Title of Invention

A POLYPROPYLENE COMPOSITION AND METHOD OF MANUFACTURING EXTRUSION BLOWN MOLDED BOTTLES WITH HIGH STIFFNESS AND TRANSPARENCY

Abstract A polypropylene composition comprising a random propylene copolymer (R-PP), a high melt strength polypropylene (HMS-PP), a polypropylene (B) and a clarifier (C), wherein (a) the random propylene copolymer (R-PP) (i) comprises units derived from propylene and at least another C2 to C20 a- olefin and (ii) has a higher branching index g' than the high melt strength polypropylene (HMS-PP), (b) the high melt strength polypropylene (HMS-PP) has a branching index g' of less than 1.0, (c) the polypropylene (B) has a MFR2 (230 °C) measured according to ISO 1133 of at least 400 g/10min, (d) the clarifier (C) comprises at least one a-nucleating agent (N), and (e) the polypropylene composition has a MFR2 (230 °C) measured according to ISO 1133 of at least 2.0 g/10min. wherein further, (f) the polypropylene (B) is different to the random propylene copolymer (R-PP) at least in view of the melt flow rate MFR2 (230 °C) and (g) the polypropylene (B) has a higher melt flow rate MFR2 (230 °C) than the high melt strength polypropylene (HMS-PP).
Full Text The present inventions relates to a new polypropylene composition, its use and
manufacture as well as to new articles comprising said polypropylene composition.
It is well known in the polymer field that different applications require specifically
tailored polymers to achieve the individual demanding properties. For instance a
polymer used for injection molding must necessarily have other properties as a
polymer used for blow molding.
The extrusion blow molding process for instance is a very special process that allows
in a flexible and cheap way the preparation of different kind of bottles with respect to
size and shape. Main drawback in this process is that the solidification step is very
special compared to normal injection molding.
In the extrusion blow molding process a polymer melt is first extruded through a
tubular die into air forming a polymer tube, subsequently blowing up said polymer
tube (typically called "parison" in this technical field) until the outside of the tube
reaches the boundaries of the mold. To cover the wall of the mold fully with the
blown up polymer tube is rather difficult compared to injection molding because the
air between polymer tube and mold has to be removed totally which is a demanding
process step. Further the inside of the polymer tube is not in contact with the mold
and therefore there is only little possibility to influence the inner surface structure of
the tube. As a consequence thereof extrusion blown molded articles, like bottles,
normally show less transparency compared to any injection molded articles or
injection stretched blown molded articles (ISBM). For instance, the surface property
inside and/or outside of extrusion blown bottles is typically non-uniform (flow lines,
melt fracture) leading to lower overall transparency compared to injection molded
bottles. A certain improvement of the transparency can be achieved by visbreaking
the polymer material but this concept has quite some limitation and can only be
applied for relatively small bottles since a certain level of melt strength is essential
for proper processing. Accordingly bigger bottles (volume of 11 or more) are not
producible with visbroken polypropylene in an extrusion blow molding process.
Beside transparency also stiffness is very important for the performance of a bottle.
Higher stiffness would allow reducing the wall thickness of a bottle and is also
important for the filling process (no deterioration of the bottle). Moreover a better
stiffness leads also to improved stackability. The stiffness of bottles is reflected by
the so called top load (top load is the maximum force applied to a bottle before it
starts to collapse).
Further it is well known that the extruded parison tends to swell inter alia in wall
thickness. Even though the swell effect is to some extent desired it should not
diverge too much from known reference grades, in particular from the specific
reference grade "RB307MO" of Borealis.
Thus the object of the present invention is to provide a polypropylene composition
which enables the preparation of bottles, in particular big sized bottles, i.e. bottles
with more than 1 liter filling volume, by an extrusion blow molding process, wherein
the bottles are featured by good haze, gloss and stiffness. Further it is desired that
during the preparation of the bottles a weight swell occurs, which differs only little
from known grades (i.e. "RB307MO" of Borealis) used in extrusion blow molding
processes.
The finding of the present invention is that a polypropylene must be combined with a
branched polypropylene, like a Y/H-shaped polypropylene, i.e. a high melt strength
polypropylene, and a further polypropylene with high melt flow rate.
Accordingly the present invention is directed to a polypropylene composition
comprising a random propylene copolymer (R-PP), a high melt strength
polypropylene (HMS-PP), a polypropylene (B) being different to the random
propylene copolymer (R-PP) at least in view of the melt flow rate MFR2 (230 °C)
and a clarifier (C), wherein
(a) the random propylene copolymer (R-PP) comprises units derived from
propylene and at least another C2 to C20 a-olefin,
(b) optionally the high melt strength polypropylene (HMS-PP) has a branching
index g' of less than 1.0, preferably of 0.9 or less,
(c) the polypropylene (B) has a MFR2 (230 °C) of at least 400 g/lOmin,
(d) the clarifier (C) comprises at least one a-nucleating agent (N), and
(e) the polypropylene composition has a MFR2 (230 °C) of at least 2.0 g/lOmin.
Thus in a specific embodiment the polypropylene composition according to this
invention comprises a random propylene copolymer (R-PP), a high melt strength
polypropylene (HMS-PP), a polypropylene (B), and a clarifier (C), wherein
(a) the random propylene copolymer (R-PP) comprises units derived from
propylene and at least another C2 to C20 a-olefin, and additionally
(i) has a higher branching index g' than the high melt strength
polypropylene (HMS-PP), preferably is unbranched, more preferably
has a branching index g' of 1.0,
and/or
(ii) has a gel content below 0.15 wt.-%,

(b) the high melt strength polypropylene (HMS-PP) has a branching structure,
preferably has a branching index g' of less than 1.0, more preferably of 0.9 or
less,
(c) the polypropylene (B) has a MFR2 (230 °C) of at least 400 g/10min,
(d) the clarifier (C) comprises at least one a-nucleating agent (N), and
(e) the polypropylene composition has a MFR.2 (230 °C) of at least 2.0 g/lOmin,
wherein further
(f) the polypropylene (B) is (chemically) different to the random propylene
copolymer (R-PP), preferably the polypropylene (B) is different to the
random propylene copolymer (R-PP) at least in view of the melt flow rate
MFR2 (230 °C), still more preferably the polypropylene (B) has a higher melt
flow rate MFR2 (230 °C) than the random propylene copolymer (R-PP) and
(g) optionally the polypropylene (B) is (chemically) different to high melt
strength polypropylene (HMS-PP), preferably the polypropylene (B) is
(chemically) different to high melt strength polypropylene (HMS-PP) at least
in view of the melt flow rate MFR2 (230 °C), still more preferably the
polypropylene (B) has a higher melt flow rate MFR2 (230 °C) than the high
melt strength polypropylene (HMS-PP).
Preferably the polypropylene compositions as defined above comprise as polymer
components only the random propylene copolymer (R-PP), the polypropylene (B)
and the high melt strength polypropylene (HMS-PP) as defined above and in further
detail below.
It has been surprisingly found out that such a polypropylene composition has
superior properties compared to known polypropylene compositions, in particular to
those used for extrusion blown molding processes. The polypropylene composition
of the present invention enables in particular to produce extrusion blown bottles with
low haze, exceptional good gloss and stiffness in terms of high top load. Further it
has been observed that the weight swell does not differ from commercial products
(see table 1).
In the following the present invention is described in more detail.
One essential requirement of the inventive polypropylene composition is its
increased melt flow rate. The melt flow rate mainly depends on the average
molecular weight. This is due to the fact that long molecules render the material a
lower flow tendency than short molecules. An increase in molecular weight means a
decrease in the MFR-value. The melt flow rate (MFR) is measured in g/10 min of the
polymer discharged through a defined die under specified temperature and pressure
conditions and the measure of viscosity of the polymer which, in turn, for each type
of polymer is mainly influenced by its molecular weight but also by its degree of
branching. The melt flow rate measured under a load of 2.16 kg at 230 °C
(ISO 1133) is denoted as MFR2 (230 °C). Accordingly, it is preferred that the
inventive polypropylene composition has an MFR2 (230 °C) of at least 2.0 g/10min,
more preferably of at least 2.2 g/lOmin. Accordingly it is in particular appreciated
that the inventive polypropylene composition has a MFR2 (230 °C) in the range of
2.0 to 4.5 g/10 min, more preferably of 2.1 to 3.8 g/10 min, still more preferably of
2.2 to 3.5 g/10 min.
Further, as stated above the new polypropylene composition must comprise a high
melt strength polypropylene (HMS-PP). Such polymer types improve the melt
strength of the polypropylene composition. Accordingly it is preferred that the
polypropylene composition is further characterized by a strain hardening behavior
with a haul-off force Fmax of at least 7.0 cN and a draw down velocity vmax of at least

