CN111433271A

CN111433271A - Adhesive composition comprising amorphous propylene/ethylene copolymer and polyolefin

Info

Publication number: CN111433271A
Application number: CN201880050543.0A
Authority: CN
Inventors: T·R·卡瓦诺; S·马克斯; 袁明; 张大余; B·H·J·昂; M·S·萨默斯; R·P·科特尔; B·H·诺瓦克; P·R·拉加
Original assignee: Eastman Chemical Co
Current assignee: Xintema Adhesive Technology Co ltd
Priority date: 2017-06-09
Filing date: 2018-06-08
Publication date: 2020-07-17

Abstract

Amorphous propylene-ethylene copolymers are described herein that can contain large amounts of ethylene and exhibit desirable softening points and strikethrough. The desirable combination of softening point and penetration in these propylene-ethylene copolymers makes them have a wide operating window. Due to their wide operating window, the propylene-ethylene copolymers are useful in a variety of applications and products, including hot melt adhesives.

Description

Adhesive composition comprising amorphous propylene/ethylene copolymer and polyolefin

Background

1. Field of the invention

The present invention generally relates to amorphous propylene-ethylene copolymers and methods of making such copolymers. In particular, the present invention relates generally to amorphous propylene-ethylene copolymers having desirable needle penetration, softening point, crystallinity, viscosity, and viscoelastic characteristics. More particularly, the present invention relates to low molecular weight amorphous propylene-ethylene copolymers useful in adhesive compositions having a wide process window and high peel strength, especially in sanitary applications.

2. Description of the related Art

Amorphous polyolefins are commonly used in industry to make a variety of products, including, for example, adhesives. Common polyolefins used in adhesives generally include polyolefins derived from propylene, ethylene and various C' s₄-C₁₀α -copolymers of olefin monomers, such as 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene and 1-decene in particular propylene-butene copolymers are distinguished by a higher adhesion strength resulting from these copolymersAnd are commonly used in the manufacture of hot melt adhesives. Most of the adhesive strength derived from these copolymers can be attributed to C contained therein₄-C₁₀α -olefins, which greatly improve the subsequent adhesive properties of the copolymer unfortunately, C₄-C₁₀α -olefins can be quite expensive due to market conditions and may also exhibit limited reactivity in the polymerization process.

Due to C₄-C₁₀α -olefins, some manufacturers have attempted to replace C with ethylene₄-C₁₀α -olefins with a plurality of C₄-C₁₀α -unlike olefins, ethylene is more readily available and is more than many of the commonly used Cs₄-C₁₀α -olefins such as 1-butene are more reactive unfortunately, propylene-ethylene copolymers can exhibit deficiencies in hardness, thereby resulting in adhesives that lack desirable bond strength over time some manufacturers have attempted to increase the hardness of these copolymers by incorporating crystalline polypropylene therein.

Thus, there is a need for amorphous copolymers that exhibit a desirable balance between hardness and softening point and that are also useful in the manufacture of adhesives having improved adhesion characteristics.

In addition, the present invention relates to low molecular weight amorphous propylene-ethylene copolymers useful in adhesive compositions having a wide process window and high peel strength, especially in sanitary applications. The motivation for the need for high peel strength is to consider the safety of users of hygiene products, especially users of diapers. Lower peel strength can lead to premature failure of the bond lines that maintain the various elements of the diaper structure and subsequent exposure of the diaper user to the superabsorbent material. Another problem with low peel strength is localized adhesive failure, which can lead to fluid channeling when the diaper is worn, resulting in reduced overall protection for the diaper wearer.

The introduction of more complex styrenic copolymers (styrene-ethylene-propylene-styrene (SEEPS), styrene-isoprene-butylene-styrene (SIBS), styrene-ethylene-butylene (SEB), styrene-ethylene-butylene-styrene (SEBS), styrene-ethylene-propylene-styrene (SEPS), and styrene-butylene-styrene (SBBS)), various other thermoplastic rubbers, chain shuttle catalyzed Olefin Block Copolymers (OBC), and amorphous α olefins (APAO) are examples of such efforts.

Summary of The Invention

One or more embodiments of the present invention relate to copolymers comprising propylene and ethylene having a softening point in the range of 90 to 140 ℃. Furthermore, the copolymer has a penetration equal to y, defined by the formula:

y ≤ -0.000000262249x⁶+ 0.000172031278x⁵- 0.046669720165x⁴+6.701746779438x³- 537.286013331959x²+ 22,802.983472587x-400,204.018086126. In the above formula, x is the softening point of the copolymer.

Further, one or more embodiments of the present invention relate to a copolymer comprising propylene and ethylene. The copolymer has a softening point of 110 to 135 ℃ and a penetration of less than 25 dmm.

Further, one or more embodiments of the present invention relate to a copolymer comprising propylene and ethylene. The copolymer has a softening point of 90 to 121 ℃ and a penetration of less than 35 dmm.

In addition, one or more embodiments of the present invention relate to copolymers comprising propylene and ethylene. The copolymer has a softening point of 90 to less than 115 ℃ and a penetration of equal to or less than 53 dmm.

In addition, one or more embodiments of the present invention relate to low molecular weight copolymers comprising propylene and ethylene. The low molecular weight copolymer has a softening point of 90 to 140 ℃. The low molecular weight copolymer has a penetration equal to y, wherein y is defined by the formula:

y ≤ -0.000000262249x⁶+ 0.000172031278x⁵- 0.046669720165x⁴+6.701746779438x³- 537.286013331959x²+ 22,802.983472587x - 400,204.018086126，

wherein x in the above formula is the softening point of the copolymer;

wherein the low molecular weight copolymer has a molecular weight polydispersity index of about 3 to about 25, a crystallinity of about 18% to about 30% by X-ray diffraction, and at 190 as measured by ASTM D3236^◦A Brookfield viscosity at C of from about 1,000 to about 4,000 cp.

Furthermore, one or more embodiments of the present invention relate to hot melt adhesives. The hot melt adhesive contains a copolymer comprising propylene and ethylene. The copolymer has a softening point of 90 to 140 ℃ and a penetration equal to y, defined by the formula:

Further, one or more embodiments of the present invention relate to a method of manufacturing the copolymer. The process comprises reacting propylene with ethylene in the presence of a catalyst system comprising an electron donor to form the copolymer. The copolymer has a softening point of 90 to 140 ℃ and a penetration equal to y, defined by the formula:

In yet another embodiment of the present invention, a method of making a copolymer is provided. The process comprises reacting propylene with ethylene in the presence of a catalyst system comprising an electron donor to form the copolymer. The copolymer has a softening point of 110 to 140 ℃ and a penetration equal to y, defined by the formula:

y ≤ -0.000751414552642x⁴+ 0.374053308337937x³- 69.5967657676062x²+ 5,734.02599677759x-176,398.494888882. In the above formula, x is the softening point of the copolymer.

One or more embodiments of the present invention are directed to adhesive compositions comprising at least one propylene-ethylene copolymer and at least one propylene polymer, wherein the propylene-ethylene copolymer comprises at least 10 wt.% ethylene and has a softening point of at least 99 ℃.

One or more embodiments of the present invention are directed to adhesive compositions comprising at least one propylene-ethylene copolymer and at least one propylene polymer, wherein the propylene-ethylene copolymer has a polydispersity of at least 3.

Brief description of the drawings

Embodiments of the present invention are described herein with reference to the following drawings, wherein:

FIG. 1A depicts the viscoelastic characteristics of a particular propylene-ethylene copolymer made in example 1;

FIG. 1B depicts the viscoelastic characteristics of the specific propylene-ethylene copolymer made in example 1;

FIG. 2 depicts the viscoelastic characteristics of the adhesive made in example 4;

FIG. 3 depicts the viscoelastic characteristics of the adhesive made in example 5;

FIG. 4 depicts the viscoelastic characteristics of the adhesive made in example 6;

FIG. 5 depicts a comparative Aerfin ^®180 viscoelastic properties of the copolymer as a function of temperature;

FIG. 6 depicts the viscoelastic properties of low molecular weight copolymers of the present invention as a function of temperature;

FIG. 7 depicts a low molecular weight copolymer of the present invention and a comparative Aerafin ^®180 capillary rheology of the copolymer;

FIG. 8 depicts the experimental layout of molecular weights;

FIG. 9 depicts the peel strength performance of adhesive compositions of various molecular weight distributions;

FIG. 10 depicts peel strength as a function of low molecular weight copolymer content of the present invention in various adhesive formulations; and

FIGS. 11-20 depict the peel strength vs spray temperature of adhesive compositions containing the low molecular weight copolymers of the present invention, and comparative data.

Detailed Description

The present invention relates generally to amorphous propylene-ethylene copolymers and their various applications. Many of the existing propylene-ethylene copolymers currently on the market often exhibit deficiencies with respect to their softening point or hardness. The copolymers of the invention described herein exhibit improved properties not currently available in these commercially available copolymers. In particular, as described in more detail below, the copolymers of the present invention can exhibit desirable softening points and strikethrough, thereby obtaining copolymers that can be used in a variety of applications. In addition, the low molecular weight copolymers of the present invention provide additional features including a wide operating window for adhesive applications and high peel strength.

Propylene-ethylene copolymer

Commercial propylene-ethylene copolymers are often not strong enough to be used in adhesives for packaging applications or hygiene products (e.g., diapers and feminine care products). Generally, this is related to the lack of a balance between strength and adhesion properties of the copolymer. Historically, in order to produce a copolymer with sufficient strength, the ethylene content of the copolymer must be limited. It has been observed that there is a correlation between the ethylene content of a copolymer and its softening point and penetration (which is indicative of copolymer strength). In general, the ethylene content can have a negative correlation with the softening point of the copolymer and a positive correlation with the penetration of the copolymer. In other words, the more ethylene present in the copolymer, the lower the softening point of the copolymer and the higher the penetration. Thus, increasing the ethylene content of a propylene-ethylene copolymer can lower the softening point of the copolymer, but can also compromise its strength as indicated by the increased penetration.

In contrast to conventional propylene-ethylene copolymers currently available, the copolymers of the present invention can exhibit desirable softening points and degrees of penetration at relatively high ethylene contents it may be desirable to utilize ethylene as a comonomer in propylene copolymers due to the high availability and low cost of ethylene compared to other α -olefins, as previously described.

According to various embodiments, the propylene-ethylene copolymers described herein may comprise different amounts of ethylene. For example, the propylene-ethylene copolymer may comprise at least 1, 3, 5,7, 10, 12, 14, 15, 17, 18, or 20 and/or no more than 70, 65, 60, 55, 50, 45, 40, 35, 30, 27, or 25 wt% ethylene. In addition, the propylene-ethylene copolymer may comprise 1 to 70, 3 to 65, 5 to 60, 7 to 55, 10 to 50, 12 to 45, 14 to 40, 15 to 35, 17 to 30, 18 to 27, or 20 to 25 weight percent ethylene.

Further, in various embodiments, the propylene-ethylene copolymers may contain varying amounts of propylene. For example, the propylene-ethylene copolymer may comprise at least 40, 50, 60, 65, or 70 and/or not more than 99, 95, 90, 85, or 80 weight percent propylene. In addition, the propylene-ethylene copolymer may comprise 40 to 99, 50 to 95, 60 to 90, 65 to 85, or 70 to 80 weight percent propylene.

In various embodiments, the copolymer may comprise at least 50, 65, 75, or 85 and/or no more than 99, 97.5, 95, or 90 weight percent of a combination of ethylene and propylene. Further, the copolymer can comprise 50 to 99, 65 to 97.5, 75 to 95, or 85 to 90 weight percent of a combination of ethylene and propylene. Additionally or alternatively, the copolymer may have a weight ratio of propylene to ethylene of at least 0.5:1, 1:1, 2:1, or 2.5:1 and/or not more than 20:1, 15:1, 10:1, or 5: 1. Further, the copolymer can have a weight ratio of propylene to ethylene of 0.5:1 to 20:1, 1:1 to 15:1, 2:1 to 10:1, or 2.5:1 to 5: 1.

In various embodiments, the copolymer may contain one or more C₄-C₁₀α -olefin as previously mentioned, C₄-C₁₀α -olefins may be used to improve the resulting bond strength of the copolymer when used in an adhesive₄-C₁₀α -olefins may include, for example, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, and combinations thereof according to one or more embodiments, the copolymer may include at least 0.5, 1,2, 3, 4, or 5 and/or no more than 40, 30, 25, 20, 15, or 10 weight percent of at least one C₄-C₁₀α -olefin the copolymer may further comprise 0.5 to 40, 1 to 30, 2 to 25, 3 to 20, 4 to 15, or 5 to 10 weight percent of at least one C₄-C₁₀α -olefins.

As noted above, a lower softening point of the copolymer is desirable so that the copolymer can be used and processed at lower application temperatures. In various embodiments, the copolymer can have a softening point of at least 85, 90, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 113, 115, 116, 119, 120, 121, 124, 125, or 127 ℃. Additionally or alternatively, the copolymer may have a Softening Point of no greater than 145, 140, 138, 137, 136, 135, 134, 132, 130, 129, 128, 127, 126, 125, 124, 123, 122, 121, 120, 118, 117, 115, 110, or 109.9 ℃ as measured by a ring and ball apparatus using a heating rate of 5 ℃/minute and a USP Glycerin bath according to ASTM E28 Standard Test Method for software Point of resin derived from Pin Chemicals and Hydrocarbons.

Further, the copolymer can have a softening point of 85 to 145 ℃,90 to 140 ℃,90 to 110 ℃,90 to 121 ℃,90 to 115 ℃, 95 to 138 ℃, 95 to 110 ℃, 96 to 136 ℃, 97 to 135 ℃,98 to 134 ℃, 99 to 132 ℃, 100 to 130 ℃, 101 to 129 ℃, 102 to 128 ℃, 103 to 127 ℃, 104 to 126 ℃, 105 to 125 ℃, 106 to 124 ℃, 107 to 123 ℃, 108 to 122 ℃, 109 to 121 ℃, or 110 to 120 ℃ as measured according to ASTM E28 as previously described.

Despite exhibiting the low softening point described above, the copolymer may also exhibit desirable penetration values. Generally, the lower the penetration value, the higher the strength characteristics and modulus of the copolymer; however, if the penetration is too low, the adhesive properties may be adversely affected. In various embodiments, the penetrometer value of the copolymers described herein can be defined by the following formula when the softening point is from 90 to 140 ℃:

y ≤ -0.000000262249x⁶+ 0.000172031278x⁵- 0.046669720165x⁴+6.701746779438x³- 537.286013331959x²+ 22,802.983472587x-400,204.018086126. In the above formula, "y" defines the penetration (dmm) of the copolymer, and "x" is the softening point (. degree. C.) of the copolymer.

The Penetration was measured according to ASTM D5 Standard Test Method for the networking of Bituminous materials and using the following specifications:

spindle weight 47.5 +/-0.05 grams.

The weight of the snare needle assembly was 2.50 +/-0.05 grams.

The total weight of the needle and spindle assembly is 50.0 +/-0.05 grams.

Weights of 50 +/-0.05 grams should also be provided to achieve a total load of 100 grams.

The samples were conditioned in a water bath at a temperature of 25 +/-0.1 ℃ [77 +/-0.2 ° F ].

The time for the needle to penetrate the sample was 5 +/-0.1 seconds.

In various other embodiments, the penetrometer value of the copolymers described herein can be defined by the following formula when the softening point is from 110 to 140 ℃:

y ≤ -0.000751414552642x⁴+ 0.374053308337937x³- 69.5967657676062x²+ 5,734.02599677759x-176,398.494888882. In the above formula, "y" defines the penetration (dmm) of the copolymer, and "x" is the softening point (. degree. C.) of the copolymer.

In various embodiments, the copolymer can have a penetration of at least 1,2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 15, 20, 30, or 35 decimillimeters ("dmm"), as measured according to ASTM D5, as previously described. Additionally or alternatively, the copolymer may have a penetration of no more than 75, 73.8, 70, 60, 50, 45, 40, 30, 29, 28, 27, 26, 25, 24, 23, 22, 21, 20, or 15 dmm, as measured according to ASTM D5, as previously described. Further, the copolymer can have a penetration of 1 to 75, 2 to 50, 3 to 30, 4 to 29, 5 to 28, 6 to 27, 7 to 26, 8 to 25, 9 to 24, 10 to 23, 11 to 22, 12 to 21, or 13 to 20 dmm, as measured according to ASTM D5, as previously described.

The copolymers may have different softening points and penetration ranges depending on their intended end use. In various embodiments, the copolymer can have a softening point of 90 to 121 ℃ and a penetration of less than 35 dmm. In other embodiments, the copolymer may have a softening point of 90 to 115 ℃ and a penetration of less than 53 dmm. In various embodiments, the copolymer can have a softening point of 110 to 138 ℃ and a penetration of 1 to 15 dmm. Further, in certain embodiments, the copolymer can have a softening point of 110 to 135 ℃ and a penetration of 5 to 15 dmm. Further, in certain embodiments, the copolymer may have a softening point of 110 to 130 ℃ and a penetration of 10 to 15 dmm.

In various embodiments, the copolymer can have a softening point of 110 to 137 ℃ and a penetration of 1 to 22 dmm. Further, in certain embodiments, the copolymer can have a softening point of 110 to 135 ℃ and a penetration of 5 to 22 dmm. In other embodiments, the copolymer may have a softening point of 110 to 135 ℃ and a penetration of 10 to 24 dmm. Further, in certain embodiments, the copolymer can have a softening point of 110 to 130 ℃ and a penetration of 10 to 20 dmm.

