CN1265693A - 全同立构聚丙烯与α一烯烃/丙烯共聚物的热塑性聚合物共混物 - Google Patents

全同立构聚丙烯与α一烯烃/丙烯共聚物的热塑性聚合物共混物 Download PDF

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CN1265693A
CN1265693A CN98807959A CN98807959A CN1265693A CN 1265693 A CN1265693 A CN 1265693A CN 98807959 A CN98807959 A CN 98807959A CN 98807959 A CN98807959 A CN 98807959A CN 1265693 A CN1265693 A CN 1265693A
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S·达塔
A·C·加德卡瑞
C·科泽维斯
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Abstract

一种热塑性聚合物共混物组合物,其中包含全同立构聚丙烯成分与α烯烃和丙烯的共聚物,所说的共聚物中含有可结晶的α烯烃序列。在一个优选的实施方案,提供一种改进的热塑性聚合物共混物,其中包含约35—约85wt%全同立构聚丙烯和约30—约70wt%乙烯和丙烯的共聚物,其中所说的共聚物中含有可全同立构结晶的丙烯序列并且是丙烯为主。所得的共混物具有相容性、增加的拉伸强度、和改进的加工性能,单一的熔点。

Description

全同立构聚丙烯与α-烯烃/丙烯共聚物的热塑性聚合物共混物
发明领域
本发明涉及一种至少两种聚合物的聚合物共混物，该共混物当与共混前的各自聚合物相比时具有出人意料的特性。更具体说，本发明涉及热塑性聚合物的共混物，例如，根据一个实施方案，是涉及全同立构聚丙烯与烯烃共聚物的共混物。本发明还涉及包含全同立构聚丙烯的热塑性聚合物的共混物，根据一个实施方案，是包含全同立构聚丙烯与乙烯和丙烯共聚物的共混物，其中共聚物包含可结晶的全同立构α烯烃序列。此外，本发明涉及制作上述聚合物及其共混物的方法。
发明背景
虽然全同立构聚丙烯与乙烯丙烯橡胶的共混物是为现有技术所公知的，但现有技术的齐格勒-纳塔催化剂体系在实际、经济的聚合条件下仅能生产含30wt％以上乙烯的乙烯丙烯橡胶组合物。因而存在着对聚合材料的需求，这种材料应当具有有利的加工性能，同时能够赋予由其形成的制品适宜的最终特性，如抗拉伸性和抗冲击性。为尝试和满足上述需求，人们开发了共聚物和聚合物的共混物。US专利3,882,197(Fritz等)描述了有规立构丙烯/α烯烃共聚物、有规立构丙烯、与乙烯共聚物橡胶的共混物。在US专利3,888,949(Chi-KaiShih，授让给E.I.DuPont)中，描述了包含全同立构聚丙烯与丙烯和含6-20碳原子α烯烃的共聚物的共混物组合物的合成，该共混物具有超过共聚物或全同立构聚丙烯的改进的伸长性和拉伸强度。所描述的丙烯和α烯烃的共聚物其中α烯烃是己烯、辛烯或十二碳烯。然而，共聚物要用多相钛催化剂来制造，这种催化剂造成组成的分布不均匀并且一般分子量分布较宽。组成分布是共聚物的一个特性，其中存在聚合物组合物中的统计学意义的分子间或分子内差异。后面将描述组成分布的测定方法。US专利3,888,949中在聚合物的叙述中通过使用术语“嵌段”描述了分子内组成分布的存在，其中共聚物被描述为具有“不同α烯烃含量的序列”。在本发明的内容中，所述的术语“序列”是描述通过化学键连接在一起并且通过聚合工艺获得的烯烃单体残基的数。
US专利4,461,872中，A.C.L.Su通过使用另一种多相催化剂体系对US专利3,888,949所述的共混物的性能作了改进。然而，由于期望对这些丙烯和α烯烃聚合所用的催化剂形成能够具有统计学意义的分子间和分子内组成差异的共聚物，共聚物的性能和组成，无论是单体(含6-20碳原子的α烯烃)的性质和类型还是聚合物中α烯烃的嵌段状多相分子内/分子间分布方面，都没有得到解决。
在大分子(Macromolecules)杂志中的两篇连续报道中(1989，v22，P3851-3866)，E.I.DuPont的J.W.Collette描述了全同立构聚丙烯与部分无规立构聚丙烯的共混物，该共混物具有所期望的拉伸伸长性能。然而，部分无规立构的丙烯具有如第一篇报道图8的较宽分子量分布。部分无规立构的聚丙烯还由数个片段组成，其丙烯单元的立构规整度不同，如在不同溶剂中的不同溶解度所示。通过共混物的相应物理分解用不同溶剂提取分离获得均匀溶解性能的各个成分(如上述报道中表IV所示)证明了这一点。
US专利3,853,969和3,378,606(E.G.Kontos)公开了全同立构聚丙烯、与丙烯和另一种2-12碳原子烯烃(包括乙烯和己烯)的“立构嵌段”共聚物的原位共混物的形成。该发明的共聚物在分子间和分子内的组成分布中必须是多相的。这可通过所说共聚物的合成过程来证实，其中包括将不同组成的单体混合物顺序注射到同样是不同组成的合成聚合部分中。另外，上述两篇专利的图1显示了“立构嵌段”特性，这便是本发明说明书所说的分子内或分子间组成差异，它对共混物的拉伸和伸长性能的效益是必要的。全同立构聚丙烯与组成均匀的无规乙烯丙烯共聚物的原位共混物具有较差性能。此外，所有这些组合物都没有满足各种用途的所需性能，并且/或者使用了昂贵和累赘的加工步骤来达到所需的结果。
