Polypropylene composition
The polypropylene composition, with its specific blend of propylene homopolymer and ethylene copolymer, addresses the challenge of balancing processability, stiffness, and transparency, resulting in improved mechanical properties and haze for molded articles.
Patent Information
- Application Number
- PCT/EP2024/073848
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2023-09-12
- Filing Date
- 2024-08-26
- Publication Date
- 2025-03-20
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Abstract
Description
TITLEPOLYPROPYLENE COMPOSITIONFIELD OF THE INVENTION
[0001] The present disclosure relates to a polypropylene copolymer composition with an improved combination of processability, stiffness and transparency. These compositions may be employed for the production of molded articles, in particular injection molded articles or thermoformed articles such as containers.BACKGROUND OF THE INVENTION
[0002] Injection molded parts such as food packaging and plastic cups place specific requirements on the polymeric materials employed to produce these articles.
[0003] Polypropylene-based polymers have many characteristics, which make them suitable for applications such as molded articles, but also pipes, fittings and foams.
[0004] Frequently, polypropylene products of high stiffness are based on high molecular weight materials, which are often nucleated by adding nucleating agents, i.e. crystallization starts at a higher temperature and the crystallization speed is highWO 2018 / 104092 relates to a polypropylene composition comprising:A) from 50 wt% to 90 wt%; of a propylene homopolymer having a MFR L from 0.5 to 200 g / 10 min;B) from 10 wt% to 50 wt%; %; of a copolymer of propylene and ethylene having from 30.0 wt% to 70.0wt%, of ethylene derived units; the sum of the amount of component A) and B) being 100; the composition having: i) an intrinsic viscosity of the fraction soluble in xylene at 25 °C comprised between 2.2 and 4.0 dl / g; ii) a MFR L (from 0.5 to 50 g / 10 min; iii) a xylene soluble fraction ranging from 20 wt% to 50 wt%.
[0005] It has now been found that by fine tuning a polypropylene copolymer composition containing propylene homopolymer and propylene ethylene homopolymer it is possible to obtain a copolymer having good mechanical properties and good haze.SUMMARY OF THE INVENTION
[0006] Thus, the present disclosure provides a polypropylene composition comprising:A) From 65.5 wt% to 82.5 wt%; of a propylene homopolymer having a fraction insoluble in xylene at 25°C greater than 95.0 wt%; and a melt flow rate, MFR, measured according to ISO 1133 at 230 °C with a load of 2.16 kg comprised between 50.0 g / 10 min and 80.0 g / 10 min;B) From 17.5 wt% to 34.5 wt%; of a propylene ethylene copolymer having an ethylene derived units content ranging from 38.2 wt% to 48.3 wt%, measured by13C NMR; said polypropylene composition having: i) xylene soluble fraction at 25°C ranging from 24.0 wt% to 32.3 wt%; ii) the ethylene derived units content on the fraction soluble in xylene at 25°C ranging from 34.6 wt% to 42.0 wt%, measured by13C NMR;(iii) melt flow rate, MFR, measured according to ISO 1133 at 230 °C with a load of 2.16 kg, comprised between 12.0 g / 10 min and 38.0 g / 10 min;(iv) the intrinsic viscosity measured in tetrahydronaphthalene at 135° C, of the fraction soluble in xylene at 25°C ranging from 2.2 dl / g to 3.5 dl / g. the sum of the amounts of A) and B) being 100 wt% .DETAILED DESCRIPTION OF THE INVENTION
[0007] Thus, the present disclosure provides a polypropylene composition comprising:A) from 65.5 wt% to 82.5 wt%, preferably from 69.2 wt% to 80.2 wt%; more preferably from 71.0 wt% to 78.0 wt% of a propylene homopolymer having a fraction insoluble in xylene at 25°C greater than 95.0 wt%; preferably greater than 97.2 wt%; and a melt flow rate, MFR, measured according to ISO 1133 at 230 °C with a load of 2.16 kg comprised between 50.0 g / 10 min and 80.0 g / 10 preferably comprised between 55.0 g / 10 min and 75.0 g / 10; more preferably comprised between 60.0 g / 10 min and 70.0 g / 10 min;B) from 17.5 wt% to 34.5 wt%; preferably from 19.8 wt% to 30.8 wt%; more preferably from 22.0 wt% to 29.0 wt% of a propylene ethylene copolymer