180 mm/s, more preferably by a strain hardening behavior with a haul-off force Fmax
of at least 7.5 cN and a draw down velocity vmax of at least 185 mm/s.
Further the polypropylene composition can be additionally defined by the gel
content. The gel content is a good indicator for the chemical modification of the
polypropylene composition or its components. Accordingly the present invention is
featured by relatively moderate gel content, i.e. of not more than 1.00 wt.-%, even
more preferred of not more than 0.80 wt.-%, still more preferred of not more than
0.50 wt.-% determined as the relative amount of polymer insoluble in boiling xylene
(xylene hot insoluble fraction, XHI). On the other hand the polypropylene
composition must comprise a certain amount of high melt strength polypropylene
(HMS-PP). Accordingly the amount of gel content in the polypropylene composition
is preferably more than 0.15 wt.-%, more preferably of at least 0.27 wt.-%. Thus a
preferred range for the gel content of the polypropylene composition is 0.05 to
0.90 wt.-%, like 0.15 to 0.90 wt.-%, more preferred 0.26 to 0.8 wt.-%.
Further it is appreciated that the polypropylene composition is free of any
elastomeric polymer component, like an ethylene propylene rubber. In other words
the polypropylene composition shall be not a heterophasic polypropylene
composition, i.e. a system consisting of a polypropylene matrix in which an
elastomeric phase is dispersed. Such systems are featured by a rather high xylene
cold soluble content. Accordingly, the present polypropylene composition differs
from such a heterophasic system by a rather low xylene cold soluble (XCS) content.
Therefore the polypropylene composition has preferably a xylene cold soluble
fraction (XCS) of not more than 15.0 wt-%, more preferably of not more than 14.0
wt.-%, yet more preferably of not more than 12.0 wt.-%, like not more than 11.5 wt.-
%.

Further the polypropylene composition can be specified by the amount of
comonomer units other than propylene within the polypropylene composition.
Accordingly it is appreciated that the amount of units derived from d to C20 olefins other than propylene is not more than 7.0 wt.-%, preferably not more than 6.0
wt.-%, like not more than 5.5 wt.-%, in the polypropylene composition.
In the following the present polypropylene composition is further defined by the
polymer components within the composition.
The random propylene copolymer (R-PP) comprises units derived from propylene
and at least another C2 to C20 a-olefin, preferably at least another C2 to C10 a-olefin.
Accordingly the random propylene copolymer (R-PP) comprises units derived from
propylene and at least another a-olefin selected from the group consisting of ethylene
C4 a-olefin, C5 a-olefin, C6 a-olefin, C7 a-olefin, C8 a-olefin, C9 a-olefin and C10 a-
olefin. More preferably the random propylene copolymer (R-PP) comprises units
derived from propylene and at least another a-olefin selected from the group
consisting of ethylene, 1-butene, 1-pentene, l-hexene, 1-heptene, 1-octene, 1-nonene
and 1-decene, wherein ethylene, 1-butene and l-hexene are preferred. It is in
particular preferred that the random propylene copolymer (R-PP) consists of units
derived from propylene and ethylene. The amount of units derived from C2 to C20 ot-
olefins other than propylene in the random propylene copolymer (R-PP) is in the
range of 1.0 to 7.0 wt.-%, more preferably 1.5 to 6.0 wt.-%, still more preferably 2.0
to 5.5 wt.-%.
Preferably the random propylene copolymer (R-PP) is isotactic. Accordingly it is
appreciated that the random propylene copolymer (R-PP) has a rather high pentad
concentration, i.e. higher than 90 %, more preferably higher than 92 %, still more

preferably higher than 93 % and yet more preferably higher than 95 %, like higher
than 99 %.
One requirement in the present invention is that units derived from C2 to C20 a-
olefins other than propylene within the propylene copolymer (R-PP) are randomly
distributed. The Randomness indicates the amount of isolated comonomer units, i.e.
those which have no other comonomer units in the neighbour, compared to the total
amount of comonomers in the polymer chain. In a preferred embodiment, the
randomness of the random propylene copolymer (R-PP) is at least 30 %, more
preferably at least 50 %, even more preferably at least 60 %, and still more
preferably at least 65 %.
Further it is appreciated that the xylene soluble content of the random propylene
copolymer (R-PP) is a rather low. Accordingly the random propylene copolymer (R-
PP) has preferably a xylene cold soluble fraction (XCS) measured according to ISO
6427 (23 °C) of not more than 14.0 wt-%, more preferably of not more than 13.0 wt.-
%, yet more preferably of not more than 12.0 wt.-%, like not more thanl 1.5 wt.-%.
Thus a preferred range is 1.0 to 14.0 wt.-%, more preferred 1.0 to 13.0 wt.-%, still
more preferred 1.2 to 11.0 wt.-%.
The random propylene copolymer (R-PP) can be unimodal or multimodal, like
bimodal in view of the molecular weight distribution and/or the comonomer content
distribution.
When the random propylene copolymer (R-PP) is unimodal with respect to the
molecular weight distribution and/or comonomer content, it may be prepared in a
single stage process e.g. as slurry or gas phase process in a slurry or gas phase
reactor. Preferably, the unimodal the random propylene copolymer (R-PP) is
polymerized as a slurry polymerization. Alternatively, the unimodal the random
propylene copolymer (R-PP) may be produced in a multistage process using at each
stage process conditions which result in similar polymer properties.
The expression "multimodal" or "bimodal" used herein refers to the modality of the
polymer, i.e.
¦ the form of its molecular weight distribution curve, which is the graph of the
molecular weight fraction as a function of its molecular weight,
or more preferably
¦ the form of its comonomer content distribution curve, which is the graph of
the comonomer content as a function of the molecular weight of the polymer
fractions.
As will be explained below, the polymer components of the the random propylene
copolymer (R-PP) can be produced in a sequential step process, using reactors in
serial configuration and operating at different reaction conditions. As a consequence,
each fraction prepared in a specific reactor will have its own molecular weight
distribution and/or comonomer content distribution.
When the distribution curves (molecular weight or comonomer content) from these
fractions are superimposed to obtain the molecular weight distribution curve or the
comonomer content distribution curve of the final polymer, these curves may show
two or more maxima or at least be distinctly broadened when compared with curves
for the individual fractions. Such a polymer, produced in two or more serial steps, is
called bimodal or multimodal, depending on the number of steps.
Accordingly the random propylene copolymer (R-PP) may be multimodal, like
bimodal, in view of the comonomer content and/or molecular weight. It is in
particular appreciated that the the random propylene copolymer (R-PP) is
multimodal, like bimodal, in view of the comonomer content.
Further in case the random propylene copolymer (R-PP) is of multimodal, like
bimodal, character, in particular multimodal, like bimodal, in view of the comonomer
content, it is appreciated that the individual fractions are present in amounts
influencing the properties of the material. Accordingly it is appreciated that each of
these fractions is at least present in the amount of 10 wt.-% based on the random
propylene copolymer (R-PP). Accordingly in case of a bimodal system, in particular
in view of the comonomer content, the split of the two fractions is roughly 50 : 50.
Thus in one embodiment the random propylene copolymer (R-PP) comprises two
fractions which differ in their comonomer content, like ethylene content (preferably
as the only comonomer in the random propylene copolymer (R-PP)), wherein the
first fraction is present from 40 to 60 wt.-% and the second fraction from 60 to 40
wt.-%. In such a case the random propylene copolymer (R-PP) comprises at least two
fractions, more preferably consists of two fractions, that have a comonomer content,
like ethylene content, which differ of at least 2.0 wt.-%, more preferably differ of at
least 2.5 wt.-%. On the other hand the difference in the comonomer content in the
two fractions should be not too high, i.e. not higher than 6.0 wt.-%, preferably not
higher than 5.0 wt%, to avoid any separation tendencies. Thus it is appreciated that
the random propylene copolymer (R-PP) comprises at least two fractions, more
preferably consists of two fractions, that have comonomer contents which differ of
2.0 to 6.0 wt.-%, more preferably of 2.5 to 5.0 wt.-%. Accordingly in one
embodiment the random propylene copolymer (R-PP) consists of a first fraction
being a propylene homopolymer and a second fraction being a propylene copolymer
having a comonomer content, preferably ethylene content, of at least 2.0 wt.-%, more
preferably of at least 3.0 wt.-%, like at least 3.5 wt.-%.
As comes already appereant from the wording used in the instant invention the
random propylene copolymers (R-PP) is not only chemically different to the
propylene (B) but different to the high melt strenght polypropylene (HMS-PP). One
essential difference is that the random propylene copolymers (R-PP) (compared to
the high melt strenght polypropylene (HMS-PP)) is unbranched. In other words the
random propylene copolymers (R-PP) has preferably a branching index g' of 1.0. A
further distingushing feature between the high melt strenght polypropylene (HMS-
PP) and the the random propylene copolymers (R-PP) is preferably the gel content
expressed in the amount of the xylene hot insoluble fraction (XHI). Accordingly the
random propylene copolymers (R-PP) has a gel content below 0.15 wt.-%, more
preferably has no detectable gel content.
In particular suitable random propylene copolymers (R-PP) are those as for instance
described in EP 1 580 207 Al and WO 2003/002639 Al.
As stated above, the inventive polypropylene composition must at least comprise - as
polymer components - a random propylene copolymer (R-PP), a polypropylene (B)
and a high melt strength polypropylene (HMS-PP). The three components must be
chosen in such a way that in particular the required MFR2 (230 °C) of at least 2.0
g/10min for the final polypropylene composition is met. In principle visbreaking is
an option to increase the melt flow rate of the polypropylene composition. However
even though it has been discovered that visbreaking of a polypropylene composition
may improve the haze and gloss of the extrusion blown molded articles, it has been
now surprisingly found out that the increase of the melt flow rate by the
incorporation of a viscous polypropylene, i.e. polypropylene (B), leads to much
better properties. Without be bonded to the theory, it is believed that the addition of a
polypropylene with rather high melt flow rate to a mixture of non-visbroken random

