variation in MFR relative to the weight percentage of the second polypropylene composition in the blend is shown in Table 2. Figure 2 As shown, with various amounts of the second polypropylene, the MFR of the first polypropylene composition is adjusted, resulting in a new polypropylene composition having a desired MFR value.

[0109] C. Example 3 (Polymer blend containing polypropylene having an MFR of about 25 g / 10 min)

[0110] Polymer blends containing a first polypropylene composition and Total Polypropylene 3962 as a second polypropylene composition are prepared. The first polypropylene composition contains a polypropylene having an MFR of 24.7 g / 10 min as measured according to ASTM D1238 (230°C / 2.16 kg), a density of 0.90 g / cc as measured according to ASTM D1505, and a melting point of 151°C as measured using differential scanning calorimetry (DSC). The first polypropylene composition is Total Polypropylene M3766 (see Table 3 above). Four (4) polymer blends having 2 wt%, 5 wt%, 10 wt%, and 20 wt% of the second polypropylene composition and the remainder being the first polypropylene composition (e.g., 98 wt%, 95 wt%, 90 wt%, and 80 wt%, respectively). The variation in MFR relative to the weight percentage of the second polypropylene composition in the blend is as follows: Figure 3 As shown, with the use of various amounts of the second polypropylene masterbatch, the MFR of the first polypropylene composition is adjusted, thereby generating a new polypropylene composition with a desired MFR value.

[0111] D. Example 4 (Polymer blend containing a polypropylene having an MFR of about 30 g / 10 min and a second polypropylene composition)

[0112] Polymer blends containing a first polypropylene composition and Total Polypropylene 3962 as a second polypropylene composition were prepared. The first polypropylene composition contained a polypropylene having an MFR of 30 g / 10 min as measured according to ASTM D1238 (230°C / 2.16 kg), a density of 0.905 g / cc as measured according to ASTM D1505, and a melting point of 165°C as measured using differential scanning calorimetry (DSC). The first polypropylene composition was Total Polypropylene 3825 (see Table 4 above). Two (2) polymer blends were prepared having 10 wt%, and 20 wt% of the second polypropylene composition, with the remainder being the first polypropylene composition (e.g., 90 wt% and 80 wt%, respectively). The variation in MFR relative to the percentage of the second polymer in the blend was Figure 4 As shown, with the use of various amounts of the second polypropylene masterbatch, the MFR of the first polypropylene composition is adjusted to produce a new polypropylene composition with a desired MFR value.

[0113] E. Example 5 (fiber containing polypropylene)

[0114] A polymer blend was prepared, the polymer blend having a first polypropylene composition, and Total Polypropylene 3962 as the second polypropylene. The first polypropylene composition contained a polypropylene having an MFR of 4.2 g / 10 min, measured according to ASTM D1238 (230°C / 2.16 kg), a density of 0.905 g / cc, measured according to ASTM D1505, and a melting point of 165°C, measured using differential scanning calorimetry (DSC). The first polypropylene composition was Total Polypropylene 3462 (see Table 5 above). The first polypropylene composition had been reextruded. Blend A had 5 wt% of the second polypropylene composition of Example 2, and 95 wt% of the reextruded first polypropylene composition. Blend B had 10 wt% of the second polypropylene composition and 90 wt% of the reextruded first polypropylene composition. Fully oriented yarns (FOY) and partially oriented yarns (POY) were prepared. The fiber production line used to form the fibers in Tables 7 and 8 had a melting temperature of 230°C. The properties of FOY at different draft ratios are listed in Table 7, while the properties of POY at different spinning rates are listed in Table 8. From this data it can be concluded that the blends of the present invention can be used to make fully oriented yarns and partially oriented yarns that are comparable to yarns made using homopolymers produced by the Ziegler Natta process.

[0115] Table 7

[0116]

[0117]

[0118] Table 8

[0119]

[0120] As can be seen from Table 7, the blends of the present invention can be processed at standard temperatures and give relatively good FOY properties. As can be seen from Table 8, blending the second polymer composition allows very high spinning rates.

