US5605936A — Foamed articles comprising high melt strength pro…

Claim 1

Independent Claim 580 words

A foamed article comprising a normally solid, high molecular weight, non-linear, substantially gel-free, propylene polymer material having strain hardening elongational viscosity and enhanced melt strength selected from the group consisting essentially of: (1) a propylene polymer composition consisting essentially of: (a) from 10 to 50% by weight of a propylene homopolymer having an isotactic index of from 80 to 99%, or a copolymer selected from the group consisting of (i) propylene and ethylene, (ii) propylene, ethylene and a CH 2 ═CHR alpha-olefin, where R is a C 2-8 straight or branched alkyl, and (iii) propylene and an alpha-olefin, as defined above in (a) (ii), wherein said copolymer contains from 85 to 99% by weight propylene and having an isotactic index greater than 80 to 99% (b) from 5 to 20% by weight of a semi-crystalline, essentially linear copolymer having a crystallinity of about 20 to 60%, by differential scanning calorimetry (DSC), wherein the copolymer is selected from the group consisting of (i) ethylene and propylene containing over 55% by weight ethylene; (ii) ethylene, propylene, and an alpha-olefin, as defined above in (a) (ii) , containing from 1 to 10% by weight of the alpha-olefin and over 55% up to 98% by weight of both ethylene and alpha-olefin; and (iii) ethylene and an alpha-olefin, as defined in (a) (ii), containing over 55% up to 98% by weight of said alpha-olefin, which copolymer is insoluble in xylene at room or ambient temperature, and (c) from 40 to 80% by weight of a copolymer selected from the group consisting of a copolymer of (i) ethylene and propylene wherein the copolymer contains from 20% to less than 40% by weight ethylene; (ii) ethylene, propylene, and an alpha-olefin, as defined in (a) (ii), wherein the alpha-olefin is present in an amount of from 1 to 10% by weight and the amount of ethylene and alpha-olefin present is from 20% to less than 40% by weight; and (iii) ethylene and an alpha-olefin, as defined in (a) (ii), containing from 20 to less than 40% by weight of the alpha-olefin, and optionally containing 0.5 to 10% by weight of a diene, said copolymer being soluble in xylene at ambient temperature, and having an intrinsic viscosity of from 1.7 to 3.0 dl/g, wherein the total amount of ethylene units or said alpha-olefin units or of ethylene and said alpha-olefin units when both are present in the composition is from 15 to 35% by weight, the total amount of (b) and (c), based on the total olefin polymer composition is from about 65% to 80% by weight, the weight ratio of (b)/(c) is from 0.1 to about 0.3, and the total content of ethylene or C 4-8 alpha-olefin or combination thereof in (b+c) is less than 50% by weight; and (2) a propylene polymer composition consisting essentially of: (a) 10-60 parts by weight of homopolymer polypropylene having an isotactic index greater than 90 to 99, or of crystalline propylene copolymer with ethylene, with a CH 2 ═CHR olefin where R is a 2-6 carbon alkyl radical, or combinations thereof, containing over 85% by weight of propylene and having an isotactic index greater than 85 to 94%; (b) 8-40 parts by weight of a crystalline copolymer containing ethylene and propylene, having an ethylene content greater than 50% by weight and insoluble in xylene at room temperature; (c) 30-60 parts by weight of an amorphous ethylene-propylene copolymer, soluble in xylene at room temperature and containing 40 to 70% by weight ethylene.