类似的结果还出现在R.Holzer和K.Mehnert的US专利3,262,992中(授让给Hercules)，其中作者公开了向全同立构聚丙烯添加乙烯和丙烯的立构嵌段共聚物导致共混物的机械性能比单独的全同立构聚丙烯有所改进。然而，这些优点仅是对乙烯和丙烯的立构嵌段共聚物来说的。共聚物的合成是在聚合条件下设计的，其中通过随时间改变反应器中单体的浓度来实现在乙烯和丙烯不同组合物中产生聚合物链。这可参见实施例1和2。聚合物的立构嵌段特性以图显示在分子描述(65行第2栏)，并且相对于不期望的无规共聚物而不同(60行第2栏)。聚合物中立构嵌段特性的存在通过聚合物的高熔点来显示，该熔点比本发明的第二聚合物组分的熔点要高(如表1)，并且这些立构嵌段材料的溶解性作为材料的乙烯wt％函数较差(如表3)。
因此，将期望生产一种结晶聚合物(以下称“第一聚合物组分”)与可结晶聚合物(以下称“第二聚合物组分”)的共混物，该共混物具有有利的加工性能同时仍能赋予由共混物组合物制造的最终产品所需的性能，即增加的拉伸强度、伸长性和总体韧度。第一聚合物组分在下表中简写成“FPC”，而第二聚合物组分在下表中简写成“SPC”。事实上，需要整个聚烯烃组合物是热稳定的、耐热、耐光的，并且通常适合于具有有利加工性能的热塑弹性体(TPE)用途。如果第一聚合物组分和第二聚合物组分结合物的机械性能明显区别于单独第一聚合物组分和第二聚合物组分相应性能的组合加权平均，则整个聚烯烃组合物是最好的。我们预计(但不是指限制)如果第二聚合物组分仅由定义为均匀分子内和分子间组成和微结构的一种或两种聚烯烃共聚物材料所组成，则可以增加第二聚合物组分。
这里对第一聚合物组分所说的术语“结晶”，表征为这些聚合物拥有高度的分子间和分子内有序，并且其熔点高于110℃优选高于115℃且其熔化热根据DSC分析测定为至少75J/g。而且，对第二聚合物组分所说的术语“可结晶的”，是指这些聚合物或序列主要是未变形态的非晶形，但一旦拉伸或退火则发生结晶。结晶也可以在有结晶聚合物如第一聚合物组分的存在下发生。这些聚合物的熔点低于105℃优选低于100℃且其熔化热根据DSC分析测定为小于75J/g。
发明概述
根据一个实施方案，本发明涉及使用手性茂金属催化剂来(1)容易地生产第二聚合物组分，该成分是具有约4-约25wt％乙烯的乙烯丙烯橡胶组合物；和(2)容易地生产第二聚合物组分，该成分含有长度足以结晶的全同立构丙烯序列。因此，本发明的一个实施方案涉及半结晶材料(第二聚合物组分)，该材料当与全同立构聚合物(第一聚合物组分)共混时显出增加程度的乙烯丙烯和全同立构聚丙烯相之间的相容性。我们相信(但不是指限制于此)增加的相容性是由于第一聚合物组分和所有第二聚合物组分的组成类似性。因此，第二聚合物组分的分子内和分子间组成的均匀性是重要的。具体说，第二聚合物组分的基本上所有成分应当在上述定义的乙烯和丙烯窄组成范围内是重要的。此外，第二聚合物组分中存在全同立构丙烯序列对改进聚合物共混物组合物中第一聚合物组分和第二聚合物组分起支配作用的粘合性是有益的。结果，本发明的全同立构聚丙烯与乙烯丙烯共聚物的共混物具有可与现有技术的乙烯丙烯橡胶的全同立构聚丙烯共混物相对比的改进的物理性能。
根据本发明的一个实施方案，本发明的组合物包含至少一种第一聚合物组分与第二聚合物组分的共混物。共混物包含约2wt％以上的含有α烯烃丙烯共聚物的第一聚合物组分，其中所说的α烯烃丙烯共聚物含具有约115-约170℃熔点的全同立构聚丙烯结晶度。共混物还包含第二聚合物组分，该成分含有丙烯和至少一种小于6碳原子、优选2碳原子的其它α烯烃的共聚物。根据一个实施方案，本发明的第二聚合物组分中共聚物包含可全同立构结晶的丙烯序列和75wt％以上且优选大于80wt％的丙烯。
根据另一个实施方案，本发明的热塑性聚合物共混物组合物包含第一聚合物组分和第二聚合物组分。第一聚合物组分含全同立构聚丙烯，并且占共混物总重量的约2-约95wt％，更优选2-70wt％。第一聚合物组分还可以由被称为抗冲共聚物或反应器共聚物的普通可获得的全同立构聚丙烯组合物组成。然而，在共混物中对第一聚合物组分的标定仅可接受一定程度的偏差，即第一聚合物组分的所有成分在组成上基本类似，并且第一聚合物组分是在上述指出的结晶度和熔点范围内。第一聚合物组分还可包含诸如流动改进剂、成核剂和抗氧化剂等通常添加给全同立构聚丙烯以改进或保持其性能的添加剂。所有这些聚合物均称为第一聚合物组分。
第二聚合物组分是包含乙烯和丙烯无规共聚物的热塑材料，其中所说的共聚物具有25-105℃、优选25-90℃、更优选40-90℃的DSC熔点和至少75wt％、更优选至少80wt％的平均丙烯含量。使用当所有或基本上所有丙烯序列在第二聚合物组分中全同立构排列时形成本质上或基本上全同立构聚丙烯的聚合催化剂制造第二聚合物组分。该共聚物含有归因于全同立构聚丙烯的可结晶丙烯序列。第二聚合物组分链上的乙烯和丙烯残基的分布为统计学无规的。通过考虑第二聚合物组分的实验测定的竞聚率可以获得乙烯和丙烯序列分布无规性的定量评价。我们相信第二聚合物组分的乙烯和丙烯序列的无规分布是由于(1)它是用单位点的茂金属催化剂制造的，该催化剂仅允许乙烯和丙烯单统计模式的添加，以及(2)它在混合充分、连续单体进料搅拌罐聚合反应器中制造，该反应器仅允许便于第二聚合物组分中基本上所有聚合物链的单聚合环境。因此，第二聚合物组分中无论是两个聚合物链之间还是任何一个链上基本上没有统计学意义的组成差异。
