Process for making a propylene polymer with free-end long chain branching and use thereof

Claim 2

A process for making normally solid,gel-free, propylene polymer material with a branching index of less than 1 and with a strain hardening elongational viscosity from normally solid, amorphous to predominantly crystalline propylene polymer material without strain hardening elongational viscosity, which comprises: (1) mixing a low decomposition temperature peroxide with a linear propylene polymer material, which material is at room temperature to 120° C., in a mixing vessel in the substantial absence of atmospheric oxygen or its equivalent, (2) heating or maintaining the resulting mixture in the substantial absence of atmospheric oxygen or its equivalent at room temperature to 120° C. for a period of time sufficient for decomposition of the peroxide, for a substantial amount of fragmentation of the linear propylene polymer material to occur, and for a significant amount of long chain branches to form, but insufficient to cause gelation of the propylene polymer material; (3) treating the propylene polymer material in the substantial absence of atmospheric oxygen or its equivalent to deactivate substantially all the free radicals present in said propylene polymer material.

Claim 3

A process according to claim 1 in which said amorphous to predominantly crystalline propylene polymer material is a normally solid, gel-free, predominantly isotactic, semi-crystalline polypropylene.

Claim 4

A process according to claim 1 in which the low decomposition temperature peroxide has a half life of less than or equal to 5 minutes in the temperature range from about 90° C. to 120° C., or less than 40 minutes in the temperature range from about 60° C. to about 90° C., or has a half life of less than 60 minutes in the temperature range of room temperature to about 60° C.

Claim 5

A process according to claim 3 wherein the low decomposition temperature peroxide is selected from the group consisting of di(sec-butyl)peroxy dicarbonate, bis(2-ethoxy)peroxy dicarbonate, di-cyclohexylperoxy dicarbonate, di-n-propyl-peroxy dicarbonate, di-n-butylperoxy dicarbonate, di-sec-butylperoxy dicarbonate, di-isopropylperoxy dicarbonate, t-butylperoxy neodecanoate, t-amylperoxy neodecanoate and t-butylperoxy pivalate.

Claim 6

A process according to claim 1 in which the half life of the low decomposition temperature peroxide is about 10 seconds to about 5 minutes at the temperature employed in step (2).

Claim 7

A process according to claim 1 in which the temperature of step (2) is 60°-110° C.

Claim 8

A process according to claim 1 in which the temperature is 70°-105° C.

Claim 9

A process according to claim 1 in which the concentration of the low decomposition temperature peroxide is from 0.005 to 0.05 mmoles/g propylene polymer starting material.

Claim 10

A process according to claim 3 in which the concentration of the low decomposition temperature peroxide is from 0.005 to 0.05 mmoles/g propylene polymer starting material.

Claim 11

A process according to claim 1 wherein the propylene polymer material is established and maintained at the temperature to be used in step (2) for at least 20 seconds prior to the addition of the low decomposition temperature peroxide.

Claim 12

A process for making normally solid, gel-free, propylene polymer material with a branching index of less than 1 and with a strain hardening elongational viscosity from normally solid, amorphous to predominantly crystalline propylene polymer material without strain hardening elongational viscosity, which comprises: (1) mixing a low decomposition temperature peroxide and a high decomposition temperature peroxide with a linear propylene polymer material, which material is at room temperature to 120° C., in a mixing vessel in the substantial absence of atmospheric oxygen or its equivalent, (2) heating or maintaining the resulting mixture material in the substantial absence of atmospheric oxygen or its equivalent at room temperature to 120° C. for a period of time sufficient for decomposition of the low decomposition temperature peroxide, for a substantial amount of fragmentation of the linear propylene polymer material to occur, and for a significant amount of long chain branches to form, but insufficient to cause gelation of the propylene polymer material; (3) treating the propylene polymer material in the substantial absence of atmospheric oxygen or its equivalent to deactivate substantially all the free radicals present in said propylene polymer material from the low decomposition temperature peroxide, to decompose the high decomposition temperature peroxide and then to deactivate any remaining free radicals present in said propylene polymer material from the high decomposition temperature peroxide.

