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    公开号:ES2643339T9
    申请号:ES10767944.1T
    申请日:2010-10-13
    公开日:2018-11-20
    发明作者:Detlef Busch；Dominic Klein；Bertram Schmitz
    申请人:Treofan Germany GmbH and Co KG；
    IPC主号:
    专利说明:

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    NANOESCALA NUCLEATION AGENT FOR POLYPROPYLENE
    DESCRIPTION
    The invention relates to a nanoscale p nucleating agent for polypropylene, as well as a method for increasing the proportion of the p-crystalline modification in polypropylene, as well as a porous sheet.
    In addition to the amorphous phase, three different crystalline phases are known from polypropylene, phases a, p and y. During cooling of polypropylene melts, a-crystalline PP is usually predominantly formed. By a certain temperature control during the cooling of a polypropylene melt a greater proportion of crystalline phase p can be generated. The proportion of p-crystalline PP produced in this way is less than 10% (first heating). The hexagonal p-modification of the PP is distinguished from the a-monocline modification by better mechanical properties, for example better impact resistance and tensile cracking resistance. In addition, the modification p of the polypropylene has a melting point clearly below 140-155 ° C than that of the modification a, with a melting point of at least 160 ° C. A higher proportion of p-crystalline PP therefore has a favorable effect in some applications on certain functional properties of polypropylene. For this reason, additives have been developed in the past which, when a melt cools, give rise to high proportions of polypropylene in the p modification, the so-called p-nucleating or p-nucleating agents.
    As a p-nucleator with high activity, the Y-quinacridone dye is described in German patent 1188278. The disadvantage of this nucleating agent, however, is the intense red coloration and the lack of thermal stability. US Patent 3,540,979 describes the calcium salt of phthalic acid as a thermally stable nucleating agent. The drawback of this nucleating agent is the low activity. The proportion of p-crystalline PP that is thus achieved is a maximum of 70% (K ~ 0.5-0.7).
    DE 3610644 describes a two component nucleation system of calcium carbonate and organic dicarboxylic acids. However, this nucleation system shows in practice a fluctuating activity. The direct use of the calcium salts of the dicarboxylic acids described in DE 3 610 644 is described in DE 4 420 989. The p nucleating activity of various dicarboxamides, in particular N, N-dicyclohexyl-2,6- Naphthalenedicarboxamides is described in EP-0557721. The disadvantage of this nucleator is the high cost of the reactant, as well as complicated stages of synthesis during manufacturing.
    The article "Preparation and characteristics of the nucleating agent p supported by polypropylene nanoscale COaCa" ISSN 0014-3057 describes nanoscale particles of COaCa that are coated with pimelic acid. The nanoparticles are mixed in polypropylene. The polypropylene melts, is maintained at this temperature and cooled to room temperature with a cooling rate of 10 K / min. The nanoscale CO3Ca carrier is then coated with pimelic acid. When the melt containing these coated particles cools, a high proportion of p-crystalline polypropylene results.
    WO 02/081557 describes a process for manufacturing a microporous material. Propylene polymer and nucleating agent p and a diluent are mixed. The diluent is miscible above the melting temperature with the polypropylene melt and forms a separate phase below the crystallization temperature. After cooling the melt mixture, it is stretched biaxially and a microporous sheet is obtained. The nucleating agent p is calcium pimelate.
    The objective of the present invention was to provide an improved p nucleating agent, as well as a process for manufacturing p-crystalline polypropylene, as well as an improved process for manufacturing a sheet with a high gas permeability. This procedure should be able to achieve high proportions of p in a reproducible and reliable way. The procedure must be simple and efficient. Modification with a nucleating agent p should not impair the usual important functional properties of polypropylene. The safety of operation in the manufacture of porous sheets must be improved.