本发明共混物组合物中第一聚合物组分与第二聚合物组分重量比可以为2∶98-95∶5，更优选2∶98-70∶30的重量比。
根据本发明的另一个实施方案，第二聚合物组分可以含有少量非共轭二烯以帮助硫化和其它化学改性第一聚合物组分和第二聚合物组分的共混物。二烯的量被限制为不超过10wt％，并且优选不超过5wt％。二烯可以选自那些用于硫化乙烯丙烯橡胶的二烯，优选亚乙基降冰片烯、乙烯基降冰片烯和二环戊二烯。
根据本发明的再一个实施方案，本发明涉及一种制备热塑性聚合物共混物组合物的方法。该方法包括(a)将丙烯或丙烯与一种或多种选自C2或C4-C10α烯烃单体的混合物在聚合催化剂的存在下聚合，获得含有至少约90wt％被聚合丙烯的基本上全同立构的丙烯聚合物；(b)将乙烯和丙烯的混合物在手性茂金属催化剂的存在下聚合，获得乙烯和丙烯的共聚物，其中包含最多约25wt％乙烯、优选最多20wt％乙烯并且含有可全同立构结晶的丙烯序列；并且(c)将步骤(a)的丙烯聚合物与步骤(b)的共聚物共混，形成共混物。本发明优选实施方案的详细描述
本发明的共混物组合物一般由以下两种成分组成：(1)含全同立构聚丙烯的第一聚合物组分，和(2)含α烯烃(除丙烯外)和丙烯共聚物的第二聚合物组分。第一聚合物组分(FPC)
根据本发明，第一热塑性聚合物组分(第一聚合物组分)即聚丙烯聚合物成分可以是均聚聚丙烯、或丙烯共聚物、或其一些共混物。本发明共混物中使用的聚丙烯可以是各种形式。例如，可以使用基本上全同立构的聚丙烯均聚物，或者聚丙烯可以是以含小于或等于约10wt％其它单体的共聚物形式(即至少约90wt％的丙烯)。此外，聚丙烯可以是接枝或嵌段共聚物，其中聚丙烯的嵌段基本上具有与丙烯-α烯烃共聚物相同的立构规整性，只要接枝或嵌段共聚物具有大于110℃、优选大于115℃、更优选大于130℃的高熔点，这是有规立构丙烯序列的特征。本发明的第一聚合物组分是结晶性占主导，即通常具有大于约110℃、优选大于约115℃、首选大于约130℃的熔点。丙烯聚合物成分可以是这里所述的均聚丙烯和/或无规和/或嵌段共聚物的组合。当上述丙烯聚合物成分是无规共聚物时，共聚物中共聚的α烯烃的百分比一般来说最多约9wt％、优选约2-约8wt％、首选约2-约6wt％。优选的α烯烃包含2个或4-12个碳原子。首选的α烯烃是乙烯。可以将一种、两种或多种α烯烃与丙烯共聚。
α烯烃的实例可以选自乙烯；丁烯-1；戊烯-1，2-甲基戊烯-1，3-甲基丁烯-1；己烯-1，3-甲基戊烯-1，4-甲基戊烯-1，3，3-二甲基丁烯-1；庚烯-1；己烯-1；甲基己烯-1；二甲基戊烯-1三甲基丁烯-1；乙基戊烯-1；辛烯-1；甲基戊烯-1；二甲基己烯-1；三甲基戊烯-1；乙基己烯-1；甲基乙基戊烯-1；二乙基丁烯-1；丙基戊烷-1；癸烯-1；甲基壬烯-1；壬烯-1；二甲基辛烯-1；三甲基庚烯-1；乙基辛烯-1；甲基乙基丁烯-1；二乙基己烯-1；十二碳烯-1；和十六碳烯-1。
本发明的热塑性聚合物共混物组合物可以包含约2-约95wt％的第一聚合物组分。根据一个优选的实施方案，本发明的热塑性聚合物共混物组合物可以包含约2-约70wt％的第一聚合物组分。根据首选的实施方案，本发明的组合物可以包含约5-约70wt％的第一聚合物组分。
对用于制备本发明这种丙烯聚合物成分的方法没有特别的限制。然而，通常来说，聚合物是通过在单级或多级反应器中均聚丙烯获得的丙烯均聚物。共聚物可以通过在单级或多级反应器中将丙烯与2或4至约20碳原子α烯烃、优选乙烯共聚获得。聚合方法包括高压、浆液、气相、本体或液相聚合，或者它们的组合，使用齐格勒纳塔催化剂或单点茂金属催化剂体系。所用的催化剂优选具有高的等特异性。聚合可以通过连续式或间歇式工艺来完成，并且可以包括使用链转移剂、清除剂或其它认为可用的添加剂。第二聚合物组分(SPC)
本发明聚合物共混物组合物的第二聚合物组分包含丙烯和另一种小于6碳原子α烯烃、优选乙烯的共聚物。选择性地，除了上述提及的以外，本发明组合物的第二组分还可以包含一定量的二烯。根据一个实施方案，本发明组合物的第二聚合物组分优选包含具有窄组成分布的无规共聚物。据信(但不限制于此)第二聚合物组分的窄组成分布是重要的。通过在溶剂中热分级来测定聚合物的分子间组成分布。典型的溶剂是饱和烃，如己烷或庚烷。这种热分级过程描述如下。一般来说，聚合物的大约75wt％、更优选85wt％被离析为一个或两个相邻的、可溶馏分，而其余的聚合物在直接的前面或后面馏分中。这些馏分的每个具有差异不超过20wt％(相对)、更优选10wt％(相对)整个第二聚合物组分平均wt％乙烯含量的组成(wt％乙烯含量)。如果满足上述概括的分级试验，则第二聚合物组分的组成分布是窄的。
在所有第二聚合物组分中，乙烯残基的数量和分布符合乙烯、丙烯和选择量二烯的无规统计聚合。在立构嵌段结构中，任何一类与另一类相邻的单体残基的数目大于从具有相同组成的无规共聚物的统计分布中预测的数目。先前具有立构嵌段结构的聚合物，其乙烯残基的分布符合嵌段状结构而不是聚合物中单体残基的无规统计分布。聚合物的分子内组成分布可以通过C-13 NMR确定，其相对于相邻的丙烯残基定位乙烯残基。一种更实际和一致的乙烯和丙烯序列分布无规性的评价方法可以通过以下考虑来获得。我们相信第二聚合物组分中乙烯和丙烯序列的分布无规的原因是(1)它是用单 点的茂金属催化剂制造的，该催化剂仅允许乙烯和丙烯单统计模式的添加，以及(2)它在混合充分、连续单体进料搅拌罐聚合反应器中制造，该反应器仅允许便于第二聚合物组分中基本上所有聚合物链的单聚合环境。