Claim 2

Dependent Claim 580 words

A foamed article comprising a normally solid, high molecular weight, non-linear, substantially gel-free, propylene polymer material having strain hardening elongational viscosity and enhanced melt strength selected from the group consisting essentially of: (1) a propylene polymer composition consisting essentially of: (a) from 10 to 50% by weight of a propylene homopolymer having an isotactic index of from 80 to 99%, or a copolymer selected from the group consisting of (i) propylene and ethylene, (ii) propylene, ethylene and a CH 2 ═CHR alpha-olefin, where R is a C 2-8 straight or branched alkyl, and (iii) propylene and an alpha-olefin, as defined above in (a) (ii), wherein said copolymer contains from 85 to 99% by weight propylene and having an isotactic index greater than 80 to 99% (b) from 5 to 20% by weight of a semi-crystalline, essentially linear copolymer having a crystallinity of about 20 to 60%, by differential scanning calorimetry (DSC), wherein the copolymer is selected from the group consisting of (i) ethylene and propylene containing over 55% by weight ethylene; (ii) ethylene, propylene, and an alpha-olefin, as defined above in (a) (ii) , containing from 1 to 10% by weight of the alpha-olefin and over 55% up to 98% by weight of both ethylene and alpha-olefin; and (iii) ethylene and an alpha-olefin, as defined in (a) (ii), containing over 55% up to 98% by weight of said alpha-olefin, which copolymer is insoluble in xylene at room or ambient temperature, and (c) from 40 to 80% by weight of a copolymer selected from the group consisting of a copolymer of (i) ethylene and propylene wherein the copolymer contains from 20% to less than 40% by weight ethylene; (ii) ethylene, propylene, and an alpha-olefin, as defined in (a) (ii), wherein the alpha-olefin is present in an amount of from 1 to 10% by weight and the amount of ethylene and alpha-olefin present is from 20% to less than 40% by weight; and (iii) ethylene and an alpha-olefin, as defined in (a) (ii), containing from 20 to less than 40% by weight of the alpha-olefin, and optionally containing 0.5 to 10% by weight of a diene, said copolymer being soluble in xylene at ambient temperature, and having an intrinsic viscosity of from 1.7 to 3.0 dl/g, wherein the total amount of ethylene units or said alpha-olefin units or of ethylene and said alpha-olefin units when both are present in the composition is from 15 to 35% by weight, the total amount of (b) and (c), based on the total olefin polymer composition is from about 65% to 80% by weight, the weight ratio of (b)/(c) is from 0.1 to about 0.3, and the total content of ethylene or C 4-8 alpha-olefin or combination thereof in (b+c) is less than 50% by weight; and (2) a propylene polymer composition consisting essentially of: (a) 10-60 parts by weight of homopolymer polypropylene having an isotactic index greater than 90 to 99, or of crystalline propylene copolymer with ethylene, with a CH 2 ═CHR olefin where R is a 2-6 carbon alkyl radical, or combinations thereof, containing over 85% by weight of propylene and having an isotactic index greater than 85 to 94%; (b) 8-40 parts by weight of a crystalline copolymer containing ethylene and propylene, having an ethylene content greater than 50% by weight and insoluble in xylene at room temperature; (c) 30-60 parts by weight of an amorphous ethylene-propylene copolymer, soluble in xylene at room temperature and containing 40 to 70% by weight ethylene.

Claim 3

Dependent Claim 24 words

A foamed article of claim 1 further comprising from 5 to 95% by weight of a normally solid, predominantly isotactic, semi-crystalline, linear propylene material.

Claim 4

Dependent Claim 176 words

The foamed article of claim 1, wherein said normally solid, high molecular weight, non-linear, substantially gel-free, propylene polymer material having strain hardening elongational viscosity and enhanced melt strength is prepared from normally solid, high molecular weight, linear propylene polymer material without strain hardening elongational viscosity by a process which comprises: (1) irradiating said linear propylene polymer material: (a) in an environment in which the active oxygen concentration is established and maintained at less than about 15% by volume of said environment; (b) with high energy ionizing radiation at a dose rate in the range from about 1 to about 1×10 4 megarads per minute for a period of time sufficient for a substantial amount of chain scission of the amorphous content of said material to occur, but insufficient to cause gelation of the material; (2) maintaining the thus irradiated material in such an environment for a period of up to one hour; and (3) then treating the irradiated material while in such environment to deactivate substantially all of the free radicals present in the irradiated material.

Claim 5

Dependent Claim 65 words

The foamed article of claim 3, wherein said foamed article is prepared by a process which comprises: (1) heating said normally solid, high molecular weight, non-linear, substantially gel-free, propylene polymer material having strain hardening elongational viscosity and enhanced melt strength to a molten state, thereby producing a molten polymer material; (2) mixing said molten polymer material with a blowing agent, thereby producing a foamed article.

Claim 6

Dependent Claim 13 words

The foamed article of claim 4, wherein said blowing agent comprises a chlorofluorocarbon.