having an ethylene derived units content,measured by13C NMR; ranging from 38.2 wt% to 48.3 wt%; preferably from 40.6 wt% to 47.4 wt%; more preferably from 42.5 wt% to 47.0 wt%; said polypropylene composition having: i) xylene soluble fraction at 25°C ranging from 24.0 wt% to 32.3 wt%; preferably from 24.5 wt% to 30.5 wt%; more preferably from 25.0 wt% to 29.0 wt; ii) the ethylene derived units content on the fraction soluble in xylene at 25°C ranging from 34.6 wt% to 42.0 wt%; preferably from 35.2 wt% to 41.0 wt%; more preferably from 36.5 wt% to 40.0 wt% , measured by13C NMR; iii) a melt flow rate, MFR, measured according to ISO 1133 at 230 °C with a load of 2.16 kg comprised between 12.0 g / 10 min and 38.0 g / 10 min preferably comprised between 14.0 g / 10 min and 32.0 g / 10 min; more preferably comprised between 16.0 g / 10 min and 28.0 g / 10 min;(iv) the intrinsic viscosity measured in tetrahydronaphthalene at 135° C, of the fraction soluble in xylene at 25°C ranging from 2.2 dl / g to 3.5 dl / g; preferably from 2.4 dl / g to 3.2 dl / g; more preferably 2.6 dl / g to 3.0 dl / g. the sum of the amounts of A) and B) being 100 wt%.
[0008] For the present disclosure, the term “copolymer” is referred to polymers containing only two kinds of comonomers, such as propylene and ethylene.
[0009] The polypropylene composition of the present disclosure is not subjected to a chemical or physical visbreaking, i.e. the MFR is obtained with the polymerization process.
[0010] The polypropylene composition according to the present disclosure is preferably characterized by having one or more of the following properties: a) tensile modulus comprised between 1000 MPa and 700 MPa; preferably comprised between 920 MPa and 750 MPa; b) Charpy impact measured at 23°C higher than 35.0 kJ / m2; preferably higher than 40 kJ / m2; more preferably higher than 43.0 kJ / m2; the highest value being 80 kJ / m2; c) the elongation at break higher than 300 % preferably higher than 380 %, more preferably higher than 450 %; the higher value being 1000 %.
[0011] These features, due to the particular polymerization process used and the particular Ziegler Natta catalyst used in the polymerization, make the polypropylene composition accordingto the present disclosure particularly fit for the production of molded articles, in particular injection molded articles or thermoformed articles .The polypropylene composition of the present disclosure is obtained with a polymerization process in two or more stages in which component A) is obtained in the first stages and then component B) is obtained in the second stages in the presence of component A), each stage can be in gas-phase, operating in one or more fluidized or mechanically agitated bed reactors, slurry phase using as diluent an inert hydrocarbon solvent, or bulk polymerization using the liquid monomer (for example propylene) as a reaction medium. Preferably component B) is polymerized in a gas phase process in the presence of component A)
[0012] The polymerization is generally carried out at temperature of from 20 to 120°C, preferably of from 40 to 80°C. When the polymerization is carried out in gas-phase the operating pressure is generally between 0.5 and 5 MPa, preferably between 1 and 4 MPa. In the bulk polymerization the operating pressure is generally between 1 and 8 MPa, preferably between 1.5 and 5 MPa. Hydrogen is typically used as a molecular weight regulator.
[0013] The polypropylene composition herein disclosed is obtainable by a process comprising polymerizing propylene in the first stage (A) and copolymerizing propylene with ethylene in a second stage (B), in the presence in both stages of a solid catalyst component for the polymerization of olefins comprising a magnesium halide, a titanium compound having at least a Ti-halogen bond and at least an electron donor of formula (I)in which R1and R2are, independently, Ci-Cs alkyl groups, X is Si or C, R3and R4groups, independently, are selected from hydrogen, Ci-Cio hydrocarbon groups and halogens with the proviso that at least two R3are not hydrogen.
[0014] Preferably, R1and R2are the same and are selected from C1-C4 linear or branched alkyl groups and more preferably from methyl groups.