In various embodiments, the copolymer can have a softening point of 110 to 134 ℃ and a penetration of 1 to 25 dmm. Further, in certain embodiments, the copolymer can have a softening point of 110 to 132 ℃ and a penetration of 5 to 25 dmm. Further, in certain embodiments, the copolymer can have a softening point of 110 to 130 ℃ and a penetration of 10 to 25 dmm.

In various embodiments, the copolymer can have a softening point of 110 to 124 ℃ and a penetration of 1 to 30 dmm. Further, in certain embodiments, the copolymer can have a softening point of 110 to 122 ℃ and a penetration of 5 to 30 dmm. Further, in certain embodiments, the copolymer may have a softening point of 110 to 120 ℃ and a penetration of 10 to 30 dmm.

In various embodiments, the copolymer can have a softening point of 110 to 120 ℃ and a penetration of 30 to 50 dmm. Further, in certain embodiments, the copolymer can have a softening point of 110 to 120 ℃ and a penetration of 35 to 50 dmm. Further, in certain embodiments, the copolymer can have a softening point of 110 to 120 ℃ and a penetration of 30 to 45 dmm.

In various embodiments, the copolymer can have a softening point of 90 to 125 ℃ and a penetration of less than 30 dmm. Further, in certain embodiments, the copolymer may have a softening point of 90 to 123 ℃ and a penetration of less than 35 dmm. Further, in certain embodiments, the copolymer may have a softening point of 90 to 125 ℃ and a penetration of 10 to 30 dmm.

In various embodiments, the copolymer can have a softening point of 90 to 109.9 ℃ and a penetration of less than 73.8 dmm. Further, in certain embodiments, the copolymer can have a softening point of 127 to 140 ℃ and a penetration of less than 25 dmm. Further, in certain embodiments, the copolymer can have a softening point of 124 to 126 ℃ and a penetration of less than 30 dmm.

In various embodiments, the copolymer can have a softening point of 121 to 123 ℃ and a penetration of less than 40 dmm. Further, in certain embodiments, the copolymer may have a softening point of 119 to 120 ℃ and a penetration of less than 50 dmm. Further, in certain embodiments, the copolymer can have a softening point of 116 to 118 ℃ and a penetration of less than 60 dmm. In other embodiments, the copolymer may have a softening point of 113 to 117 ℃ and a penetration of less than 70 dmm.

In general, lower softening points in the copolymer can sometimes be accompanied by lower glass transition ("Tg") temperatures. In various embodiments, the copolymer can have a glass transition temperature of at least-100, -80, -60, or-40 and/or not more than about 20,0, -10, or-20 ℃ as measured by DMA. Further, the copolymer may have a Tg of-100 to 20 ℃, -80 to 0 ℃, -60 to-10 ℃ or-40 to-20 ℃ as measured by DMA.

Further, in various embodiments, the copolymer can have a melt viscosity at 190 ℃ of at least 100, 500, 1,000, 3,000, or 5,000 and/or no more than about 100,000, 75,000, 50,000, 35,000, or 25,000 cP measured according to ASTM D3236. Further, the copolymer can have a melt viscosity at 190 ℃ of 100 to 100,000, 500 to 75,000, 1,000 to 50,000, 3,000 to 35,000, or 5,000 to 25,000 cP measured according to ASTM D3236.

According to one or more embodiments, the copolymer may have a brookfield viscosity at 190 ℃ of at least 100, 300, 500, or 750 and/or no more than 30,000, 10,000, 5,000, or 2,500 cps, measured according to ASTM D3236. Further, the copolymer can have a brookfield viscosity at 190 ℃ of 100 to 30,000, 300 to 10,000, 500 to 5,000, or 750 to 2,500 cps.

In one or more embodiments, the copolymers described herein may also have a number average molecular weight (Mn) of less than 100,000, 50,000, or 25,000 as determined by gel permeation chromatography.

In various embodiments, the copolymers described herein do not exhibit a significant color change when subjected to storage conditions at elevated temperatures for extended periods of time. The copolymer of the present invention may have an initial gardner color of less than 4, 3, 2, or 1 as measured according to ASTM D1544 before any aging due to storage occurs. After heat aging at 177 ℃ for at least 96 hours, the copolymers of the present invention can exhibit a final gardner color of less than 7, 5, 3, or 2 as measured according to ASTM D1544. Thus, the copolymers of the present invention can maintain a desirable color even after long-term storage and exposure.

Further, the copolymers described herein may be amorphous or semi-crystalline. As used herein, "amorphous" means that the copolymer has a crystallinity of less than 5% as measured using differential scanning calorimetry ("DSC") according to ASTM E794-85. As used herein, "semi-crystalline" means that the copolymer has a crystallinity of 5 to 40% as measured by DSC according to ASTM E794-85. In various embodiments, the copolymer can have a crystallinity of no more than 60, 40, 30, 20, 10, 5, 4, 3, 2, or 1% as measured using DSC according to ASTM E794-85.

Low molecular weight propylene-ethylene copolymers

In various embodiments of the present invention, the propylene-ethylene copolymers of the present invention may comprise low molecular weight propylene-ethylene copolymers. These low molecular weight propylene-ethylene copolymers may have any of the features and properties described hereinabove with respect to the propylene-ethylene copolymers and are described in more detail hereinbelow.

In various embodiments of the present invention, copolymers are provided comprising propylene and ethylene and having a softening point of from 90 to 140 ℃. Further, the copolymer can have a penetration equal to y, where y is defined by the formula:

y ≤ -0.000000262249x⁶+ 0.000172031278x⁵- 0.046669720165x⁴+6.701746779438x³- 537.286013331959x²+ 22,802.983472587x-400,204.018086126, wherein "x" in the above formula is the softening point of the copolymer. Further, the copolymer can have a molecular weight polydispersity of about 3 to about 25, a crystallinity of about 18 to about 30% as measured by X-ray diffraction, and a brookfield viscosity of about 1,000 to about 4,000 cP at 190 ℃ as measured by ASTM D3236.

The low molecular weight copolymers of the present invention are useful in the manufacture of polyolefin-based hot melt adhesives for use in the manufacture of laminated articles. Adhesives comprising the low molecular weight copolymers are also useful in the preparation of personal care hygiene articles such as infant and adult incontinence diapers, pads, and feminine hygiene napkins. Despite the use of low molecular weight polyolefins, the hot melt adhesives of the present invention provide both a wide process window during the manufacture of laminated structures and high peel strength. The hot melt adhesives of the present invention can produce substantially consistent peel strengths for laminates that span a wide process window.

Furthermore, surprisingly, hot melt adhesive compositions containing the low molecular weight copolymers of the present invention can be easily applied at lower temperatures, although the low molecular weight copolymers of the present invention have relatively high softening points and crystallinities, as opposed to the softening points and crystallinities of the comparative polymers. Adhesive formulations containing the low molecular weight copolymers of the present invention can be applied using a variety of spray nozzles and slot dies at temperatures of about 120 to about 160 ℃. Other ranges are from about 130 ℃ to about 160 ℃ and from about 130 ℃ to about 150 ℃, and at various machine speeds of 100 to 600 meters per minute.

Certain properties of the low molecular weight copolymer were measured according to the procedures outlined in examples 14-16. Otherwise, the test methods listed in this specification were used.

In various embodiments, the low molecular weight propylene-ethylene copolymer may have a weight average molecular weight (Mw) of about 25,000 to about 50,000. Other exemplary ranges of Mw are from about 30,000 to about 45,000 and from about 35,000 to about 40,000. In other embodiments, the low molecular weight propylene-ethylene copolymer may have a number average molecular weight (Mn) of from about 1,000 to about 20,000. Other exemplary ranges are from about 1,500 to about 16,000, from about 2,000 to about 15,000, and from 2,500 to 14,000. In other embodiments, the z-average molecular weight (Mz) of the low molecular weight propylene-ethylene copolymer may be from about 80,000 to about 140,000. Other exemplary ranges of Mz are from about 85,000 to about 130,000, from about 90,000 to about 120,000, and from about 100,000 to about 120,000. The molecular weights (Mn, Mw and Mz) of the low molecular weight copolymers can be measured according to the procedures outlined in examples 14-16.

In various embodiments, the polydispersity (Mw/Mn) of the low molecular weight propylene-ethylene copolymer may be from about 3 to about 25, from about 4 to about 24, from about 5 to about 20, from about 6 to about 15, and from about 8 to about 10. In various embodiments, the low molecular weight propylene-ethylene copolymer may have a polydispersity of at least 3, 4, 5, 6, 7, or 8 and/or not more than 25, 24, 20, 15, or 10.

In various embodiments, the low molecular weight propylene-ethylene copolymer may have a glass transition temperature (Tg) of about-45 to about-30 ℃.

In various embodiments, the low molecular weight propylene-ethylene copolymer can have a melting temperature (Tm) of about 90 to about 138 ℃, about 100 to about 135 ℃, and about 120 to about 130 ℃.

In various embodiments, the melting energy Hm (J/g) of the low molecular weight propylene-ethylene copolymer may be less than 15J/g.

In various embodiments, the crystallinity of the low molecular weight propylene-ethylene copolymer may be from about 18 to about 30 percent as measured by X-ray diffraction. Other exemplary ranges of crystallinity include about 20 to about 30%, about 22 to about 28%, and about 22 to about 26%.

In various embodiments, the low molecular weight propylene-ethylene copolymer can have a crystallization temperature (Tc) of from about 50 to about 110 ℃, from about 60 to about 80 ℃, and from about 50 to about 70 ℃.

In various embodiments, the crystallization energy (Δ Hc) of the low molecular weight propylene-ethylene copolymer may be less than 20J/g, less than 15J/g, or less than 10J/g.

In various embodiments, the low molecular weight propylene-ethylene copolymer can have a brookfield viscosity at 190 ℃ of about 1,000 cP to about 4,000 cP, about 1,200 cP to about 3,600 cP, and about 1,500 cP to about 3,000 cP.

In various embodiments, the low molecular weight propylene-ethylene copolymer can have a storage modulus (G') at 25 ℃ of from about 1 MPa to 10MPa, from about 2 MPa to about 8 MPa, and from about 3 MPa to about 5 MPa.

In various embodiments, the low molecular weight propylene-ethylene copolymer may have a tensile strength of from about 2.5 MPa to about 4.5 MPa or from about 2.7 MPa to about 3.5 MPa.

In various embodiments, the G'/G "crossover temperature of the low molecular weight propylene-ethylene copolymer can be from about 100 to about 120 ℃ or from about 105 to about 110 ℃.

In various embodiments, the low molecular weight propylene-ethylene copolymer can have a tan at the crossover temperature of about 0.35 to about 0.50 or about 0.38 to about 0.48.

In various embodiments of the invention, the low molecular weight propylene-ethylene copolymer has a weight average molecular weight of about 25,000 to about 45,000, a number average molecular weight of about 1,000 to about 12,000, a z average molecular weight of about 90,000 to about 140,000, a polydispersity (Mw/Mn) of about 3 to about 25, a crystallinity of about 20% to about 30%, and a brookfield viscosity of 1,000 to 4,000 cP at 190 ℃. Additional exemplary characteristics of the low molecular weight propylene-ethylene copolymers used in the formulations of the present invention include a storage modulus (G' at 25 ℃) of 1 to 10 MPa; a crossover temperature (for G' and G ") of 110 to 120 ℃ and a correlation tan of 0.35 to 0.50; and a glass transition temperature of-40 to-25 ℃.

Process for producing propylene-ethylene copolymer

In various embodiments, the copolymer may be made by reacting propylene monomers with ethylene monomers in the presence of a catalyst system comprising at least one electron donor.

In various embodiments, the catalyst system may comprise a Ziegler-Natta catalyst. According to one or more embodiments, the Ziegler-Natta catalyst may contain a titanium-containing component, an aluminum component, and an electron donor. In certain embodiments, the catalyst comprises titanium chloride on a magnesium chloride support.

In various embodiments, the cocatalyst can comprise an aluminum alkyl cocatalyst ("TEA L").

In one or more embodiments, the catalyst system can have a molar ratio of aluminum to titanium of at least 1:1, 5:1, 10:1, or 15:1 and/or not more than 100:1, 50:1, 35:1, or 25: 1. Further, the catalyst system can have a molar ratio of aluminum to titanium of 1:1 to 100:1, 5:1 to 50:1, 10:1 to 35:1, or 15:1 to 25: 1. Additionally or alternatively, in various embodiments, the catalyst system can have a molar ratio of aluminum to silicon of at least 0.5:1, 1:1, 2:1, 3:1, 4:1, 5:1, or 6:1 and/or not more than 100:1, 50:1, 35:1, 20:1, 15:1, 10:1, or 8: 1. Further, the catalyst system can have a molar ratio of aluminum to silicon of 0.5:1 to 100:1, 1:1 to 50:1, 2:1 to 35:1, 2:1 to 20:1, 2:1 to 15:1, 2:1 to 10:1, or 2:1 to 8: 1.

The electron donor can improve the stereospecificity of the copolymer. However, it can be important to strictly adjust the electron donor content, since in some cases they can inhibit the catalyst activity to an unacceptable level. The electron donor used in the polymerization process may include, for example, organic esters, ethers, alcohols, amines, ketones, phenols, phosphines, and/or organosilanes. Furthermore, the catalyst system may comprise an internal donor and/or an external donor.

In various embodiments, the catalyst system comprises at least one external electron donor. In one or more embodiments, the external electron donor comprises at least one alkoxysilane. In particular, in certain embodiments, the alkoxysilane may comprise dicyclopentyldimethoxysilane, cyclohexylmethyldimethoxysilane, or a combination thereof. Further, in some embodiments, the alkoxysilane may comprise, consist essentially of, or consist entirely of dicyclopentyldimethoxysilane.

It has been observed that the addition of the above external donor to the catalyst system can increase the hardness (i.e. reduce the penetration) and the viscosity of the copolymer. However, contrary to what has been previously observed in the prior art, the above electron donor can actually lower the softening point of the copolymer obtained, instead of increasing it. Furthermore, it has been observed that when the above-mentioned electron donors are used, substantially all (i.e., greater than 95%) of the ethylene added to the reactor during the polymerization can react. This makes it possible to obtain copolymers having a higher ethylene content and a lower propylene content. Thus, when the above electron donor is used, a propylene-ethylene copolymer having a higher ethylene content but still exhibiting a desired balance between softening point and hardness can be produced.

Further, according to various embodiments, the catalyst system may have a molar ratio of electron donor to titanium of at least 0.1:1, 0.5:1, 1:1, 1.25:1, 1.5:1 or 2:1 and/or not more than 20:1, 15:1, 10:1, 5:1, 4.5:1 or 4: 1. additionally, the catalyst system may have a molar ratio of electron donor to titanium of 0.1:1 to 20:1, 0.5:1 to 15:1, 1:1 to 10:1, 1.25:1 to 5:1, 1.5:1 to 4.5:1 or 2:1 to 4: 1. additionally or alternatively, in various embodiments, the catalyst system may have a molar ratio of electron donor to titanium of at least 0.5:1, 1:1, 2:1, 3:1, 4:1, 5:1 or 6:1 and/or not more than 100:1, 50:1, 35:1, 351: 1 to 6:1, 35:1 to 2:1, 8:1, e.g., the molar ratio of electron donor to 2:1, e.g., TEA may be less than that is needed for certain embodiments.

The catalyst system may exhibit a catalyst activity of 200 to 2,000, 400 to 1,200, or 500 to 1,000 g/g. The catalyst activity was calculated by measuring the ratio of the weight of the polymer produced in the reactor to the weight of the catalyst charged into the reactor. These measurements are based on a reaction time of 1 hour.

Since the addition of an external donor can increase viscosity and molecular weight, the addition of hydrogen may be required to act as a chain terminator during polymerization. For example, the process can be carried out at a hydrogen pressure of 5 to 100, 10 to 80, or 15 to 50 psig.

In various embodiments, the polymerization reaction may occur at a temperature of 100 to 200, 110 to 180, or 120 to 150 ℃. Further, the polymerization reaction can be conducted at a pressure of 500 to 2,000, 700 to 1500, or 800 to 1250 psig.

In certain embodiments, the reactor may comprise a stirred reactor, and the polymerization reaction may have a residence time in the reactor of 0.1 to 6, 0.5 to 4, or 1 to 2 hours. In various embodiments, ethylene may be added to the reactor as a gas and propylene may be added as a liquid.

End products incorporating the propylene-ethylene copolymers

The propylene-ethylene copolymers of the present invention and compositions comprising these copolymers described herein are useful in a variety of applications including, for example, adhesives, sealants, caulks, roofing membranes, waterproofing membranes and underlayments (underlayments), carpets, laminates, tapes (e.g., tamper evident tapes), water activated tapes, gummed tapes, sealing tapes, scrim reinforced tapes, facing tapes, reinforced and non-reinforced adhesive tapes, box making tapes (box makertapes), paper tapes, packaging tapes, HVAC strength tapes, masking tapes, concealed tapes, electrical tapes, appliance (gaffer) tapes, hockey tapes, medical tapes, and the like), labels (e.g., general purpose labels, beverage labels, freezer labels, smart labels, consumer electronics labels, and the like), caulks (massics), polymer blends, Cable coatings, molded articles, heat seal coatings, disposable hygiene products, Insulating Glass (IG) components, bridge decks, waterproofing membranes, waterproofing compounds, underlayment, cable coating/filling compounds, sheet molding compounds, bulk molding compounds, overmolding compounds, rubber compounds, polyester composites, glass fiber reinforced plastics, wood plastic composites, polyacrylic blend compounds, lost wax precision castings, investment casting wax compositions, candles, windows, films, gaskets, seals, O-rings, automotive molded parts, automotive extruded parts, apparel articles, rubber additives/processing aids, and fibers.