根据本发明的一个实施方案，第二聚合物组分优选具有一个单一熔点。熔点通过DSC来测定。一般来说，本发明的共聚物第二组分比共混物的第一聚合物组分低的熔点，约为105-25℃。优选，第二聚合物组分的熔点为约90-25℃。根据本发明的一个实施方案，本发明组合物的第二聚合物组分的熔点首选为90-40℃。
第二聚合物组分优选具有约1.8-约5.0的窄分子量分布(MWD)，优选MWD为约2.0-约3.2。
本发明组合物的第二聚合物组分包含可全同立构结晶的α烯烃序列，例如优选丙烯序列(NMR)。根据一个实施方案，第二聚合物组分的结晶度通过聚合物退火样品的熔化热测定优选为均全同立构聚丙烯的约2-约65％，优选5-40％。
根据本发明的另一个实施方案，组合物的第二聚合物组分包含约5-约25wt％α烯烃，优选约6-约20wt％的α烯烃，首选包含约6-约18wt％的α烯烃，并且更优选10-16wt％的α烯烃。第二聚合物组分的组成范围被认为是本发明的一个目的。α烯烃组成低于上述低限的第二聚合物组分，第一聚合物组分和第二聚合物组分的共混物较硬，并且不具有本发明共混物的良好伸长性能。当第二聚合物组分的α烯烃组成高于上述的上限，第二聚合物组分和第一聚合物组分的共混物不具有本发明共混物的良好拉伸性能。据信(但不限制于此)第二聚合物组分必须具有最佳量的全同立构聚丙烯结晶度，以便与第一聚合物组分结晶，达到本发明的有益效果。如上所述，优选的α烯烃是乙烯。
本发明的组合物可以包含约5-约98wt％的第二聚合物组分。根据一个优选的实施方案，本发明的组合物可以包含约30-约98wt％的第二聚合物组分。首选，本发明的组合物包含约30-约95wt％的第二聚合物组分。
一般来说(不以任何方式限制本发明的范围)，一种实施本发明方法中生产共聚物第二聚合物组分的途径如下是：(1)将液体丙烯引入搅拌罐反应器中，(2)通过喷嘴以气相或以液相引入催化剂体系，(3)将原料乙烯气体引入反应器的气相中，或者如现有技术公知技术喷射入液相中，(4)反应器包含基本上由丙烯以及与溶解的α烯烃、优选乙烯组成的液相，和含有所有单体蒸汽的气相，(5)通过气化丙烯的回流(自动制冷作用)、以及通过冷却盘管、夹套等控制反应器的温度和压力，(6)通过催化剂浓度、温度来控制聚合速率，并且(7)通过控制反应器中乙烯/丙烯比来确定聚合物产品中的乙烯(或其它α烯烃)含量，所说的控制是通过操纵所说成分到反应器的相对进料速率。
例如，典型的聚合过程由在含二(环戊二烯基)金属化合物、和1)非配位相容性阴离子活化剂或2)铝氧烷活化剂的存在下聚合组成。根据本发明的一个实施方案，该过程包括将乙烯和丙烯与催化剂在适宜的聚合稀释剂中接触的步骤，根据一个优选的实施方案，所说的催化剂包括例如手性茂金属催化剂，如US专利5,198,401中描述的二(环戊二烯基)金属化合物，该专利引入这里供US实践和活化剂的参考为目的。所用的活化剂可以是铝氧烷活化剂或非配位相容性阴离子活化剂。优选以提供约1∶1-约20,000∶1或更高铝/茂金属摩尔比的量使用铝氧烷活化剂。优选以提供10∶1-约1∶1二环戊二烯基金属化合物/非配位相容性阴离子摩尔比的量使用非配位相容性阴离子活化剂。通过将这些单体在所说催化剂体系的存在下于约-100℃至约300℃下反应约1秒至约10小时的时间来进行上述聚合反应，以便生产重均分子量为约5,000或更小至约1,000,000或更高且分子量分布为约1.8至约4.5的共聚物。
虽然本发明的方法包括使用液相(浆液、溶液、悬浮液或本体相或其组合)催化剂体系，但根据本发明的其它实施方案，还可以使用高压液相或气相聚合方法。当使用气相、浆液相或悬浮液相聚合时，催化剂体系优选是带载体的催化剂体系。例如参见US专利5,057,475，该专利为US实践的目的而引入这里作参考。这种催化剂体系还可以包含其它公知添加剂，例如清除剂。例如参见US专利5,153,157，该专利为US实践的目的引入这里作参考。这些方法的使用可以在不限制反应容器类型和聚合进行方式。如上所述，并且对使用载体催化剂体系的系统来说也是这样，液相方法包括将乙烯和丙烯与催化剂体系在适宜的聚合稀释剂中接触、并且在催化剂体系的存在下让单体在足以产生具有所需分子量和组成的乙烯-丙烯共聚物的时间和温度下反应的步骤。
应当了解在本发明的内容中，在一个实施方案中，可以在单独一种共混物中使用一种以上的第二聚合物组分与第一聚合物组分共混。每种第二聚合物组分如上所述，并且在该实施方案中第二聚合物组分的数量小于3并且更优选是2。在本发明的这个实施方案中第二聚合物组分的α烯烃含量与5-9wt％α烯烃的范围不同，而是10-22wt％α烯烃。优选的α烯烃是乙烯。据信，使用两种第二聚合物组分与单一一种第一聚合物组分结合会对共混物的拉伸-伸长性能产生有益的改进。第一和第二聚合物组分的共混。