[0015] Preferably, R4groups, independently, are selected from hydrogen, C1-C4 linear or branched alkyl groups and halogens. More preferably, only one or two of R4groups are C1-C4 linear or branched alkyl groups or halogen. Preferred alkyl groups are methyl, isopropyl or t-butyl, while preferred halogens are Cl and F. The structures in which all R4groups are hydrogen are also preferred.
[0016] When R3is a hydrocarbon group it is preferably selected from C1-C4 linear or branched alkyl groups and more preferably from methyl groups.
[0017] When R3is a halogen it is preferably selected from Cl and F. More preferably it is F.
[0018] According to a preferred embodiment, X is carbon and R3is a hydrogen or hydrocarbon group preferably selected from C1-C4 linear or branched alkyl groups more preferably from methyl. Most preferred are the structures in which one R3is selected from hydrogen and the remaining two from methyl groups.
[0019] Another group of preferred structures are those in which X is carbon and R3is hydrogen or a halogen group preferably selected from Cl and F more preferably from F. Most preferred are the structures in which at least two of R3are selected from F and more preferably those in which all the R3groups are F.
[0020] According to another preferred embodiment, X is Si and R3is a hydrogen or hydrocarbon group preferably selected from C1-C4 linear or branched alkyl groups more preferably from methyl or ethyl. Most preferred are the structures in which all R3groups are selected from methyl.
[0021] Preferably the electron donor of formula (I) is 2-cyclohexyl-2-isopentyl-l,3- dim ethoxypropane; or 2-cyclohexyl-2-(3 ,3,3 -trifluoro -n-propyl)- 1 ,3 -dimethoxypropane.
[0022] By using the described catalyst component is possible to obtain The propylene ethylene copolymer herein disclosed having the reported particular properties.
[0023] The preparation of the solid catalyst component can be carried out according to several methods.
[0024] According to one method the solid catalyst component can be prepared by reacting a titanium compound of formula Ti(OR)q-yXy, where q is the valence of titanium and y is a number between 1 and q, preferably TiCk, with a magnesium chloride deriving from an adduct of formulaMgCk’pROH, where p is a number between 0.1 and 6, preferably from 2 to 3.5, and R is a hydrocarbon radical having 1-18 carbon atoms. The adduct can be suitably prepared in spherical form by mixing alcohol and magnesium chloride, operating under stirring conditions at the melting temperature of the adduct (100-130°C). Then, the adduct is mixed with an inert hydrocarbon immiscible with the adduct thereby creating an emulsion which is quickly quenched causing the solidification of the adduct in form of spherical particles. Examples of spherical adducts prepared according to this procedure are described in USP 4,399,054 and USP 4,469,648. The so obtained adduct can be directly reacted with Ti compound or it can be previously subjected to thermal controlled dealcoholation (80-130°C) so as to obtain an adduct in which the number of moles of alcohol is generally lower than 3, preferably between 0.1 and 2.5. The reaction with the Ti compound can be carried out by suspending the adduct (dealcoholated or as such) in cold TiCh (generally 0°C); the mixture is heated up to 80-130°C and kept at this temperature for 0.5-2 hours. The treatment with TiCh can be carried out one or more times. The electron donor compound can be added in the desired ratios during the treatment with TiCk
[0025] Suitable external electron-donor compounds include silicon compounds, ethers, esters, amines, heterocyclic compounds and particularly 2,2,6,6-tetramethylpiperidine and ketones.
[0026] A preferred class of external donor compounds is that of silicon compounds of formula (R6)a(R7)bSi(ORs)c, where a and b are integers from 0 to 2, c is an integer from 1 to 4 and the sum (a+b+c) is 4; Re, Rz, and Rs, are alkyl, cycloalkyl or aryl radicals with 1-18 carbon atoms optionally containing heteroatoms. Particularly preferred are the silicon compounds in which a is 1, b is 1, c is 2, at least one of Re and Rz is selected from branched alkyl, cycloalkyl or aryl groups with 3-10 carbon atoms optionally containing heteroatoms and Rs is a Ci-Cio alkyl group, in particular methyl. Examples of such preferred silicon compounds are methylcyclohexyldimethoxysilane (C donor), diphenyldimethoxysilane, methyl-t-butyldimethoxysilane, dicyclopentyldimethoxysilane (D donor), diisopropyldimethoxysilane, (2-ethylpiperidinyl)t-butyldimethoxysilane, (2- ethylpiperidinyl)thexyldimethoxysilane, (3,3,3-trifluoro-n-propyl)-(2-ethylpiperidinyl)- dimethoxysilane, methyl(3,3,3-trifluoro-n-propyl)dimethoxysilane. Moreover, the silicon compounds in which a is 0, c is 3, R? is a branched alkyl or cycloalkyl group, optionally containing heteroatoms, and Rs is methyl are also preferred. Examples of such preferred silicon compounds are cyclohexyltrimethoxysilane, t-butyltrimethoxysilane and thexyltrimethoxysilane.