Films comprising the inventive propylene-ethylene copolymers and compositions containing these copolymers described herein include, but are not limited to, multilayer films, coextruded films, calendered films, and cast films. Laminates comprising the propylene-ethylene polymers of the present invention or compositions comprising the propylene-ethylene polymers of the present invention include, but are not limited to, paper-foil laminates, paper-film laminates, and nonwoven-film laminates.

Adhesive compositions comprising the propylene-ethylene copolymers of the invention and compositions containing these copolymers described herein include packaging adhesives, food contact grade adhesives, indirect food contact packaging adhesives, product assembly adhesives, woodworking adhesives, flooring adhesives, automotive assembly adhesives, structural adhesives, mattress adhesives, Pressure Sensitive Adhesives (PSAs), PSA tapes, PSA labels, PSA protective films, self-adhesive films, laminating adhesives, flexible packaging adhesives, heat seal adhesives, industrial adhesives, sanitary non-woven construction adhesives, sanitary core integrity adhesives (hygienic) and sanitary elastic attachment adhesives.

In certain embodiments, the copolymers described herein are useful in adhesives such as hot melt adhesives, water-based adhesives, solvent-based adhesives, hot melt pressure sensitive adhesives, solvent-based pressure sensitive adhesives, hot melt nonwoven/hygiene adhesives, hot melt product assembly adhesives, hot melt woodworking adhesives, and hot melt packaging adhesives. In particular, due to their unique combination of softening point and penetration as previously described, adhesives made from the copolymers of the present invention can be used in a variety of end products, including sanitary packaging and other packaging applications. In many embodiments, various properties of the copolymers of the present invention, such as softening point and penetration, can be selected to suit the intended end use of the composition incorporating the copolymer.

In certain embodiments, the copolymers of the present invention are useful in the manufacture of adhesives for packaging, product assembly, film lamination, woodworking, and/or profile sheathing.

In various embodiments, the adhesive of the present invention comprises a hot melt adhesive. The hot melt adhesive may be applied to the substrate in its molten state and cooled to harden the adhesive layer. Such adhesives are widely used in various commercial and industrial applications, such as product assembly and packaging. In these applications, an adhesive is applied to at least one substrate to bond the substrate to a similar or different second substrate.

Adhesive formulators and users often desire heat stable, light colored hot melt adhesives that have an advantageous balance of physical properties including high temperature resistance, chemical resistance, bond strength, viscosity, adhesion to various substrates, and open and set times (open and set times) that can be tailored to specific use and application conditions. The balance of properties desired varies with the application, and the hot melt compositions of the present invention described herein provide an improved balance of properties for a variety of end uses.

The hot melt adhesive composition may have melt rheology and thermal stability suitable for use in conventional hot melt adhesive application equipment. In various embodiments, the blend components of the hot melt adhesive composition have a low melt viscosity at the application temperature, thereby facilitating flow of the composition through a coating apparatus, such as a coating die or nozzle.

The hot melt adhesive composition can be used to bond a variety of substrates including, for example, paperboard, coated paperboard, fiberboard, unused and recycled kraft paper, high and low density kraft paper, particle board, treated and coated kraft paper and particle board, as well as corrugated forms thereof, clay-coated particle board carton stock, composites, leather, polymeric films (e.g., polyolefin films (e.g., polyethylene and polypropylene), polyvinyl chloride films, ethylene vinyl acetate films, polyester films, metallized polymeric films, multilayer films, and combinations thereof), fibers and substrates made from fibers (e.g., unused fibers, recycled fibers, synthetic polymeric fibers, cellulosic fibers, and combinations thereof), release liners, porous substrates (e.g., woven webs, nonwoven scrims, and perforated films), cellulose-based substrates, cellulosic-based substrates, paper-based substrates, Sheets (e.g., paper, and fibrous sheets), paper products, tape backings, and combinations thereof. Useful composite materials include, for example, particle board laminated to a metal foil (e.g., aluminum foil), which optionally may be laminated to at least one polymeric film, particle board bonded to a film, kraft paper bonded to a film (e.g., polyethylene film), and combinations thereof.

The hot melt adhesive composition can be used to bond a first substrate to a second substrate in a variety of applications and configurations, including, for example, packaging, bags, boxes, cartons, cases, trays, multi-layer bags, articles including accessories (e.g., straw attached to a beverage box), ream wrap (ream wrap), cigarettes (e.g., plugwrap), filters (e.g., pleated filters and filter frames), book bindings, footwear, disposable absorbent articles (e.g., disposable diapers, sanitary napkins, medical dressings (e.g., wound care products), bandages, surgical pads, drapes, surgical gowns, and meat wraps), paper products, including, for example, paper towels (e.g., multipurpose towels), toilet tissue, facial tissue, wet wipes, paper towels (e.g., paper towels), sheets, mattress covers, and components of absorbent articles, including, for example, absorbent elements, absorbent cores, absorbent articles, Impermeable layers (e.g., backings), tissues (e.g., packaging tissues), liquid-collecting layers, and woven and nonwoven web layers (e.g., cover papers, absorbent papers), and combinations thereof.

The hot melt adhesive composition can also be used to form laminates of porous substrates and polymeric films, such as those used to make disposable articles including, for example, medical drapes, medical gowns, drapes, feminine hygiene products, diapers, adult incontinence products, absorbent pads for animals (e.g., pet pads) and humans (e.g., bodies and cadavers), and combinations thereof.

The hot melt adhesive composition can be applied to a substrate in any useful form, including, for example, as fibers, as coatings (e.g., continuous and discontinuous coatings (e.g., random, pattern, and array)), as beads, as films (e.g., continuous and discontinuous films), and combinations thereof, using any suitable application method, including, for example, slot coating, spraying (e.g., spiral spraying, random spraying, and random fiberization (e.g., melt blowing)), foaming, extrusion (e.g., applying beads, fine line extrusion, single screw extrusion, and twin screw extrusion), wheel coating, non-contact coating, gravure printing, embossing rollers, roll coating, transfer coating, screen printing, flexography, and combinations thereof.

Typical, but non-limiting, industrial applications of the hot melt adhesive composition include packaging, particularly for low temperature applications, such as freezer packaging for dairy products or for food products, and in disposable hygienic consumer products, such as diapers, feminine care pads, sanitary napkins, and the like. Conventional end-use applications (e.g., book binding, woodworking, and labeling) would also benefit from low temperature flexibility, heat resistance, and end-use efficiency in automated equipment that applies the hot melt adhesive composition to various substrates.

Furthermore, in various embodiments, the copolymers of the invention described herein can also be used to modify existing polymer blends, which are typically used in plastics, elastomeric applications, roofing applications, cable filling, and tire modification. The copolymers of the present invention can improve the adhesion, processability, stability, viscoelasticity, thermal properties and mechanical properties of these polymer blends.

In various embodiments, the propylene-ethylene copolymers of the present invention may be modified to produce graft copolymers. In such embodiments, the copolymers of the present invention may be grafted with maleic anhydride, fumaric and maleic esters, methacrylic esters (e.g., glycidyl methacrylate and hydroxyethyl methacrylate), methacrylic acid, vinyl derivatives, silane derivatives, or combinations thereof. These graft copolymers may be made using any conventional method known in the art, including, for example, transesterification and free radical induced coupling.

The various end uses and end products described above may use the copolymers of the present invention by themselves or may be combined with other additives and polymers. Suitable polymers that can be combined with the copolymers of the present invention to form polymer blends can include, for example, isoprene-based block copolymers; a butadiene-based block copolymer; a hydrogenated block copolymer; ethylene-vinyl acetate copolymers; a polyester; a polyester-based copolymer; chloroprene rubber; a carbamate; acrylic acids; a polyacrylate; acrylate copolymers such as, but not limited to, ethylene-acrylic acid copolymers, ethylene-n-butyl acrylate copolymers and ethylene-methyl acrylate copolymers; polyether ether ketone; a polyamide; styrenic block copolymers; hydrogenated styrenic block copolymers; random styrenic copolymers; ethylene-propylene rubbers; ethylene-vinyl acetate copolymers; butyl rubber; styrene-butadiene rubber; butadiene-acrylonitrile rubber; natural rubber; a polyisoprene; polyisobutylene; polyvinyl acetate; and a polyolefin.

Propylene in the present invention and the present inventionIn one embodiment of the present invention, the polyolefin may be at least one selected from the group consisting of amorphous polyolefins, semi-crystalline polyolefins, α -polyolefins, reactor-ready (reactor-ready) polyolefins, metallocene-catalyzed polyolefin polymers and elastomers, reactor-made (reactor-master) thermoplastic polyolefin elastomers, olefin block copolymers, thermoplastic polyolefins, atactic polypropylene, polyethylene, ethylene-propylene polymers, propylene-hexene polymers, ethylene-butene polymers, ethylene-octene polymers, propylene-butene polymers, propylene-octene polymers, metallocene-catalyzed polypropylene polymers, metallocene-catalyzed polyethylene polymers, propylene-based terpolymers (including ethylene-propylene-butene terpolymers), copolymers of propylene and linear or branched C₄-C₁₀α -copolymers made from olefin monomers, made from ethylene and linear or branched C₄-C₁₀α -copolymers made from olefin monomers, and functionalized polyolefins.

There are a variety of methods in the art for functionalizing polymers that can be used with the polymers described herein. These include selective oxidation, free radical grafting, ozonolysis, epoxidation, and the like. Functionalized components include, but are not limited to, functionalized olefin polymers (e.g., functionalized C₂To C₄₀Homopolymer, functionalized C₂To C₄₀Functionalized olefin polymers and copolymers useful in the present invention include maleated polyethylene, maleated metallocene polypropylene, maleated ethylene propylene rubber, maleated polypropylene, maleated ethylene copolymers, functionalized polyisobutylene (typically functionalized with maleic anhydride to form succinic anhydride), and the like.

In various embodiments, the propylene-ethylene copolymers of the present invention described herein can be used to make hot melt adhesives. According to one or more embodiments, the adhesive may comprise at least 1,5, 10, 15, 20, 25, 30, 35, 40, or 45 and/or no more than 95, 90, 80, 70, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, or 10 weight percent of the copolymer of the present invention. Furthermore, the adhesive may comprise 1 to 95, 5 to 90, 10 to 80, 20 to 70, 30 to 60, or 40 to 55 weight percent of the copolymer of the invention. In certain embodiments, the adhesive may consist entirely of the copolymer of the present invention.

In addition, depending on the intended end use, these hot melt adhesives may also contain various additives including, for example, polymers, tackifiers, processing oils, waxes, antioxidants, plasticizers, pigments, and fillers.

In various embodiments, the adhesive may comprise at least 10, 20, 30, or 40 and/or no more than 90, 80, 70, or 55 weight percent of at least one polymer other than the copolymer of the present invention. Furthermore, the adhesive may comprise 10 to 90, 20 to 80, 30 to 70 or 40 to 55 wt% of at least one polymer different from the copolymer of the invention. These polymers may include any of the polymers listed above.

In addition, it has been found that blends of the copolymers of the present invention with various types of polyolefins can provide adhesives with improved adhesion, bond strength, high temperature resistance, viscosity, and open and cure times. Thus, in various embodiments, the above-described polymers that may be combined with the propylene-ethylene copolymers of the present invention may comprise at least one polyolefin. In certain embodiments, the adhesive may comprise, in addition to the propylene-ethylene copolymer described above, at least 1,5, 10, 15, 20, 25, 30, 35, 40, 45, or 50 weight percent of at least one polyolefin. Additionally or alternatively, the adhesive may comprise no more than 99, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, or 5 wt% of at least one polyolefin in addition to the propylene-ethylene copolymer described above. For example, the adhesive may comprise 1 to 90, 1 to 60, 1 to 40, 1 to 20, 10 to 90, 20 to 80, 20 to 40, 30 to 70, 30 to 40, or 40 to 55 weight percent of at least one polyolefin. In one or more embodiments, the polyolefins may be amorphous polyolefins having a heat of fusion of less than 25J/g or less than 15J/g.

Commercial examples of acceptable amorphous polyolefins include Aerafin from Eastman Chemical ^TM17; aerfin by Eastman Chemical ^TM180, Rextac manufactured by REXtac LL C^TMPolymers, including Rextac^TME-63, e-65, 2760, 2815 and 2830; vestoplast^®Including Vestoplast^®408 and 708; and Eastoflex by Eastman chemical^®Including Eastoflex^®E1060 and P1010.

Some examples of metallocene-catalyzed polymers include polyolefins such as polyethylene, polypropylene and copolymers thereof, polypropylene-based elastomers such as those sold by ExxonMobil Chemical under the trade name VIS Α Μ Α cell, and polyethylene-based elastomers such as those sold by the Dow Chemical Company under the trade names affine |, and engag |. Other metallocene-catalyzed polymers include the polyolefin elastomers VISTA MAXX. sup.8816, VISTA MAXX. sup.2230 and ENGAGE. sup.8200. AFFINITY-like GA1900 has a density of 0.870 g/cm³According to ASTM D792, a heat of fusion of 46.1J/g, and a Brookfield viscosity of 8,200 cP at 177 ℃ according to ASTM D1084. AFFINITY-GA 1950 has a density of 0.874 g/cm³According to ASTM D792, a heat of fusion of 53.4J/g and a Brookfield viscosity of 17,000 cP at 177 ℃ according to ASTM D1084. ENGAGE 8200 with a density of 0.87 g/cm³According to ASTM D792 and a melt index at 190 ℃ of 5 g/10 min. These polyolefin elastomers are compatible with the copolymers of the present invention when used in hot melt adhesives.

In one embodiment of the invention, the propylene-ethylene copolymers of the present invention may be used with at least one high propylene content polymer to make compositions useful as adhesives. As used herein, a high propylene content polymer is a polymer comprising at least 60 mole% propylene monomer. In other embodiments of the invention, the high propylene content polymer comprises at least 65, 70, 75, 80, 85, 90, 95 mole percent propylene monomer. In another embodiment, the high propylene content polymer is a homopolymer of propylene. The high propylene polymer may be any polymer known in the artIncluding homopolymers, copolymers, terpolymers and propylene waxes. Other monomers used include straight or branched C₂-C₂₀An olefin. As used in this disclosure, a "wax" is defined as a polymer or oligomer having a heat of fusion greater than 50 joules/gram and a viscosity no greater than 750 Centipoise (CP) at 190 ℃.

Examples of high propylene content polymers include, but are not limited to, propylene homopolymers; metallocene-catalyzed polypropylene; propylene-ethylene copolymers; metallocene-catalyzed propylene-ethylene copolymers; propene and straight-chain or branched C₄To C₂₀Copolymers of olefins; propene and straight-chain or branched C₄To C₂₀Metallocene-catalyzed copolymers of olefins; propylene, ethylene and C₄To C₂₀Terpolymers of olefins; a propylene wax; a terpolymer formed from ethylene, propylene, and a diene (EPDM), or a combination thereof.

Suitable high propylene content polymers are commercially available under various trademarks including, but not limited to, the L-MODU series trademarks sold by Idemitsu Kosan Co., L td (Japan), including, for example, L-MODU series trademarks S400, S600, and S900, the VISTA MAX series and ACHIEVE series trademarks sold by ExxonMobil Chemical Company (Houston, Texas), including, for example, VISTA MAX 8880 and ACHIEVE 6936, and the polymers L l COMAN 2602 and 6502 sold by Clariant Int' l L td (Muttenz, Switzerland), and the EASTMAN G-5 sold by Eastman Chemical Company.

In various embodiments, the olefin polymer comprises a mixture of at least two different olefin polymers, such as a blend comprising an olefin homopolymer and an olefin copolymer, a blend comprising different olefin homopolymers of the same or different monomers, a blend comprising different olefin copolymers, and various combinations thereof. Useful olefin polymers also include, for example, modified, unmodified, grafted, and ungrafted olefin polymers, unimodal olefin polymers, multimodal olefin polymers, and combinations thereof.

In various embodiments of the present invention, the propylene polymer preferably comprises at least 50 mole%, at least about 60 mole%, at least about 70 mole%, at least about 80 mole%, at least about 90 mole%, at least about 95 mole%, or even from about 50 mole% to about 100 mole% propylene the propylene polymer optionally comprises at least 2 mole%, at least about 5 mole%, at least about 10 mole%, at least about 20 mole%, at least about 30 mole%, no more than about 50 mole%, or even from about 20 mole% to about 50 mole% of at least one α -olefin comonomer.

In various embodiments, these added polyolefins may improve the cohesive strength, adhesive properties, tack, low temperature flexibility, overall crystallinity, and/or high temperature resistance of the adhesives of the invention. Furthermore, the addition of the aforementioned polyolefins may reduce the production cost of the adhesive due to its wide availability.

In certain embodiments, the adhesive may comprise the propylene-ethylene copolymer described above and a metallocene-catalyzed polyethylene copolymer, such as an ethylene-octene copolymer. In such embodiments, the propylene-ethylene copolymers of the present invention may be used to replace polyethylene in various types of adhesives, such as those used in packaging applications.

In certain embodiments, the added polymer and/or polyolefin may be functionalized with groups including, but not limited to, silanes, anhydrides (such as maleic anhydride), hydroxyl, ethoxy, epoxy, siloxane, amine, aminosiloxane, carboxyl, and acrylate at the polymer chain ends and/or at pendant positions in the polymer.