本发明的第一聚合物组分和第二聚合物组分的共聚物共混物可以通过保证将成分均质混合的任何过程来制备。例如，可以通过在Carver压机上和约180℃下将成分熔融压制在一起压制成厚约0.5毫米(20密耳)，将所得的厚片收卷，将端部折叠在一起，并且重复压制、收卷和折叠操作约10次。密炼机对溶液或熔体共混是特别有用的。据发现在布拉本德塑性描绘仪(Brabender Plastograph)在约180-240℃下共混约1-20分钟是令人满意的。可以用于混合成分的另一种方法是在大于所有成分熔融温度(例如180℃)的班伯里密炼机中将聚合物共混约5分钟。聚合物成分的完全混合通过成分聚丙烯结晶性的结晶和熔化转变特性缩小、达到共混物的单个或小范围结晶点和熔点来指示。工业中这些分批式混合的过程将被连续式混合过程取替。这些方法为现有技术所公知的，并且使用单螺杆和双螺杆混合挤出机、混合低粘度熔融聚合物流用的静态混合机、碰撞式混合机、以及设计为将第一聚合物组分和第二聚合物组分均质接触方式分散的其它设备和工艺。
本发明的聚合物共混物表现出显著组合的所需物理性能。在丙烯/α烯烃共聚物中掺合小至5％的第一聚合物组分便可增加丙烯序列熔点或聚合物软化点，但更明显地，与丙烯/α烯烃共聚物相比降低了范围。此外，掺合本发明的第一聚合物组分可几乎消除由丙烯/α烯烃共聚物引起的粘性。还有，共聚物共混物的热性能被明显改进超过第二聚合物组分丙烯/α烯烃共聚物。
共混操作的结果改变了共混物的结晶温度和熔点。在本发明的一个实施方案中，第一聚合物组分和第二聚合物组分的共混物具有单一的结晶温度和熔点。其温度高于第二聚合物组分的相应温度并且接近第一聚合物组分的温度。在其它实施方案中，第二聚合物组分和第一聚合物组分具有不同的熔点和结晶温度，却具有比第二聚合物组分和第一聚合物组分相组合所能预料的更靠近一起的温度。在这些情况中，聚合物共混物保留了第二聚合物组分的玻璃化转变温度。这种有利的热性能的组合使得它们令人满意地在注塑操作中使用而没有以前遇到的取向性。因而，由本发明共聚物共混物制备的注塑制品显出杰出的长期尺寸稳定性。这些优点的获得不需要费力地纯化丙烯/α烯烃共聚物或者烦琐地制备仔细结构化的嵌段共聚物。另外，通过使用第二聚合物组分和第一聚合物组分，共混物可以获得较低的玻璃化转变温度，低于同样组成的无规共聚物作为共混物所能预料的温度。具体说，共混物的玻璃化转变温度接近于第二聚合物组分的温度而低于第一聚合物组分的温度。这可以在聚合物共混物中没有特别高含量α烯烃的情况下实现，我们相信(但不是指限制于此)高含量的α烯烃将导致共混物的拉伸-伸长性能下降。
之所以能够获得本发明共聚物共混物所需性能的机理并不完全清楚。然而，据信是各种聚合物成分中具有类似立构规整性的丙烯序列之间的共结晶现象，在一个实施方案中造成了共聚物共混物具有单一的结晶温度和单一的熔化温度，高于共混物中第二聚合物组分丙烯/α烯烃成分的那些温度。在另一个实施方案中，第一聚合物组分和第二聚合物组分的组合的熔点比对比各个单独成分性能时所能预料的更靠近于一起。在一个实施方案中，共混物出人意料地具有单一的结晶温度和单一的熔化温度，因为本领域技术人员所能够预料的是两种结晶聚合物的共混将产生反映这两种聚合物成分的两个结晶温度以及两个熔化温度。然而，具有所需结晶性的聚合物的均质共混明显产生了改进丙烯/α烯烃共聚物其它物理性能的结晶现象，从而适度增加了其商业用途和应用范围。
上述讨论限于本发明只具有一种和两种成分的描述，但对本领域技术人员显而易见的是，本发明的聚合物共混物组合物可以包含其它添加剂。本发明的组合物中可以存在各种添加剂以增强特定的性能或者可以作为加工各个成分的结果。可以掺加的添加剂包括例如阻燃剂；抗氧化剂；增塑剂和色料。可以用来增强性能的其它添加剂包括防粘连剂；着色剂；稳定剂和氧化、热和紫外线抑制剂。还可以使用润滑剂、脱模剂、成核剂、补强剂和填料(包括颗粒、纤维或粉末状)。成核剂和填料可以改进制品的刚性。这里所列举的并不包括所有类型的本发明可以使用的添加剂。当读到这些公开内容时，本领域技术人员将领会到可以使用其它添加剂来增强组合物的性能。正如本领域技术人员理解的，可以将本发明的聚合物共混物组合物进行改性来调整共混物所需的性能。
根据ASTM D 1646在125℃下测定ML(1+4)，作为这里用到的门尼粘度，以门尼单位计。
根据ASTM D 3900测定乙烯wt％，作为乙烯丙烯共聚物(用作对比实施例)的组成。
第二聚合物组分的组成根据以下技术测定乙烯wt％。将在大约或大于150℃下压制的第二聚合物组分的均匀薄膜安装在Perkin ElmerPE 1760远红外分光光度计中。记录样品从600cm-1至400cm-1的全光谱，并且根据以下等式1计算第二聚合物组分的乙烯wt％：乙烯wt％＝82.585-111.987X+30.045X2其中X是1155cm-1下的峰高度与722cm-1或732cm-1下的峰高度之比，722cm-1或732cm-1下的峰高度较高。
分子量(Mn和Mw)和分子量分布(MWD)的测量技术见US专利4,540,753(Cozewith，Ju和Verstrate)(该专利引入这里为US实践的目的供参考)并且这里引用作为参考，以及Macromolecules，1988，第21册P3360(Verstrate等)(该文献引入这里为US实践的目的供参考)并且这里引用作为参考。
