Alkyl acrylate copolymer modified oriented polypropylene films, tapes, fibers and woven and nonwoven textiles

Abstract

Disclosed are films, tapes, slit film fibers and melt-spun fibers comprising (a) at least one polypropylene polymer selected from the group consisting of polypropylene homopolymers; random copolymers or block copolymers of polypropylene and ethylene; and random terpolymers or block terpolymers of polypropylene, ethylene and one other olefin; and (b) from 1 to 30 weight % of at least one ethylene/alkyl acrylate copolymer. The tapes can be stretched (i.e. uniaxially oriented) to provide monofilament slit film fibers. Also disclosed are processes for preparing such fibers. Also disclosed are nonwoven textiles prepared from the melt-spun fibers.

1 . A film prepared from a composition comprising: 
 (a) at least one polypropylene polymer selected from the group consisting of polypropylene homopolymers; random copolymers or block copolymers of polypropylene and ethylene; and random terpolymers or block terpolymers of polypropylene, ethylene and one other olefin; and    (b) from 1 to 30 weight % of at least one ethylene/alkyl acrylate copolymer.    
     
     
         2 . The film of  claim 1  wherein said alkyl acrylate is present in said ethylene/alkyl acrylate copolymer in a range from about 5 to about 30 weight %.  
     
     
         3 . The film of  claim 1  wherein said alkyl acrylate is present in said ethylene/alkyl acrylate copolymer in a range from about 10 to about 25 weight %.  
     
     
         4 . The film of  claim 1  wherein said alkyl acrylate is selected from the group consisting of methyl acrylate, ethyl acrylate and butyl acrylate.  
     
     
         5 . The film of  claim 4  wherein said alkyl acrylate is methyl acrylate.  
     
     
         6 . The film of  claim 1  wherein component (b) is present in an amount of from 2 to 30 weight %.  
     
     
         7 . The film of  claim 6  wherein component (b) is present in an amount of from 2 to 20 weight %.  
     
     
         8 . The film of  claim 6  wherein component (b) is present in an amount of from 2 to 10 weight %.  
     
     
         9 . The film of  claim 1  further comprising 
 (c) from 0.01 to 40 weight % of at least one additional component selected from the group consisting of fillers, delustrants, UV stabilizers, pigments and other additives.  
 
     
     
         10 . The film of  claim 9  wherein component (c) is present in an amount of from 0.1 to 15 weight %.  
     
     
         11 . The film of  claim 1  that is prepared by extrusion of said composition into a cooling water bath for quenching.  
     
     
         12 . The film of  claim 1  that is prepared by extrusion of said composition onto chilled rolls for quenching.  
     
     
         13 . The film of  claim 1  that is prepared by extrusion of said composition through an annular die into a tubular blown film that is air-quenched.  
     
     
         14 . The film of  claim 1  wherein said composition comprises a tubular reactor produced ethylene/alkyl acrylate copolymer.  
     
     
         15 . A tape prepared by slitting a film of any of claims  1  through  14 .  
     
     
         16 . A woven textile prepared from a split tape film of  claim 15 .  
     
     
         17 . An article manufactured from woven textile of  claim 16  selected from the group consisting of rope, string, cord, synthetic lawn, sacking, heavy-duty sack, primary and secondary carpet backing, geotextile, agrotextile, industrial fabric, strapping, belting, apparel, diaper, netting, container, filter, tarpaulin, awning, canopy, banner, roofing membrane, luggage liner, package, and upholstery.  
     
     
         18 . A heavy-duty sack made of split tape film of  claim 15 .  
     
     
         19 . A geotextile made of split tape film of  claim 15 .  
     
     
         20 . An agrotextile made of split tape film of  claim 15 .  
     
     
         21 . A fiber prepared by hot-drawing and annealing a split tape of  claim 15 .  
     
     
         22 . An article manufactured from split tape of  claim 21  selected from the group consisting of rope, string, cord, synthetic lawn, sacking, heavyduty sack, primary and secondary carpet backing, geotextile, agrotextile, industrial fabric, strapping, belting, apparel, diaper, netting, container, filter, tarpaulin, awning, canopy, banner, roofing membrane, luggage liner, package, and upholstery.  
     
