US008883280B2
`
`(12) United States Patent
`Leser et al.
`
`(10) Patent No.:
`
`(45) Date of Patent:
`
`US 8,883,280 B2
`Nov. 11, 2014
`
`(54)
`
`(75)
`
`POLYMERIC MATERIAL FOR AN
`INSULATED CONTAINER
`
`Inventors: Chris K. Leser, Evansville, IN (US);
`Philip A. Driskill, Newburgh, IN (US);
`Charles T. Wallace, Evansville, IN
`(US); John B. Euler, Evansville, IN
`(US); Jason J. Paladino, Newburgh, IN
`(US); Milan C. Maravich, Newburgh,
`IN (US); Daniel O. Davis, Cynthiana, IN
`(US); Jeffrey A. Mann, Evansville, IN
`(US); Randy A. Bowlds, Evansville, IN
`(US); Svetlana I. Contrada, Manalapan,
`NJ (US)
`
`(58) Field of Classification Search
`CPC ......... .. E04B 1/78; C08L 23/10; C08L 23/12;
`C08L 23/04; C08L 23/06; C08] 9/10; C08]
`9/06; C08] 9/12; C08] 9/122; B32B 1/02;
`B32B 1/08; B32B 33/00; B29D 22/00; B29D
`23/00
`
`USPC ............ .. 428/36.92, 304.4, 308.4, 35.6, 36.5,
`428/36.9; 252/62; 220/660
`See application file for complete search history.
`
`(56)
`
`References Cited
`U.S. PATENT DOCUMENTS
`
`(73)
`
`Assignee: Berry Plastics Corporation, Evansville,
`IN (US)
`
`1,396,282 A
`1,920,529 A
`
`11/1921 Penn
`8/1933 Sidebotham
`
`(*)
`
`Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 320 days.
`
`(21)
`
`Appl. No.: 13/491,327
`
`(22)
`
`Filed:
`
`Jun. 7, 2012
`
`(65)
`
`Prior Publication Data
`
`US 2013/0052385 A1
`
`Feb. 28, 2013
`
`Related U.S. Application Data
`
`(60)
`
`Provisional application No. 61/529,632, filed on Aug.
`31, 2011, provisional application No. 61/618,604,
`filed on Mar. 30, 2012.
`
`Int. Cl.
`
`(51)
`
`E04B 1/78
`C08L 23/10
`
`U.S. Cl.
`
`(52)
`
`(2006.01)
`(2006.01)
`
`(Continued)
`
`CPC ................ .. C0819/0023 (2013.01); E04B 1/78
`(2013.01); C08L 23/04 (2013.01);
`
`(Continued)
`
`FOREIGN PATENT DOCUMENTS
`
`CA
`CA
`
`2291607
`2765489
`
`6/2000
`12/2010
`
`(Continued)
`
`OTHER PUBLICATIONS
`
`International Search Report dated Mar. 1 1, 2014, relating to Interna-
`tional Application No. PCT/US2013/66811.
`
`(Continued)
`
`Primary Examiner — Michael C Miggins
`(74) Attorney, Agent, or Firm — Barnes & Thornburg LLP
`
`(57)
`
`ABSTRACT
`
`A formulation includes a polymeric material, a nucleating
`agent, a blowing agent, and a surface active agent. The for-
`mulation can be used to form a container.