差式扫描量热法的过程描述如下。用冲模取出在大约200-230℃下压制的约6-10mg聚合物片。在室温下退火80-100小时。时间结束时，将样品放在差式扫描量热计(Perkin Elmer 7系列热分析系统)并且冷却至约-50℃至-70℃。以20℃/分钟加热样品，以便达到约200-约220℃的最终温度。将样品熔化峰下测量的面积记录为产热量(以焦耳计)，所说的样品一般在约30-约175℃达到峰值并且在约0-约200℃之间出现熔化峰，以此作为熔融热测量值。将样品熔化范围内的最大吸收热温度记录为熔化点。在这些条件下，第二聚合物组分的熔化点和熔融热要比上述第一聚合物组分低。
第二聚合物组分的组成分布如下所述测定。将约30mg的第二聚合物组分切成各边约1/8”的小块。将其引入一厚壁玻璃瓶中，用螺旋盖以及加入50mg Irganox1076(一种可从汽巴嘉基公司市售获得的抗氧化剂)密封。然后，将425ml己烷(普通和ISO异构体的主要混合物)添加到瓶中内含物中，并且将密封的瓶保持在23℃下24小时。时间结束时，倾出溶液并且用附加的己烷将残余物处理另外24小时。时间结束时，合并两份己烷溶液并且蒸发产生可在23℃下溶解的聚合物残余物。向残余物添加足够的己烷，使体积达到425ml并且用覆盖的循环水浴将瓶保持在约31℃下24小时。倾出可溶的聚合物并且在约31℃下另外24小时内添加附加量的己烷，然后倾出。按此方式，在每个阶段之间增加约8℃温度，获得可在40℃、48℃、55℃和62℃下溶解的第二聚合物组分的馏分。此外，如果使用庚烷取代己烷溶剂用于大于约60℃的所有温度的话，则温度可以调整为增加至95℃。将可溶聚合物干燥、称重并且通过上述IR技术进行组成分析(即乙烯含量wt％)。相邻温度增加所获得的可溶馏分是以上说明的相邻馏分。
以下数据表中的EPR是Vistalon 457，由Exxon化学公司出售(Houston TX)。
本发明将通过以下的具体实施例作进一步的说明，但不限于此：实施例实施例1：乙烯/丙烯的共聚形成第二聚合物组分
聚合在1升的恒温连续进料搅拌罐反应器中进行，使用己烷作为溶剂。聚合反应器装满液体。在反应器中的停留时间一般为7-9分钟，并且压力保持在400kpa。将己烷、乙烯和丙烯计量成一股物料流并且冷却，然后引入反应器的底部。连续将所有反应物的溶液和聚合催化剂引入反应器中，以引发放热聚合反应。通过改变己烷原料的温度和在外层夹套中循环水将反应器温度保持在41℃。对于典型的聚合反应，原料温度为约0℃。
乙烯以45gms/min的速度引入并且丙烯以480gms/min的速度引入。聚合催化剂--用N’，N’-二甲基苯铵-四(五氟苯基)硼酸盐1∶1摩尔比二甲基活化的二甲基甲硅烷基桥连的二茚基铪--以0.00897gms/hr的速度引入。将三异丁基铝的稀溶液引入反应器中作为催化剂终止物的清除剂：每mol催化剂大约28.48mol清除剂的比率对此聚合是足够的。经过稳定聚合的5个停留时间之后，收集该聚合中产生的聚合物的代表性样品。从顶部抽出聚合物溶液，然后蒸汽蒸馏以分离聚合物。聚合物的形成速率为285.6gms/hr。此聚合生产的聚合物具有13％的乙烯含量、12.1的ML@125(1+4)并且具有全同立构丙烯序列。
通过改变乙烯/丙烯之比理论上获得聚合物组成的变化。聚合物的分子量可以通过乙烯和丙烯的量大于聚合催化剂的量来使之增加。聚合物中可以掺加二烯，诸如降冰片烯和乙烯基降冰片烯，通过在聚合期间将它们连续加入。实施例2对比乙烯/丙烯聚合，其中丙烯残基是无规立构的
聚合在1升的恒温连续进料搅拌罐反应器中进行，使用己烷作为溶剂。聚合反应器装满液体。在反应器中的停留时间一般为7-9分钟，并且压力保持在400kpa。将己烷、乙烯和丙烯计量成一股物料流并且冷却，然后引入反应器的底部。连续将所有反应物的溶液和聚合催化剂引入反应器中，以引发放热聚合反应。通过改变己烷原料的温度和在反应器外夹套中使用冷却水将反应器温度保持在45℃。对于一个典型的聚合，原料温度为约-10℃。乙烯以45gms/min的速度引入并且丙烯以310gms/min的速度引入。聚合催化剂--用N’，N’-二甲基苯铵-四(五氟苯基)硼酸盐1∶1摩尔比二甲基活化的二甲基甲硅烷基桥连的(四甲基环戊二烯基)环十二烷基酰基钛--以0.002780 gms/hr的速度引入。将三异丁基铝的稀溶液引入反应器中作为催化剂终止物的清除剂：每mol催化剂大约36.8mol清除剂的比率对此聚合是足够的。经过稳定聚合的5个停留时间之后，收集该聚合中产生的聚合物的代表性样品。从顶部抽出聚合物溶液，然后蒸汽蒸馏以分离聚合物。聚合物的形成速率为258 gms/hr。此聚合生产的聚合物具有14.1wt％的乙烯含量、95.4的ML@125(1+4)。
通过改变乙烯/丙烯之比理论上获得聚合物组成的变化。聚合物的分子量可以通过增大乙烯和丙烯的量超过聚合催化剂的量来增加。在下表中这些聚合物作为aePP描述。实施例3数种第二聚合物组分的分析和溶解性
按照上述实施例1所述的方式，合成以上说明的数种第二聚合物组分。下表对此已作描述。表1描述了聚合物的GPC、组成、ML和DSC分析结果。表1
    SPC   (Mn)通过GPC   (Mw)通过GPC   乙烯wt％通过IR     熔融热J/g  熔点通过DSC(℃)   ML(1+4)@125℃
    SPC-1   102000   248900   7.3     71.9  84.7   14