propylene copolymer (R-PP) and a high melt strength polypropylene (HMS-PP)
leads to much better haze and gloss properties compared to a visbroken
polypropylene of random propylene copolymer (R-PP) and optionally high melt
strength polypropylene (HMS-PP), since the viscous polypropylene may improve the
surface of the extrusion blown molded articles and therewith the overall transparency
of said article. Accordingly it is preferred that neither the polypropylene composition
as whole nor the random propylene copolymer (R-PP) has been visbroken.
Accordingly, it is appreciated that the random propylene copolymer (R-PP) has a
MFR2 (230 °C) of at least 0.5 g/10min, more preferably in the range of 0.5 to 2.8
g/10min, yet more preferably of 1.0 to 2.5 g/10min, like 1.3 to 2.0 g/10min.
The preparation of the random propylene copolymer (R-PP) will be defined in more
detail below.
As a further essential requirement of the present invention a high melt strength
polypropylene (HMS-PP) must be used. Such polymer types are characterized by a
certain degree of branching. Possible high melt strength polypropylenes (HMS-PP)
are so called Y/H-polypropylenes and for instance described in EP 0 787 750, i.e.
single branched polypropylene types (Y polypropylenes having a backbone with a
single long side-chain and an architecture resembles a "Y") and polypropylene types
in which polymer chains are coupled with a bridging group (an architecture
resembles a "H")- Such polypropylenes are characterized by rather high melt
strength. A parameter of the degree of branching is the branching index g'. The
branching index g' correlates with the amount of branches of a polymer. The
branching index g' is defined as g' = [IV]br/[IV]lin in which g' is the branching index,
[IV]br is the intrinsic viscosity of the branched polypropylene and [IV]lin is the
intrinsic viscosity of the linear polypropylene having the same weight average

molecular weight (within a range of ±10 %) as the branched polypropylene. Thereby,
a low g'-value is an indicator for a high branched polymer. In other words, if the g'-
value decreases, the branching of the polypropylene increases. Reference is made in
this context to B.H. Zimm and W.H. Stockmeyer, J. Chem. Phys. 17,1301 (1949).
This document is herewith included by reference. Thus it is preferred that the
branching index g' of the high melt strength polypropylene (HMS-PP) shall be less
than 1.0, more preferably equal or less than 0.9, like less than 0.8. In another
preferred embodiment the branching index g' of the high melt strength polypropylene
(HMS-PP) shall be preferably less than 0.7.
The high degree of branching of the high melt strength polypropylene (HMS-PP)
contributes also to its melt strength. Accordingly it is preferred that the high melt
strength polypropylene (HMS-PP) is further characterized by a strain hardening
behavior with a haul-off force Fmax of at least 10.0 cN and a draw down velocity vmax
of at least 200 mm/s, more preferably by a strain hardening behavior with a haul-off
force Fmax of at least 20.0 cN and a draw down velocity vmax of at least 250 mm/s, yet
more preferably by a strain hardening behavior with a haul-off force FmaX of at least
25.0 cN and a draw down velocity vmax of at least 250 mm/s.
Such a high melt strength polypropylene (HMS-PP) is preferably obtained by
modifying, i.e. chemically modifying, a polypropylene. Such a modification is
necessary to achieve the branching structure and/or the strain hardening phenomena
of the high melt strength polypropylene (HMS-PP). Such a modification has also
influence on the gel content of the high melt strength polypropylene (HMS-PP).
Accordingly it is justified to define the high melt strength polypropylene (HMS-PP)
further and/or alternatively by its gel content. Thus it is appreciated that the high melt
strength polypropylene (HMS-PP) is featured by a relatively moderate gel content,
i.e. of not more than 1.00 wt.-%, even more preferred of not more than 0.80 wt.-%,
still more prefeixed of not more than 0.50 wt.-% determined as the relative amount of
polymer insoluble in boiling xylene (xylene hot insoluble fraction, XHI). On the
other hand the high melt strength polypropylene (HMS-PP) may show a certain
degree of branching and thus a certain amount of gel content, i.e. of at least 0.15 wt.-
%, more preferably of at least 0.27 wt.-%. Thus a preferred range for the gel content
of the high melt strength polypropylene (HMS-PP) is 0.05 to 0.90 wt.-%, more
preferred 0.26 to 0.8 wt.-%.
Additionally it is preferred that in the melt strength polypropylene (HMS-PP) has an
MFR2 (230 °C) in a range of 1.0 to 10.0 g/10 min, more preferably of 4.0 to 8.5 g/10
min, still more preferably of 6.0 to 8.0 g/10 min.
Preferably, the high melt strength polypropylene (HMS-PP) has a density of at least
850 kg/m3, more preferably of at least 875 kg/m3 and most preferably of at least 900
kg/m3.
Further, preferably, the high melt strength polypropylene (HMS-PP) has a density of
not more than 950 kg/m3, more preferably of not more than 925 kg/m3 and most
preferably of not more than 910 kg/m3.
Preferably, the high melt strength polypropylene (HMS-PP) has a melting point of at
least 140°C, more preferably of at least 150°C and most preferably of at least 160°C.
As stated above, the melt strength polypropylene (HMS-PP) is preferably a modified
polypropylene. Accordingly the melt strength polypropylene (HMS-PP) can be
further defined by the way obtained. Thus the melt strength polypropylene (HMS-
PP) is preferably the result of treating an unmodified polypropylene (A) with
thermally decomposing radical-forming agents and/or with ionizing radiation.

However in such a case a high risk exists that the polypropylene (A) is degraded,
which is detrimental. Thus it is preferred that the modification is accomplished by
the use of bifunctionally unsaturated monomer(s) and/or multifunctionally
unsaturated low molecular weight polymer(s) as chemically bound bridging unit(s).
A suitable method to obtain the melt strength polypropylene (HMS-PP) is for
instance disclosed in EP 0 787 750, EP 0 879 830 Al and EP 0 890 612 A2. All
documents are herewith included by reference. Thereby, the amount of peroxide is
preferably in the range of 0.05 to 3.00 wt.-% based on the unmodified polypropylene
(A).
Accordingly in one preferred embodiment the high melt strength polypropylene
(HMS-PP) comprises units derived from
(i) propylene and
(ii) bifunctionally unsaturated monomer(s) and/or multifunctionally unsaturated
low molecular weight polymer(s).
"Bifunctionally unsaturated or multifunctionally unsaturated" as used above means
preferably the presence of two or more non-aromatic double bonds, as in e.g.
divinylbenzene or cyclopentadiene or polybutadiene. Only such bi- or
multifunctionally unsaturated compounds are used which can be polymerized
preferably with the aid of free radicals. The unsaturated sites in the bi- or
multifunctionally unsaturated compounds are in their chemically bound state not
actually "unsaturated", because the double bonds are each used for a covalent bond to
the polymer chains of the polypropylene (A).
Reaction of the bifunctionally unsaturated monomer(s) and/or multifunctionally
unsaturated low molecular weight polymer(s), preferably having a number average
molecular weight (Mn) unsaturated monomers with the propylene polymer composition may be performed in
the presence of a thermally free radical forming agent, e. g. decomposing free
radical-forming agent, like a thermally decomposable peroxide and/or ionizing
radiation or microwave radiation.
The bifunctionally unsaturated monomers may be
- divinyl compounds, such as divinylaniline, m-divinylbenzene, p-
divinylbenzene, divinylpentane and divinylpropane;
allyl compounds, such as allyl acrylate, allyl methacrylate, allyl
methyl maleate and allyl vinyl ether;
dienes, such as 1,3-butadiene, chloroprene, cyclohexadiene,
cyclopentadiene, 2,3-dimethylbutadiene, heptadiene, hexadiene,
isoprene and 1,4-pentadiene;
aromatic and/or aliphatic bis (maleimide) bis (citraconimide) and
mixtures of these unsaturated monomers.
Especially preferred bifunctionally unsaturated monomers are 1,3-butadiene,
isoprene, dimethyl butadiene and divinylbenzene.
The multifunctionally unsaturated low molecular weight polymer, preferably having
a number average molecular weight (Mn) one or more unsaturated monomers.
Examples of such low molecular weight polymers are
- poly butadienes, especially where the different microstractures in the
polymer chain, i.e. 1,4-cis, 1,4-trans and l,2-(vinyl) are predominantly
in the 1,2-(vinyl) configuration