`
`(Continued)
`
`66 Claims, 6 Drawing Sheets
`
`
`
`PAGE 1 OF 26
`
`BOREALIS EXHIBIT 1001
`
`BOREALIS EXHIBIT 1001
`
`PAGE 1 OF 26
`
`

`
`US 8,883,280 B2
`Page 2
`
`(51)
`
`1nt_C1_
`C08L 23/12
`6.081123/04
`C08L 23/06
`C0819/00
`
`C0319/12
`B323 33/00
`
`3323008
`3323 1/02
`B29D 22/00
`
`(2006101)
`2006 01
`(
`~
`)
`(2006.01)
`(2006.01)
`<,oo,,o,>
`(2006.01)
`(2006.01)
`W01,
`1200501)
`(200601)
`(2006.01)
`
`<2,,,.,,>
`1200501)
`(200601)
`
`C08L 23/08
`C08L 23/14
`(52) U_s_c1_
`CPC ................ C08L 23/12 (2013.01); C08L 23/06
`(2013.01);C08J9/06(2013.01);C08J9/I2
`(2013.01); C08./9/00 (2013.01); C08./9/I22
`(2013.01); 3323 33/00 (2013.01); B65D [/40
`(2013.01); B323 [/02 (2013.01); B29D 22/00
`(2013.01);B29D 23/00 (2013.01); B32B 1/08
`(2013.01); C08L 23/08 (2013.01); C08L 23/10
`(2013.01); C08L 23/14 (201301); C0819/0066
`(2013.01); C0819/0095 (2013.01); C0819/04
`(201301); C08J220I/03(2013.01); C08]
`2205/04 (2013.01); C08J2323/04 (2013.01);
`C08,/2323/12 (201301)
`USPC ................ .. 428/36.92; 428/304.4; 428/308.4;
`428/356; 428/365; 428/369; 252/62; 220/660
`115151511555 51151
`
`<55)
`
`1,969,030 A
`2,097,899 A
`3,312,383 A
`3,327,038 A
`3,344,222 A
`3,458,457 A
`3,547,012 A
`3,733,381 A
`3,793,283 A
`3,845,349 A
`3,967,991 A
`3,971,595 A
`4,049,122 A
`4,171,085 A
`4,197,948 A
`4,240,558 A
`4,284,225 A
`4,299,349 A
`4,300,891 A
`4,349,400 A
`4,550,045 A
`4,720,023 A
`4,878,970 A
`4,918,112 A
`5,078,817 A
`5,158,985 A
`5,160,674 A
`5,286,428 A
`5,308,568 A
`53481795 A
`53661791 A
`53851260 A
`5,443,769 A
`5,445,315 A
`5,490,631 A
`5,547,124 A
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`5,605,936 A
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`5,759,624 A
`5,765,710 A
`2,323,312 2
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`5,840,139 A
`,
`,
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`5,944,225 A
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`6,007,437 A
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`2,321,223 2
`6,103,153 A
`6,129,653 A
`6,136,396 A
`2
`6:169:12, B1
`612311942 B1
`6,235,380 B1
`0,257,837 B1
`E1
`6:306:973 B1
`6,308,883 B1
`6,319,590 B1
`E1
`,
`,
`6,420,024 B1
`6,444,073 B1
`6,468,451 B1
`5,472,473 B1
`RE37,932 E
`§’§§1’21§§1
`2,221,122 2:
`§’§§§’§§3‘ 31
`6,593,005 B2
`6,593,384 B2
`6,613,811 B1
`6,616,434 B1
`6,646,019 B2
`6,649,666 B1
`6715139 B,
`6’720’362 B1
`6,749,913 B2
`6’779’662 B2
`6,811,843 B2
`6’814’253 B2
`6,883,677 B2
`6,884,377 B1
`6,884,851 B2
`6,908,651 B2
`6,926,507 B2
`6,926,512 B2
`7,074,466 B2
`7,094,463 B2
`7,144,532 B2
`7’173’069 B2
`7,281,650 B1
`7,355,089 B2
`7,361,720 B2
`7,365,136 B2
`7,423,071 B2
`,
`,
`7,458,504 B2
`7,504,347 B2
`7,510,098 B2
`7,513,386 B2
`7,514,517 B2
`7,524,911 B2
`7,557,147 B2
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`PAGE 2 OF 26
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`US 8,883,280 B2
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`DE
`EP
`E1’
`EP
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`E1’
`E1’
`E1’
`E1’
`E1’
`E1’
`E1’
`E1’
`G13
`11’
`11’
`11’
`11’
`11’
`11’
`11’
`11’
`11’
`KR
`KR
`W0
`W0
`W0
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`W0
`W0
`W0
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`W0
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`W0
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`W0
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`W0
`W0
`W0
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`W0
`W0
`
`102006025612
`0318167
`0659647
`0796199
`
`0940240
`1308263
`1479716
`1666530
`1921023 A1