    SPC-2   124700   265900   11.6     17.1  43.0   23.9
    SPC-3   121900   318900   16.4     7.8  42.2   33.1
    SPC-4   11.1     25.73  63.4   34.5
    SPC-5   14.7     13.2  47.8   38.4
    对比聚合物
    EPR   47.8     未检测  未检测   40
    aePP   11.7     未检测  未检测   23
表1：第二聚合物组分和对比聚合物的分析。
表2描述了第二聚合物组分的溶解度表2
Figure A9880795900211
表2：第二聚合物组分馏分的溶解度。由于聚合物馏分干燥不完全，馏分总和相加略微超过100。
表3描述了表2获得的第二聚合物组分馏分的组成。仅分析了聚合物总质量超过4％的馏分的组成。表3表3：表2中获得的第二聚合物组分馏分的组成。据信乙烯含量测定中的实验不精确度为约0.4wt％绝对值实施例4
将总共72g的第一聚合物组分和第二聚合物组分的混合物(如表4第2栏所示)在布拉本德(Brabender)强力混合器中混合3分钟，温度控制为185℃-220℃内。使用高剪切辊片进行混合，并且向共混物添加大约0.4g Irganox-1076(可从Novartis公司获得的抗氧化剂)。混合结束时，取出混合物并且在215℃压模3-5分钟成6”x 6”025”厚的垫。时间结束时，将垫冷却并且取出，让其退火3-5天。由该垫取下所需哑铃几何状的测试件，并且在Instron测试仪上进行评价，得到如表4所示的数据。
第一聚合物组分是Escorene 4292(可从Exxon化学公司(Houston，Texas)商购获得的均全同立构聚丙烯)。第二聚合物组分是SPC-1，其特征见上表1、2和3。表4
Figure A9880795900231
表4：第一聚合物组分和第二聚合物组分共混物的应力对伸长率(E)数据，其中第二聚合物组分为上表中的SPC-1成分。阴影部分表示样品被破坏。透明部分表示由于伸长度超过设备极限而缺乏数据。实施例5
第一聚合物组分是Escorene 4292(可从Exxon化学公司(Houston，Texas)商购获得的均全同立构聚丙烯)。第二聚合物组分是组分SPC-2，其特征见上表1、2和3。按照实施例4所述的相同方式混合这些成分。表5表5：第一聚合物组分和第二聚合物组分共混物的应力对伸长率(E)数据，其中第二聚合物组分为上表中的SPC-2成分。没有数据的阴影部分表示样品被破坏。透明部分表示由于伸长度超过设备极限而缺乏数据。实施例6
第一聚合物组分是Escorene 4292(可从Exxon化学公司商购获得的均全同立构聚丙烯)。第二聚合物组分是组分SPC-3，其特征见上表1、2和3。按照实施例4所述的相同方式混合这些成分。表6
Figure A9880795900271
表6：第一聚合物组分和第二聚合物组分共混物的应力对伸长率(E)数据，其中第二聚合物组分为上表中的SPC-3成分。无数据的阴影部分表示样品被破坏。透明部分表示由于伸长超过设备极限而缺乏数据。实施例7
第一聚合物组分是Escorene 4292(可从Exxon化学公司(Houston，Texas)商购获得的均全同立构聚丙烯)。第二聚合物组分是组分SPC-4，其特征见上表1、2和3。按照实施例4所述的相同方式混合这些成分。表7
Figure A9880795900291
表7：第一聚合物组分和第二聚合物组分共混物的应力对伸长率(E)数据，其中第二聚合物组分为上表中的SPC-4成分。没有数据的阴影部分表示样品被破坏。透明部分表示由于伸长超过设备极限而缺乏数据。实施例8
第一聚合物组分是Escorene 4292(可从Exxon化学公司(Houston，Texas)商购获得的均全同立构聚丙烯)。第二聚合物组分是组分SPC-1和SPC-5的混合物，其特征见上表1、2和3。按照实施例4所述的相同方式混合这些成分。表8
Figure A9880795900311
表8：第一聚合物组分和上表中的EPR共混物的应力对伸长率(E)数据。没有数据的阴影部分表示样品被破坏。实施例9(对比)
第一聚合物组分是Escorene 4292(可从Exxon化学公司(Houston，Texas)商购获得的均全同立构聚丙烯)。第二聚合物组分是组分EPR，其特征见上表1、2和3。按照实施例4所述的相同方式混合这些成分。表9
Figure A9880795900321
表9：第一聚合物组分和上表中EPR共混物的应力对伸长率(E)数据。没有数据的阴影部分表示样品被破坏。实施例10(对比)
第一聚合物组分是Escorene 4292(可从Exxon化学公司(Houston，Texas)商购获得的均全同立构聚丙烯)。第二聚合物组分是aePP，其特征见上表1、2和3。按照实施例4所述的相同方式混合这些成分。表10
Figure A9880795900331
以上具体描述了本发明的举例说明性的实施方案，在不背离本发明的实质和本发明的范围前提下，各种其它的改进对本领域技术人员来说是显而易见的并且是容易作到的。因此，后面的权利要求的范围并不为本文的实施例和说明所限制，而应当包括本发明存在的可获专利性的所有特征，包括所有本发明涉及的由本领域技术人员认为的等同特征。