    This objective is achieved by a process for manufacturing a stable dispersion formed by an anhydrous liquid phase and dispersed dicarboxylic acid salts, in which an aliphatic dicarboxylic acid reacts with a divalent metal salt in an aqueous solution to form a dicarboxylic acid salt and The dicarboxylic acid salt is then separated and dried, said dried dicarboxylic acid salt being separated by gravity in an anhydrous liquid solution and triturated until a stable dispersion is formed, containing the dispersion <1% of dicarboxylic acid salts with a particle size of> 1 pm, determining the size of the particles and the presence of agglomerates in images of the samples in the scanning electron microscope. Under a dispersion within the meaning of the present invention, a heterogeneous mixture is understood in which the dicarboxylic acid salt exists as a solid in the continuous liquid phase finely divided as a dispersed phase, the salt not dissolving or dissolving little in the liquid phase. The two phases also do not form a chemical compound. The dispersion is also characterized in that the individual phases are delimited from each other, that is, they are not dissolved in each other and can be separated from each other again by physical methods, for example filtering, centrifuging. The stable dispersion no longer substantially disintegrates itself, for example by sedimentation.
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    Within the meaning of the present invention, it is understood under an anhydrous phase an organic compound that is liquid at room temperature and whose water content is <1% by weight, for example lower alcohol alkanes, ketones and similar liquids.
    Depending on the given context, drying means, in the sense of the present invention, both the removal of water or moisture as well as the separation of the anhydrous liquid phase.
    This objective is also achieved by a compound that can be obtained by a process in which the anhydrous liquid phase produced from the dispersion according to one of claims 1 to 4 is eliminated, the remaining dicarboxylic acid salt powder being mixed with polypropylene and then the resulting preliminary mixture is melted and extruded to form a granulated compound.
    Within the meaning of the present invention, it is understood under a compound a homogeneous mixture of at least one polypropylene and dicarboxylic acid salt as additive.
    The objective is also achieved by a polypropylene having a proportion of p-crystalline polypropylene, which can be obtained by a process in which the anhydrous liquid phase of the dispersion prepared according to one of claims 1 to 4 is removed, mixed the remaining powder of dicarboxylic acid salt with polypropylene and melts at a temperature of at least 150 ° C and the melt is then slowly cooled to a temperature in the range of 60 to 135 ° C and the cooled polypropylene melt it has a proportion of p-crystalline polypropylene of 10 to 95% (first heating), this proportion of p-crystalline polypropylene being determined by means of DSC measurement (differential scanning calorimetry), as described in the description under the corresponding title.
    The objective is also achieved by a polypropylene having a proportion of p-crystalline polypropylene, which can be obtained by a process in which a compound according to claim 5 or 6, where appropriate mixed with polypropylene without nucleating agents and / or other additional polyolefins and / or additives, melts at a temperature of at least 150 ° C and then the melt is cooled slowly to a temperature in the range of 60 to 135 ° C and the cooled polypropylene melt contains a proportion from 10 to 95% p-crystalline polypropylene (first heating), said proportion of p-crystalline polypropylene by DSC measurement, as described in the description under the corresponding heading. The objective is also achieved by a biaxially stretched polypropylene sheet with at least one porous layer, which can be obtained by a method in which a compound according to claim 5 or 6, if necessary mixed with additional polypropylene and / or other Polymers and / or additional additives, melts at a temperature of at least 160 ° C and is extruded through a flat nozzle and cooled on cooling rollers at a temperature in the range of 80 to 130 ° C, with a long permanence at this temperature and the cooled preliminary sheet has at least 40% (measured according to DSC, first heating) of p-crystalline polypropylene, this proportion of p-crystalline polypropylene being determined by DSC measurement, as described in the description under corresponding title and the preliminary sheet is then heated and stretched in the longitudinal direction and in the transverse direction and the temperature during the e The stretch is chosen so that the p-crystalline polypropylene of the preliminary sheet becomes the alpha modification of the polypropylene.
    The objective is finally achieved by using a porous sheet according to one of claims 9 to 12 as a membrane in batteries, secondary batteries or in supercapacitors.