[0027] The electron donor compound (iii) is used in such an amount to give a weight ratio between the organoaluminum compound and said electron donor compound (iii) of from 2.5 to 500, preferably from 3 to 300 and more preferably from 3.5 to 100.
[0028] The polymerization process can be carried out according to known techniques for example slurry polymerization using as diluent an inert hydrocarbon solvent, or bulk polymerization using the liquid monomer (for example propylene) as a reaction medium. Moreover, it is possible to carry out the polymerization process in gas-phase operating in one or more fluidized or mechanically agitated bed reactors.
[0029] The polymerization is generally carried out at temperature of from 20 to 120°C, preferably of from 40 to 80°C. When the polymerization is carried out in gas-phase the operating pressure is generally between 0.5 and 5 MPa, preferably between 1 and 4 MPa. In the bulk polymerization the operating pressure is generally between 1 and 8 MPa, preferably between 1.5 and 5 MPa. Hydrogen is typically used as a molecular weight regulator.
[0030] The polypropylene composition of the present disclosure can contain the additives that are commonly used in the art such as anti-oxidants, process stabilizers, slip agents, antistatic agents, antiblock agents, antifog agents and nucleating agents.
[0031] The following examples are given to illustrate, not to limit, the present disclosure: EXAMPLESXylene-soluble (XS) Fraction at 25 °C
[0032] Xylene Solubles at 25°C have been determined according to ISO 16 152.Intrinsic Viscosity (TV)
[0033] The sample is dissolved in tetrahydronaphthalene at 135 °C and then poured into a capillary viscometer. The viscometer tube (Ubbelohde type) is surrounded by a cylindrical glass jacket; this setup allows for temperature control with a circulating thermostatic liquid. The downward passage of the meniscus is timed by a photoelectric device.
[0034] The passage of the meniscus in front of the upper lamp starts the counter, which has a quartz crystal oscillator. The meniscus stops the counter as it passes the lower lamp and the efflux time is registered: this is converted into a value of intrinsic viscosity through Huggins' equation (Huggins, M.L., J. Am. Chem. Soc., 1942, 64, 2716) provided that the flow time of the pure solventis known at the same experimental conditions (same viscometer and same temperature). One single polymer solution is used to determine [q],Charpy impact test
[0035] Charpy impact test has been measured according to ISO 179-leA, e ISO 1873-2Tensile modulus
[0036] Tensile Modulus has been measured according to ISO 527-2, and ISO 1873-2 on injection molded sampleOligomer content
[0037] The determination of oligomer content by solvent extraction consists of treating 5g of polypropylene sample with 10 ml of methylenedichloride (CH2CI2) in an ultrasonic bath at 25°C for 4 hours. 1 rm of the extracted solution is injected into a capillary column and analysed by using FID, without any filtration. For quantitative estimation of oligomer content a calibration based on external standard method has been applied. In particular, a series of hydrocarbons (Cl 2- C22-C28- C40) is used.Melt flow rate (MIL)The melt flow rate MIL of the polymer was determined according to ISO 1133 (230°C, 2.16 Kg).13C NMR of propylene / ethylene copolymers
[0038] 13C NMR spectra were acquired on a Bruker AV-600 spectrometer equipped with cry oprobe, operating at 160.91 MHz in the Fourier transform mode at 120°C.
[0039] The peak of the Spp carbon (nomenclature according to “Monomer Sequence Distribution in Ethylene-Propylene Rubber Measured by 13C NMR. 3. Use of Reaction Probability Mode ” C. J. Carman, R. A. Harrington and C. E. Wilkes, Macromolecules, 1977, 10, 536) was used as internal reference at 29.9 ppm. The samples were dissolved in 1,1,2,2-tetrachloroethane- d2 at 120°C with a 8 % wt / v concentration. Each spectrum was acquired with a 90° pulse, 15 seconds of delay between pulses and CPD to remove 1H-13C coupling. 512 transients were stored in 32K data points using a spectral window of 9000 Hz.