Claims (30)

1、一种包含至少一种第一聚合物组分与第二聚合物组分的共混物的组合物，所说的共混物包含：
大于2wt％所说的第一聚合物组分，其中含有全同立构聚丙烯，和
第二聚合物组分，其中含有丙烯与至少一种小于6碳原子的其它α烯烃的共聚物，所说的共聚物中含有可结晶的丙烯序列和至少75wt％的丙烯。
2、权利要求1的组合物，其中第一聚合物组分还含有共聚单体。
3、权利要求1的组合物，其中第一聚合物组分是结晶性占主导，熔点通过DSC测定为大于或等于115℃。
4、权利要求1的组合物，其中第二聚合物组分的α烯烃包括乙烯。
5、权利要求1的组合物，其中第二聚合物组分由约5-约25wt％的α烯烃组成。
6、权利要求5的组合物，其中第二聚合物组分的α烯烃包括乙烯。
7、权利要求1的组合物，其中第二聚合物组分由约6-约18wt％的乙烯组成。
8、权利要求1的组合物，其中可结晶的丙烯序列包括全同立构丙烯序列。
9、权利要求1的组合物，其中第一聚合物组分的熔点大于或等于约130℃且第二聚合物组分的熔点小于或等于约105℃。
10、权利要求9的组合物，其中所得共混物的玻璃化转变温度接近于第二聚合物组分同时低于第一聚合物组分的玻璃化转变温度。
11、权利要求1的组合物，其中第二聚合物组分的分子量分布为约2.0-约3.2。
12、权利要求1的组合物，其中第二聚合物组分的熔点通过DSC测定为约30-约100℃。
13、一种热塑性聚合物共混物组合物，其中包含：
约2-约95wt％的第一热塑性聚合物组分，其中含有全同立构聚丙烯，和
约5-约98wt％的第二热塑性聚合物成分，其中含有乙烯与DSC测定的熔点为约30-约100℃的丙烯的无规共聚物，所说的共聚物中包含可结晶的丙烯序列和最多约25wt％的乙烯。
14、权利要求13的组合物，其中所说的第一热塑性聚合物组分还包含丙烯-α烯烃共聚物。
15、权利要求13的组合物，其中第二热塑性聚合物成分中包含约6-约18wt％的乙烯。
16、权利要求13的组合物，其中共混物组合物的玻璃化转变温度接近于第二聚合物组分同时低于第一聚合物组分的玻璃化转变温度。
17、权利要求13的组合物，其中第二热塑性聚合物成分的分子量分布为约2.0-约3.2。
18、一种热塑性聚合物共混物组合物，其中包含：
a)约2-约95wt％的第一热塑性聚合物组分，该成分选自全同立构聚丙烯和丙烯α烯烃共聚物，和
b)含两种丙烯α烯烃共聚物的共混物的第二聚合物组分，其中在一种所说的共聚物中α烯烃含量为5-9wt％，且另一种共聚物的α烯烃含量为10-22wt％。
19、权利要求18的热塑性聚合物共混物，其中第二聚合物成分中的α烯烃是乙烯。
20、一种制备热塑性聚合物共混物组合物的方法，该方法包括：
(a)将丙烯或丙烯与一种或多种选自C2或C4-C10α烯烃的单体的混合物在聚合催化剂的存在下聚合，获得含有至少约90wt％被聚合丙烯的基本上全同立构的丙烯聚合物；
(b)将乙烯和丙烯的混合物聚合，其中得到包含最多约25wt％乙烯并且含有可全同立构结晶的丙烯序列的乙烯和丙烯的共聚物；并且
(c)将步骤(a)的丙烯聚合物与步骤(b)的共聚物共混，形成共混物。
21、权利要求18的方法，其中全同立构丙烯聚合物的熔点大于130℃。
22、权利要求18的方法，其中共聚物包含约6-约18wt％的乙烯。
23、权利要求18的方法，其中通过DSC测定的共聚物的熔点为约30-约100℃。
24、权利要求18所述方法获得的共混物，其中共混物的玻璃化转变温度接近于第二聚合物组分同时低于第一聚合物组分的玻璃化转变温度。
25、权利要求18的方法，其中乙烯和丙烯的共聚物是分子量分布为约2.0-约3.2的无规共聚物。
26、权利要求18的方法，其中在步骤(a)的全同立构丙烯聚合物组合物的存在下于反应器中聚合乙烯和丙烯，形成反应器共混物。
27、权利要求18的方法，其中在茂金属催化剂的存在下聚合乙烯和丙烯。
28、权利要求18的方法，其中在茂金属或齐格勒纳塔催化剂的存在下聚合丙烯。
29、权利要求18的方法，其中将约2-约95wt％全同立构丙烯聚合物与约5-约98wt％乙烯丙烯共聚物共混。
30、通过权利要求18所述方法生产的热塑性聚合物共混物组合物。
CN98807959A 1997-08-12 1998-07-23 全同立构聚丙烯与α一烯烃/丙烯共聚物的热塑性聚合物共混物 Pending CN1265693A (zh)

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US20060089460A1 (en) 2006-04-27
EP1624020A1 (en) 2006-02-08
JP2010180413A (ja) 2010-08-19
US7056982B2 (en) 2006-06-06
US20040014896A1 (en) 2004-01-22
DE69808488D1 (de) 2002-11-07
EP1624020B1 (en) 2008-12-17
EA200000207A1 (ru) 2000-10-30
DE69841111D1 (de) 2009-10-08
US7056992B2 (en) 2006-06-06

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