Additional polymers and polyolefins that may be added to the adhesives of the present invention may be prepared by Ziegler-Natta catalysts, single site catalysts (metallocenes), multiple site catalysts, non-metallocene heteroaryl catalysts, combinations thereof, or other polymerization methods. The additional polymers may comprise a combination of amorphous, semi-crystalline, random, branched, linear, or block structures.

Any conventional polymerization synthesis method can be used to prepare the additional polyolefin component. In one or more embodiments, one or more catalysts (which are typically metallocene catalysts or Zeigler-Natta catalysts) are used in the polymerization of an olefin monomer or monomer mixture. Polymerization processes include high pressure, slurry, gas phase, bulk, suspension, supercritical or solution phase, or combinations thereof. The catalyst may be in a homogeneous solution, supported form, or a combination thereof. The polymerization may be carried out by a continuous, semi-continuous, or batch process, and may include the use of chain transfer agents, scavengers, or other such additives as are deemed suitable. In one or more embodiments, the additional polymer is produced using a single polymerization catalyst in a single or multiple polymerization zones. Metallocene (or heterophasic) polymers are typically manufactured using a blend of metallocene catalysts that achieve the desired heterophasic structure.

In various embodiments, the crystalline content of the added polymer or polyolefin may increase the cohesive strength of the adhesive. Generally, adhesive formulations based on metallocene polymerized semi-crystalline copolymers can ultimately develop sufficient crystalline content over time to achieve good bond strength in the formulation.

In various embodiments, the adhesive may comprise at least 10, 20, 30, or 40 and/or no more than 90, 80, 70, 55, 50, 45, or 40 weight percent of at least one tackifier. In addition, the adhesive may comprise 10 to 90, 20 to 80, 20 to 40, 20 to 30, 30 to 70, or 40 to 55 weight percent of at least one tackifier. The tackifier imparts tack to the adhesive and may also reduce the viscosity of the adhesive. Lower viscosity can improve application flow characteristics, enable easier processing, reduce energy requirements, and reduce processing temperatures. The lower viscosity also helps the adhesive to "wet" or substantially uniformly coat surfaces and penetrate substrates. Tack is required in most adhesive formulations in order to properly join the articles before the hot melt adhesive sets. The desirability and selection of a particular tackifier may depend on the particular type of olefin copolymer and additional polymer used.

Suitable tackifiers may include, for example, cycloaliphatic hydrocarbon resins, C₅A hydrocarbon resin; c₅/C₉A hydrocarbon resin; aromatic modified C₅A resin; c₉Hydrocarbon resins, pure monomer resins, e.g. styrene with α -methylstyrene, vinyltoluene, p-methylstyrene, indene, methylindene, C₅Resin and C₉A copolymer of a resin; a terpene resin; terpene phenolic resin; terpene styrene resin; rosin esters; modified rosin esters; liquid resins of fully or partially hydrogenated rosin; fully or partially hydrogenated rosin esters; fully or partially hydrogenated modified rosin resins; fully or partially hydrogenated rosin alcohols; fully or partially hydrogenated C₅A resin; fully or partially hydrogenated C₅/C₉A resin; fully or partially hydrogenated aromatic modified C₅A resin; fully or partially hydrogenated C₉A resin; fully or partially hydrogenated pure monomer resins; fully or partially hydrogenated C₅A cycloaliphatic resin; fully or partially hydrogenated C₅cycloaliphatic/styrene/C₉A resin; fully or partially hydrogenated cycloaliphatic resins; and combinations thereof. Exemplary commercially available hydrocarbon resins include Regalite^TMHydrocarbon resin (Eastman Chemical). In certain embodiments, the tackifier may comprise a functionalized tackifier.

In various embodiments, the binder may comprise at least 1,2, 5, 8, or 10 and/or no more than 40, 30, 25, 20, or 15 weight percent of at least one processing oil. Furthermore, the binder may comprise 2 to 40, 5 to 30, 8 to 25 or 10 to 20 wt% of at least one processing oil. The process oil can include, for example, mineral oil, naphthenic oil, paraffinic oil, aromatic oil, castor oil, rapeseed oil, triglyceride oil, or combinations thereof. As will be appreciated by those skilled in the art, the processing oil may also include extender oil, which is commonly used in adhesives. The use of oil in the adhesive may be desirable if the adhesive is to be used as a pressure sensitive adhesive to make a tape or label or as an adhesive to bond nonwoven articles. In certain embodiments, the adhesive may not contain any processing oil.

In various embodiments, the adhesive may comprise at least 1,2, 5, 8, or 10 and/or no more than 40, 30, 25, 20, or 15 weight percent of at least one wax. In addition, the adhesive may comprise 1 to 40, 5 to 30, 8 to 25, or 10 to 20 weight percent of at least one wax. The wax serves to reduce the overall viscosity of the adhesive, thereby liquefying it and enabling the hot melt adhesive to be properly applied or coated onto the intended substrate. The type and melting point of the wax, as well as its compatibility with the other components of the adhesive composition, control the open time and cure speed of the adhesive. Open time is known in the art as the amount of time the adhesive wets and bonds to the substrate after application. Any conventionally known wax suitable for use in formulating hot melt adhesives may be used in the practice of the present invention.

In one embodiment of the present invention, when the propylene-ethylene copolymer of the present invention is used with a propylene polymer as the propylene wax, no other wax may be required.

Suitable waxes may include, for example, microcrystalline waxes, paraffin waxes, waxes made by the fischer-tropsch process, functionalized waxes (maleated, fumarated, or functional waxes, etc.), polyolefin waxes, petroleum waxes, polypropylene waxes, polyethylene waxes, ethylene vinyl acetate waxes, and vegetable waxes. If the adhesive is used as a hot melt packaging adhesive, it may be desirable to use a wax in the adhesive.

Non-limiting examples of commercially available waxes suitable for the present invention include Sasol, available from Sasol Wax Americas, inc^®H-1, A-C-9 and A-C810 available from Honeywell International Inc., EPO L ENE-15 available from Eastman chemical, and PO L YWAX-400, 850, 1000 and 3000 from Baker Hughes Inc.

Other exemplary waxes include, but are not limited to, Evonik L icocene cell PE4201, Westlake EPO L ENE C-10, EPO L ENE C-17 and EPO L ENE C-18, and microcrystalline wax Be Square 195.

As used herein, "functionalized" means that the component is prepared in the presence of a functional group incorporated into the component or contacted with a functional group and optionally a catalyst, heat, initiator, or source of free radicals such that all or a portion of the functional group (e.g., maleic acid or maleic anhydride) is incorporated, grafted, bonded, physically attached, and/or chemically linked to the polymer.

Exemplary functionalized wax polymers useful as functionalizing components include those modified with alcohols, acids, ketones, anhydrides, etc. commercially available functionalized waxes include maleated polypropylene available under the tradenames moΑ Α 40 from Chusei, maleated metallocene waxes (such as TP L icomene Ρ 1602 available from Clariant), maleated polyethylene waxes and maleated polypropylene waxes available under the tradenames EPO L enep C-16, EPO L enep C-18, EPO L1 enep 43 from Westlake, Eastman G-3003 from Eastman Chemical, maleated polypropylene waxes L icompropar 504 available from Clariant, maleated polyethylene waxes and maleated polypropylene waxes available under the tradenames bap Ρ pr p.

In certain embodiments, the adhesive may not comprise a wax. For example, the adhesive may comprise less than 10, 5, 4, 3, 2, or 1 weight percent of a wax, such as, but not limited to, a polyethylene wax and/or a fischer-tropsch wax.

In various embodiments, the adhesive may comprise at least 0.1, 0.2, 0.5, 1,2, or 3 and/or no more than 20, 10, 8, 5, 1, or 0.5 weight percent of at least one antioxidant. Furthermore, the adhesive may comprise 0.1 to 20, 1 to 10, 2 to 8, or 3 to 5 weight percent of at least one antioxidant.

In various embodiments, the binder may comprise at least 0.5, 1,2, or3 and/or not more than 20, 10, 8 or 5 wt% of at least one plasticizer. Furthermore, the adhesive may comprise 0.5 to 20, 1 to 10, 2 to 8 or 3 to 5 wt% of at least one plasticizer. Suitable plasticizers may include, for example, olefin oligomers, low molecular weight polyolefins such as liquid polybutene, polyisobutylene, mineral oil, dibutyl phthalate, dioctyl phthalate, chlorinated paraffins, and phthalate-free plasticizers. Commercially available plasticizers may include, for example, Benzoflex^TMPlasticizer (Eastman Chemical); eastman 168^TM（Eastman Chemical）；Oppanol^®B10 (BASF), REGA L REZ 1018 (Eastman Chemical), Calsol5550 (Calumet L ubicants), Kaydol oil (Chevron), or Para L ux oil (Chevron).

In various embodiments, the adhesive may comprise at least 10, 20, 30, or 40 and/or no more than 90, 80, 70, or 55 weight percent of at least one filler. Furthermore, the adhesive may comprise 1 to 90, 20 to 80, 30 to 70, or 40 to 55 weight percent of at least one filler. Suitable fillers may include, for example, carbon black, calcium carbonate, clay, titanium oxide, zinc oxide, or combinations thereof.

The adhesive composition may be produced using conventional techniques and equipment. For example, the components of the adhesive composition may be blended in a mixer, such as a sigma blade mixer, a plastometer, a Brabender mixer, a twin screw extruder, or a tank blender (pint tank). In various embodiments, the adhesive can be formed into a desired form, such as a tape or sheet, by suitable techniques, including, for example, extrusion, compression molding, calendering or roll coating techniques (e.g., gravure, reverse roll, etc.), curtain coating, slot die coating, or spray coating.

In addition, the adhesive may be applied to the substrate by a solvent casting method or by melting the adhesive and then using conventional hot melt adhesive application equipment known in the art. Suitable substrates may include, for example, nonwovens, textiles, paper, glass, plastics, films (polyethylene, polypropylene, polyester, etc.), and metals. Generally, about 0.1 to 100 g/m may be used²Is applied to a substrate.

According to one or more embodiments, the hot melt adhesive may have a brookfield viscosity at 177 ℃ of at least 100, 300, 500, 750, or 1,000 and/or not more than 30,000, 10,000, 5,000, 4,000, 3,000, or 2,500 cps measured according to ASTM D3236. Further, the hot melt adhesive can have a brookfield viscosity at 177 ℃ of 100 to 30,000, 300 to 10,000, 500 to 5,000, or 750 to 2,500 cps. Additionally or alternatively, the hot melt adhesive may have a loop tack (loop tack) of 0.1, 0.5, 1, or 1.5 and/or not more than 20, 15, 10, or 5 lbf, measured according to ASTM D6195. Further, the hot melt adhesive can have an loop tack of 0.1 to 20, 0.5 to 15, 1 to 10, or 1.5 to 5 lbf, measured according to ASTM D6195.

Further, in various embodiments, the hot melt adhesive can have a peel strength of at least 1,2, 5, 10, or 15 and/or not more than 50, 40, 35, 30, or 25 g/mm, measured according to ASTM D903. Further, the hot melt adhesive can have a peel strength of 1 to 50, 2 to 40, 5 to 35, 10 to 30, or 15 to 25 g/mm measured according to ASTM D903. Additionally or alternatively, the hot melt adhesive can have a 90 ° peel strength of at least 0.05, 0.1, 0.2, or 0.5 and/or not more than 20, 10, 5, or 1 lbf/inch, measured according to ASTM D903. Further, the hot melt adhesive can have a 90 ° peel strength of 0.05 to 20, 0.1 to 10, 0.2 to 5, or 0.5 to 1 lbf/inch, measured according to ASTM D903.

According to various embodiments, adhesives containing the copolymers of the present invention may have a wide operating window and may have an application window of 80 to 230 ℃. This wide operating window can be demonstrated by the peel strength of the adhesive at different temperatures. For example, the added level may be 0.5-30 gsm. In one or more embodiments, the hot melt adhesive can have a peel strength of at least 2,5, 25, or 40 and/or not more than 250, 200, or 175g/mm, measured according to ASTM D903, for samples applied at lower temperatures (e.g., 100 to 145 ℃). Further, the hot melt adhesive can have a peel strength of 2 to 250, 25 to 200, or 40 to 175g/mm, measured according to ASTM D903, for samples applied at lower temperatures (e.g., 100 to 145 ℃). Additionally or alternatively, the hot melt adhesive may have a peel strength of at least 1,5, 30 or 40 and/or not more than 250, 200 or 150 g/mm, measured according to ASTM D903, for samples applied at higher temperatures (e.g., 145 to 180 ℃). Further, the hot melt adhesive can have a peel strength of 1 to 250, 30 to 200, or 40 to 150 g/mm, measured according to ASTM D903, for samples applied at higher temperatures (e.g., 145 to 180 ℃).

According to one or more embodiments, the hot melt adhesive may have a probe tack force of at least 0.1, 0.2, or 0.3 and/or not more than 5, 3, 2, or 1 kg, measured according to ASTM D9279. Furthermore, the hot melt adhesive may have a probe tack force of 0.1 to 3, 0.2 to 2, or 0.3 to 5 kg, measured according to ASTM D9279. Further, in various embodiments, the hot melt adhesive can have a holding power at 50 ℃ of at least 0.1, 0.5, or 1 and/or not more than 50,000, 10,000, 5,000, 1,000, 500, 100, 50, 20, 10, 7, or 4 hours, measured according to ASTM D3654. Further, the hot melt adhesive may have a holding power at 50 ℃ of 0.1 to 10, 0.5 to 7, or 1 to 4 hours measured according to ASTM D3654.

In other embodiments, the hot melt adhesive may exhibit a holding power at 60 ℃ of at least 5, 15, 20, or 25 minutes and/or not more than 150 minutes. Additionally or alternatively, the hot melt adhesive may exhibit a holding power at 50 ℃ of at least 400, 600, 800, or 1,000 minutes. The retention at 50 ℃ and 60 ℃ can be measured by the following method: the glued carton substrate is stabilized at room temperature (which is typically about +/-20 to 23 ℃) overnight, and then the substrate is hung in a peel mode in a shear bank oven (shear bank oven). The weight was then suspended below the glue base. The time to drop the weight due to failure was recorded for each specimen. A minimum of eight specimens are required for this test. The parameters of the test are listed below.

Standard of merit	Unit of	Condition
			Size of sample	mm		25×60
Application temperature	C						180+/-2
			Open time	s	2
Curing time	s	2
			Linear velocity	m/min	15
Bonding pressure	kgf	1.2 (0.08kgf/cm²)
			Coating weight	g/m	3+/-0.09
Suspended weight	g	500

According to various embodiments, the hot melt adhesive may have a peel failure temperature ("PAFT") of at least 2, 10, 25, or 45 and/or not more than 200, 120, or 80 ℃ measured according to ASTM D4498. Further, the hot melt adhesive may have a PAFT of 2, 10 to 200, 25 to 120, or 45 to 80 ℃ measured according to ASTM D4498. Additionally or alternatively, the hot melt adhesive may have a shear failure temperature ("SAFT") of at least 2,5, 10, 25, 50, 75, or 90 and/or not more than 200, 150, or 125 ℃ measured according to ASTM D4498. Further, the hot melt adhesive may have a SAFT of 2 to 200, 50 to 150, or 75 to 125 ℃ measured according to ASTM D4498.

In various embodiments, the hot melt adhesive may exhibit an effective cure time of at least 0.1, 0.5, or 1 second and/or no more than 5 seconds. In other embodiments, the hot melt adhesive may exhibit an open time of at least 1,5, or 10 and/or no more than 40, 30, or 20 seconds.

In various embodiments, the hot melt adhesive can exhibit at least 65, 70, 75, 80, or 85% of low temperature performance fiber tear at-15 ℃ ("L TFT"). additionally or alternatively, the hot melt adhesive can exhibit at least 40, 50, 60, 70, or 80% of L TFT at-25 ℃, the L TFT test includes manually tearing the glued carton substrate at-15 ℃ or-25 ℃ by hand.

Standard of merit	Unit of	Condition
			Size of sample	mm		50×100
Application temperature	C						180+/-2
			Open time	s	2
Curing time	s	2
			Linear velocity	m/min	15
Bonding pressure	kgf	4 (0.08 kgf/cm²)
			Coating weight	g/m	3+/-0.09

In various embodiments, adhesives containing the copolymers of the present invention do not exhibit a significant change in color when subjected to storage conditions at elevated temperatures for extended periods of time. The adhesive may have an initial gardner color of less than 18, 15, 10, 8, 5, 4, 3, 2, or 1 as measured according to ASTM D1544 before any aging due to storage occurs. After heat aging at 177 ℃ for at least 96 hours, the adhesive can exhibit a final gardner color of less than 18, 15, 10, 7, 5, 3, 2, or 1 as measured according to ASTM D1544. Thus, the adhesive can maintain a desirable color even after prolonged storage and exposure.