`1939099
`2266894
`2386584
`1078326
`52123043
`58029618
`3140847
`1’310847
`2001310429
`2004168421
`2006130814
`2009066856 A
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`
`PAGE 5 OF 26
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`PAGE 5 OF 26
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`

`
`U.S. Patent
`
`Nov. 11,2014
`
`Sheet 1 of6
`
`US 8,883,280 B2
`
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`
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`PAGE 6 OF 26
`
`PAGE 6 OF 26
`
`
`
`
`

`
`U.S. Patent
`
`Nov. 11,2014
`
`Sheet 2 of6
`
`US 8,883,280 B2
`
`PAGE 7 OF 26
`
`PAGE 7 OF 26
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`

`
`U.S. Patent
`
`Nov. 11,2014
`
`Sheet 3 of6
`
`US 8,883,280 B2
`
`11
`
`PAGE 8 OF 26
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`PAGE 8 OF 26
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`

`
`U.S. Patent
`
`Nov. 11,2014
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`Sheet 4 of6
`
`US 8,883,280 B2
`
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`PAGE 9 OF 26
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`PAGE 9 OF 26
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`

`
`U.S. Patent
`
`Nov. 11,2014
`
`Sheet 5 of6
`
`US 8,883,280 B2
`
`16
`
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`
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`PAGE 10 OF 26
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`PAGE 10 OF 26
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`

`
`U.S. Patent
`
`Nov. 11,2014
`
`Sheet 6 of6
`
`US 8,883,280 B2
`
`16 OZ CUP
`
`
`
`
`
`SurfaceTemperature,DegreesF
`
`0
`
`100
`
`200
`
`30 i
`
`400
`
`500
`
`Time, Seconds
`
`FIG“ 10
`
`PAGE 11 OF 26
`
`PAGE 11 OF 26
`
`

`
`1
`POLYMERIC MATERIAL FOR AN
`INSULATED CONTAINER
`
`PRIORITY CLAIM
`
`This application claims priority under 35 U.S.C. §1 19(e) to
`U.S. Provisional Applications Ser. No. 61/529,632, filedAug.
`31, 2011 and Ser. No. 61/618,604, filed Mar. 30, 2012, which
`are expressly incorporated by reference herein.
`
`BACKGROUND
`
`The present disclosure relates to polymeric materials that
`can be formed to produce a container, and in particular, poly-
`meric materials that insulate. More particularly, the present
`disclosure relates to polymer-based formulations that can be
`formed to produce an insulated non-aromatic polymeric
`material.
`
`SUMMARY
`
`A polymeric material in accordance with the present dis-
`closure includes a polymeric resin and cell-forming agents. In
`illustrative embodiments, a blend of polymeric resins and
`cell-forming agents is extruded or otherwise formed to pro-
`duce an insulated cellular non-aromatic polymeric material.
`In illustrative embodiments, an insulative cellular non-
`aromatic polymeric material produced in accordance with the
`present disclosure can be formed to produce an insulative cup
`or other product. Polypropylene resin is used to form the
`insulative cellular non-aromatic polymeric material in illus-
`trative embodiments.
`In illustrative embodiments, an insulative cellular non-
`aromatic polymeric material comprises a polypropylene base
`resin having a high melt strength, a polypropylene copolymer
`or homopolymer (or both), and cell-forming agents including
`at least one nucleating agent and a blowing agent such as
`carbon dioxide. In illustrative embodiments, the insulative
`cellular non-aromatic polymeric material further comprises a
`slip agent. The polypropylene base resin has a broadly dis-
`tributed unimodal (not bimodal) molecular weight distribu-
`tion.
