High Melt Strength Polypropylene and Methods of Making Same

Abstract

A high melt strength polypropylene is formed using maleated polypropylene and a combination of coupling agents and acid neutralizers. The maleated polypropylene can be formed using multi-functional monomers. The high melt strength polypropylene can be useful for foaming, sheet extrusion thermoforming, extrusion blow molding, extrusion coating, fiber, film, and the like.

1 . A high melt strength polypropylene comprising a functionalized polypropylene and a coupling agent. 
     
     
         2 . The high melt strength polypropylene of  claim 1 , wherein the high melt strength polypropylene exhibits enhanced processability and performance in the molten state, as compared to neat polypropylene. 
     
     
         3 . The high melt strength polypropylene of  claim 1 , wherein the functionalized polypropylene is maleated polypropylene. 
     
     
         4 . The high melt strength polypropylene of  claim 1 , wherein the functionalized polypropylene is maleated polypropylene that is formed by the reactive extrusion of polypropylene, a peroxide, maleic anhydride, and 0.1 to 5% by weight of a multi-functional monomer. 
     
     
         5 . The high melt strength polypropylene of  claim 4 , wherein the multi-functional monomer is chosen from the group consisting of di- and tri-acrylates. 
     
     
         6 . The high melt strength polypropylene of  claim 1 , wherein the coupling agent is 1,3-phenylenediamine or other diamines. 
     
     
         7 . The high melt strength polypropylene of  claim 1  further comprising an acid neutralizer. 
     
     
         8 . The high melt strength polypropylene of  claim 7 , wherein the acid neutralizer is a metal salt. 
     
     
         9 . The high melt strength polypropylene of  claim 7 , wherein the acid neutralizer is chosen from the group consisting of: potassium hydroxide, zinc stearate, zinc acetate, sodium hydroxide, and combinations thereof 
     
     
         10 . The high melt strength polypropylene of  claim 7  further comprising a commercial ionic monomer. 
     
     
         11 . An article made from the high melt strength polypropylene of  claim 1 . 
     
     
         12 . A high melt strength polypropylene comprising maleated polypropylene that has been formed in the presence of an acrylate multi-functional monomer, an amine coupling agent, and an acid neutralizer. 
     
     
         13 . The high melt strength polypropylene of  claim 12 , used as a masterbatch for enhancing the melt strength of conventional polypropylene resin. 
     
     
         14 . The high melt strength polypropylene of  claim 12 , used in one of the following applications: foaming, sheet extrusion thermoforming, extrusion blow molding, extrusion coating, fiber, and film. 
     
     
         15 . A method of making a high melt strength polypropylene, comprising:
 reactively blending a combination a functionalized polypropylene and an amine coupling agent, and recovering a polypropylene product of enhanced melt strength.   
     
     
         16 . The method of  claim 15 , wherein the functionalized polypropylene is maleated polypropylene, that is formed by the reactive extrusion of a peroxide, maleic anhydride, and 0.1 to 5% by weight of a multi-functional monomer. 
     
     
         17 . The method of  claim 16 , wherein the multi-functional monomer is chosen from the group consisting of di- and tri-acrylates. 
     
     
         18 . The method of  claim 15 , wherein the coupling agent is 1,3-phenylenediamine. 
     
     
         19 . The method of  claim 15 , wherein the step of reactive blending includes an acid neutralizer. 
     
     
         20 . The method of  claim 19 , wherein the acid neutralizer is a metal salt. 
     
     
         21 . The method of  claim 19 , wherein the acid neutralizer is chosen from the group consisting of: potassium hydroxide, zinc stearate, zinc acetate, sodium hydroxide, and combinations thereof 
     
     
         22 . The method of  claim 19 , wherein the step of reactive blending further includes a commercial ionic monomer. 
     
     
         23 . A method of making a high melt strength polypropylene, comprising:
 reactively blending a combination of maleated polypropylene that has been formed in the presence of an acrylate multi-functional monomer, an amine coupling agent, and an acid neutralizer; and   recovering a polypropylene product of enhanced melt strength.