[0040] The assignments of the spectra, the evaluation of triad distribution and the composition were made according to Kakugo (“Carbon- 13 NMR determination of monomer sequence distribution in ethylene-propylene copolymers prepared with 8-titanium trichloridediethylaluminum chloride” M. Kakugo, Y. Naito, K. Mizunuma and T. Miyatake, Macromolecules, 1982, 15, 1150) using the following equations:PPP = 100 Tpp / S PPE = 100 Tps / S EPE = 100 T55 / SPEP = 100 Spp / S PEE= 100 Sps / S EEE = 100 (0.25 Syg+0.5 S55) / SS = Tpp + Tps + Tss + Spp + Sps + 0.25 Syg + 0.5 S55
[0041] The molar percentage of ethylene content was evaluated using the following equation: E% mol = 100 * [PEP+PEE+EEE]The weight percentage of ethylene content was evaluated using the following equation:100 * E% mol * MWEE% wt. = >E% mol * MWE + P% mol * MWp where P% mol is the molar percentage of propylene content, while MWE and MWP are the molecular weights of ethylene and propylene, respectively.
[0042] The product of reactivity ratio nr? was calculated according to Carman (C.J. Carman,R.A. Harrington and C.E. Wilkes, Macromolecules, 1977; 10, 536) as:
[0043] The tacticity of Propylene sequences was calculated as mm content from the ratio of the PPP mmTpp (28.90-29.65 ppm) and the whole Tpp (29.80-28.37 ppm).
[0044] The ethylene content (C2) of component B) has been calculated by using the following equation: C2tot=C2bX2; wherein X2 is the fraction of component B) present in the composition X2 (ranges from 0 to 1).Flexural modulusFlexural Modulus is measured according to ISO 178, and supplemental conditions according to ISO 1873-2.Charpy impact test at 23°CCharpy impact test measured according to ISO 179-leA, e ISO 1873-2.Elongation at breakElongation at break measured according to ISO 527-2, and ISO 1873-2Head deflection temperature (HPT) measured at 0.45 MPa according to ASTM D 648.Catalyst systemThe catalyst system has been produced according to the method described in PCT / EP2023 / 068696. The catalyst used in example 1 is described in example 15 ofPCT / EP2023 / 068696. The catalyst used in example 2 is described in example 16 ofPCT / EP2023 / 068696.Propylene / Ethylene copolymerization Examples 1-2Prepolymerization treatment
[0045] Before introducing it into the polymerization reactors, the solid catalyst component described above have been contacted with triethyl aluminum (TEAL) and di-cyclopentyldimethoxy silane (donor D) in a ratio reported on table 1. Then the resulting mixture is subjected to prepolymerization by maintaining it in suspension in liquid propylene at 20 °C for about 5 minutes before introducing it into the polymerization reactor.Polymerization
[0046] The polymerization run is conducted in continuous mode in a series of three reactors equipped with devices to transfer the product from one reactor to the one immediately next to it. The first two reactors are liquid phase reactors, and the third is a fluid bed gas phase reactor. Component (A) is prepared in the first and second reactor, the first and second reactor have the same polymeriziton parameters, while component (B) is prepared in the third.
[0047] Hydrogen is used as molecular weight regulator.
[0048] The gas phase (propylene, ethylene and hydrogen) is continuously analyzed via gaschromatography.
[0049] At the end of the run the powder is discharged and dried under a nitrogen flow.
[0050] The main polymerization conditions are reported in Tablet.Table 1C3 propylene, C2 ethylene H2 hydrogen
[0051] The polymer of examples 1 and 2 and comparative example 3 have been characterized as reported in table 2Table 2
[0052] Comparative example 3 is the commercial grade SG702 sold by Lyondellbasell.
[0053] Examples 1 and 2 shows a better Charpy and elongation at break with respect to comparative example 3.