`
`In illustrative embodiments, a polypropylene-based for-
`mulation in accordance with the present disclosure is heated
`and extruded in two stages to produce a tubular extrudate (in
`an extrusion process) that can be sliced to provide a strip of
`insulative cellular non-aromatic polymeric material. A blow-
`ing agent in the form of an inert gas is introduced into a molten
`resin in the first extrusion stage in illustrative embodiments.
`In illustrative embodiments, an insulative cup is formed
`using the strip of insulative cellular non-aromatic polymeric
`material. The insulative cup includes a body having a sleeve-
`shaped side wall and a floor coupled to the body to cooperate
`with the side wall to form an interior region for storing food,
`liquid, or any suitable product. The body also includes a
`rolled brim coupled to an upper end ofthe side wall and a floor
`mount coupled to a lower end of the side wall and to the floor.
`The insulative cellular non-aromatic polymeric material is
`configured in accordance with the present disclosure to pro-
`vide means for enabling localized plastic deformation in at
`least one selected region of the body (e.g., the side wall, the
`rolled brim, the floor mount, and a floor-retaining flange
`included in the floor mount) to provide (1) a plastically
`deformed first material segment having a first density in a first
`portion of the selected region of the body and (2) a second
`material segment having a relatively lower second density in
`an adjacent second portion of the selected region of the body.
`
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`PAGE 12 OF 26
`
`US 8,883,280 B2
`
`2
`
`In illustrative embodiments, the first material segment is thin-
`ner than the second material segment.
`Additional features of the present disclosure will become
`apparent to those skilled in the art upon consideration of
`illustrative embodiments exemplifying the best mode of car-
`rying out the disclosure as presently perceived.
`
`BRIEF DESCRIPTIONS OF THE DRAWINGS
`
`The detailed description particularly refers to the accom-
`panying figures in which:
`FIG. 1 is a diagrammatic and perspective view of a mate-
`rial-forming process in accordance with the present disclo-
`sure showing that the material-forming process includes,
`from left to right, a formulation of insulative cellular non-
`aromatic polymeric material being placed into a hopper that is
`fed into a first extrusion zone ofa first extruder where heat and
`
`pressure are applied to form molten resin and showing that a
`blowing agent is injected into the molten resin to form an
`extrusion resin mixture that is fed into a second extrusion
`zone of a second extruder where the extrusion resin mixture
`
`exits and expands to form an extrudate which is slit to form a
`strip of insulative cellular non-aromatic polymeric material;
`FIG. 2 is a perspective view of an insulative cup made from
`a strip of material including the insulative cellular non-aro-
`matic polymeric material of FIG. 1 showing that the insula-
`tive cup includes a body and a floor and showing that four
`regions ofthe body have been broken away to reveal localized
`areas ofplastic deformation that provide for increased density
`in those areas while maintaining a predetermined insulative
`characteristic in the body;
`FIG. 3 is an enlarged sectional view of a portion of a side
`wall included in the body of the insulative cup of FIG. 2
`showing that the side wall is made from a sheet that includes,
`from left to right, a skin including a film, an ink layer, and an
`adhesive layer, and the strip of insulative cellular non-aro-
`matic polymeric material of FIG. 1;
`FIG. 4 is an exploded assembly view of the insulative cup
`ofFIG. 2 showing that the insulative cup includes, from top to
`bottom, the floor and the body including a rolled brim, the
`side wall, and a floor mount configured to interconnect the
`floor and the side wall as shown in FIG. 2;
`FIG. 5 is a sectional view taken along line 5-5 of FIG. 2
`showing that the side wall included in the body of the insu-
`lative cup includes a generally uniform thickness and that the
`floor is coupled to the floor mount included in the body;
`FIGS. 6-9 are a series views showing first, second, third,
`and fourth regions of the insulative cup of FIG. 2 that each
`include localized plastic deformation;
`FIG. 6 is a partial section view taken along line 5-5 of FIG.
`2 showing the first region is in the side wall of the body;
`FIG. 7 is a partial section view taken along line 5-5 of FIG.