In another embodiment of the present invention, the low molecular weight propylene-ethylene copolymer may be used in the adhesive compositions previously described in this disclosure. In particular, the low molecular weight copolymers are useful in the manufacture of hot melt adhesives having a wide process window and high peel strength (including destructive bonding to substrates) for laminates such as, but not limited to, sanitary products. The adhesive composition containing the low molecular weight copolymer may be applied at an add-on ratio of from about 0.5 gsm to about 5 gsm and suitable for producing a laminate having the desired bond strength. The peel strength produced using the formulations of the present invention can range from about 20 grams/25 millimeters (-1 gram/millimeter) to about 400 grams/25 millimeters (16 grams/millimeter) and bond strength to substrate failure. In other embodiments, the peel strength may be at least 20 g/25 mm, 30 g/25 mm, 40 g/25 mm, 50 g/25 mm, 60 g/25 mm, 70 g/25 mm, 80 g/25 mm, 90 g/25 mm, or 100 g/25 mm and/or not more than 400 g/25 mm, 375 g/25 mm, 350 g/25 mm, 300 g/25 mm, 275 g/25 mm, 250 g/25 mm, 225 g/25 mm, or 200 g/25 mm. In addition, the adhesive formulation can have a peel strength of 20 g/25 mm to 375 g/25 mm, 25 g/25 mm to 350 g/25 mm, 30 g/25 mm to 325 g/25 mm, 40 g/25 mm to 300 g/25 mm, 50 g/25 mm to 275 g/25 mm, 60 g/25 mm to 250 g/25 mm, 70 g/25 mm to 225 g/25 mm, or 80 g/25 mm to 200 g/25 mm. In various embodiments of the present invention, the adhesive formulation is used as a hot melt adhesive and comprises at least one copolymer of the present invention and at least one tackifying resin. Optionally, the hot melt adhesive may further comprise a wax, an oil and/or an antioxidant. In a particular embodiment, the hot melt adhesive comprises from about 50 to about 60 weight percent of the low molecular weight copolymer of the present invention and from about 40 to about 45 weight percent of the tackifying resin.

The invention may be further illustrated by the following examples of embodiments of the invention, although it will be understood that these examples are included merely for purposes of illustration and are not intended to limit the scope of the invention unless otherwise specifically indicated.

Examples

Example 1

In this example, various propylene-ethylene copolymers were made in a2 liter stirred reactor with an average residence time of about 1 hour, the reactor temperature was maintained at about 140 ℃ and a pressure of 900 psig propylene was fed as a liquid to the reactor while ethylene was fed as a gas to the reactor polymerization occurred in the presence of a Ziegler-Natta catalyst, which was titanium chloride on a magnesium chloride support, this particular catalyst was a heterogeneous supported catalyst system formed from a titanium compound in combination with an alkylaluminum cocatalyst ("TEA L"), which catalyst system had an Al/Ti molar ratio of 21.

Samples 1-11 were made using the foregoing catalyst system and an external electron donor. As described below, the electron donor is cyclohexylmethyldimethoxysilane ("C") or dicyclopentyldimethoxysilane ("D"). Comparative sample 1 (C1) was made using the above catalyst system in the absence of any electron donor. The amount of electron donor added is different for each sample as indicated by the donor/Ti molar ratio.

The copolymers made by this reaction, as well as their various properties and reaction conditions used to make them, are described in table 1 below. It should be noted that the penetrometer was used to measure penetrometer according to ASTM D5 as previously discussed, without actually running the test specimen in water; however, the samples were conditioned in water prior to running the test.

TABLE 1

Copolymer samples	1A	1B	1C	1D	1E	1F	1G	1H	1I	1J	1K	C1
													Molar ratio of Al to Ti	21	21	21	21	21	21	21	21	21	21	21	21
Silane donors	C	C	D	D	D	D	D	D	D	D	D	-
													donor/Ti molar ratio	0.5	1.2	1.0	2.0	2.0	2.0	2.5	2.5	3.0	2.0	2.0	-
Hydrogen (psig)	40	20	15	25	25	40	40	25	50	80	80	-
													Reactor temperature,. deg.C	140	140	140	140	140	140	140	140	140	140	140	140
The pressure of the reactor is measured and the pressure, (psig)	900	900	900	900	900	900	900	900	900	900	900	900
													catalyst Activity (g/g)	714.3	1003.3	920.4	887.8	817.1	728.4	803.1	842.9	780.8	824.3	841.7	-
Viscosity @ 190 ℃ cP	1853	5863	9088	9838	21125	6850	10238	16575	5525	1122	1748	7013
													Softening Point (. degree. C.)	130.3	142.2	134.8	131.6	128.6	121.8	126.3	132.6	119	117.7	129.1	120.7
Penetration (dmm)	20	14	15	29	17	20	22	21	28	26	20	82
													Weight% ethylene	15.2	12.5	17.5	24.6	20.2	22.6	25.3	22.6	25.2	21.1	19.5	21.7
Weight% propylene	84.8	87.5	82.5	75.4	79.8	77.4	74.7	77.4	74.8	78.9	80.5	78.3
													Polymer yield (g)	537.5	780.0	709.6	712.9	656.1	584.9	657.7	690.3	652.0	661.9	675.9	720.9

As shown in table 1 above, the addition of an external donor generally increases the hardness, as indicated by the reduced penetration and increases the softening point and viscosity of the copolymer. As shown in table 1, the samples made with the external donor had significantly lower penetration values than the comparative sample (C1). Furthermore, the comparative sample was observed to be very viscous, but still lacking in sample strength as indicated by penetration values below 30 dmm.

Previous studies have shown that external donor levels greater than 1.25:1 (donor: Ti molar ratio) begin to adversely affect the properties of the copolymer. In contrast to these studies, improved polymer properties were observed in this example at external donor levels greater than 1.25:1 (donor: Ti molar ratio). Since the addition of an external donor can increase viscosity and molecular weight, the addition of hydrogen or higher levels of hydrogen may be required to act as a chain terminator during the polymerization process as compared to the polymerization of a similar composition without the addition of an external donor.

Fig. 1A and 1B depict viscoelastic characteristics of samples 1B, 1E, and 1F from table 1. In addition, fig. 1A and 1B also provide viscoelastic characteristics of various commercially available copolymers for comparison. These commercially available copolymers include INFUSE^TM9817（Dow）、AFFINITY^TMGA1900 (Dow) and Eastoflex^TME1060 (Eastman). Fig. 1A depicts the elastic modulus (G') of the copolymer, while fig. 1B depicts the tan of the copolymer.

As shown in FIGS. 1A and 1B, sample 1B shows a desirable elastic modulus (G ') plateau from-15 to 100 ℃ representing elastic characteristics over a wide range of application temperatures this is important in hot melt pressure sensitive adhesive ("PSA") applications, such as tapes and labels, because the G' plateau (i.e., the flatness of the curve) generally represents energy absorbing and desorbing characteristics, as well as the strength of the adhesive over a measured temperature range after which the copolymer can begin to flow.

Example 2

In this example, various propylene-ethylene copolymers were produced using the process and system described in example 1; however, the external electron donor used in this example was cyclohexylmethyldimethoxysilane. Furthermore, the amount of electron donor added to each sample was not equal as indicated by the donor/Ti molar ratio. The copolymers produced during this process, as well as their various properties and reaction conditions for producing them, are described in table 2 below.

TABLE 2

Copolymer samples	2A	2B	2C	2D	2E	2F	2G
								Molar ratio of Al to Ti	21	21	21	21	21	21	21
donor/Ti molar ratio	1.1	1.2	0.5	1.0	1.0	1.5	2.0
								TEA L/donor molar ratio	31.3	29.6	70.0	32.9	32.9	24.7	16.5
Hydrogen (psig)	40	20	20	25	25	25	25
								Reactor temperature,. deg.C	140	140	140	140	140	140	140
Reactor pressure, (psig)	900	900	900	900	900	900	900
								Catalyst Activity (g/g)	843.9	1003.3	1006.8	1001.3	957.2	962.9	904.1
Viscosity @ 190 ℃ cP	3600	6600	5175	4865	7263	5538	4715
								Softening Point (. degree. C.)	140.3	138.4	145.3	126.6	135.9	133	129.6
Penetration (dmm)	10	14	17	32	24	23	32
								Weight% ethylene stream	10.0	10.0	10.0	15.0	13.0	15.0	15.0
Weight% ethylene	11.7	11.9	11.3	19.3	17.2	18.2	19.3
								Weight% propylene	88.3	88.1	88.7	80.7	82.8	81.8	80.7
Polymer yield (g)	648.7	780.0	760.1	772.0	738.0	757.8	726.0

As described in table 2, copolymers having the desired combination of penetration and softening point can be made using cyclohexylmethyldimethoxysilane as external donor. However, this balance is largely influenced by the donor/Ti molar ratio. As shown in samples 2F and 2G in table 2, when the donor/Ti molar ratio was increased from 1.5:1 to 2:1, the softening point was slightly lowered and the penetration was significantly increased, which is undesirable.

Example 3

In this example, various propylene-ethylene copolymers were made using the method and system described in example 1. The external electron donor used in this example was dicyclopentyldimethoxysilane. Furthermore, the amount of electron donor added to each sample was not equal as indicated by the donor/Ti molar ratio. The copolymers produced during this process, as well as their various properties and reaction conditions for producing them, are described in table 3 below.

As shown in table 3, the amount of dicyclopentyldimethoxysilane required to make a copolymer with the desired softening point and penetration was different from the amount of cyclohexylmethyldimethoxysilane required as shown in example 2 above. As demonstrated by comparing samples C1 and C2, dicyclopentyldimethoxysilane levels typically need to be 2:1 or greater to achieve the desired properties in the resulting copolymer. It was also observed that the copolymers made using dicyclopentyldimethoxysilane generally had much lower softening points than the copolymers made using cyclohexylmethyldimethoxysilane. In addition, the copolymers made using dicyclopentyldimethoxysilane were able to maintain the desired penetration values.

Comparing samples 3C and 3F in table 3 shows that increasing the dicyclopentyldimethoxysilane level from 3:1 to 4:1 (at 17.5% ethylene flow) results in more ethylene being incorporated into the polymer, thereby producing a copolymer with a lower softening point.

Another noteworthy result was observed when comparing samples 3D and 3F, both made with the same ethylene stream (13%) and having the same penetration (21 dmm). However, by increasing the dicyclopentyldimethoxysilane level from 2:1 to 3:1, sample 3F surprisingly had an increased ethylene content (24.2%) compared to sample 3D (18.2%). This increased amount of ethylene resulted in a lower softening point for sample 3F. Further, the propylene portion of sample 3F is theoretically more stereoregular (i.e., harder) than sample 3D, thereby offsetting the softness that is normally associated with higher ethylene content.

Example 4

Adhesives were made using samples 1B, 1E and 1F from example 1. The adhesive was made in pint size cans using mechanical agitation with a paddle agitator controlled by a variable speed motor with a heating block set at 177 ℃. The copolymer and antioxidant were introduced into pint size cans under a nitrogen blanket and heated to 177 ℃. The resin and oil are then introduced into the mixture after the copolymer has melted. In some cases, waxes may also be added with or in place of the resin and/or oil. The mixture was stirred for 30 minutes until it was completely homogeneous. After thorough mixing, the adhesive was poured into a silicone lined cardboard box and allowed to cool. Table 4 below describes the composition and properties of these adhesives. In addition, INFUSE was used^TM9807 Block copolymer (Dow) and Kraton D1102 copolymer (Kraton) make comparative adhesives. It should be noted that the constituent components listed in table 4 are based on weight percentage.

TABLE 4

Material	Comparative adhesive	1	Comparative adhesive 2	Adhesive 1 according to the invention	Hair brushClear adhesive 2	Adhesive 3 according to the invention
							INFUSE^TM 9807	20
Kraton^® D1102		19.7
						Copolymer sample 1B			40
Copolymer sample 1E				40
						Copolymer sample 1F					40
Regalite^TM S5100		59.7
						Regalite^TM R1090	54		48.5	48.5	48.5
Kaydol mineral oil			10.5	10.5	10.5
						Calsol5550 oil	25	19.6
Irganox ^® 1010	1	1	1	1	1
						Total of	100	100	100	100	100
Peel strength 300 mm (g/mm)	13.1	14.6	2.3	21.5	13.3
						"viscosity 177 ℃ (cps)	~1800	~1400	806	2167	940

The viscoelastic characteristics of comparative adhesive 1, comparative adhesive 2, inventive adhesive 2, and inventive adhesive 3 in table 4 were analyzed using dynamic mechanical analysis ("DMA"). Fig. 2 depicts the viscoelastic characteristics of these adhesives. The adhesives in table 4 were also tested as disposable diaper construction adhesives and evaluated for adhesive peel strength using an Instron as measured according to ASTM D903 after applying the adhesive between a nonwoven fabric and a polyethylene backing using an air assisted spiral spray apparatus (Acumeter spray).

Based on fig. 2 and table 4, the adhesives of the present invention exhibit viscoelastic characteristics similar to adhesives made from commercially available copolymers. In addition, the adhesives of the present invention also exhibit excellent strength as shown by the higher peel strength.

Example 5

A pressure sensitive adhesive for labels was made using the method described in example 4. An adhesive was made using sample 1E from example 1. Table 5 below describes the composition of the adhesive.

TABLE 5

Adhesive of the invention	By weight%
		Copolymer sample 1E	60
Eastotac^TM H100W	29.5
		Calsol 5550	9.5
Antioxidant agent	1

The viscoelastic characteristics of the adhesive were measured using DMA and are depicted in fig. 3. The adhesive peel (90 ° peel) strength and loop tack force of the adhesive were also evaluated using an Instron after the adhesive was coated directly onto kraft paper using a hot melt knife coater. The adhesive had a 90 peel strength of 0.6 lbf/inch and a loop tack of 1.8 lbf.

Thus, the adhesive can be used as a label adhesive because it exhibits desirable viscoelastic characteristics and desirable adhesive peel and tack properties as shown in fig. 3.

Example 6

A hot melt adhesive for packaging applications was made using the method described in example 4. All adhesives made in this example contained 39.8 wt% of the corresponding propylene-ethylene copolymer, 39.8 wt% of Eastotac^TMH-100W hydrocarbon resin, 19.9 wt% Sasol H1 wax (Sasol), and 0.6 wt% antioxidant. It should be noted that some of these adhesives were formed from the copolymers (samples 1F and 2B) made and described in the previous examples, which are labeled in table 6 below. With respect to the remaining exemplified copolymers (samples 6A-6D), they were prepared according to the method described in example 1. Table 6 below provides various properties and characteristics of the adhesives produced. In addition, table 6 identifies the electron donors used to make the listed copolymers. These electron donors include cyclohexylmethyldimethoxysilane ("C"), dicyclopentyldimethoxysilane ("D"), and tetraethoxysilane ("TEOS"). The adhesive was evaluated for various adhesive properties, such as peel failure temperature ("PAFT") (ASTM D4498), shear failure temperature ("SAFT") (ASTM D4498),% fiber tear (ASTM D4498), andopen time/cure time (astm d 4497).

TABLE 6

。

It should be noted that the adhesive made with sample 6D did not have any significant fiber tear due to its low penetration as shown in table 6.

In FIG. 4, the adhesive made from sample 1F (labeled "inventive adhesive 5") is compared to the adhesive made from Affinity^TMViscoelastic characteristics of adhesives made by GA1950 (Dow). The comparative adhesives were made based on the same formulation used to make the adhesives in table 6. This comparative adhesive is listed as "comparative adhesive 3" in fig. 6. It is also noted that the comparative adhesive has a SAFT of 93.6/3.6 deg.C, a PAFT of 71.8/3.4 deg.C, an open/cure time of 15/5 seconds, and a Brookfield viscosity of 177 cps at 177 deg.C. As shown in fig. 4 and table 6, the adhesives of the present invention exhibit desirable viscoelastic characteristics and adhesive properties comparable to standard adhesives in the industry.

Example 7

The propylene-ethylene copolymer of the present invention and various polymers are used to manufacture a hot melt adhesive for nonwoven fabrics. The propylene-ethylene copolymers used to make these adhesive samples were made according to the method described in example 1. Various properties and characteristics of the copolymers used to make the adhesive samples are listed in table 7 below. In addition, table 7 shows the electron donor (cyclohexylmethyldimethoxysilane ("C") or dicyclopentyldimethoxysilane ("D")) used to make the corresponding copolymer.

TABLE 7

Copolymer samples	7A	7B	7C	7D
					Viscosity @ 190 ℃ cP	2520	2960	2590	7363
Softening Point (. degree. C.)	137.5	139.4	134.1	116.1
					Penetration (dmm)	14	15	14	27
Weight% ethylene	11.7	11.9	11.3	19.3
					Weight% propylene	88.3	88.1	88.7	80.7
Electron donors	D	C	C	D

An adhesive was made according to the method described in example 4. The adhesives are made with various polymers and additives including Vistamaxx^TM6202（ExxonMobil）、Infuse^TM9807（Dow）、L-MODU S400（Idemitsu）、Kraton^®1102（Kraton）、Kraton^®1161（Kraton）、Kraton^®1657（Kraton）、Regalite^TMR1090 (Eastman Chemical), Kaydol mineral oil (Sonneborn), and Irganox^®1010 (BASF). The brookfield viscosity and peel strength of the adhesives produced were measured as described above. Table 8 below describes the composition and properties of these adhesives of the present invention (which are labeled as "IA"). It should be noted that the compositional components listed in table 8 are all based on weight percent, and all components add up to 100%; however, this did not include 1% antioxidant (Irganox)^®1010) It is added after combining all other components. The weight percent of antioxidant is calculated separately from the combined weight percent of the other components.

TABLE 8

。

As shown in table 8, the adhesives of the present invention exhibit desirable adhesive properties comparable to standard adhesives in the industry.

Example 8

The propylene-ethylene copolymers of the present invention described in table 9 were used to make hot melt adhesives for hygiene applications. The copolymer was made according to the method described in example 1 using dicyclopentyldimethoxysilane as electron donor.

