Hexene-1 Containing Amorphous Polyalphaolefins For Improved Hot Melt Adhesives

Abstract

Propylene-co-hexene-1-co-butene-1 terpolymers, made either with or without an in-reactor-added organosilicon external donor, are used in the formulation of improved-performance, APAO-based, hot melt adhesives. The addition of an external donor during the manufacture of hexene-1 based amorphous polyalpha-olefins (APAO's) results in products having enhanced physical and mechanical properties compared to similar adhesive products made without the addition of the external donor.

What is claimed is: 
     
         1 . A hot-melt formulation comprising:
 a propylene-co-hexene-1-co-butene-1 terpolymer made using a supported Ziegler-Natta catalyst, at a process temperature between about 130° F. and about 175° F. and at a reactor pressure sufficient to maintain propylene in the liquid phase (in the absence of any added solvent) and the hydrogen concentration present during the manufacture of the subject terpolymers is adjusted so that their melt viscosity, measured at 190° C., is less than 3500 cps, preferably less than 3000 cps, optionally in the presence of an organo-silane external donor and optionally with,   a tackifier; and/or   a styrenic block copolymer; and/or   a high melt flow index metallocene or single-site catalyzed polyethylene; and/or   a high melt flow rate polypropylene, either a homopolymer or random copolymer, of varying degrees of crystallinity or isotacticity, functionalized or without any polar functionality; and/or   a wax component; and/or   a liquid plasticizer.   
     
     
         2 . The hot-melt formulation of  claim 1  wherein the copolymer is made in the presence of an externally-added organosilicon donor. 
     
     
         3 . The hot-melt formulation of  claim 8  wherein the terpolymer is made in the presence of an externally-added organosilicon donor. 
     
     
         4 . The hot-melt formulation of  claim 1  comprising a propylene-co-hexene-1 copolymer with a boiling heptane insolubility of less than 20 wt. %. 
     
     
         5 . The hot-melt formulation of  claim 1  comprising a propylene-co-hexene-1 copolymer manufactured in the absence of any added solvent 
     
     
         6 . The hot-melt formulation of  claim 1  wherein the liquid plasticizer comprises a naphthenic oil. 
     
     
         7 . The hot-melt formulation of  claim 8  wherein the liquid plasticizer comprises a naphthenic oil. 
     
     
         8 . The hot-melt formulation of  claim 1  wherein the liquid plasticizer comprises a paraffinic oil. 
     
     
         9 . The hot-melt formulation of  claim 8  wherein the liquid plasticizer comprises a paraffinic oil. 
     
     
         10 . The hot-melt formulation of  claim 1  wherein the wax component comprises a paraffinic wax. 
     
     
         11 . The hot-melt formulation of  claim 8  wherein the wax component comprises a paraffinic wax. 
     
     
         12 . The hot-melt formulation of  claim 1  wherein the wax component comprises a metallocene wax. 
     
     
         13 . The hot-melt formulation of  claim 2  wherein the wax component comprises a metallocene wax. 
     
     
         14 . The hot-melt formulation of  claim 1  wherein the terpolymer is made at a process temperature between about 130° F. and about 175° F. and at a reactor pressure sufficient to maintain propylene in the liquid phase (in the absence of any added solvent). 
     
     
         15 . The hot-melt formulation of  claim 1  wherein the hydrogen concentration present during the manufacture of the terpolymer is adjusted such that its melt viscosity, measured at 375° F., is less than 3500 cps. 
     
     
         16 . The hot-melt formulation of  claim 1  wherein the hydrogen concentration present during the manufacture of the terpolymer is adjusted such that its melt viscosity, measured at 375° F., is less than 3000 cps.