Alkyl peroxides: allyl t-butyl peroxide, 2,2-bis(t-butylperoxybutane), l,l-bis(t-
butylperoxy)-3,3,5-trimethylcyclohexane, n-butyl-4,4-bis(t-butylperoxy) valerate,
diisopropylaminomethyl-t-amyl peroxide, dimethylaminomethyl-t-amyl peroxide,
diethylaminomethyl-t-butyl peroxide, dimethylaminomethyl-t-butyl peroxide, 1,1-di-
(t-amylperoxy)cyclohexane, t-amyl peroxide, t-butylcumyl peroxide, t-butyl peroxide
and/or 1-hydroxybutyl n-butyl peroxide.
Peresters and peroxy carbonates: butyl peracetate, cumyl peracetate, cumyl
perpropionate, cyclohexyl peracetate, di-t-butyl peradipate, di-t-butyl perazelate, di-t-
butyl perglutarate, di-t-butyl perthalate, di-t-butyl persebacate, 4-nitrocumyl
peipropionate, 1-phenylethyl perbenzoate, phenylethyl nitro-perbenzoate, t-
butylbicyclo-(2,2,l)heptane percarboxylate, t-butyl-4-carbomethoxy perbutyrate, t-
butylcyclobutane percarboxylate, t-butylcyclohexyl peroxycarboxylate, t-
butylcyclopentyl percarboxylate, t-butylcyclopropane percarboxylate, t-
butyldimethyl percinnamate, t-butyl-2-(2,2-diphenylvinyl) perbenzoate, t-butyl-4-
methoxy perbenzoate, t-butylperbenzoate, t-butylcarboxycyclohexane, t-butyl
pernaphthoate, t-butyl peroxyisopropylcarbonate, t-butyl pertoluate, t-butyl-1-
phenylcyclopropyl percarboxylate, t-butyl-2-propylperpentene-2-oate, t-butyl-1-
methylcyclopropyl percarboxylate, t-butyl-4-nitrophenyl peracetate, t-
butylnitrophenyl peroxycarbamate, t-butyl-N-succiimido percarboxylate, t-butyl
percrotonate, t-butyl permaleic acid, t-butyl permethacrylate, t-butyl peroctoate, t-
butyl peroxyisopropylcarbonate, t-butyl perisobutyrate, t-butyl peracrylate and/or t-
butyl perpropionate.
Or mixtures of these above listed free radical-forming agents.
The unmodified polypropylene (A) to prepare such a high melt strength
polypropylene (HMS-PP) has preferably a MFR2 (230 °C) in a range of 0.05 to

45.00 g/10 min. More preferably the MFR2 (230 °C) is in a range of 0.05 to
35.00 g/10 min in case the unmodified polypropylene (A) is a homopolymer. On the
other hand the MFR2 (230 °C) is in a range of 0.05 to 45.00 g/10 min in case the
unmodified polypropylene (A) is a copolymer.
Preferably the unmodified polypropylene (A) is a homopolymer. The expression
homopolymer used in the instant invention relates to a polypropylene that consists
substantially, i.e. of at least 97 wt.-%, preferably of at least 98 wt.-%, more
preferably of at least 99 wt.-%, still more preferably of at least 99.8 wt.-% of
propylene units. In a preferred embodiment only propylene units in the propylene
homopolymer are detectable. The comonomer content can be determined with FT
infrared spectroscopy, as described below in the examples.
Preferably the high melt strength polypropylene (HMS-PP) is produced from the
unmodified polypropylene (A) as defined above under process conditions as defined
in detail below.
As a further polymer component a viscous polypropylene is required. As stated
above this polypropylene (B) must be chemically different to the random propylene
copolymer (R-PP). Of course the propylene (B) is also prefeably chemically different
to the high melt strenght polypropylene (HMS-PP).
One essential difference between the polypropylene (B) and the high melt strenght
polypropylene (HMS-PP) is that the the polypropylene (B) is an unbranched
polypropylene whereas the high melt strenght polypropylene (HMS-PP) shows a
branching structure. In other words the polypropylene (B) has preferably a branching
index g' of 1.0. A further distingushing feature between the high melt strenght
polypropylene (HMS-PP) and the polypropylene (B) is preferably the gel content
expressed in the amount of the xylene hot insoluble fraction (XHI). Accordingly the
polypropylene (B) has a gel content below 0.15 wt.-%, more preferably has no
detectable gel content. A further difference between the polypropylene (B) and the
high melt strenght polypropylene (HMS-PP) is preferably that they differ in the melt
flow rate MFR2 (230 °C), i.e. the polypropylene (B) has a higher MFR2 (230 °C)
than the high melt strenght polypropylene (HMS-PP).
The difference between the polypropylene (B) and the random propylene copolymer
(R-PP) is preferably that they differ in the melt flow rate MFR2 (230 °C), i.e. the
polypropylene (B) has a higher MFR2 (230 °C) than the random propylene
copolymer (R-PP). Accordingly it is appreciated that the polypropylene (B) has a
MFR2 (230 °C) of at least 400 g/10min, more preferably at least 430 g/10min, like at
least 450 g/10min, yet more preferably at least 800 g/10min, like about 1,200
g/10min. On the other hand the hand the polypropylene (B) should be not to viscous
not to deteriorate the stiffness of the final product. Accordingly it is appreciated that
the polypropylene (B) has a MFR2 (230 °C) in the range of 400 to 3,000 g/10min,
more preferably in the range of 420 to 2,000 g/10min, like 440 to 1,500 g/10min.
Further the molecular weight distribution (MWD) is desirable rather low.
Accordingly it is preferred that the Mw/Mn (MWD) of the polypropylene (B) is
below 4.5, like from 0.5 to 4.5, more preferably below 4.0, like from 0.5 to 4.0.
Additionally it is appreciated that the polypropylene (B) has xylene cold soluble
fraction (XCS) of not more than 5.0 wt-%, like 0.5 to 4.5 wt.-%, more preferably of
not more than 3.5 wt.-%, like 0.5 to 3.0 wt.-%.
The polypropylene (B) as defined throughout the present invention can be obtained
by visbreaking as defined in detail below or by polymerization of propylene for
instance in the presence of a metallocene catalyst. One suitable polypropylene
obtained by metallocene polymerization technology is the commercial product
MF650W of Basell. However it is appreciated in the present application that the
polypropylene is in particular obtained by visbreaking.
Accordingly, to achieve the desired MFR range, the polypropylene (B) is typically
prepared by polymerizing propylene and optional comonomers to a relatively high
molecular weight, which is then treated with peroxide to reduce its molecular weight
to a desked average ("visbroken"). Accordingly the polypropylene (B) is preferably a
visbroken polypropylene.
More preferably the initial polypropylene used for the preparation of the
polypropylene (B) is chosen in such a manner that the visbreaking ratio (final MFR2
(230 °C) / initial MFR2 (230 °C)) is 3.5 to 40.0, more preferably 4.0 to 30.0, wherein
"initial MFR2 (230 °C)" is the MFR2 (230 °C) of the polypropylene before
visbreaking and
"final MFR2 (230 °C)" is the MFR2 (230 °C) of the polypropylene (B).
The preparation of the polypropylene (B) will be defined in more detail below.
Further, the polypropylene (B) can be a propylene copolymer, like a random
propylene copolymer (B') or a propylene homopolymer (B"), the latter being
preferred. In case polypropylene (B) is a random propylene copolymer (B'), the
copolymer (B') comprises preferably units derived from propylene and at least
another C2 to C20 a-olefin, preferably at least another C2 to C10 a-olefin. Accordingly
such a random propylene copolymer (B') comprises units derived from propylene
and at least another a-olefin selected from the group consisting of ethylene, 1-butene,
1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene and 1-decene, wherein ethylene,