`2 showing the second region is in the rolled brim of the body;
`FIG. 8 is a partial section view taken along line 5-5 of FIG.
`2 showing the third region is in a connecting web included in
`the floor mount of the body;
`FIG. 9 is a partial section view taken along line 5-5 of FIG.
`2 showing the fourth region is in a web-support ring included
`in the floor mount of the body; and
`FIG. 10 is a graph showing performance over time of
`insulative cups in accordance with the present disclosure
`undergoing temperature testing.
`
`DETAILED DESCRIPTION
`
`An insulative cellular non-aromatic polymeric material
`produced in accordance with the present disclosure can be
`
`PAGE 12 OF 26
`
`

`
`US 8,883,280 B2
`
`3
`formed to produce an insulative cup 10 as suggested in FIGS.
`2-9. As an example, the insulative cellular non-aromatic poly-
`meric material comprises a polypropylene base resin having a
`high melt strength, a polypropylene copolymer or homopoly-
`mer (or both), and cell-forrning agents including at least one
`nucleating agent and a blowing agent such as carbon dioxide.
`As a further example, the insulative cellular non-aromatic
`polymeric material further comprises a slip agent. The
`polypropylene base resin has a broadly distributed ummodal
`(not bimodal) molecular weight distribution.
`A material-forrning process 100 uses a polypropylene-
`based formulation 121 in accordance with the present disclo-
`sure to produce a strip 82 of insulative cellular non-aromatic
`polymeric material as shown in FIG. 1. Formulation 121 is
`heated and extruded in two stages to produce a tubular extru-
`date 124 that can be slit to provide strip 82 of insulative
`cellular non-aromatic polymeric material as illustrated, for
`example, in FIG. 1. A blowing agent in the form of a liquified
`inert gas is introduced into a molten resin 122 in the first
`extrusion zone.
`
`Insulative cellular non-aromatic polymeric material is used
`to form insulative cup 10. Insulative cup 10 includes a body
`11 having a sleeve-shaped side wall 18 and a floor 20 as
`shown in FIGS. 2 and 4. Floor 20 is coupled to body 11 and
`cooperates with side wall 18 to form an interior region 14
`therebetween for storing food, liquid, or any suitable product.
`Body 11 also includes a rolled brim 16 coupled to an upper
`end of side wall 18 and a floor mount 17 coupled to a lower
`end of side wall 18 and to floor 20 as shown in FIG. 5.
`
`Insulative cellular non-aromatic polymeric material is con-
`figured in accordance with the present disclosure to provide
`means for enabling localized plastic deformation in at least
`one selected region of body 11 (e.g., side wall 18, rolled brim
`16, floor mount 17, and a floor-retaining flange 26 included in
`floor mount 17) to provide (1) a plastically deformed first
`material segment having a first density in a first portion of the
`selected region of body 11 and (2) a second material segment
`having a relatively lower second density in an adjacent second
`portion of the selected region of body 11 as suggested, for
`example, in FIGS. 2 and 6-9. In illustrative embodiments, the
`first material segment is thinner than the second material
`segment.
`One aspect ofthe present disclosure provides a formulation
`for manufacturing an insulative cellular non-aromatic poly-
`meric material. As referred to herein, an insulative cellular
`non-aromatic polymeric material refers to an extruded struc-
`ture having cells formed therein and has desirable insulative
`properties at given thicknesses. Another aspect of the present
`disclosure provides a resin material for manufacturing an
`extruded structure of insulative cellular non-aromatic poly-
`meric material. Still another aspect of the present disclosure
`provides an extrudate comprising an insulative cellular non-
`aromatic polymeric material . Yet another aspect ofthe present
`disclosure provides a structure of material formed from an
`insulative cellular non-aromatic polymeric material. A fur-
`ther aspect of the present disclosure provides a container
`formed from an insulative cellular non-aromatic polymeric
`material.