TABLE 9

Copolymer samples	8A	8B	8C
				Viscosity @ 190 ℃ cP	20000	16000	2200
Softening Point (. degree. C.)	135	125	133
				Penetration (dmm)	22	17	20
Weight% ethylene	22	22	22
				Weight% propylene	78	78	78

According to the description in example 4The method of (1) producing the adhesive. The adhesive is made with various additives including Eastotac^TMH-100W（Eastman Chemical）、Regalite^TMR1090 (Eastman Chemical), Kaydol mineral oil (Sonneborn), and Irganox^®1010 (BASF). Table 10 below describes the composition and properties of these adhesives of the present invention (which are labeled as "IA"). It should be noted that the constituent components listed in table 10 are based on weight percentage.

As shown in table 10, coatability, sprayability, and adhesive performance of the adhesives of the invention were compared to adhesives containing commercially available styrenic block copolymers ("SBC") and commercially available olefin-based copolymers. The coating/spray analysis was performed using an Acumeterand Nordson CF nozzle at two different temperatures (137 ℃ and 163 ℃) at 800, 600 and 400 ft/min (6 gsm at 350 ft/min for 3 samples) at different addition levels (2, 3 and 4 gsm). The test substrates were 1 mil polyethylene and 15 gsm spunbond nonwoven. Sprayability was observed and marked as "good", "poor" or "none" (i.e., non-sprayable) after observing the spray of the adhesive at the specified temperature. The brookfield viscosity, softening point, penetration, and peel strength of the prepared adhesive were also measured as described above. The width of the adhesive samples used for testing peel strength was 15 to 20 mm.

Watch 10

Adhesive agent	IA1	IA2	IA3	IA4	IA5	IA6	IA7	Commercial base In SBC	Commercial base In olefins
										Sample 8A
	40	40	40	60
										Sample 8B					40	60
Sample 8C							70
										Eastotac^TM H- 100W			48.5
Regalite^TM R1090	48.5	48.8		34.5	48.5	34.5	29
										Mineral oil	10.5	10.5	10.5	4.5	10.5	4.5
Irganox ^® 1010	1	1	1	1	1	1	1
										Brookfield viscosity 190 ℃ (cps)	1688	2133	2760	6425	1515	5300	913	N/A	N/A
Of samples at 137 deg.C Peel strength (g)	N/A	172	143	136	111	84	49	N/A	N/A
										Of samples at 163 ℃ Peel strength (g)	130	136	122	116	117.7	60	50	101	137
137℃/163℃ Sprayability under	Well or- Good effect	Well or- Good effect	Well or- Good effect	Well or- Good effect	Well or- Good effect	Well or- Good effect	Well or- Good effect	Poor/good Good taste	No/difference
										Softening Point (. degree. C.)	120.4	113.3	115.9	125.2	106.7	114.8	123.7	N/A	N/A
Penetration (dmm)	55	51	43	32	38	26	28	N/A	N/A

It should be noted that the peel strength test of the 137 ℃ samples was unproductive for the two comparative commercial adhesives, due to the poor sprayability of these adhesives. As shown in table 10, the adhesives of the present invention exhibit desirable coatability and sprayability at low and high temperatures, thereby indicating a wide operating window. Furthermore, the adhesives of the present invention exhibit adhesive properties that may be comparable to or superior to standard adhesives in the industry.

Example 9

Hot melt adhesives for packaging applications were made using the propylene-ethylene copolymers of the present invention described in table 11. Further, as shown in table 11, comparative adhesives were made from comparative propylene homopolymer ("CPH"). The copolymers used to make these adhesive samples were made according to the method described in example 1. In addition, table 11 also shows the electron donor (cyclohexylmethyldimethoxysilane ("C") or dicyclopentyldimethoxysilane ("D")) used to make the copolymer.

TABLE 11

Copolymer samples	CPH	9A	9B
				Viscosity @ 190 ℃ cP	1028	3165	2520
Softening Point (. degree. C.)	135	132.1	137.5
				Penetration (dmm)	22	12	14
Weight% ethylene	0	9.9	16.7
				Weight% propylene	100	90.1	83.3
Electron donors	C	C	D

An adhesive was made according to the method described in example 4. The adhesive is produced with various additives including Eastotac^TMH-100W（Eastman Chemical）、Eastotac^TMH-130W (Eastman chemical), Sasol wax H-1 (Sasol) and Irganox^®1010 (BASF). Table 12 below describes the composition and properties of the inventive binder, labeled "IA", and a comparative binder ("CA"). It should be noted that the constituent components listed in table 12 are based on weight percentage. The initial viscosity of the adhesive was measured at 162 ℃ and 177 ℃, as well as the SAFT, PAFT and open/cure time. SAFT measurements were made to understand the shear strength of the adhesive in the temperature zone in the SAFT furnace. A viscosity profile of the adhesive was generated to determine processability characteristics. In addition, the initial gardner color before aging and the adhesive clarity at 177 ℃ were also measured and observed.

TABLE 12

Adhesive agent	CA1	CA2	IA1	IA2	IA3
						CPH	39.8	59.8
Sample 9A			39.8	59.8
						Sample 9B					39.8
Eastotac^TM H-100W					39.8
						Eastotac^TM H-130W	39.8	19.8	39.8	19.8
Sasol wax H-1	19.8	19.8	19.8	19.8	19.8
						Irganox ^® 1010	0.6	0.6	0.6	0.6	0.6
Brookfield viscosity 162 deg.C (cps)	465	750	3250	9062	575
						Brookfield viscosity 177 ℃ (cps)	330	545	2192	6366	417
Open/set time(s)	20/10	N/A	15/10	15/10	N/A
						PAFT（℃）	77.4 (4.7)	43.3 (3.8)	83.6 (2.6)	54.9 (9)	63 (2)
SAFT（℃）	108.6 (5)	199.6(2.5)	120.3(0.4)	136.5(0.4)	101 (2)
						Gardner color (initial)	2	4	5	6	1
Adhesive clarity (177 ℃ C.)	Clarification	Clarification	Turbidity	Turbidity	Clarification

As shown in table 12, the adhesives of the present invention exhibited adhesive properties that were comparable or superior to those made from propylene. The adhesives of the invention may exhibit desirable clarity and color, as well as desirable processability as indicated by their viscosity.

Example 10

Hot melt adhesives for packaging applications were made using the propylene-ethylene copolymers of the present invention described in table 13. Furthermore, by Affinity^TMGA1950 (Dow) and a comparative polymer ("CP") as described in table 13 made a comparative adhesive. The copolymers used to make these adhesive samples were made according to the method described in example 1. In addition, table 13 also shows the electron donor used to make the copolymer.

Watch 13

Copolymer samples	CP1	CP2	CP3	10A	10B
						Viscosity @ 190 ℃ cP	8350	8812	29950	7825	19975
Softening Point (. degree. C.)	157.5	155.8	157.3	111.9	107.7
						Penetration (dmm)	7	9	1	29	37
Weight% ethylene	0	0	6.2	22.8	27.9
						Weight% propylene	100	100	93.8	97.2	92.1
Electron donors	Is free of	Is free of	Anisole	D	D

An adhesive was made according to the method described in example 4. The adhesive is produced with various additives including Regalite^TMR1090（Eastman Chemical）、Escorez^®5300（Exxonmobil）、Piccotac^TM1095（Eastman Chemical）、Piccotac^TM7590 (Eastman Chemical), Sasol wax H-1 (Sasol) and Irganox^®1010 (BASF). Table 14 below describes the composition and properties of the inventive binder (labeled "IA") and the comparative binder (labeled "CA"). It should be noted that the compositional components listed in table 14 are based on weight percent, and all components add up to 100%; however, this did not include 1% antioxidant (Irganox)^®1010) It is added after combining all other components. The weight percent of antioxidant is calculated separately from the combined weight percent of the other components.

The initial viscosity of the adhesive as well as the SAFT, PAFT and open/cure time were measured at 150 ℃, 162 ℃ and 177 ℃. A viscosity profile of the adhesive was generated to determine the processability characteristics of the adhesive. SAFT measurements were made to understand the shear strength of the adhesive in the temperature zone in the SAFT furnace. In addition, the transparency of the adhesive at 177 ℃ was also observed.

As shown in table 14, the adhesives of the present invention exhibited adhesive properties comparable to or superior to those of ordinary adhesives in the industry. The adhesives of the invention can exhibit the desired clarity and desirable processability as indicated by their viscosity. Furthermore, as shown in table 14, the adhesives of the present invention can exhibit excellent adhesive properties.

Example 11

The propylene-ethylene copolymer of the present invention (sample 7D from example 7) was used to make hot melt pressure sensitive adhesives for tapes and labels. An adhesive was made according to the method described in example 4. Vistamaxx for adhesive^TM6202（Exxonmobil）、Kraton^®1162（Kraton）、Kraton^®1657（Kraton）、Regalite^TMR1090 (Eastman Chemical), Kaydol mineral oil (Sonneborn), and Irganox^®1010 (BASF). The composition and properties of the adhesives of the present invention are described in table 15 below. It should be noted that the compositional components listed in table 15 are based on weight percent. The probe tack (kg) of the adhesive was measured according to ASTM D9279 and the retention (hours) was measured according to ASTM D3654.

Watch 15

。

As shown in table 15, the adhesives of the present invention exhibited adhesive properties comparable to or superior to those of common adhesives in the industry.

Example 12

Polymer blends were made to observe the effect of certain polymers on a particular blend. In this example, a commercial propylene homopolymer (Exxon) is compared^TMPP 3155) with the propylene homopolymer prepared according to example 1. The propylene homopolymer was made without electron donor ("sample 12A") and had a softening point of 157.5 ℃ and a penetration of 7 dmm. The two homopolymers are separately reacted with Kraton^®G1650（Kraton）、Kraton^®G1651（Kraton）、CaCO₃、Drakeol^®34 oil (Calumet Specialty Products) and Kristalex^TM5140 (Eastman Chemical) to make polymer blends. The composition and properties of these polymer blends are described in table 16 below. It should be noted that all composition values in table 16 are based on weight percent.

In addition, various properties of the polymer blends were measured as shown in table 16. The tested properties included Shore A hardness (ASTM D2240), melt flow rate (ASTM D1238), tear strength (ASTM D624), 100% modulus (ASTM D412), 200% modulus (ASTM D412), 300% modulus (ASTM D412), elongation at break (ASTM D412), tensile strength (ASTM D412), and Young's modulus (ASTM E111-04).

TABLE 16

。

As shown above, non-commercially available homopolymers made using the above process can improve the polymer blend in a similar manner to commercially available homopolymers.

The inventors hereby state their intent to rely on the doctrine of equivalents to determine and assess the reasonably fair scope of the present invention as pertains to any apparatus not materially departing from but outside the literal scope of the invention as set forth in the following claims.

The preferred forms of the invention described above are to be used as illustration only, and should not be used in a limiting sense to interpret the scope of the present invention. Modifications to the exemplary embodiments described above may be readily made by those skilled in the art without departing from the spirit of the present invention.

Example 13

Hot melt adhesives for hygiene and packaging applications were made using the propylene-ethylene copolymers of the present invention described in table 17. The copolymers used to make these adhesive samples were made according to the method described in example 1. In addition, table 17 also shows the electron donors used to make the copolymers.

TABLE 17

Copolymer samples	13A	13B	13C	13D	13E	13F
							Viscosity @ 190 ℃ cP	1813	2063	16525	18400	19000	1840
Softening Point (. degree. C.)	133.5	130.6	110.4	115.9	117.4	132.7
							Penetration (dmm)	22.8	22.7	32.8	28.1	23.6	22.8
Weight% ethylene	16	16	22	21	20	16
							Weight% propylene	84	84	78	79	80	84
Electron donors	D	D	D	D	D	D

An adhesive was made according to the method described in example 4. The adhesive is produced with various additives including Regalite^TMR1090（Eastman Chemical）、Eastotac^TMH100W（Eastman Chemical）、Kaydol^®Mineral oil (Sonneborn), L icocene^®Wax (Clarient), Sasol wax H-1 (Sasol) and Irganox^®1010 (BASF). Tables 18 and 19 below describe the composition and properties of the adhesives of the present invention. Watch 18 includes a sanitary systemCommercially available adhesives of the present invention, and table 19 includes adhesives of the present invention that may be used for packaging. It should be noted that the constituent components listed in tables 18 and 19 are based on weight percent, and all components add up to 100%.

Table 18 above describes the composition and properties of the adhesives of the present invention, which are labeled IA1-IA 9. Comparative commercial binders were also analyzed and labeled as CA1-CA 4. CA1-CA3 used olefin-based polymers for adhesives in sanitary manufacture. CA4 is also a commercial binder using styrenic block copolymers for use in hygiene manufacturing. The hygienic adhesives prepared using the polymers of the present invention in table 18 show a wide operating window, excellent sprayability/coatability characteristics over a wide temperature range (270 ° F to 350 ° F), good bond peel at room temperature, body temperature and under aging conditions (high and room temperature), with 0.5 to 8.0 gsm add-on level variation, using a wide range of spray/coating techniques (signature, summit, CF, omega, intermittent, slit, etc.). The adhesives prepared using the polymers of the invention are also excellent in thermal stability, Gardner color and Brookfield viscosity stability, and the adhesives prepared using the polymers of the invention are transparent, colorless and odorless at room temperature.

The initial viscosities as well as the SAFT, PAFT,% fiber tear and open/cure times of the adhesives in table 19 were measured at 177 ℃. The aged viscosity of the adhesive is generated to determine the processability characteristics and long term aging stability of the adhesive. PAFT and SAFT measurements were made to understand the peel adhesion and shear strength of the adhesive in the temperature regime in the SAFT furnace. In addition, the initial and aged color in terms of gardner color were also measured.

Watch 19

。

Example 14

For this example, an adhesive containing the low molecular weight propylene-ethylene copolymer was prepared. The adhesive comprises 60% by weight of the low molecular weight ethylene/propylene copolymer and 40% by weight of Regalite^®1090 hydrocarbon resin (copolymer 60/40 of the invention).

21.91 kg (48.2 bs.) of the adhesive composition were prepared in a conical reactor equipped with an intermeshing helical agitator and distillation column. The composition of the adhesive composition is as follows:

(a) 12.71 kilograms (27.99 lbs.) of low molecular weight propylene-ethylene copolymer (59.5 wt%);

（b）Regalite^®1090 resin 8.98 kilograms (19.75 lbs.) (-39.5 wt%);

（c）Irganox^®0.22 kg (0.4925 lbs.) of 1010 antioxidant (-0.985 wt%); and

（d）Eastobrite^®kg (0.0025 lbs.) of optical brightener OB-10.0011 (0.005 wt%).

Prior to starting the batch, the vacuum header in the column is adjusted, and then the system temperature is set to 150 ℃ by circulating hot oil in the jacket of the distillation column, Isopar L and dry ice are charged into the cold trap, and actions are recorded on the production batch list, then the oil circulation in the distillation column is closed to maintain the temperature at 150 ℃³The following were charged to the reactor in the amounts indicated above under a nitrogen purge: (a) regalite (r)^®1090 a resin; (b) irganox^®1010 antioxidant; and (c) Eastobrite^®Fluorescent whitening agent OB-1.

The temperature of the heating oil is then raised to 190 ℃ to ensure that the adhesive composition temperature reaches a maximum temperature of 180 ℃. When the adhesive composition temperature reached 130 ℃, the stirrer was started and run forward at 25rpm for 6 minutes and reverse for 6 minutes. When the oil temperature reached 180 ℃, the low molecular weight copolymer (13.52 kg (29.75 lbs.) or 59.50% of the total formulation) was divided in two equal portions of 6.82 kilo-unitsGrams (15 lbs.) and 6.59 kilograms (14.75 lbs.) are added through the main port, respectively. After addition of each aliquot at 180 ℃, the mixture was stirred at 25rpm for 30 minutes. When the final aliquot of the copolymer was added, the mixture was stirred at 180 ℃ and 25rpm for 60 minutes, after which the hot melt adhesive composition was extruded through a plunger valve into a waxed box. By 30 ft³The system was purged with nitrogen/hr and the reactor was vented at 180 ℃ for 30 minutes. After a discharge hold time of 30 minutes, the binder composition temperature was reduced to 75 ℃ and the discharge of the reactor was continued.

Example 15

For this example, an adhesive comprising about 52% by weight of the low molecular weight propylene-ethylene copolymer of the present invention was prepared.

113.56 kilograms (250.14 lbs.) of adhesive composition were prepared in a cone reactor equipped with an intermeshing helical agitator and distillation column. The adhesive composition was as follows:

(a) low molecular weight copolymer of the invention-59.07 kg (130.12 lbs.) 52.0 wt%;

（b）Regalite^®1090 resin-51.08 kg (112.5 lbs.) 45.0 wt%;

（c）Sasol^®h1 wax-2.27 kg (5.0 lbs.) 2.0 wt%;

（d）Irganox ^®1010 antioxidant-1.13 kg (2.49 lbs.) 0.995 wt%; and

（e）Eastobrite^®0.005% by weight of optical brightener OB-10.0057 kg (0.0125 lbs.).

Prior to starting the batch, the vacuum header in the column is adjusted, and then the system temperature is set to 150 ℃ by circulating hot oil in the jacket of the distillation column, Isopar L and dry ice are charged into the cold trap, and actions are recorded on the production batch list, then the oil circulation in the distillation column is closed to maintain the temperature at 150 ℃³The ingredients listed below were charged to the reactor under a nitrogen purge.