1-butene and 1-hexene are preferred. It is in particular preferred that such a random
propylene copolymer (B') consists of units derived from propylene and ethylene. The
amount of units derived from C2 to C20 a-olefins other than propylene in the random
propylene copolymer (B') is in the range of 1.0 to 7.0 wt.-%, more preferably 1.5 to
6.0 wt.-%, still more preferably 2.0 to 5.5 wt.-%.
Preferably the polypropylene (B) is isotactic. Accordingly it is appreciated that the
polypropylene (B) has a rather high pentad concentration, i.e. higher than 90 %, more
preferably higher than 92 %, still more preferably higher than 93 % and yet more
preferably higher than 95 %, like higher than 99 %.
Another essential requirement of the present invention is that polypropylene
composition comprises a clarifier (C) comprising at least one a-nucleating agent (N).
Thus as ß-nucleating agents negatively influences a-nucleating effect (of the a-
nucleating agent) it is preferred that the clarifier (C) and/or the polypropylene
composition is (essentially) free of ß-nucleating agents. Thus even more preferably
the clarifier (C) consists of at least one a-nucleating agent (N). Accordingly the
clarifier (C) may comprise, preferably consists of, one, two or three a-nucleating
agent(s) (N). However it is appreciated that the clarifier (C) is a-nucleating agent
(N).
In principle any a-nucleating agent (N) can be used.
Examples of suitable a-nucleating agents are selected from the group consisting of
(i) salts of monocarboxylic acids and polycarboxylic acids, e.g. sodium benzoate or
aluminum tert-butylbenzoate, and
(ii) dibenzylidenesorbitol (e.g. 1,3 : 2,4 dibenzylidenesorbitol) and C1-C8-alkyl-
substituted dibenzylidenesorbitol derivatives, such as methyldibenzylidenesorbitol,
ethyldibenzylidenesorbitol or dimemyldibenzylidenesorbitol (e.g. 1,3 : 2,4
di(methylbenzylidene) sorbitol), nonitol, 1,2,3,-trideoxy-4,6:5,7-bis-O-[(4-
propylphenyl)methylene] -nonitol, and
(iii) salts of diesters of phosphoric acid, e.g. sodium 2,2'-methylenebis (4,6,-di-tert-
butylphenyl) phosphate or aluminium-hydroxy-bis[2,2'-methylene-bis(4,6-di-t-
butylphenyl)phosphate], and
(iv) vinylcycloalkane polymer and vinylalkane polymer.
Such additives are generally commercially available and are described, for example, in
Gachter/Muller, Plastics Additives Handbook, 4th Edition, Hansa Publishers, Munich, 1993.
The nucleating agent content of the polypropylene composition is preferably up to 5 wt.-%.
In a preferred embodiment, the polypropylene composition of the present invention contain
from 0.01 to 5.0 wt.-%, preferably from 0.02 to 0.50 wt.-%, of a a-nucleating, in particular
dibenzylidenesorbitol (e.g. 1,3 : 2,4 dibenzylidene sorbitol) or a dibenzylidenesorbitol
derivative, preferably dimethyldibenzylidenesorbitol (e.g. 1,3 : 2,4 di(methylbenzylidene)
sorbitol) and/or nonitol, 1,2,3,-trideoxy-4,6:5,7-bis-O-[(4-propylphenyl)methylene]-nonitol,
The most preferred a-nucleating is nonitol,1,2,3,-trideoxy-4,6:5,7-bis-O-[(4-
propylphenyl)methylene]-nonitol. Accordingly in a especially preferred embodiment
the clarifier (C) comprises, even more preferred consists of, nonitol,1,2,3,-trideoxy-
4,6:5,7-bis-O-[(4-propylphenyl)mefhylene]-nonitol.
In case the a-nucleating agents are polymeric a-nucleating agents selected from the
group consisting of vinylcycloalkane polymers and vinylalkane polymers, these
polymeric nucleating agents are either accomplished by a special reactor technique,
where the catalyst is prepolymerised with monomers like e.g. vinylcyclohexane
(VCH), or by blending the polypropylene composition with the vinylcycloalkane
polymer or vinylalkane polymer. These methods are described in greater detail in e.g.
EP 0 316 187 A2 and WO 99/24479

copolymers of butadiene and styrene having 1,2- (vinyl) in the
polymer chain.
A preferred low molecular weight polymer is polybutadiene, in particular a
polybutadiene having more than 50.0 wt.-% of the butadiene in the l,2-(vinyl)
configuration.
The high melt strength polypropylene (HMS-PP) may contain more than one
bifunctionally unsaturated monomer and/or multifunctionally unsaturated low
molecular weight polymer. Even more preferred the amount of bifunctionally
unsaturated monomer(s) and multifunctionally unsaturated low molecular weight
polymer(s) together in the high melt strength polypropylene (HMS-PP) is 0.01 to
10.0 wt.-% based on said high melt strength polypropylene (HMS-PP).
As stated above it is preferred that the bifunctionally unsaturated monomer(s) and/or
multifunctionally unsaturated low molecular weight polymer(s) are used in the
presence of a thermally decomposing free radical-forming agent.
Peroxides are preferred thermally decomposing free radical-forming agents. More
preferably the thermally decomposing free radical-forming agents are selected from
the group consisting of acyl peroxide, alkyl peroxide, hydroperoxide, perester and
peroxycarbonate.
The following listed peroxides are in particular preferred:
Acyl peroxides: benzoyl peroxide, 4-chlorobenzoyl peroxide, 3-
methoxybenzoyl peroxide and/or methyl benzoyl peroxide.
To obtain especially good results the required components as defined above may be
present in specific amounts within the new polypropylene composition. Thus it is
preferred that the polypropylene composition according to the instant invention
comprises
(a) 50.0 to 92.0 wt.-%, more preferably 60.0 to 90.0 wt.-%, yet more preferably
65.0 to 90.0 wt.-%, of the random propylene copolymer (R-PP),
(b) 5.0 to 26.0 wt.-%, more preferably 6.0 to 18.0 wt.-%, yet more preferably 6.5
to 16.0 wt.-%, of the high melt strength polypropylene (HMS-PP),
(c) 1.0 to 15.0 wt.-%, more preferably 1.5 to 17.0 wt.-%„ yet more preferably 2.0
to 10.0 wt.-%, of the polypropylene (B), and
(d) 0.01 to 5.0 wt.-%, more preferably 0.02 to 1.0 wt.-%, yet more preferably
0.03 to 0.7 wt.-%, of the clarifier (C),
based on the total polypropylene composition.
The polypropylene composition of the present invention may comprise further
components. However it is preferred that the polypropylene composition comprises
as polymer components only the random propylene copolymer (R-PP), the
polypropylene (B) and the high melt strength polypropylene (HMS-PP) as defined
above. Accordingly the amounts of the random propylene copolymer (R-PP), the
polypropylene (B), the high melt strength polypropylene (HMS-PP) and the clarifier
(C) may not result in 100 wt.-% based on the total polypropylene composition. Thus
the remaining part up 100.0 wt.-% may be accomplished by further additives known
in the art. However this remaining part shall be not more than 10.0 wt.-% within the
total composition. For instance the inventive polypropylene composition may
comprise additionally small amounts of stabilizers, acid scavengers, lubricants and
mold release agents, fillers, nucleating agents, antistatics, plasticizers, dyes, pigments
or flame retardants. In general, these are incorporated during granulation of the
pulverulent product obtained in the polymerization.

The present invention is also directed to the use of the above defined polypropylene
composition. Accordingly the polypropylene composition as defined in the instant
invention is used for the preparation of extrusion blown molded products. More
particularly the present invention is directed to the use of the polypropylene
composition of the instant invention to improve the haze and/or gloss of extrusion
blown molded articles, like extrusion blown molded bottles, i.e. extrusion blown
molded bottles with a filling volume of 1 liter or more, made out of said
polypropylene composition compared to conventional extrusion blown molded
bottles, in particular compared to extrusion blown molded bottles made out of the
commercial product "RB307MO" of Borealis. Moreover the use of the
polypropylene composition of the instant invention shall preferably and additionally
improve the top load of extrusion blown molded articles, like extrusion blown
molded bottles, i.e. extrusion blown molded bottles with a filling volume of 1 liter or
more, made out of said polypropylene composition compared to conventional
extrusion blown molded bottles. Accordingly the present invention is in particular
directed to the use of polypropylene composition of the instant invention to
accomplish at least one requirement, preferably all requirements, selected from the
group consisting of a haze of below 14 %, more preferably below 11 %, a gloss
(inside and/or outside of the bottle) of at least 16 %, more preferably at least 19 %,
and top load of at least 280 N, more preferably at least 300 N, for extrusion blown
molded articles, like extrusion blown molded bottles, i.e. extrusion blown molded
bottles with a filling volume of 1 liter or more.
Further the present invention is directed to extrusion blown molded articles
comprising, preferably comprising at least 90 wt.-%, more preferably consisting of, a
polypropylene composition according to this invention. More particularly the present
invention is directed to bottles, especially to bottles with a filling volume of 1 liter or
more, produced by an extrusion blown process comprising, preferably comprising at
least 90 wt.-%, more preferably consisting of, a polypropylene composition
according to this invention.
In the following the preparation of the inventive polypropylene composition is
described in more detail.
The individual components used for the inventive polypropylene composition are
known by the person skilled in the art and thus can be readily produced by the
information provided herein.
For instance the random propylene copolymer (R-PP) as defined in the instant
invention may be prepared by polymerizing, in a slurry reactor, for example a loop
reactor, propylene optionally together with at least another C2 to C20 a-olefin
(comonomers), in the presence of a polymerization catalyst to produce a part of the
random propylene copolymer (R-PP). This part is then transferred to a subsequent
gas phase reactor, wherein in the gas phase reactor propylene is reacted in the
presence of suitably selected other C2 to C20 a-olefin(s) (comonomers) in order to
produce a further part in the presence of the reaction product of the first step. This
reaction sequence provides a reactor blend of parts (i) and (ii) constituting a random
propylene copolymer (R-PP). It is of course possible by the present invention that the
first reaction is carried out in a gas phase reactor while the second polymerization
reaction is carried out in a slurry reactor, for example a loop reactor. It is furthermore
also possible to reverse the order of producing parts (i) and (ii), which has been
described above in the order of first producing part (i) and then producing part (ii).
The above-discussed process, comprising at least two polymerization steps, is
advantageous in view of the fact that it provides easily controllable reaction steps
enabling the preparation of a desired reactor blend. The polymerization steps may be