`
`In exemplary embodiments, a formulation includes at least
`one polymeric material. In one exemplary embodiment a
`primary or base polymer comprises a high melt strength
`polypropylene that has long chain branching. Long chain
`branching occurs by the replacement of a substituent, e.g., a
`hydrogen atom, on a monomer subunit, by another covalently
`bonded chain ofthat polymer, or, in the case of a graft copoly-
`mer, by a chain of another type. For example, chain transfer
`reactions during polymerization could cause branching ofthe
`
`10
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`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`4
`
`polymer. Long chain branching is branching with side poly-
`mer chain lengths longer than the average critical entangle-
`ment distance of a linear polymer chain. Long chain branch-
`ing is generally understood to include polymer chains with at
`least 20 carbon atoms depending on specific monomer struc-
`ture used for polymerization. Another example of branching
`is by crosslinking of the polymer after polymerization is
`complete. Some long chain branchpolymers are formed with-
`out crosslinking Polymer chain branching can have a signifi-
`cant
`impact on material properties. Final selection of a
`polypropylene material may take into account the properties
`of the end material, the additional materials needed during
`formulation, as well as the conditions during the extrusion
`process.
`In exemplary embodiments high melt strength
`polypropylenes may be materials that can hold a gas (as
`discussed hereinbelow), produce desirable cell size, have
`desirable surface smoothness, and have an acceptable odor
`level (if any).
`One illustrative example of a suitable polypropylene base
`resin is DAPLOYTM WB140 homopolymer (available from
`Borealis A/S), a high melt strength structural isomeric modi-
`fied polypropylene homopolymer
`(melt strength:36, as
`tested per ISO 16790 which is incorporated by reference
`herein, melting temperature:325.4° F. (163° C.) using ISO
`1 1357, which is incorporated by reference herein).
`Borealis DAPLOYTM WB140 properties (as described in a
`Borealis product brochure):
`
`Property
`
`Melt Flow Rate (230/2.16)
`Flexural Modulus
`Tensile Strength atYield
`Elongation atYield
`Tensile Modulus
`Charpy impact strength, notched
`(+23 ° C.)
`Charpy impact strength, notched
`(—20° C.)
`Heat Deflection Temperature A
`(at 1.8 MPa load)
`Heat Deflection Temperature B
`(at 0.46 MPa load)
`
`Typical
`Value
`
`2.1
`1900
`40
`6
`2000
`3.0
`
`Unit
`
`Test Method
`
`g/10 min ISO 1133
`MPa
`ISO 178
`MPa
`ISO 527-2
`%
`ISO 527-2
`MPa
`ISO 527-2
`kl/m2
`ISO 179/leA
`
`1.0
`
`kl/m2
`
`ISO 179/leA
`
`60
`
`110
`
`° C.
`
`° C.
`
`ISO 75-2
`Method A
`ISO 75-2
`Method B
`
`Other polypropylene polymers having suitable melt
`strength, branching, and melting temperature may also be
`used. Several base resins may be used and mixed together.
`In certain exemplary embodiments, a secondary polymer
`may be used with the base polymer. The secondary polymer
`may be, for example, a polymer with sufficient crystallinity.
`In exemplary embodiments the secondary polymer may be at
`least one crystalline polypropylene homopolymer, an impact
`copolymer, mixtures thereof or the like. One illustrative
`example is a high crystalline polypropylene homopolymer,
`available as F020HC from Braskem. Another illustrative
`
`example is a polymer commercially available as PRO-FAX
`SC204TM (available from LyndellBasell Industries Holdings,
`B.V.). Another illustrative example is Homo PP-INSPIRE
`222, available from Braskem. In one aspect the polypropy-
`lene may have a high degree of crystallinity, i.e., the content
`of the crystalline phase exceeds 51% (as tested using differ-
`ential scanning calorimetry) at 10° C./min cooling rate. In
`exemplary embodiments several different secondary poly-
`mers may be used and mixed together.
`In exemplary embodiments, the secondary polymer may be
`or may include polyethy