    The dependent claims describe preferred embodiments of the invention. The present invention is based on the discovery that salts of nanoscale dicarboxylic acid, when cooling a polypropylene melt containing these salts of nanoscale dicarboxylic acid, form a high proportion of p-crystalline polypropylene (also referred to below as the proportion of 13). The molten mass cooled with a high proportion of p forms a transparent PP matrix, since the particle size of the nanoscale dicarboxylic acid salts is clearly smaller than the wavelength of visible light. The salts of nanoscale dicarboxylic acids generally have a particle size of 1 to 500 nm, preferably 5 to 300 nm, while particles or agglomerates with a particle size of> 1 pm are included in less than 3%, preferably of > 0 to <1%. Likewise, the average particle size of the nanoscale dicarboxylic acid salts is in said range from 1 to 500 nm, preferably from 5 to 300 nm.
    Within the meaning of the present invention, salts of nanoscale dicarboxylic acid include salts whose base of aliphatic dicarboxylic acid has at least 4 to 15 carbon atoms, in particular 5 to 10 carbon atoms. Especially preferred are salts of pimelic acid or suberic acid, for example Ca pimelate or Ca suberate. Mixtures of different salts of dicarboxylic acid can also be used. In general, alkaline earth salts are preferred, but in principle other divalent metal salts can also be used, for example based on divalent iron, nickel, zinc, etc.
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    The synthesis of the salts of dicarboxylic acid at nanoscale is carried out by the precipitation reaction, known per se, of aliphatic dicarboxylic acids, for example pimelic acid or subteric acid with divalent metal salts, such as chlorides, carbonates or hydroxides, preferably alkaline earth salts, such as alkaline earth chloride, alkaline earth carbonate or alkaline earth hydroxide in aqueous solution. Alkaline earth hydroxides are preferred, such as Ca (OH) 2, since the formation of hydrochloric acid or CO2 as a byproduct is avoided. For the transformation, an aqueous solution of the aliphatic dicarboxylic acid is generally taken. The aliphatic dicarboxylic acid is introduced into water and heated by stirring until the aliphatic dicarboxylic acid has dissolved, for example at a temperature of 70 to 95 ° C, preferably 75 to 90 ° C. Then, with stirring, an aqueous metal salt solution is added, preferably an alkaline earth salt solution, in particular a solution of Ca (OH) 2. Reagents are used here in stoichiometric amounts. Then the dicarboxylic acid salt precipitates as a fine precipitate. This precipitate is sedimented, separated and dried by suitable procedures, for example in a drying cabinet at 100-120 ° C. The residual moisture content of the dicarboxylic acid salt is then further reduced, for example under vacuum, for example in a vacuum drying cabinet, at about 150 to 200 ° C. Preferably the water content of the dried dicarboxylic acid salt is 0-2% by weight, preferably> 0 to 1% by weight. In this way a powdery dry dicarboxylic acid salt is obtained. This powder contains after drying agglomerates with a particle size of 1 to more than 100 pm, the predominant part of these agglomerates having a particle size of about 10 pm. The proportion of these agglomerates is generally greater than 5%.
    According to the invention, the dicarboxylic acid salt is separated by gravity in a next stage in an anhydrous liquid phase. The water content of the liquid phases is generally less than 1% by weight, preferably> 0 to <0.8% by weight. The liquid phase is for example a lower alkane, which at room temperature is liquid, for example hexane, heptane or an alcohol, for example ethanol, butanol or isopropanol or liquid ketone, for example acetone. Mixtures of these liquid phases can also be used. In general, at least 5 and up to 60% by weight are separated by gravity, preferably from 10 to 50% by weight and in particular from 15 to 40% by weight based on the weight of the liquid phase, of the dicarboxylic acid salt in the liquid phase After gravity separation of the salt in the liquid phase, the sludge is crushed. For example, conventional mortar mills, ultrasound or a ball mill or other common wet grinding or grinding processes are used for crushing. The dicarboxylic acid salt is then preferably ground to a particle size of less than 1 to 500 nm, in particular 5 to 200 nm. The nanoscale dicarboxylic acid salt forms a stable dispersion after crushing in the liquid phase in which there are no more agglomerates of more than 1000 nm or are only present in small quantities. The transition to the nanoscale dispersed phase is also observed in that the gravity-separated dicarboxylic acid salt before crushing, after gravity separation in the liquid phase, settles directly again, for example after a few minutes, but after grinding it forms a stable, milky, cloudy dispersion, in which the particles are no longer deposited. This dispersion is thus essentially stable for a usual period of time until processing, for example for at least one or even several hours. Eventually the sludge can be filtered further to separate such agglomerates, which still exist after milling. The filter medium is chosen such that all particles with a size> 1 pm are separated and the sediments are then free of particles of this size or at least contain less than 1% of them.