adjusted, for example by appropriately selecting monomer feed, comonomer feed,
hydrogen feed, temperature and pressure in order to suitably adjust the properties of
the polymerization products obtained. It is in particular possible to obtain a
multimodality, preferably the bimodality, of the random propylene copolymer (R-
PP), with respect to the comonomer, like ethylene, distribution as well as with
respect to the molecular weights and MFR2 (230 °C) values during said multistage
polymerization procedures.
Such a process can be carried out using any suitable catalyst for the preparation of
the random propylene copolymer (R-PP). Preferably, the process as discussed above
is carried out using a Ziegler-Natta catalyst, in particular a high yield Ziegler-Natta
catalyst (so-called fourth and fifth generation type to differentiate from low yield, so
called second generation Ziegler-Natta catalysts). A suitable Ziegler-Natta catalyst to
be employed in accordance with the present invention comprises a catalyst
component, a co-catalyst component and at least one electron donor (internal and/or
external electron donor, preferably at least one external donor). Preferably, the
catalyst component is a Ti-Mg-based catalyst component and typically the co-
catalyst is an Al-alkyl based compound. Suitable catalysts are in particular disclosed
in US 5,234,879, WO 92/19653, WO 92/19658 and WO 99/33843.
Preferred external donors are the known silane-based donors, such as dicyclopentyl
dimethoxy silane or cyclohexyl methyldimethoxy silane.
One embodiment of a process as discussed above is a loop-gas phase process, such as
developed by Borealis, known as Borstar® technology, described for example in
EP 0 887 379 Al and WO 92/12182.
With respect to the above-mentioned preferred slurry-gas phase process, the
following general information can be provided with respect to the process conditions.
Temperature of from 40 to 110 °C, preferably between 60 and 100 °C, in particular
between 80 and 90 °C, with a pressure in the range of from 20 to 80 bar, preferably
30 to 60 bar, with the option of adding hydrogen in order to control the molecular
weight. The reaction product of the slurry polymerization, which preferably is carried
out in a loop reactor, is then transferred to the subsequent gas phase reactor, wherein
the temperature preferably is within the range of from 50 to 130 °C, more preferably
80 to 100 °C, at a pressure in the range of from 5 to 50 bar, preferably 15 to 35 bar,
again with the option of adding hydrogen in order to control the molecular weight.
The residence time can vary in the reactor zones identified above. In embodiments,
the residence time in the slurry reaction, for example the loop reactor, is in the range
of from 0.5 to 5 hours, for example 0.5 to 2 hours, while the residence time in the gas
phase reactor generally will be from 1 to 8 hours.
The properties of the random propylene copolymer (R-PP) produced with the above-
outlined process may be adjusted and controlled with the process conditions as
known to the skilled person, for example by one or more of the following process
parameters: temperature, hydrogen feed, comonomer feed, propylene feed, catalyst,
type and amount of external donor, split between two or more components of a
multimodal polymer.
The high melt strength polypropylene (HMS-PP) is preferably obtained by a process
as described in EP 0 879 830 Al and EP 0 890 612 A2. Both documents are herewith
included by reference. Accordingly the high melt strength polypropylene (HMS-PP)
is produced by

(a) mixing
(i) a unmodified propylene homopolymer and/or copolymer (A) as defined
above, preferably a unmodified propylene homopolymer with a weight
average molecular weight (Mw) of 500,000 to 1,500,000 g/mol,
(ii) from 0.05 to 3 wt.-% based on the components of (i) and (ii), of a peroxide
selected from the group consisting of acyl peroxide, alkyl peroxide,
hydroperoxide, perester and peroxycarbonate, and
(iii) optionally diluted with inert solvents,
(b) heating to 30 to 100 °C, preferably to 60 to 90 °C,
(c) sorption of volatile bifunctional monomers, preferably ethylenically unsaturated,
multifunctional monomers, like C4 to C10 dienes and/or C7 to C10 divinyl
compounds, by the unmodified propylene homopolymer and/or copolymer (A),
preferably unmodified propylene homopolymer (A), from the gas phase at a
temperature of from 20 to 120 °C, preferably of from 60 to 100 °C, where the
amount of the absorbed bifunctionally unsaturated monomers is from 0.01 to
10.00 wt.-%, preferably from 0.05 to 2.00wt.-%, based on the propylene
homopolymer (A),
(d) heating and melting the polypropylene composition in an atmosphere comprising
inert gas and/or the volatile bifunctional monomers, from sorption temperature
to 210 °C, whereupon the free-radical generators are decomposed and then
(e) heating the melt up to 280 °C in order to remove unreacted monomers and
decomposition products, and
(f) agglomerating the melt.
The process for producing the high melt strength polypropylene (HMS-PP)
preferably is a continuous method, performed in continuous reactors, mixers,
kneaders and extruders. Batchwise production of the high melt strength
polypropylene (HMS-PP), however is feasible as well.
Practical sorption times x of the volatile bifunctional monomers range from 10 to
1000 s, where sorption times x of 60 to 600 are preferred.
The visbreaking may be carried out in any known manner, but typically the present
invention envisages chemical visbreaking using a peroxide visbreaking agent.
Suitable amounts of peroxide to be employed in accordance with the present
invention are in principle known to the skilled person and can easily be calculated on
the basis of the amount of polypropylene composition and/or random propylene
copolymer (R-PP) to be subjected to visbreaking, the MFR2 (230 °C) value of the
polypropylene composition and/or random propylene copolymer (R-PP) to be
subjected to visbreaking and the desired target MFR2 (230 °C) of the product to be
obtained. Accordingly, typical amounts of peroxide visbreaking agent are from 0.005
to 1.0 wt.-%, more preferably from 0.01 to 0.5 wt.-%, based on the amount of
propylene polymer employed.
Typically, visbreaking in accordance with the present invention is carried out in an
extruder, so that under the suitable conditions, an increase of melt flow rate is
obtained. During visbreaking, higher molar mass chains of the starting product are
broken statistically more frequently than lower molar mass molecules, resulting in an
overall decrease of the average molecular weight and an increase in melt flow rate.
As mentioned above, the polypropylene (B) is preferably obtained by visbreaking in
a manner well known to those skilled in the art. Preferably it is performed as follows:
a propylene polymer in particulate form, e.g. "as polymerized" flake or pelletized,
has sprayed thereon or blended therewith, a prodegradant or free radical generating
source, e.g. a peroxide in liquid or powder form or absorbed on and/or in a carrier,
e.g. polypropylene/peroxide concentrate. Typical visbreaking agents are 2,5-
dimethyl-2,5-bis(tert.butyl-peroxy)hexane (DHBP) (for instance sold under the
tradenames Luperox 101 and Trigonox 101), 2,5-dimethyl-2,5-bis(tert.butyl-
peroxy)hexyne-3 (DYBP) (for instance sold under the tradenames Luperox 130 and
Trigonox 145), dicumyl-peroxide (DCUP) (for instance sold under the tradenames
Luperox DC and Perkadox BC), di-tert.butyl-peroxide (DTBP) (for instance sold
under the tradenames Trigonox B and Luperox Di), tert.butyl-cumyl-peroxide
(BCUP) (for instance sold under the tradenames Trigonox T and Luperox 801) and
bis (tert.butylperoxy-isopropyl)benzene (DIPP) (for instance sold under the
tradenames Perkadox 14S and Lupperox DC). Suitable amounts of peroxide to be
employed in accordance with the present invention are in principle known to the
skilled person and can easily be calculated on the basis of the amount of
polypropylene to be subjected to visbreaking, the MFR2 (230 °C) value of the
polypropylene to be subjected to visbreaking and the desired target MFR2 (230 °C)
of the polypropylene (B) to be obtained. Accordingly, typical amounts of peroxide
visbreaking agent are from 0.005 to 0.5 wt.-%, more preferably from 0.01 to 0.2 wt.-
%, based on the amount of propylene polymer employed. The propylene polymer
and peroxide or propylene polymer/peroxide concentrate is introduced into a means
for thermally plasticizing or melt blending and conveying the mixture, e.g., an
extruder at elevated temperature. Residence time and temperature are controlled in
relation to the particular peroxide selected (i.e., based on the half-life of the peroxide
at the process temperature of the extruder) so as to effect the desired degree of
polymer chain degradation.
Further, the polymer composition in accordance with the present invention may be
prepared by compounding the components within suitable melt mixing devices for
preparing polymeric compounds, including in particular extruders single screw
extruders as well as twin screw extruders. Other suitable melt mixing devices include
planet extruders and single screw co-kneaders. Especially preferred are twin screw

extruders including high intensity mixing and kneading sections. Suitable melt
temperatures for preparing the compositions are in the range from 170 to 300 °C,
preferably in the range from 200 to 260 °C and at a throughput of 10 to 500 kg/h and
a screw speed of 50 to 200 rpm.
For the preparation of extrusion molded articles an extrusion blown process as
known in the art is applied. For instance, for the production of 1 liter round bottles
like used for testing in the inventive work a "Fischer Miiller" Blow Molding Machine
may be used. The main processing parameters for the production are as follows:
- Temperature profile: 180 to 190 °C applied in extruder, adapter and head
- Melt temperature measured: 180 to 190°C
- Speed of extruder (revolution per minute; rpm): 11 to 14 rpm
- Die gap: the die gap was adjusted to get a bottle with a weight of 40 g with Borealis
grade RB307MO
- Cycle time: 12 to 16 seconds
The present invention will now be described in further detail by the examples
provided below.
EXAMPLES
1. Definitions/Measuring Methods
The following definitions of terms and determination methods apply for the above
general description of the invention as well as to the below examples unless
otherwise defined.
NMR-spectroscopy measurements:

The C-NMR spectra of polypropylenes were recorded on Bruker 400MHz
spectrometer at 130 °C from samples dissolved in l,2,4-trichlorobenzene/benzene-d6
(90/10 w/w). For the pentad analysis the assignment is done according to the
methods described in literature: (T. Hayashi, Y. Inoue, R. Chiijo, and T. Asakura,
Polymer 29 138-43 (1988).and Chujo R, et al,Polymer 35 339 (1994).
The NMR-measurement was used for determining the mmmm pentad concentration
in a manner well known in the art.
Randomness
In the FTIR measurements, films of 250 -mm thickness were compression moulded
at 225 °C and investigated on a Perkin-Elmer System 2000 FTIR instrument. The
ethylene peak area (760-700 cm"1) was used as a measure of total ethylene content.
The absorption band for the structure -P-E-P- (one ethylene unit between propylene
units), occurs at 733 cm-1 This band characterizes the random ethylene content. For
longer ethylene sequences (more than two units), an absorption band occurs at 720
cm" . Generally, a shoulder corresponding to longer ethylene runs is observed for the
random copolymers. The calibration for total ethylene content based on the area and
random ethylene (PEP) content based on peak height at 733 cm-1 was made by 13C-
NMR. (Thermochimica Acta, 66 (1990) 53-68 ).
Randomness = random ethylene (-P-E-P-) content / the total ethylene content x
100%.
Number average molecular weight (Mn), weight average molecular weight (Mw)
and molecular weight distribution (MWD) are determined by size exclusion
chromatography (SEC) using Waters Alliance GPCV 2000 instrument with online
viscometer. The oven temperature is 140 °C. Trichlorobenzene is used as a solvent
(ISO 16014).
MFR2 (230 °C) is measured according to ISO 1133 (230 °C, 2.16 kg load).
Ethylene content is measured with Fourier transform infrared spectroscopy (FTIR)
calibrated with 13C-NMR. When measuring the ethylene content in polypropylene, a
thin film of the sample (thickness about 250 mm) was prepared by hot-pressing. The
area of absorption peaks 720 and 733 cm"1 was measured with Perkin Elmer FTIR
1600 spectrometer. The method was calibrated by ethylene content data measured by
13C-NMR.
Content of any one of the C4 to C20 a-olefins is determined with 13C-NMR;
literature: "IR-Spektroskopie fur Anwender"; WILEY-VCH, 1997 and "Validierung
in der Analytik", WILEY-VCH, 1997.
The xylene cold solubles (XCS, wt.-%): Content of xylene cold solubles (XCS) is
determined at 23 °C according ISO 6427.
The gel content is assumed to be identical to the xylene hot insoluble (XHI) fraction,
which is determined by extracting 1 g of finely cut polymer sample with 350 ml
xylene in a Soxhlet extractor for 48 hours at the boiling temperature. The remaining
solid amount is dried at 90°C and weighed for determining the insolubles amount.
Strain hardening behaviour (melt strength):
The strain hardening behaviour is determined by the method as described in the
article "Rheotens-Mastercurves and Drawability of Polymer Melts", M. H. Wagner,
Polymer Engineering and Sience, MID-APRIL 1SW, Vol. 36, NO. 7, pages 925 to
935. The content of the document is included by reference.
For detailed explanation of the measuring method it is also referred to the figures 1
and 2.
Figure 1 shows a schematic representation of the experimental procedure which is
used to determine strain hardening.
The strain hardening behaviour of polymers is analysed by Rheotens apparatus (1)
(product of Gottfert, Siemensstr.2, 74711 Buchen, Germany) in which a melt strand
(2) is elongated by drawing down with a defined acceleration. The haul-off force F in
dependence of draw-down velocity v is recorded.
The test procedure is performed in a standard climatized room with controlled room
temperature of 23 °C and 30 bar. The Rheotens apparatus (1) is combined with an
extruder/melt pump (3) for continuous feeding of the melt strand (2). The extrusion
temperature is 200 °C; a capillary die with a diameter of 2 mm and a length of 6 mm
is used. The strength length between the capillary die and the Rheotens wheels is 80
mm. At the beginning of the experiment, the take-up speed of the Rheotens wheels
was adjusted to the velocity of the extruded polymer strand (tensile force zero): Then
the experiment was started by slowly increasing the take-up speed of the Rheotens
wheels until the polymer filament breaks. The acceleration of the wheels was small
enough so that the tensile force was measured under quasi-steady conditions.The
acceleration of the melt strand (2) drawn down is 120 mm/sec2.
The Rheotens was operated in combination with the PC program EXTENS. This is a
real-time data-acquisition program, which displays and stores the measured data of
tensile force and drawdown speed.
The schematic diagram in figure 1 shows in an exemplary fashion the measured
increase in haul-off force F (i.e. "melt strength") versus the increase in draw-down
velocity v (i.e. "drawability").
Haze measurement on bottles
Instrument: Haze-gard plus from BYK-Gardner
Testing: according to ASTM D1003 (as for injection molded plates)
The bottles:
It is measured on the wall of the bottles. The top and bottom of the bottles is cut off.
This round wall is then split in two, horizontally. Then the haze measurement and the
wall thickness are done in six places around this wall, close to the middle. Then the
haze value is reported as average of this six parallels.
Gloss measurement on bottles
Instrument: Sceen TRI-MICROGLOSS 20-60-80 from BYK-Gardner
Testing: ASTM D 2457 (as for injection molded plates)
The bottles:

It is measured on the wall of the bottles. The top and bottom of the bottles is cut off.
This round wall is then split in two, horizontally. Then this wall is cut into six equal
samples of app. 90x90 mm, just to fit into a special light trap made for testing on
injection molded parts. Then the gloss at 60° is measured on these six samples, and
the average value is reported as gloss at 60°
Top load
Aim of this measurement is to determine the stiffness of 1 liter round bottles.
Determined by this method is the deformation force at 1 mm, 2 mm and 3 mm
deformation of the round bottle. Additionally the maximum force Fmax and the
deformation in mm at Fmax are determined.
The bottles have a height of 203 mm. The bottles are produced according to the
description given below.
Before testing, the bottles are conditioned for 7 days at a temperature of 23 °C and at
relative humidity of 50 % (+/- 5 %). The burr of the bottle orifice is removed.
Top load is tested at universal testing machine of the class 1 according to DIN
51221. Bottles to be tested are put between two parallel buffed plates of hardened
steel, one plate is fixed and the other plate is moving. Force is recorded and results
are given as Fmax (N) and Deformation at Maximum Force (mm).
Eight bottles are tested with speed of 10 mm/min by using 2.5 kN load cell. The test
results of the eight tested bottles give the average value.
Weight Swell
The weight swell is a measurement that shows the fit in process ability of a
polypropylene sample material compared to a defined reference grade.
The weight swell is defined as the ratio of the weight of a sample bottle, produced at
defined reference conditions, to the weight of a standard bottle produced at reference
conditions.
The formula is the following:
Weight swell (%) = weight of sample bottle (g) / weight of standard bottle (g) x
100
Reference conditions are defined as the appropriate set of temperature (°C),
throughput of feeding extruder (rpm) and width of the die gap (mm) needed for the
production of standard bottles showing exactly a weight of 40 +/- 1 g by using a
defined standard polypropylene grade used for extrusion blow molding. The standard
bottles described in this invention are produced from Borealis random polypropylene
grade RB307MO (ethylene content about 4 wt.-%, MFR2 (230 °C) about 1.5
g/10min) under reference condition, meaning condition necessary to get to bottles
with 40 g (+/- 1g).
2. Preparation of the Examples
The components were blended according to Table 1. For stabilization of the materials
a conventional additive package has been used like 0.2 wt/% Irganox B225
(antioxidant masterbatch supplied by Ciba Specialty Chemicals, Switzerland) and
0,05 wt% Ca-Stearate (CAS-No. 1592-23-0). Blending took place in a twin screw
extruder (PRISM TSE24 L/D ratio 40) with two high intensity mixing segments at
temperatures between 190 and 240°C at a through put of 10 kg/h and a screw speed
of 50 rpm. The material was extruded to two circular dies of 3 mm diameter into a
water bath for strand solidification and then pelletized and dried.
For the production of 1 liter round bottles like used for testing in the inventive work
a "Fischer Miiller" Blow Molding Machine was used. The main processing
parameters for the production are as follows:
- Temperature profile: 180 to 190 °C applied in extruder, adapter and head
- Melt temperature measured: 180 to 190°C
- Speed of extruder (revolution per minute; rpm): 11 to 14 rpm
- Die gap: the die gap was adjusted to get a bottle with a weight of 40 g with Borealis
grade RB307MO
- Cycle time: 12 to 16 seconds