[0121] *****

[0122] Although the embodiments of the present application and their advantages have been described in detail, it should be understood that various changes, substitutions and modifications may be made to this document without departing from the spirit and scope of the embodiments defined in the appended claims. Moreover, the scope of the present application is not intended to be limited to the specific embodiments of the processes, machines, manufactures, material compositions, means, methods and steps described in the specification. As will be readily understood by those of ordinary skill in the art from the above disclosure, processes, machines, manufactures, material compositions, means, methods or steps that currently exist or will be developed in the future and perform substantially the same functions as the corresponding embodiments herein or achieve substantially the same results may be utilized. Therefore, the appended claims are intended to include such processes, machines, manufactures, material compositions, means, methods or steps within their scope.

Claims

1. A polymer blend comprising: 75 to 99 wt% of a first polypropylene composition comprising polypropylene and having a melt flow rate (MFR) of Ag / 10 min as measured by ASTM D1238 (230°C / 2.16 kg), wherein the first polypropylene composition has been pre-extruded prior to forming the blend; and 1 to 25 wt% of a second polypropylene composition comprising polypropylene and an organic peroxide and having an MFR of B g / 10 min as measured by ASTM D1238 (230°C / 2.16 kg), wherein the second polypropylene composition has been pre-extruded prior to forming the blend, wherein the MFR of the polymer blend is C g / 10 min as measured by ASTM D1238 (230°C / 2.16 kg), and Among them, C is greater than A.

2. The polymer blend according to claim 1, wherein the polymer blend does not comprise any further organic peroxide than the organic peroxide present in the second polypropylene composition.

3. The polymer blend according to any one of claims 1 to 2, wherein the second polypropylene composition: Density specific gravity of 0.89 g / cc to 0.92 g / cc as measured in accordance with ASTM D1505; A melting point of 145°C to 175°C as measured using differential scanning calorimetry (DSC); and MFR B is 500 to 2000 g / 10 min, which is measured by ASTM D1238 (230° C. / 2.16 kg).

4. The polymer blend according to any one of claims 1 to 2, wherein the polypropylene in the second polypropylene composition is a polypropylene homopolymer, a random copolymer, or an impact copolymer, or any combination thereof.

5. The polymer blend according to anyone of claims 1 to 2, wherein the second polypropylene composition comprises at least 99 wt% of the polypropylene and less than 1 wt% of the organic peroxide, based on the total weight of the second polypropylene composition.

6. The polymer blend according to any one of claims 1 to 2, wherein the organic peroxide is 3,6,9-triethyl-3,6,9-trimethyl-1,4,7-triperoxynonane.

7. The polymer blend according to any one of claims 1 to 2, wherein MFR A is from 0.5 g / 10 min to 150 g / 10 min.

8. The polymer blend of any one of claims 1 to 2, wherein the first polymer composition comprises 90 to 95 wt% polypropylene, based on the total weight of the first composition.

9. The polymer blend according to any one of claims 1 to 2, wherein the polypropylene in the first polypropylene composition is a polypropylene homopolymer.

10. The polymer blend as claimed in claim 9, wherein the first polypropylene composition: Density specific gravity is about 0.905 g / cc, which is measured according to ASTM D1505; A melting point of about 165° C., as measured using differential scanning calorimetry (DSC); and MFR A is about 4.1 g / 10 min, which is measured by ASTM D1238 (230° C. / 2.16 kg).

11. The polymer blend of any one of claims 1 to 2, wherein the blend comprises 94 to 96 wt% of the first polypropylene composition and 4 to 6 wt% of the second polypropylene composition, based on the total weight of the blend, and wherein the MFR ratio C:A is 2 to 3.

12. The polymer blend of claim 11, wherein A is 3 to 5 g / 10 min, and C is 8 to 12 g / 10 min.

13. The polymer blend of any one of claims 1 to 2, wherein the blend comprises 89 to 91 wt% of the first polypropylene composition and 9 to 11 wt% of the second polypropylene composition, based on the total weight of the blend, and wherein the MFR ratio C:A is 4 to 5.