Claim 13

A process for making normally solid, gel-free, propylene polymer material with a branching index of less than 1 and with a strain hardening elongational viscosity from normally solid, amorphous to predominantly crystalline propylene polymer material without strain hardening elongational viscosity, which comprises: (1) mixing a low decomposition temperature peroxide and a high decomposition temperature peroxide with a linear propylene polymer material, which material is at room temperature to 120° C., in a mixing vessel in the substantial absence of atmospheric oxygen or its equivalent, (2) heating or maintaining the resulting mixture material in the substantial absence of atmospheric oxygen or its equivalent at room temperature to 120° C. for a period of time sufficient for decomposition of the low decomposition temperature peroxide, for a substantial amount of fragmentation of the linear propylene polymer material to occur, and for a significant amount of long chain branches to form, but insufficient to cause gelation of the propylene polymer material; (3) treating the propylene polymer material in the substantial absence of atmospheric oxygen or its equivalent to deactivate substantially all the free radicals present in said propylene polymer material from the low decomposition temperature peroxide, to decompose the high decomposition temperature peroxide and then to deactivate any remaining free radicals present in said propylene polymer material from the high decomposition temperature peroxide.

Claim 14

A process according to claim 11 in which said amorphous to predominantly crystalline polypropylene is a normally solid, gel-free, predominantly isotactic, semi-crystalline polypropylene.

Claim 15

A process according to claim 11 in which the low decomposition temperature peroxide is selected from the group consisting of di(sec-butyl) peroxydicarbonate, bis(2-ethoxy)peroxy propyl-peroxy dicarbonate, di-n-butylperoxy dicarbonate, di-sec-butylperoxy dicarbonate, di-isopropylperoxy dicarbonate, t-butylperoxy neodecanoate, t-amylperoxy neodecanoate and t-butylperoxy pivalate.

Claim 16

A process according to claim 11 in which the high decomposition temperature peroxide is selected from the group consisting of 2,5-dimethyl-2,5-bis(t-butylperoxy) hexane, bis(t-butylperoxy-isopropyl) benzene, dicumyl peroxide, 4,4-di-t-butylperoxy-n-butyl valerate, t-amylperoxy benzoate, t-butylperoxy benzoate, 2,2-di-t-butylperoxy butane, t-butylperoxy-3,5,5-trimethyl hexanoate, t-butylperoxy isopropyl carbonate and 1,1-di-t-butylperoxy cyclohexane.

Claim 17

A process according to claim 11 in which the low decomposition temperature peroxide has a half life of less than or equal to 5 minutes in the temperature range from about 90° C. to 120° C., or a half life of less than 40 minutes in the temperature range from about 60° C. to about 90° C., or a half life of less than 60 minutes in the temperature range from room temperature to about 60° C., and the high decomposition peroxide has a half life of greater than or equal to 20 minutes at 120° C., but greater than 60 minutes at the temperature used in step (3).

Claim 18

A process according to claim 15 in which the low decomposition temperature peroxide has a half life of 10 seconds to 5 minutes at the temperature used in step (2).

Claim 19

A process according to claim 15 in which the high decomposition temperature peroxide has a half life of 30 seconds to about 10 minutes at the temperature used in step (3).

Claim 20

A process according to claim 11 in which the temperature of step (2) is 60°-110° C.

Claim 21

A process according to claim 11 in which the temperature of step (2) is 70°-105° C.

Claim 22

A process according to claim 11 in which the temperature of step (3) is about 130° to 150° C.

Claim 23

A process according to claim 19 in which the temperature of step (3) is about 140° to 150° C.

Claim 24

A process according to claim 11 in which the temperature to be used in step (2) is established and maintained for at least 20 seconds prior to the addition of the low and high decomposition peroxides.