Claim 7

Dependent Claim 579 words

A foamed sheet comprising a normally solid, high molecular weight, non-linear, substantially gel-free, propylene polymer material having strain hardening elongational viscosity and enhanced melt strength selected from the group consisting essentially of: (1) a propylene polymer composition consisting essentially of: (a) from 10 to 50% by weight of a propylene homopolymer having an isotactic index of from 80 to 99%, or a copolymer selected from the group consisting of (i) propylene and ethylene, (ii) propylene, ethylene and a CH 2 ═CHR alpha-olefin, where R is a C 2-8 straight or branched alkyl, and (iii) propylene and an alpha-olefin, as defined above in (a) (ii), wherein said copolymer contains from 85 to 99% by weight propylene and having an isotactic index greater than 80 to 99%, (b) from 5 to 20% by weight of a semi-crystalline, essentially linear copolymer having a crystallinity of about 20 to 60%, by differential scanning calorimetry (DSC), wherein the copolymer is selected from the group consisting of (i) ethylene and propylene containing over 55% by weight ethylene; (ii) ethylene, propylene, and an alpha-olefin, as defined above in (a) (ii), containing from 1 to 10% by weight of the alpha-olefin and over 55% up to 98% by weight of both ethylene and alpha-olefin; and (iii) ethylene and an alpha-olefin, as defined in (a) (ii), containing over 55% up to 98% by weight of said alpha-olefin, which copolymer is insoluble in xylene at room or ambient temperature, and (c) from 40 to 80% by weight of a copolymer selected from the group consisting of a copolymer of (i) ethylene and propylene wherein the copolymer contains from 20% to less than 40% by weight ethylene; (ii) ethylene, propylene, and an alpha-olefin, as defined in (a) (ii), wherein the alpha-olefin is present in an amount of from 1 to 10% by weight and the amount of ethylene and alpha-olefin present is from 20% to less than 40% by weight; and (iii) ethylene and an alpha-olefin, as defined in (a) (ii), containing from 20 to less than 40% by weight of the alpha-olefin, and optionally containing 0.5 to 10% by weight of a diene, said copolymer being soluble in xylene at ambient temperature, and having an intrinsic viscosity of from 1.7 to 3.0 dl/g, wherein the total amount of ethylene units or said alpha-olefin units or of ethylene and said alpha-olefin units when both are present in the composition is from 15 to 35% by weight, the total amount of (b) and (c), based on the total olefin polymer composition is from about 65% to 80% by weight, the weight ratio of (b)/(c) is from 0.1 to about 0.3, and the total content of ethylene or C 4-8 alpha-olefin or combination thereof in (b+c) is less than 50% by weight; and (2) a propylene polymer composition consisting essentially of: (a) 10-60 parts by weight of homopolymer polypropylene having an isotactic index greater than 90 to 99, or of crystalline propylene copolymer with ethylene, with a CH 2 ═CHR olefin where R is a 2-6 carbon alkyl radical, or combinations thereof, containing over 85% by weight of propylene and having an isotactic index greater than 85 to 94%; (b) 8-40 parts by weight of a crystalline copolymer containing ethylene and propylene, having an ethylene content greater than 50% by weight and insoluble in xylene at room temperature; (c) 30-60 parts by weight of an amorphous ethylene-propylene copolymer, soluble in xylene at room temperature and containing 40 to 70% by weight ethylene.

Claim 8

Dependent Claim 579 words

A foamed sheet comprising a normally solid, high molecular weight, non-linear, substantially gel-free, propylene polymer material having strain hardening elongational viscosity and enhanced melt strength selected from the group consisting essentially of: (1) a propylene polymer composition consisting essentially of: (a) from 10 to 50% by weight of a propylene homopolymer having an isotactic index of from 80 to 99%, or a copolymer selected from the group consisting of (i) propylene and ethylene, (ii) propylene, ethylene and a CH 2 ═CHR alpha-olefin, where R is a C 2-8 straight or branched alkyl, and (iii) propylene and an alpha-olefin, as defined above in (a) (ii), wherein said copolymer contains from 85 to 99% by weight propylene and having an isotactic index greater than 80 to 99%, (b) from 5 to 20% by weight of a semi-crystalline, essentially linear copolymer having a crystallinity of about 20 to 60%, by differential scanning calorimetry (DSC), wherein the copolymer is selected from the group consisting of (i) ethylene and propylene containing over 55% by weight ethylene; (ii) ethylene, propylene, and an alpha-olefin, as defined above in (a) (ii), containing from 1 to 10% by weight of the alpha-olefin and over 55% up to 98% by weight of both ethylene and alpha-olefin; and (iii) ethylene and an alpha-olefin, as defined in (a) (ii), containing over 55% up to 98% by weight of said alpha-olefin, which copolymer is insoluble in xylene at room or ambient temperature, and (c) from 40 to 80% by weight of a copolymer selected from the group consisting of a copolymer of (i) ethylene and propylene wherein the copolymer contains from 20% to less than 40% by weight ethylene; (ii) ethylene, propylene, and an alpha-olefin, as defined in (a) (ii), wherein the alpha-olefin is present in an amount of from 1 to 10% by weight and the amount of ethylene and alpha-olefin present is from 20% to less than 40% by weight; and (iii) ethylene and an alpha-olefin, as defined in (a) (ii), containing from 20 to less than 40% by weight of the alpha-olefin, and optionally containing 0.5 to 10% by weight of a diene, said copolymer being soluble in xylene at ambient temperature, and having an intrinsic viscosity of from 1.7 to 3.0 dl/g, wherein the total amount of ethylene units or said alpha-olefin units or of ethylene and said alpha-olefin units when both are present in the composition is from 15 to 35% by weight, the total amount of (b) and (c), based on the total olefin polymer composition is from about 65% to 80% by weight, the weight ratio of (b)/(c) is from 0.1 to about 0.3, and the total content of ethylene or C 4-8 alpha-olefin or combination thereof in (b+c) is less than 50% by weight; and (2) a propylene polymer composition consisting essentially of: (a) 10-60 parts by weight of homopolymer polypropylene having an isotactic index greater than 90 to 99, or of crystalline propylene copolymer with ethylene, with a CH 2 ═CHR olefin where R is a 2-6 carbon alkyl radical, or combinations thereof, containing over 85% by weight of propylene and having an isotactic index greater than 85 to 94%; (b) 8-40 parts by weight of a crystalline copolymer containing ethylene and propylene, having an ethylene content greater than 50% by weight and insoluble in xylene at room temperature; (c) 30-60 parts by weight of an amorphous ethylene-propylene copolymer, soluble in xylene at room temperature and containing 40 to 70% by weight ethylene.