Regalite^®1090 resin 51.14 kg (112.5 lbs.)

Sasol^®H1 wax 2.27 kg (5.0 lbs.)

Irganox

^®1010 antioxidant 1.14 kg (2.49 lbs.)

Eastobrite^®OB 10.0057 kg (0.0125 lbs.).

The temperature of the heating oil is then raised to 190 ℃ thereby ensuring that the adhesive composition temperature reaches a maximum temperature of 180 ℃. When the blend temperature reached 130 ℃, the stirrer was started and run forward at 25rpm for 6 minutes and reverse for 6 minutes. When the oil temperature reached 180 ℃, then low molecular weight copolymer (59.1 kg-130 lbs. -or 52.0% of the total formulation) was added in five aliquots (four each of 13.64 kg (30 lbs.) and the last 4.55 kg (10 lbs.)) through the main port. After each addition at 180 ℃, the mixture was stirred at 25rpm for 30 minutes. When the final aliquot of the low molecular weight copolymer was added, the mixture was stirred at 180 ℃ and 25rpm for 60 minutes, followed by extrusion of the hot melt adhesive through a plunger valve into a waxed box. The system was purged with 30 SCFH of nitrogen and the reactor was vented for 30 minutes at 180 ℃. After a discharge hold time of 30 minutes, the composition temperature was reduced to 75 ℃ and the discharge of the reactor was continued.

Example 16: preparation of a composition containing Aerfin ^®180 hot melt adhesive

27.27 kilograms (59.993 lbs.) of adhesive was prepared in a conical reactor equipped with a distillation column, before starting the batch, the vacuum header in the column was adjusted, and then the system temperature was set to 150 ℃ by circulating hot oil in the jacket of the distillation column, Isopar L and dry ice were charged into the cold trap, and actions were recorded on the production batch schedule.

At this point, the ingredients listed below were charged to the reactor under a nitrogen purge of 10 SCFH.

（a）Regalite^®1090 resin-12.68 kilograms (27.9 lbs.) 46.50 wt%;

（b）Kaydol^®mineral oil-2.86 kilograms (6.3 lbs.) 10.00 wt%;

（c）Sasol^®1.91 kilograms (4.2 lbs.) of H1 wax 7.00 wt%;

(d) irganox 1010 antioxidant 0.27 kg (0.59 lbs.) 0.983 wt%; and

（e）Eastobrite^®OB-10.0014 kg (0.003 lbs.) 0.005 wt%.

The temperature of the heating oil is then raised to 190 ℃ thereby ensuring that the adhesive composition temperature reaches a maximum temperature of 180 ℃. When the adhesive composition temperature reached 130 ℃, the stirrer was started and run forward at 25rpm for 6 minutes and reverse for 6 minutes. When the oil temperature reached 180 ℃, then Aerafin comparison was made^®180 copolymer (9.55 kg-21 lbs. -or 35% of the total formulation) was added in three aliquots of 7 lbs. through the main port. After each addition at 180 ℃, the mixture was stirred at 25rpm for 30 minutes. When the final aliquot of the copolymer was added, the mixture was stirred at 180 ℃ and 25rpm, and then the hot melt adhesive was extruded through a plunger valve into a waxed box. The system was purged with 30 SCFH of nitrogen and the reactor was vented for 30 minutes at 180 ℃. After a discharge hold time of 30 minutes, the polymer temperature was reduced to 75 ℃ and the discharge of the reactor was continued. The final composition of the adhesive was as follows:

comparison of Aerfin^®1809.55 kg (21 lbs.) 35.017%

Regalite^®1090 resin 12.68 kg (27.9 lbs.) 46.50%

Kaydol^®Mineral oil 2.86 kg (6.3 lbs.) 10.00%

Sasol^®H1 wax 1.91 kg (4.2 lbs.) 7.00%

Irganox

^®1010 antioxidants 0.27 kg (0.59 lbs.) 0.983%

Eastobrite^®Fluorescent whitening agent OB 10.0014 kg (0.003 lbs.) 0.005%。

The following test methods and sample preparation techniques were used to test the adhesives prepared and the copolymers used in examples 14-16.

Thermal property measurement

Thermal properties such as melting temperature and energy Mettler Toledo differential scanning calorimeter DSC2 STAR equipped with a 400 w furnace supply and a ceramic FRS2 High DSC sensor^eThe system (1900 Polaris Parkway, Columbus, OH, USA 43240) was evaluated. The instrument consists of a DSC STAR mounted on an HP Z230 workstation^eSoftware, version 13.00a (Build 6917) control. The software is also used for data processing.

Samples of 10-15 mg were placed in a 40 microliter aluminum crucible (model 1/3 ME 51119870, no nail pins (pins)), and then sealed with an aluminum lid (model 1/2ME 51119871).

The sealed crucible was placed in a DSC furnace and heated from room temperature to 200 ℃, held at 200 ℃ for 10 minutes, then cooled to-100 ℃, held at that temperature for 10 minutes, and heated again to 200 ℃. Finally, the sample was cooled from 200 ℃ to room temperature. The heating rate was 10 ℃/min and the cooling rate was-10 ℃/min. The thermograms of the heating and cooling phases were recorded. Melting and crystallizing, and energy of melting and crystallizing Using the DSC STAR^eThe software was evaluated from the data in the thermogram (second heating and first cooling).

Crystallinity by X-ray diffraction measurement

The crystallinity of the polymer was evaluated using a PANALYTICAL Empyrean XRD spectrometer (255555 th Street, Boulder, CO, USA 80301) equipped with an anode powered to 45 kilovolts and 40 milliamps to produce collimated monochromatic copper K α radiation that strikes the sample and produces a diffraction pattern in Bragg Brentano reflection geometry, the pattern was collected from a 5 degree 2 theta angle to a 90 degree 2 theta angle with a sampling width of 0.02 degrees and a step time of 160 seconds using a detector angle fixed at2 times the angle of incidence (theta-2 theta).

The samples were cut into approximately 1 inch squares of 3 to 6 mm thickness and then mounted flat on a fixed xyz stage with double-sided tape. The sample was exposed to an X-ray beam and the diffraction pattern was collected.

Peak deconvolution of X-ray diffraction patterns was performed using jadex Pattern Processing, Identification and Quantification software (version 9.5.0) from Materials Data Incorporated (MDI, &lttttransformation = L "&ttt/t &tttgitt vermore, California). evaluation of percent crystallinity was calculated based on deconvolution from 10 degrees 2 θ to 32 degrees 2 θ and integrated intensity of fitted diffraction peaks.

The low molecular weight copolymers of the present invention have a crystallinity of 25+/-2% as measured by X-ray diffraction versus Aerafin ^®180 copolymer has a crystallinity of 20 +/-2.

Rheological temperature scanning

The viscoelastic properties of the polymers were evaluated using a TA Instruments 400801 series/ARES G1 controlled by TA Orchester 4800-0026 (Firmware ARESV7.2.0.4) mounted on an HP Compaq computer. Parallel plate geometries of 8 or 25mm were used. The gap between the plates was 1 mm. When 8 mm plates were used, the following experimental settings were used: 5% maximum applied strain, 1,000 g-cm maximum torque, 30 g-cm minimum torque, 300% strain adjustment of the current strain, and 0.5% strain. In the case of using a 25mm plate, the conditions employed were 50% maximum applied strain, 100 g-cm maximum torque, 30 g-cm minimum torque, 30% strain adjustment of the current strain, and 5% strain.

For all runs, a temperature rate of 6 ℃/min, a frequency of 10 rad/s, and a temperature range of-80 ℃ to 170 ℃ were employed.

Viscoelastic properties determined using this method include storage and loss moduli (G' and G ") and tangents (tan). In addition, this technique enables the determination of the glass transition temperature (Tg) of the polymer.

FIGS. 5 and 6 show comparative Aerafin ^®180 copolymer and the low molecular weight copolymer of the present invention. It is more remarkable thatThe low molecular weight copolymers of the present invention exhibit two transition temperatures, the first at about-29.5 ℃ and the second at about 68.3 ℃, compared to Aerfin ^®180 copolymers show only one transition at-31.5 ℃.

In addition, the low molecular weight copolymers of the present invention show comparative Aerafin ^®180 copolymer, which is characterized by a lower tan number. This is also highlighted by the high values of storage modulus G' shown at 25 ℃.

Rheology-capillary rheology-viscoelastic properties as a function of shear rate

Melt viscosity was measured using a Ceast SR20 Instron capillary rheometer at a shear rate of 10-30,0001/s. A 0.5 mm die was used to measure melt viscosity, pressure, fluid volume and fluid velocity as a function of shear rate at 140 ℃. A sample size of 20-30 grams is required for the measurement.

As shown in fig. 7, the low molecular weight copolymers of the present invention are relatively newtonian over a wide range of shear rates. The low flow resistance of the molten low molecular weight copolymer of the present invention makes it also easier to process and use in applications where high shear is typically encountered.

Determination of molecular weight

The samples were analyzed using a Malvern Viscotek HT-350A high temperature Gel permeation chromatograph equipped with 2 Viscotek VE1122 pumps (primary and secondary), a Viscotek Model 430 vortex heater stirrer autosampler, a VE7510 GPC degasser, an HTGPC Module 350A oven, a Microlab 500 series autoinjector for sample preparation, and a triple detection system consisting of a combination of laser light scattering, refractometer, and differential viscosity detectors GPC comprised of a P L Gel 5 micron 50 × 7.5.5 millimeter guard column and a2 × P L Gel 5 micron Mixed-C300 × 7.5.5 millimeter column operating at a flow rate of 0.7 ml/min at 135 ℃ using 1,2, 4-trichlorobenzene as the solvent, the instrument being controlled by Malvern Omni SEC software.

50 to 70 mg of each sample was weighed into a sample vial and mixed with 10 ml of 1,2, 4-trichlorobenzene to prepare a blend of approximately 5.0 to 7.0 mg/ml. The vial was placed in a viscotek model 430 vortex heater stirrer autosampler with a magnetic stir bar under stirring to equilibrate at room temperature for approximately 1 hour, and then the sample was heated at 135 ℃ for no more than 4 hours.

Analysis of results

For each sample, two injections were used and the chromatogram for each injection was collected. Samples were analyzed by conventional GPC calibrated using a single narrow polystyrene standard, light scattering, triple detection, and universal calibration. The same Malvern OmniSEC software was used to perform the analysis of the light scattering data, conventional GPC analysis, triple detection analysis, and universal calibration analysis. The weight average molecular weight (Mw), number average molecular weight (Mn) and Z average molecular weight (Mz) were determined for each sample using malvern omnisec software.

The weight average molecular weight (Mw), number average molecular weight (Mn), Z average molecular weight (Mz), polydispersity index (Mw/Mn) were determined for each sample.

Effect of molecular weight polydispersity on Hot melt adhesive Properties

The Mn, Mw, Mz, and Mw/Mn for each sample are shown in Table 20 provided below. For the purpose of statistical design of the experiment, the molecular weights expressed as Mw/Mn were encoded as design unit values of-1, -0.5, 0, 0.5 and 1 (F: molecular weight).

Watch 20

Sample (I)	Mn	Mw	Mz	Mw/Mn	F molecular weight
						A	2,968	29,017	96,653	9.78	-1.00
B	1,453	32,145	107,283	22.12	-0.50
						C	4,035	32,794	105,378	8.13	0.00
D	10,471	41,001	112,471	3.92	0.50
						E	2,306	40,523	130,662	17.57	1.00

FIG. 8 shows the layout of the molecular weights at five general levels in the design unit values (F: molecular weight) of-1, -0.5, 0, 0.5 and 1 and forty (40) sets of runs in the design.

The fully extended DOE included 153 runs, resulting in laminate samples for which peel strength was determined and then correlated with molecular weight. In addition, this run was used in statistical analysis to define optimized formulations.

The results of evaluation of the peel strength properties of the adhesive compositions prepared using the ethylene-propylene copolymers of various molecular weight distributions are shown in fig. 9.

Samples of polymers with molecular weight codes of-1, 0 and 1, which correspond to polydispersity indices of 8 to 18, provide peel strengths of greater than 160 grams/25 millimeters. The highest peel was obtained for the polymer sample with a polydispersity index of 18.

When Regalite^®When R1090 hydrocarbon resin is used with the low molecular weight copolymers of this invention, the optimum formulation is defined as a composition that does not contain mineral oil. In this case, the properties of the hot-melt adhesives based on the copolymers of the invention are independent of the molecular weight.

The peel strength values as a function of polymer content in the various formulations are shown in fig. 10.

Details regarding the optimal composition of the hot melt adhesive are provided in table 21 below.

TABLE 21

Material	By weight%	Batch weight (lbs.)
			Low molecular weight copolymers of the invention	52.700	527
Regalite^®R1090 hydrocarbon resin	45.000	450
			Sasol^®H-1 wax	2.000	20
Irganox ^®1010 antioxidant	0.295	2.95
			Eastobrite^®OB-1 fluorescent whitening agent	0.005	0.05
Total of	100.00	1000.00

Evaluation of adhesive peel bond Strength

Various adhesives are applied between the polyethylene film and the nonwoven fabric to make the laminate. Then, the laminate was debonded (debonded) with a tensile tester and the force exerted to separate the layers was measured as the peel bond strength. Details of applying the adhesive to a substrate, preparing a laminate, and measuring peel strength are provided below.

The adhesives were evaluated using a Nordson CT L4600 series hot melt coater (Nordson Corporation, 11475L akefield Drive, Duluth, GA 30097, USA) equipped with a Nordson adhesive applicator the applicator was connected by a heat insulation hose to the adhesive melt tank of the Nordson ProBlue 50 Filter.

Two types of applicators are used. They include the Nordson universal Modules and Nordson Slot Die systems with four spray nozzles mounted thereon.

Two sets of nozzles operating in continuous and batch modes, respectively, were selected for evaluation of the hot melt adhesives. Continuous spray nozzles include the Universal Signature Standard (model 1072290) and the Universal Signature Low flow (model 1095242). Nozzles for the intermittent spray process include Universal Signature standard intervals (model 1088478A) and Universal Signature low flow intervals (model 1088478). Dual-action spray nozzles-continuous and batch-Universal Summit 3 orifice (model 1033006) were also used.

Slot die systems include continuous (model 784088) and batch (model C25017897) applicators.

Samples for peel strength evaluation were made by laminating a five inch wide polyethylene film to a five inch wide nonwoven fabric using a related liquid hot melt adhesive.

The polyethylene film is a Clopay Microflex^®Film, DH284 PE White 360, 0.001 "× 5" (1 mil thick White Film) available from Clopay plastics Products Company, 531 East Fourth street, Augusta, KY nonwoven is Unipro distributed by Midwest Filtration, 9775 International Boulevard, Cincinnati, OH^®45，15 g/m²(or 0.45 oz./yd²) A spunbond polypropylene fabric.

The solid adhesive was placed in a ProBlue melt tank and heated to the target temperature to obtain a homogeneous liquid. The target temperatures selected were 120, 130, 140, 145, 150 and 160 ℃. The molten adhesive is then pumped from the melting tank through a heated insulated hose to a spray module and nozzle for deposition onto polyethylene film, moving at a speed of 400 or 600 m/min, the amount of adhesive corresponding to a preselected addition (1, 2 or 3 grams/meter)²). Then, it was moved at the same speed as the polyethylene filmThe moving nonwoven is in contact with the polyethylene film on the side with the adhesive layer. The assembly is run through a pinch nip (or gap) between the S-wrap and two (steel and rubber) rollers to contact the substrate and adhere them to each other. The laminate thus produced is wound into a roll. At the end of the process, the machine is stopped and samples (in the form of bundles of short laminates or labels) are collected from the roll by cutting into sheets and saved for subsequent peel strength evaluation.

This process was repeated for each adhesive and set of operating conditions to produce various samples for peel strength evaluation.

The coater rewinder wrap rolls and pinch clamps were operated at 21 to 25 and 30 psi gauge pressure, respectively.

The adhesive strength between the layers in the laminates of the various samples was measured as 180 degree peel strength using a Universal Tensile Tester at a crosshead speed of 30 mm/min. the instrument included a Chem Instruments addition Release Tester AR-1000 equipped with a 22.24N (5 lbf) load cell and an MTS Criterion Universal Test model C43-104e on which a 500N (112 lbf) load cell (model L PB 502) was mounted.

The test was performed in the following manner. The samples made from the several laminates of each sample were adjusted according to the type of information to be collected. Immediate peel strength was measured within 5 minutes of laminate preparation, with no special sample conditioning, and 24 hour and 1 month peel strength was evaluated on samples conditioned at 50% RH and 25 ℃ for 24 hours and 1 month, respectively. Both sets of samples were conditioned at 38 ℃ (for 4 hours) and 49 ℃ (for 2 weeks) to generate peel strength data for 4 hours and 2 weeks, respectively.

After conditioning, one end of the laminate was detached by peeling to separate the two layers by a length of about 50 mm. The ends of each layer were then clamped in two test grips initially positioned at 75 mm of each other. The laminate was then peeled at a speed of 300 mm/min for a length of 100 mm and the instantaneous force applied to separate the layers was measured continuously, stored in a computer and then processed to determine the average of the readings. Six individual specimens obtained from each sample were thus tested, and the average of the peel adhesion strengths of all six specimens was calculated and reported as the peel strength of the sample.