Table 1: Properties of the polypropylene compositions
* "MFR" is MFR2 (230 °C)
R-PP: is the commercial random propylene ethylene copolymer "RB307MO" of
Borealis with an ethylene content of 3.9 wt.-%, a MFR2 (230 °C) of 1.5 g/10min, a
density of 902 kg/m3, xylene cold soluble fraction (XCS) of 7.0 wt.-% and a
branching index g' of 1.0.
HMS: is the commercial high melt strength polypropylene Daploy™ WB 180HMS
of Borealis based on a propylene homopolymer, wherein the high melt strength
polypropylene Daploy™ WB180HMS has a density of 905 kg/m3, a melting point
of 165 °C, MFR2 (230°C) of 6.0 g/10 min, a melt strength of 11.5 cN at a maximum
speed of 242 mm/s, a xylene cold soluble fraction (XCS) of 2.5 wt.-% and a
branching index g' of 0.64.
PP: is the commercial visbroken polypropylene "HL504FB" of Borealis with a
MFR2 (230 °C) of 450 g/10min and a branching index g'
a-1: is the commercial a-nucleating agent Millad 3988 (bis (3,4,-di-methyl-
benzylidene) sorbitol)


a-2: is the commercial a-nucleating agent Millad NX 8000 (Nonitol,1,2,3,-
trideoxy-4,6:5,7-bis-O-[(4-propylphenyl)methylene]-nonitol)
WE CLAIM:
1. A polypropylene composition comprising a random propylene copolymer (R-PP), a
high melt strength polypropylene (HMS-PP), a polypropylene (B) and a clarifier (C),
wherein
(a) the random propylene copolymer (R-PP)
(i) comprises units derived from propylene and at least another C2 to C20 a-
olefin
and
(ii) has a higher branching index g' than the high melt strength
polypropylene (HMS-PP),
(b) the high melt strength polypropylene (HMS-PP) has a branching index g' of
less than 1.0,
(c) the polypropylene (B) has a MFR2 (230 °C) measured according to ISO 1133
of at least 400 g/10min,
(d) the clarifier (C) comprises at least one a-nucleating agent (N), and
(e) the polypropylene composition has a MFR2 (230 °C) measured according to
ISO 1133 of at least 2.0 g/10min.
wherein further,
(f) the polypropylene (B) is different to the random propylene copolymer (R-PP)
at least in view of the melt flow rate MFR2 (230 °C) and
(g) the polypropylene (B) has a higher melt flow rate MFR2 (230 °C) than the high
melt strength polypropylene (HMS-PP).

A polypropylene composition according to claim 1, wherein the polypropylene
composition has a strain hardening behavior with a haul-off force Fmax of at least 7.0
cN and a draw down velocity vmax of at least 180 mm/s.
A polypropylene composition according to claim 1 or 2, wherein the polypropylene
composition has an xylene hot insoluble fraction (XHI) of not more than 1.0 wt.-%.
A polypropylene composition according to anyone of the preceding claims, wherein
the polypropylene composition has a xylene cold soluble fraction (XCS) measured
according ISO 6427 of not more than 15.0 wt-%.
A polypropylene composition according to anyone of the preceding claims, wherein
the amount of units derived from C2 to C20 a-olefins other than propylene is not more
than 7.0 wt.-% in the polypropylene composition.
A polypropylene composition according to anyone of the preceding claims, wherein
the amount of units derived from C2 to C20 a-olefins other than propylene is in the
range of 1.0 to 7.0 wt.-% in the random propylene copolymer (R-PP).
A polypropylene composition according to anyone of the preceding claims, wherein
the random propylene copolymer (R-PP) has a xylene cold soluble fraction (XCS) of
not more than 15.0 wt-%.
A polypropylene composition according to anyone of the preceding claims, wherein
the random propylene copolymer (R-PP) has a MFR2 (230 °C) of not more than 4.5
g/10min.

A polypropylene composition according to anyone of the preceding claims, wherein
the high melt strength polypropylene (HMS-PP) has a strain hardening behavior with a
haul-off force Fmax of at least 10.0 cN and a draw down velocity vmax of at least 200
mm/s.
A polypropylene composition according to anyone of the preceding claims, wherein
the high melt strength polypropylene (HMS-PP) comprises units derived from
(i) propylene and
(ii) bifunctionally unsaturated monomer(s) and/or multi functionally unsaturated
low molecular weight polymer(s).
A polypropylene composition according to anyone of the preceding claims, wherein
the high melt strength polypropylene (HMS-PP) composition has an xylene hot
insoluble fraction (XHI) of not more than 1.0 wt.-%.
A polypropylene composition according to anyone of the preceding claims, wherein
the high melt strength polypropylene (HMS-PP) composition has a MFR2 (230 °C)
measured according to ISO 1133 of 1.0 to 10.0 g/10min.
A polypropylene composition according to anyone of the preceding claims, wherein
the polypropylene (B) is a propylene homopolymer (H-PP).
A polypropylene composition according to anyone of the preceding claims, wherein
the polypropylene (B) has been visbroken.
A polypropylene composition according to anyone of the preceding claims, wherein
the visbroking ratio (final MFR2 (230 °C) / initial MFR2 (230 °C)) of the
polypropylene (B) is 3.0 to 40.0.

16. A polypropylene composition according to anyone of the preceding claims, wherein
the a-nucleating agent(s) (N) are selected from the group consisting of
(i) salts of monocarboxylic acids and polycarboxylic acids, and
(ii) dibenzylidenesorbitol and Cj-Cg-alkyl-substituted dibenzylidenesorbitol
derivatives, and
(iii) salts of diesters of phosphoric acid, and
(iv) vinylcycloalkane polymer and vinylalkane polymer.
17. A polypropylene composition according to anyone of the preceding claims, wherein
the polypropylene composition comprises
(a) 50.0 to 92.0 wt.-% of the random propylene copolymer (R-PP),
(b) 5.0 to 26.0 wt.-% of the high melt strength polypropylene (HMS-PP),
(c) 1.0 to 15.0 wt.-% of the polypropylene (B), and
(d) 0.01 to 5.0 wt.-% of the clarifier (C),
based on the total polypropylene composition.
18. Use of a polypropylene composition according to anyone of the preceding claims for
the preparation of extrusion blown molded products.
19. Extrusion blown molded article comprising a polypropylene composition according to
anyone of the preceding claims 1 to 17.
20. Article according to claim 19, wherein the article is a bottle.

A polypropylene composition comprising a random propylene copolymer (R-PP), a
high melt strength polypropylene (HMS-PP), a polypropylene (B) and a clarifier (C),
wherein
(a) the random propylene copolymer (R-PP)
(i) comprises units derived from propylene and at least another C2 to C20 a-
olefin
and
(ii) has a higher branching index g' than the high melt strength
polypropylene (HMS-PP),
(b) the high melt strength polypropylene (HMS-PP) has a branching index g' of
less than 1.0,
(c) the polypropylene (B) has a MFR2 (230 °C) measured according to ISO 1133
of at least 400 g/10min,
(d) the clarifier (C) comprises at least one a-nucleating agent (N), and
(e) the polypropylene composition has a MFR2 (230 °C) measured according to
ISO 1133 of at least 2.0 g/10min.
wherein further,
(f) the polypropylene (B) is different to the random propylene copolymer (R-PP)
at least in view of the melt flow rate MFR2 (230 °C) and
(g) the polypropylene (B) has a higher melt flow rate MFR2 (230 °C) than the high
melt strength polypropylene (HMS-PP).

Documents:

http://ipindiaonline.gov.in/patentsearch/GrantedSearch/viewdoc.aspx?id=Lb2ZzOAlWDx3/ek216APkA==&loc=wDBSZCsAt7zoiVrqcFJsRw==


Patent Number 272784
Indian Patent Application Number 994/KOLNP/2011
PG Journal Number 18/2016
Publication Date 29-Apr-2016
Grant Date 26-Apr-2016
Date of Filing 08-Mar-2011
Name of Patentee BOREALIS AG
Applicant Address IZD TOWER WAGRAMERSTRAßE 17-19 A-1220 VIENNA, AUSTRIA
Inventors:
# Inventor's Name Inventor's Address
1 BERNREITNER, KLAUS ZAUBERTALSTRAßE 1, A-4010, LINZ, AUSTRIA
2 KYLMÄLÄ, MARI KARL-LEITL-STRAßE 1/22, A-4048 PUCHENAU, AUSTRIA
3 KIRCHBERGER, MANFRED MAIRING 21, A-4731 PRAMBACHKIRCHEN, AUSTRIA
4 PRAMER, HANSJÖRG TÜRKSTETTEN 10, A-4201 GRAMASTETTEN, AUSTRIA
PCT International Classification Number C08L 23/10
PCT International Application Number PCT/EP2009/064038
PCT International Filing date 2009-10-26
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 08167594.4 2008-10-27 EUROPEAN UNION