Additive compositions and polymer compositions containing the same

Abstract

An additive composition comprises phosphate ester anions conforming to a specified structure, aromatic carboxylate anions, optionally cycloaliphatic dicarboxylate anions, aluminum (III) cations, sodium cations, optionally calcium cations, optionally lithium cations, and optionally zinc (II) cations. The anions are present in the additive composition in specified molar percentages. The cations are also present in the additive composition in specified molar percentages.

1 . A method for producing a polymer composition comprising the steps of (A) providing a polypropylene polymer selected from the group consisting of polypropylene hompolymers, polypropylene copolymers, and mixtures thereof, (B) providing an additive composition, and (C) combining the polypropylene polymer and the additive composition and melt mixing the same to produce a polymer composition, wherein the additive composition comprises:
 (a) phosphate ester anions conforming to the structure of Formula (I)   
       
         
           
           
               
               
           
         
       
       wherein R 1  and R 2  are independently selected from the group consisting of hydrogen and C 1 -C 18  alkyl groups, and R 3  is an alkanediyl group;
 (b) aromatic carboxylate anions; 
 (c) aluminum (III) cations; 
 (d) sodium cations; 
 (e) optionally, lithium cations; and 
 (f) optionally, zinc (II) cations, 
 wherein: 
 (i) the phosphate ester anions are present in the additive composition in an amount of about 2 mol. % to about 90 mol. % of the total amount of phosphate ester anions and aromatic carboxylate anions present in the additive composition; 
 (ii) the aromatic carboxylate anions are present in the additive composition in an amount of about 10 mol. % to about 98 mol. % of the total amount of phosphate ester anions and aromatic carboxylate anions present in the additive composition; 
 (iii) the aluminum (III) cations are present in the additive composition in an amount of about 1 mol. % to about 35 mol. % of the total amount of aluminum (III) cations, sodium cations, lithium cations, and zinc (II) cations present in the additive composition; 
 (iv) the sodium cations are present in the additive composition in an amount of about 10 mol. % to about 96 mol. % of the total amount of aluminum (III) cations, sodium cations, lithium cations, and zinc (II) cations present in the additive composition; 
 (v) the lithium cations, if present, are present in the additive composition in an amount of about 0 mol. % to about 60 mol. % of the total amount of aluminum (III) cations, sodium cations, lithium cations, and zinc (II) cations present in the additive composition; 
 (vi) the zinc (II) cations, if present, are present in the additive composition in an amount of about 0 mol. % to about 20 mol. % of the total amount of aluminum (III) cations, sodium cations, lithium cations, and zinc (II) cations present in the additive composition; and 
 (vii) the additive composition contains 5 wt. % or more fatty acid salts. 
 
     
     
         2 . The method of  claim 1 , wherein R 1  and R 2  are selected from the group consisting of hydrogen and C 1 -C 4  alkyl groups. 
     
     
         3 . The method of  claim 2 , wherein R 1  and R 2  are tert-butyl groups. 
     
     
         4 . The method of  claim 1 , wherein R 3  is a C 1 -C 4  alkanediyl group. 
     
     
         5 . The method of  claim 4 , wherein R 3  is a methanediyl group. 
     
     
         6 . The method of  claim 1 , wherein the aromatic carboxylate anions are benzoate anions. 
     
     
         7 . The method of  claim 1 , wherein the phosphate ester anions are present in the additive composition in an amount of about 15 mol. % to about 50 mol. % of the total amount of phosphate ester anions and aromatic carboxylate anions present in the additive composition. 
     
     
         8 . The method of  claim 1 , wherein the aromatic carboxylate anions are present in the additive composition in an amount of about 50 mol. % to about 85 mol. % of the total amount of phosphate ester anions and aromatic carboxylate anions present in the additive composition. 
     
     
         9 . The method of  claim 1 , wherein the aluminum (III) cations are present in the additive composition in an amount of about 5 mol. % to about 15 mol. % of the total amount of aluminum (III) cations, sodium cations, lithium cations, and zinc (II) cations present in the additive composition; 
     
     
         10 . The method of  claim 1 , wherein the sodium cations are present in the additive composition in an amount of about 45 mol. % to about 95 mol. % of the total amount of aluminum (III) cations, sodium cations, lithium cations, and zinc (II) cations present in the additive composition. 
     
     
         11 . The method of  claim 1 , wherein the additive composition comprises lithium cations, and the lithium cations are present in the additive composition in an amount of about 10 mol. % to about 40 mol. % of the total amount of aluminum (III) cations, sodium cations, lithium cations, and zinc (II) cations present in the additive composition. 
     
     
         12 . The method of  claim 1 , wherein the additive composition comprises zinc (II) cations, and the zinc (II) cations are present in the additive composition in an amount of about 0.1 mol. % to about 5 mol. % of the total amount of aluminum (III) cations, sodium cations, lithium cations, and zinc (II) cations present in the additive composition. 
     
     
         13 . The method of  claim 1 , wherein the additive composition contains about 20 wt. % to about 55 wt. % fatty acid salts. 
     
     
         14 - 29 . (canceled)