Comparative data on peel Strength compared to examples 14-16

FIGS. 11-20 are graphs showing comparative peel strength data for laminates bonded using a comparative Aerafin 180 copolymer, inventive copolymer 60/40, and inventive copolymer 52/45, as well as a commercially available rubber-based hot melt adhesive. Peel strength relates to laminates exposed to various conditioned environments as described above in the peel strength measurement procedure.

Hot melt adhesives prepared using the low molecular weight propylene-ethylene copolymers of the present invention produce high peel strength laminates over the entire application temperature range. Furthermore, the peel value is relatively constant over a wide spray temperature range. The consistency of peel strength provides a great commercial advantage to the user of hot melt adhesives based on the low molecular weight propylene-ethylene copolymers of the present invention, because the adhesives provide a consistent high quality finished product when laminated with the adhesives of the present invention, regardless of the temperature used during the manufacturing process of the article.

At the same addition level, the low molecular weight propylene-ethylene copolymers of the invention provide a significantly higher level of improvement than the use of comparative Aerafin ^®180 copolymer, peel strength. Furthermore, at a given application temperature below 152 ℃, the hot-melt adhesive based on the low molecular weight propylene-ethylene copolymer of the invention offers the possibility of saving expenses for the user, since the application of only a small amount of adhesive can be produced similarly to when using a hot-melt adhesive based on the comparative Aerfin ^®180 copolymer and higher addition levels of hot melt adhesive.

Example 17

The adhesives were made in aluminum cans with mechanical agitation using a paddle mixer controlled by a variable speed motor with a heating mantle set at 177 ℃ one or more propylene-ethylene copolymers, one or more polypropylene (co) polymers, tackifying resin, wax and antioxidant were introduced into the cans under a nitrogen blanket and heated to 177 ℃.

The viscosity of the adhesive was measured using a standard brookfield viscometer equipped with a Thermosel. The measurements were made 30 minutes after the composition had melted.

The laminate section was 1 "× 1" × 10 mils adhesive thickness using a standard US PAFT (peel failure temperature) method with a 60 # kraft paper for a 100 gram peel.

The laminate was then laminated to an adhesive thickness of 1 "× 1" × 10 mils using 60 # kraft paper for 500 grams of shear according to ASTM D4498-SAFT (shear failure temperature) method.

Open time was evaluated according to ASTM D4497.

The adhesion test to the corrugated board was performed by hand bonding and then leaving the adhesive standing at room temperature for at least 12 hours. The adhesive pieces were then placed in a conditioning chamber at the indicated temperature and stood on edge for at least 24 hours. The bonds were evaluated by tearing them apart at the conditioning temperature and reading the percentage of adhesive area covered by the paper fibers. The freezer temperature was 4 ℃.

Tables 22 and 23 provide the formulations and various measured properties of the various adhesives. It should be noted that all adhesives contained 0.5 wt.% of Irganox 1010.

TABLE 22

。

TABLE 23

Excellent = 80-100% fiber tear; good = 50-79% fiber tear; weak = 20-49% fiber tear; failure =0-19% fiber tear.

Speed 1-5, where 1 = fast.

As shown in tables 22 and 23, a low molecular weight polymer containing Aerafin of the present invention was produced^®17 and the high molecular weight polymer Aerafin of the invention ^®180 with various waxes and polymers. The "target" adhesion value is from a commercially available adhesive (HB FullerAdvantra PHC 9256) based on ethylene-octene copolymers produced using metallocene catalysts ("mPE").

Samples 1 and 2 show that the use of waxes commonly used in EVA and ethylene-octene (mPE) packaging adhesives in the usual amounts results in stiff, brittle and brittle compositions with little mechanical integrity. Samples 5-8 produced clear, flexible compositions with excellent room temperature adhesion to corrugated board. Unexpectedly,

samples

5, 6 and 8 had shear failure temperature (SAFT) performance 27.6%, 34% and 33% higher than the target values, respectively. Surprisingly, high SAFT values are combined with acceptable cure times on commercial packaging lines.

In addition, the flexibility and elasticity of the formulation, particularly F7 comprising Aerafin polymers and Vistamaxx 8880 polymers (an isotactic metallocene-catalyzed propylene/ethylene copolymer), show potential advantages for elastic attachment adhesives for disposable hygiene articles such as diapers, feminine pads and adult incontinence articles.

Example 18

A hot melt adhesive of the invention for packaging applications was made using the method described in example 17, the composition (wt%) and properties of which are listed in Table 24. the adhesive was made with various polypropylene additives including L icocene ™ PP 6102, a metallocene catalyzed polypropylene polymer wax having high crystallinity, L icocene PP1302, a metallocene catalyzed propylene-ethylene polymer wax having low crystallinity, both available from Clariant International L td, (Muttenz, Switzerland), Epolene @ N-15 (Westlake) and A-C596, a propylene maleic anhydride copolymer wax (Honeywell). for comparison, a second commercially available adhesive FT6 was tested, which is based on a metallocene catalyzed ethylene-octene polymer (mPE).

Samples FT2 and FT3 comprising the propylene-ethylene copolymer of the present invention and polypropylene polymer/wax unexpectedly exhibited a combination of viscosity at 177 ℃ and an increase in SAFT value of over 34% and 19% with about 800-1800 cp and improved adhesion (percent fiber tear) at-7 ℃ and-15 ℃ as compared to the commercial comparative adhesive FT 6.

Watch 24

。

Example 19

Assembly adhesives AF3, AF4 and AF5 were prepared by adding tackifier, oil and antioxidant to metal containers and heating the mixture to 180 ℃ according to the weight percentages given in table 27. The mixture was melted, stirred, and then propylene-ethylene copolymers Aerafin 180, Vestoplast 703, propylene-ethylene-butene terpolymers with short open times, Vestoplast 792, propylene-ethylene-butene terpolymers with long open times and/or Eastoflex polymers of the invention were added. The mixture was continued to be mixed until it was completely melted. Degassing is performed when it is necessary to remove air bubbles trapped in the adhesive. Brookfield viscosity and Ring and Ball Softening Point (RBSP) were measured as described previously. It should be noted that the compositional components listed in table 27 are all based on weight percent, and all components add up to 100%; however, this did not include 0.3% antioxidant (Irganox 1010), which was added after combining all the other components. The weight percent of antioxidant is calculated separately from the combined weight percent of the other components.

The adhesive was hand coated as a pressure sensitive adhesive onto one mil PET film at 180 ℃ using a doctor blade with a 50 micron gap. The adhesive coated PET was applied to a Stainless Steel (SS) coupon and tested for 180 ° peel strength using an Instron 5543 at 300 mm/min according to standard method PSTC-101.

The open time of the adhesive was determined manually by pouring the adhesive in about 3 g/inch bead strings at 180 ℃ onto a nonwoven substrate WYPA L X60 from Kimberly-Clark, applying a second nonwoven to the adhesive beads with finger pressure and slowly peeling the second nonwoven until the adhesive no longer adhered to the second nonwoven substrate, and then recording this time as open time.

Watch 27

Components	AF3	AF4	AF5	--
					Vestoplast™ 703	40	20	0	--
Vestoplast™ 792	15	15	0	--
					Propylene-ethylene copolymer Aerafin 180	0	15	38	--
Eastoflex™ 1023	0	0	9.5	--
					Regalite™ R1100	40	40	43	--
KN4010 oil	10	10	9.5	--
					Adhesive testing	AF3	AF4	AF5	Target
Viscosity at 180 ℃ (cP)	2112	3150	2250	1500-3000
					RBSP (°C)	102	98	123	100-130
180 degree peel strength, SS (N/25mm)	60	61	41	Is unknown
					Open time, non-woven to non-woven (min)	>10	>10	Not tested	>10

Example 20

Adhesives were prepared and tested as described in example 17 above, and the compositions and adhesive properties are shown in tables 28 and 29. For comparison, a commercial packaging adhesive ("com. D") based on ethylene-octene copolymer (mPE) was tested. As shown by the percent fiber tear on corrugated board AT-18 ℃, when aeafin 180 and the low molecular weight copolymers of the invention were used with various resins and waxes, the adhesives of the invention AT2, AT3 and AT7 exhibited a surprising increase in low temperature adhesion compared to AT1 and com. The adhesives AT5 and AT6 of the invention have a polymer loading of 70 wt.% or more and less than 15 wt.% of tackifying resin, but surprisingly also have a fiber tear (low temperature adhesion) of 80-100%. In addition, surprisingly, the adhesives AT2 to AT7 of the invention have RBSP and SAFT values higher than com. D and excellent low temperature adhesion. The combination of propylene wax with ethylene wax demonstrates the ability to achieve cure times approaching com. D while improving low temperature adhesion, increasing SAFT and maintaining the 177 ℃ brookfield viscosity of the adhesive.

Watch 28

Material	AT1	AT2	AT3	AT4	AT5	AT6	AT7
								Low molecular weight copolymers of the invention	0	40	40	37	76	70	40
Propylene-ethylene copolymer Aerafin 180	40	10	10	8	0	0	15
								Eastotac™ H130W	0	30	30	35	0	10	10
Regalite™ R1100	0	0	0	0	14	0	0
								Regalite™ R1090	30	0	0	0	0	0	0
Polywax™ 3000	30	0	0	0	6	0	0
								Licocene™ PP6102	0	0	15	0	0	20	0
Licocene™ PP1302	0	0	0	5	0	0	0
								Epolene™ N-15	0	15	0	10	0	0	0
Polywax™ 850	0	0	0	0	0	0	20
								Polywax™ 500	0	0	0	0	0	0	10
Bareco™ 4040	0	0	0	0	0	0	5
								Sasolwax™ H-1	0	0	0	0	2	0	0
A-C™ 596	0	5	5	5	2	0	0

Watch 29

Adhesive Properties	AT1	AT2	AT3	AT4	AT5	AT6	AT7	Com. D
									RBSP (°C)	125	150	132	148	125	138	115	111
Viscosity at 177 ℃ (cP)	1715	1660	1098	1295	1200	1075	800	1000
									PAFT JAI, 300g, 0.5°C/min (°C)	41	65	59	60	34	Not tested	Not tested	68
SAFT JAI, 500g 0.5°C/min (°C)	80	113	108	105	99	Not tested	Not tested	87
									Open time(s)	10	30	>60	>60	30	35	15	10
Curing time(s)	10	15	25	25	15	15	30	10 = fast
									50 ℃ Retention, JAI Peel, 300g (min)	12	106	35	45	11	Not tested	Not tested	1200
Fiber tear at-18 ℃ (%)	>50	>80	>80	>50	>80	100	100	<50

Claims

1. An adhesive comprising at least one propylene-ethylene copolymer and at least one polyolefin, wherein the at least one propylene-ethylene copolymer comprises at least 10 wt.% ethylene and has a softening point of at least 99 ℃.

2. The adhesive of claim 1, wherein the at least one polyolefin is selected from the group consisting of amorphous polyolefins, semi-crystalline polyolefins, α -polyolefins, reactor-ready polyolefins, metallocene-catalyzed polyolefin polymers and elastomers, reactor-made thermoplastic polyolefin elastomers, olefin block copolymers, thermoplastic polyolefins, atactic polypropylene, polyethylene, ethylene-propylene polymers, propylene-hexene polymers, ethylene-butene polymers, ethylene-octene polymers, propylene-butene polymers, propylene-octene polymers, metallocene-catalyzed polypropylene polymers, metallocene-catalyzed polyethylene polymers, propylene-based terpolymers, including ethylene-propylene-butene terpolymers, copolymers made from propylene and linear or branched C4-C10 α -olefin monomers, copolymers made from ethylene and linear or branched C4-C10 α -olefin monomers, and functionalized polyolefins.

3. The adhesive of claim 1, wherein the at least one propylene-ethylene copolymer comprises from 12 to 40 weight percent ethylene.

4. The adhesive of claim 1, wherein the at least one propylene-ethylene copolymer has a softening point of 105 to 145 ℃.

5. The adhesive of claim 1, wherein the at least one propylene-ethylene copolymer has a penetration of from 8 to 75 dmm, measured according to ASTM D5.

6. The adhesive of claim 1, wherein the at least one propylene-ethylene copolymer has a crystallinity of less than 30% as determined using DSC according to ASTM E794-85 and a number average molecular weight (Mn) of less than 25,000 as determined by gel permeation chromatography.

7. The adhesive of claim 1, wherein the at least one propylene-ethylene copolymer has a brookfield viscosity at 190 ℃ of less than 30,000 cps measured according to ASTM D3236.

8. The adhesive of claim 1, wherein the at least one propylene-ethylene copolymer exhibits a glass transition temperature (Tg) of from-60 to 20 ℃.

9. The adhesive of claim 1, wherein the adhesive comprises:

(a) 5 to 95 weight percent of the at least one propylene-ethylene copolymer;

(b) 5 to 90 weight percent of the at least one polyolefin;

(c) up to 70 wt% of at least one tackifier;

(d) no more than 20 wt% of a processing oil; and

(e) not more than 30% by weight of at least one wax.

10. The adhesive of claim 1 wherein the adhesive has a brookfield viscosity at 177 ℃ of 800-5000 cP; and/or a shear failure temperature at least about 10 ℃ higher than an equivalent composition not comprising the at least one propylene polymer; and/or a greater percentage fiber tear on corrugated board at-15 ℃ than an equivalent composition not comprising the at least one propylene polymer.

11. The adhesive of claim 1, wherein the adhesive comprises:

(a) 10 to 70 weight percent of the at least one propylene-ethylene copolymer;

(b) 5 to 55 weight percent of the at least one polyolefin;

(c) up to 70 wt% of at least one tackifier;

(d) no more than 20 wt% of a processing oil; and

(e) not more than 20% by weight of at least one wax.

12. An adhesive comprising at least one propylene-ethylene copolymer and at least one polyolefin, wherein the at least one propylene-ethylene copolymer has a polydispersity of at least 3.

13. The adhesive of claim 12 wherein the at least one polyolefin is selected from the group consisting of amorphous polyolefins, semi-crystalline polyolefins, α -polyolefins, reactor-ready polyolefins, metallocene-catalyzed polyolefin polymers and elastomers, reactor-made thermoplastic polyolefin elastomers, olefin block copolymers, thermoplastic polyolefins, atactic polypropylene, polyethylene, ethylene-propylene polymers, propylene-hexene polymers, ethylene-butene polymers, ethylene-octene polymers, propylene-butene polymers, propylene-octene polymers, metallocene-catalyzed polypropylene polymers, metallocene-catalyzed polyethylene polymers, propylene-based terpolymers, including ethylene-propylene-butene terpolymers, copolymers made from propylene and linear or branched C4-C10 α -olefin monomers, copolymers made from ethylene and linear or branched C4-C10 α -olefin monomers, and functionalized polyolefins.

14. The adhesive of claim 12, wherein the at least one propylene-ethylene copolymer comprises 10 to 40 weight percent ethylene and has a softening point of 99 to 145 ℃.

15. The adhesive of claim 12, wherein the at least one polyolefin comprises an amorphous polyolefin having a heat of fusion of less than 25J/g and/or wherein the at least one propylene-ethylene copolymer has a brookfield viscosity at 190 ℃ of less than 30,000 cps measured according to ASTM D3236.

16. The adhesive of claim 12, wherein the at least one propylene-ethylene copolymer has a polydispersity of 3 to 25, a crystallinity of less than 30% as determined using DSC according to ASTM E794-85 and a number average molecular weight (Mn) of less than 20,000 as determined by gel permeation chromatography.

17. The adhesive of claim 12, wherein the at least one propylene-ethylene copolymer has a penetration of from 8 to 75 dmm, measured according to ASTM D5, and a melting temperature of from 90 ℃ to 135 ℃.

18. The adhesive of claim 12, wherein the adhesive comprises:

(a) 5 to 95 weight percent of the at least one propylene-ethylene copolymer;

(b) 5 to 90 weight percent of the at least one polyolefin;

(c) up to 70 wt% of at least one tackifier;

(d) no more than 20 wt% of a processing oil; and

(e) not more than 20% by weight of at least one wax.

19. The adhesive of claim 12, wherein the adhesive comprises:

(a) 30 to 80 weight percent of the at least one propylene-ethylene copolymer;

(b) 1 to 45 weight percent of the at least one polyolefin;

(c) up to 70 wt% of at least one tackifier;

(d) no more than 20 wt% of a processing oil; and

(e) not more than 20% by weight of at least one wax.

20. An article comprising the adhesive of claim 1, wherein the article is selected from the group consisting of adhesives, sealants, caulks, roofing membranes, waterproofing membranes and liners, carpets, laminates, tapes (e.g., tamper tape, water activated tape, gummed tape, sealing tape, scrim reinforced tape, facing tape, reinforced and non-reinforced adhesive tape, box making tape, paper tape, packaging tape, HVAC reinforcement tape, masking tape, stealth tape, electrical tape, appliance tape, hockey tape, medical tape, and the like), labels (e.g., utility labels, beverage labels, freezer labels, smart labels, consumer electronics labels, and the like), caulks, polymer blends, cable coatings, molded articles, heat seal coatings, disposable hygiene products, Insulating Glass (IG) components, bridge decks, waterproofing membranes, roofing membranes, waterproofing membranes, and liners, Water-proofing compounds, underlayment, cable coating/filling compounds, sheet molding compounds, bulk molding compounds, overmolding compounds, rubber compounds, polyester composites, glass fiber reinforced plastics, wood plastic composites, polyacrylic blend compounds, lost wax precision castings, investment casting wax compositions, candles, windows, films, gaskets, seals, O-rings, automotive molded parts, automotive extruded parts, apparel articles, rubber additives/processing aids, and fibers.