Claims
CLAIMSWhat is claimed is:
1. A polypropylene composition comprising:A) From 65.5 wt% to 82.5 wt%; of a propylene homopolymer having a fraction insoluble in xylene at 25°C greater than 95.0 wt%; and a melt flow rate, MFR, measured according to ISO 1133 at 230 °C with a load of 2.16 kg comprised between 50.0 g / 10 min and 80.0 g / 10 min;B) From 17.5 wt% to 34.5 wt%; of a propylene ethylene copolymer having an ethylene derived units content ranging from 40.6 wt% to 47.4 wt% measured by13C NMR; said polypropylene composition having: i) xylene soluble fraction at 25°C, measure according to ISO 16 152, ranging from 24.0 wt% to 32.3 wt%; ii) the ethylene derived units content on the fraction soluble in xylene at 25°C ranging from 34.6 wt% to 42.0 wt%, measured by13C NMR;(iii) melt flow rate, MFR, measured according to ISO 1133 at 230 °C with a load of 2.16 kg, comprised between 14.0 g / 10 min and 38.0 g / 10 min;(iv) the intrinsic viscosity measured in tetrahydronaphthalene at 135° C, of the fraction soluble in xylene at 25°C ranging from 2.2 dl / g to 3.5 dl / g. the sum of the amounts of A) and B) being 100 wt% .
2. The polypropylene composition according to claim 1 wherein the polypropylene composition comprises from 69.2 wt% to 80.2 wt% of component A) and from 19.8 wt% to 30.8 wt% of component B).
3. The polypropylene composition according to anyone of claims 1-2 wherein the xylene soluble fraction at 25 °C ranges from 24.5 wt% to 30.5 wt%.
4. The polypropylene composition according to anyone of claims 1-3 wherein in component A) the melt flow rate, MFR, measured according to ISO 1133 at 230 °C with a load of 2.16 kg is comprised between 55.0 g / 10 min and 75.0 g / 10 min.
5. The polypropylene composition according to anyone of claims 1-4 wherein the intrinsic viscosity measured in tetrahydronaphthalene at 135° C, of the fraction soluble in xylene at 25°C ranges from 2.4 dl / g to 3.2 dl / g.
6. The polypropylene composition according to anyone of claims 1-5 wherein the ethylene derived units content on the fraction soluble in xylene at 25°C ranges from 35.2 wt% to 41.0 wt%.
7. The polypropylene composition according to anyone of claims 1-6 wherein the ethylene derived units content on the fraction soluble in xylene at 25 °C ranges from 36.5 wt% to 40.0 wt%.
8. The polypropylene composition according to anyone of claims 1-7 wherein the intrinsic viscosity measured on the fraction soluble in xylene at 25°C ranges from 2.6 dl / g to 3.0 dl / g.
9. The polypropylene composition according to anyone of claims 1-8 wherein the melt flow rate, MFR, measured according to ISO 1133 at 230 °C with a load of 2.16 kg is comprised between 14.0 g / 10 min and 32.0 g / 10 min.
10. The polypropylene composition according to anyone of claims 1 -9 wherein the polypropylene composition comprises from 71.0 wt% to 78.0 wt% of component A) and from 22.0 wt% to 29.0 wt% of component B).
11. The polypropylene composition according to anyone of claims 1-10 being obtainable by a process comprising polymerizing propylene in the first stage (A) and copolymerizing propylene with ethylene in a second stage (B), in the presence in both stages of a solid catalyst component for the polymerization of olefins comprising a magnesium halide, a titanium compound having at least a Ti-halogen bond and at least an electron donor of formula (I)in which R1and R2are, independently, C1-C5 alkyl groups, X is Si or C, R3and R4groups, independently, are selected from hydrogen, C1-C10 hydrocarbon groups and halogens with the proviso that at least two R3are not hydrogen.
12. The polypropylene composition according to claim 11 wherein in the compound of formula (I) R1and R2are the same and are selected from C1-C4 linear or branched alkyl groups.
13. The polypropylene composition copolymer according to claims 11 or 12 wherein in the compound of formula (I) R4groups, independently, are selected from hydrogen, C1-C4 linear or branched alkyl groups and halogens.14 The polypropylene composition according to claims 11 or 12 wherein in the compound of formula (I) R3is selected from C1-C4 linear or branched alkyl groups.
15. An injection molded article comprising the polypropylene composition of claims 1-14.
Citation Information
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