Claim 9

Dependent Claim 25 words

A foamed sheet of claim 6 further comprising from 5 to 95% by weight of a normally solid, predominantly isotactic, semi-crystalline, linear propylene polymer material.

Claim 10

Dependent Claim 578 words

A foamed bead comprising a normally solid, high molecular weight, non-linear, substantially gel-free, propylene polymer material having strain hardening elongational viscosity and enhanced melt strength selected from the group consisting essentially of: (1) a propylene polymer composition consisting essentially of: (a) from 10 to 50% by weight of a propylene homopolymer having an isotactic index of from 80 to 99%, or a copolymer selected from the group consisting of (i) propylene and ethylene, (ii) propylene, ethylene and a CH 2 ═CHR alpha-olefin, where R is a C 2-8 straight or branched alkyl, and (iii) propylene and an alpha-olefin, as defined above in (a) (ii), wherein said copolymer contains from 85 to 99% by weight propylene and having an isotactic index greater than 80 to 99%, (b) from 5 to 20% by weight of a semi-crystalline, essentially linear copolymer having a crystallinity of about 20 to 60%, by differential scanning calorimetry (DSC), wherein the copolymer is selected from the group consisting of (i) ethylene and propylene containing over 55% by weight ethylene; (ii) ethylene, propylene, and an alpha-olefin, as defined above in (a)(ii), containing from 1 to 10% by weight of the alpha-olefin and over 55% up to 98% by weight of both ethylene and alpha-olefin; and (iii) ethylene and an alpha-olefin, as defined in (a)(ii), containing over 55% up to 98% by weight of said alpha-olefin, which copolymer is insoluble in xylene at room or ambient temperature, and (c) from 40 to 80% by weight of a copolymer selected from the group consisting of a copolymer of (i) ethylene and propylene wherein the copolymer contains from 20% to less than 40% by weight ethylene; (ii) ethylene, propylene, and an alpha-olefin, as defined in (a) (ii), wherein the alpha-olefin is present in an amount of from 1 to 10% by weight and the amount of ethylene and alpha-olefin present is from 20% to less than 40% by weight; and (iii) ethylene and an alpha-olefin, as defined in (a) (ii), containing from 20 to less than 40% by weight of the alpha-olefin, and optionally containing 0.5 to 10% by weight of a diene, said copolymer being soluble in xylene at ambient temperature, and having an intrinsic viscosity of from 1.7 to 3.0 dl/g, wherein the total amount of ethylene units or said alpha-olefin units or of ethylene and said alpha-olefin units when both are present in the composition is from 15 to 35% by weight, the total amount of (b) and (c), based on the total olefin polymer composition is from about 65% to 80% by weight, the weight ratio of (b)/(c) is from 0.1 to about 0.3, and the total content of ethylene or C 4-8 alpha-olefin in or combination thereof in (b+c) is less than 50% by weight; and (2) a propylene polymer composition consisting essentially of: (a) 10-60 parts by weight of homopolymer polypropylene having an isotactic index greater than 90 to 99, or of crystalline propylene copolymer with ethylene, with a CH 2 ═CHR olefin where R is a 2-6 carbon alkyl radical, or combinations thereof, containing over 85% by weight of propylene and having an isotactic index greater than 85 to 94%; (b) 8-40 parts by weight of a crystalline copolymer containing ethylene and propylene, having an ethylene content greater than 50% by weight and insoluble in xylene at room temperature; (c) 30-60 parts by weight of an amorphous ethylene-propylene copolymer, soluble in xylene at room temperature and containing 40 to 70% by weight ethylene.