     
         23 . A process for preparing a fiber comprising 
 (1) preparing a composition comprising    (a) at least one polypropylene polymer selected from the group consisting of polypropylene homopolymers; random copolymers or block copolymers of polypropylene and ethylene; and random terpolymers or block terpolymers of polypropylene, ethylene and one other olefin; and    (b) from 1 to 30 weight % of at least one ethylene/alkyl acrylate copolymer;    (2) forming said composition into a film;    (3) slitting the film into tapes;    (4) hot-drawing and annealing a tape of step (3).    
     
     
         24 . The process of  claim 23  wherein said alkyl acrylate is present in said ethylene/alkyl acrylate copolymer in a range from about 5 to about 30 weight %.  
     
     
         25 . The process of  claim 24  wherein said alkyl acrylate is present in said ethylene/alkyl acrylate copolymer in a range from about 10 to about 25 weight %.  
     
     
         26 . The process of  claim 23  wherein said alkyl acrylate is selected from the group consisting of methyl acrylate, ethyl acrylate and butyl acrylate.  
     
     
         27 . The process of  claim 26  wherein said alkyl acrylate is methyl acrylate.  
     
     
         28 . The process of  claim 23  wherein component (b) is present in an amount from 2 to 30 weight %.  
     
     
         29 . The process of  claim 28  wherein component (b) is present in an amount of from 2 to 20 weight %.  
     
     
         30 . The process of  claim 29  wherein component (b) is present in an amount of from 2 to 10 weight %.  
     
     
         31 . The process of  claim 23  further comprising 
 (c) from 0.01 to 40 weight % of at least one additional component selected from the group consisting of fillers, delustrants, UV stabilizers. pigments and other additives.  
 
     
     
         32 . The process of  claim 27  wherein component (c) is present in an amount of from 0.1 to 15 weight %.  
     
     
         33 . The process of  claim 23  that is prepared by extrusion of said composition into a cooling water bath for quenching.  
     
     
         34 . The process of  claim 23  that is prepared by extrusion of said composition onto chilled rolls for quenching.  
     
     
         35 . The process of  claim 23  that is prepared by extrusion of said composition through an annular die into a tubular blown film that is air-quenched.  
     
     
         36 . The process of  claim 23  wherein said composition comprises a tubular reactor produced ethylene/alkyl acrylate copolymer.  
     
     
         37 . A melt-spun fiber prepared from a composition comprising; 
 (a) at least one polypropylene polymer selected from the group consisting of polypropylene homopolymers; random copolymers or block copolymers of polypropylene and ethylene; and random terpolymers or block terpolymers of polypropylene, ethylene and one other olefin; and    (b) from 1 to 15 weight % of at least one ethylene/alkyl acrylate copolymer.    
     
     
         38 . The fiber of  claim 37  wherein said alkyl acrylate is present in said ethylene/alkyl acrylate copolymer in a range from about 5 to about 30 weight %.  
     
     
         39 . The fiber of  claim 38  wherein said alkyl acrylate is present in said ethylene/alkyl acrylate copolymer in a range from about 10 to about 25 weight %.  
     
     
         40 . The fiber of  claim 37  wherein said alkyl acrylate is selected from the group consisting of methyl acrylate, ethyl acrylate and butyl acrylate.  
     
     
         41 . The fiber of  claim 40  wherein said alkyl acrylate is methyl acrylate.  
     
     
         42 . The fiber of  claim 37  wherein component (b) is present in an amount of from 2 to 10 weight %.  
     
     
         43 . The fiber of  claim 37  further comprising 
 (c) from 0.01 to 15 weight % of at least one additional component selected from the group consisting of fillers, delustrants, UV stabilizers, pigments and other additives.  
 
     
     
         44 . The fiber of  claim 43  wherein component (c) is present in an amount of from 0.1 to 5 weight %.  
     
     
         45 . The fiber of  claim 37  wherein said composition comprises a tubular reactor produced ethylene/alkyl acrylate copolymer.  
     
     
         46 . A nonwoven textile prepared from a melt-spun fiber of  claim 37 .  
     
     
         47 . An article manufactured from melt-spun fiber of  claim 37  selected from the group consisting of diapers, hygiene product, medical apparel, mask, drapes, cover, blanket, packaging, durable paper, wipe, wrap, banner, carpet backing, filter, geotextile, agrotextile, industrial fabric, roofing membrane, luggage liner, upholstery, and construction wrap.