14. The polymer blend of claim 13, wherein A is 3 to 5 g / 10 min, and C is 16 to 20 g / 10 min.

15. The polymer blend of any one of claims 1 to 2, wherein the first polypropylene composition: Density specific gravity of 0.89 g / cc to 0.92 g / cc as measured in accordance with ASTM D1505; A melting point of 145°C to 160°C as measured using differential scanning calorimetry (DSC); and MFR A is 10 to 20 g / 10 min, which is measured by ASTM D1238 (230° C. / 2.16 kg).

16. The polymer blend of any one of claims 1 to 2, wherein the first polypropylene composition: Density specific gravity of 0.89 g / cc to 0.92 g / cc as measured in accordance with ASTM D1505; A melting point of 145°C to 160°C as measured using differential scanning calorimetry (DSC); and MFR A is 20 to 30 g / 10 min, which is measured by ASTM D1238 (230° C. / 2.16 kg).

17. The polymer blend of any one of claims 1 to 2, wherein the first polypropylene composition: Density specific gravity of 0.89 g / cc to 0.92 g / cc as measured in accordance with ASTM D1505; A melting point of 160°C to 170°C as measured using differential scanning calorimetry (DSC); and MFR A is 25 to 35 g / 10 min, which is measured by ASTM D1238 (230° C. / 2.16 kg).

18. The polymer blend of any one of claims 1 to 2, wherein the first polypropylene composition: Density specific gravity of 0.89 g / cc to 0.92 g / cc as measured in accordance with ASTM D1505; A melting point of 160°C to 170°C as measured using differential scanning calorimetry (DSC); and MFR A is 90 to 110 g / 10 min, which is measured by ASTM D1238 (230° C. / 2.16 kg).

19. The polymer blend of any one of claims 1 to 2, wherein the blend is in the form of fibers.

20. The polymer blend of claim 19, wherein a plurality of said fibers are contained in fully oriented yarn (FOY), wherein said FOY has a denier of 300 and 400 at a 2:1 draw ratio, a maximum tenacity of 2 to 3, and a maximum elongation of 150 to 250.

21. The polymer blend of claim 19, wherein a plurality of said fibers are contained in a partially oriented yarn (POY), wherein said POY has a denier of 100 to 150, a maximum tenacity of 1.85 to 2.50, and a maximum elongation of 150 to 200 at a spinning rate of 4000 m / min.

22. A fabricated article comprising the polymer blend of any one of claims 1 to 21.

23. The fabricated article of claim 22, wherein the fabricated article is an extruded, blow molded, injection molded, rotationally molded, compression molded, 3-D printed, or thermoformed composition.

24. A method of making a fiber comprising the polymer blend of any one of claims 1 to 21, the method comprising: blending the second polypropylene composition with the first polypropylene composition to form the polymer blend; and Fibers are formed from the polymer blend.

25. The method of claim 24, wherein forming the fibers comprises: melting the polymer blend at a melt temperature of 250° C. or less to form a molten composition; extruding the molten composition through a spinneret to form extruded fiber filaments; and The extruded fiber filaments are drawn.

26. The method of claim 25, wherein the molten composition is extruded through a spinneret at a speed of 1500 to 4500 m / min.

27. The method of claim 25, wherein the drafting process has a draft ratio of 1.5:1 to 4.5:

1.

28. A method of increasing the melt flow rate (MFR) of a first polypropylene composition comprising polypropylene, the method comprising: blending the first polypropylene polymer composition with a second polypropylene composition to form a polymer blend, the second polypropylene composition comprising polypropylene and an organic peroxide, wherein the second polypropylene composition has been pre-extruded prior to forming the blend, Wherein the MFR of the polymer blend is greater than that of the first polypropylene composition.

29. The method of claim 28, wherein the polymer blend does not comprise any further organic peroxide than the organic peroxide present in the second polypropylene composition.

30. The process of any one of claims 28 to 29, wherein the second polypropylene composition: Density specific gravity of 0.89 g / cc to 0.92 g / cc as measured in accordance with ASTM D1505; A melting point of 145°C to 170°C as measured using differential scanning calorimetry (DSC); and The MFR is 500 to 2000 g / 10 minutes, which is measured by ASTM D1238 (230° C. / 2.16 kg).

31. The process according to any one of claims 28 to 29, wherein the polypropylene in the second polypropylene composition is a polypropylene homopolymer.

Images