Claim 11

Dependent Claim 578 words

A foamed bead comprising a normally solid, high molecular weight, non-linear, substantially gel-free, propylene polymer material having strain hardening elongational viscosity and enhanced melt strength selected from the group consisting essentially of: (1) a propylene polymer composition consisting essentially of: (a) from 10 to 50% by weight of a propylene homopolymer having an isotactic index of from 80 to 99%, or a copolymer selected from the group consisting of (i) propylene and ethylene, (ii) propylene, ethylene and a CH 2 ═CHR alpha-olefin, where R is a C 2-8 straight or branched alkyl, and (iii) propylene and an alpha-olefin, as defined above in (a) (ii), wherein said copolymer contains from 85 to 99% by weight propylene and having an isotactic index greater than 80 to 99%, (b) from 5 to 20% by weight of a semi-crystalline, essentially linear copolymer having a crystallinity of about 20 to 60%, by differential scanning calorimetry (DSC), wherein the copolymer is selected from the group consisting of (i) ethylene and propylene containing over 55% by weight ethylene; (ii) ethylene, propylene, and an alpha-olefin, as defined above in (a)(ii), containing from 1 to 10% by weight of the alpha-olefin and over 55% up to 98% by weight of both ethylene and alpha-olefin; and (iii) ethylene and an alpha-olefin, as defined in (a)(ii), containing over 55% up to 98% by weight of said alpha-olefin, which copolymer is insoluble in xylene at room or ambient temperature, and (c) from 40 to 80% by weight of a copolymer selected from the group consisting of a copolymer of (i) ethylene and propylene wherein the copolymer contains from 20% to less than 40% by weight ethylene; (ii) ethylene, propylene, and an alpha-olefin, as defined in (a) (ii), wherein the alpha-olefin is present in an amount of from 1 to 10% by weight and the amount of ethylene and alpha-olefin present is from 20% to less than 40% by weight; and (iii) ethylene and an alpha-olefin, as defined in (a) (ii), containing from 20 to less than 40% by weight of the alpha-olefin, and optionally containing 0.5 to 10% by weight of a diene, said copolymer being soluble in xylene at ambient temperature, and having an intrinsic viscosity of from 1.7 to 3.0 dl/g, wherein the total amount of ethylene units or said alpha-olefin units or of ethylene and said alpha-olefin units when both are present in the composition is from 15 to 35% by weight, the total amount of (b) and (c), based on the total olefin polymer composition is from about 65% to 80% by weight, the weight ratio of (b)/(c) is from 0.1 to about 0.3, and the total content of ethylene or C 4-8 alpha-olefin in or combination thereof in (b+c) is less than 50% by weight; and (2) a propylene polymer composition consisting essentially of: (a) 10-60 parts by weight of homopolymer polypropylene having an isotactic index greater than 90 to 99, or of crystalline propylene copolymer with ethylene, with a CH 2 ═CHR olefin where R is a 2-6 carbon alkyl radical, or combinations thereof, containing over 85% by weight of propylene and having an isotactic index greater than 85 to 94%; (b) 8-40 parts by weight of a crystalline copolymer containing ethylene and propylene, having an ethylene content greater than 50% by weight and insoluble in xylene at room temperature; (c) 30-60 parts by weight of an amorphous ethylene-propylene copolymer, soluble in xylene at room temperature and containing 40 to 70% by weight ethylene.

Claim 12

Dependent Claim 25 words

A foamed bead of claim 8 further comprising from 5 to 95% by weight of a normally solid, predominantly isotactic, semi-crystalline, linear propylene polymer material.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	2000-02-25	2000-08-26	2001-02-25	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2004-02-25	2004-08-26	2005-02-25	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2008-02-25	2008-08-26	2009-02-25	$7700.00	Window Closed / Lapsed

Foamed articles comprising high melt strength propylene polymer material

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