    This stable dispersion can be mixed directly with the polypropylene, for example in the form of powder or granules and dried. Alternatively, the liquid phase of the dispersion is separated and the powder thus obtained from the nanoscale dicarboxylic acid salt is mixed with polypropylene in the form of powder or granules. Through these two possible variants of the process, a preliminary mixture of salts of dicarboxylic acid at nanoscale and polypropylene is obtained. The separation of the anhydrous liquid phase is carried out in both processes by suitable conventional means, for example by evaporation, vacuum evacuation, distillation or by means of a filter press. Preliminary mixtures generally contain 0 to 2% by weight of the liquid phase, preferably> 0 to 1% by weight.
    Eventually, in order to avoid the agglomeration of the dicarboxylic acid salts at the nanoscale more safely and to improve the dispersibility of the dicarboxylic acid salts in the polypropylene matrix, either in obtaining the dispersion or by mixing the acid salts dicarboxylic with polypropylene, a surfactant can be added, such as higher carboxylic acids, silanes, amines or sulphonates. Especially preferred for these purposes are long chain fatty acids, such as oleic acid or stearic acid. But surprisingly the dispersions according to the invention are, however, largely stable, even without such auxiliary means.
    Then, these preliminary mixtures of polypropylene and dicarboxylic acid salt can be made directly to generate products, possibly adding other polyolefins and / or additional additives. In a preferred variant, these preliminary mixtures are converted into an additional stage of the process into granulate grains with nanoscale dicarboxylic acid salts. The compound is manufactured in the usual manner by melting the preliminary mixture at suitable temperatures, for example in a range of 160 to 300 ° C. The melting is preferably carried out in a suitable extruder, for example in a twin screw extruder, which at the same
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    time ensures a good mixture of the nanoscale dicarboxylic acid salt in the polypropylene. The molten mixture is extruded into granules and they are cooled to suitable temperatures. In the formation of the compound, in addition to polypropylene, other additives and / or other polyolefins, for example polyethylenes, can also be added. These compounds are then used in the manufacture of the products, for example injection molded parts, sheets, porous sheets, fibers, etc.
    In general, the preliminary mixtures and / or the granulated compounds therefrom contain from 0.0001 to 5% by weight, preferably from 0.001 to 3% by weight, of nanoscale aliphatic dicarboxylic acid salts. Particularly for sheet applications, a content of 0.001 to 1% by weight of dicarboxylic acid salts in the compound or preliminary mixture is preferred. The data in% by weight refer in each case to the weight of the mixture or compound. Eventually various salts of dicarboxylic acid can also be mixed and then used.
    Preliminary mixtures or compounds of at least one polypropylene and nanoscale dicarboxylic acid salts, which are used in the manufacture of the products, generally contain at least 50 to <100% by weight, preferably 60 to 99% by weight, in particular from 70 to 99% by weight, of a polypropylene and, possibly other polyolefins, such as polyethylenes and / or other additives. The data in% by weight refer in each case to the weight of the mixture.
    Suitable polypropylenes are, for example, isotactic propylene homopolymers with a melting point of 140 to 170 ° C, preferably 155 to 168 ° C, and a melt index (measured according to DIN 53 735 to 21.6 N of charge and 230 ° C) 1.0 to 50 g / 10 min, preferably 1.5 to 20 g / 10 min. The n-heptane soluble fraction of the polymer is generally 1 to 10% by weight, preferably 2 to 5% by weight, based on the initial polymer. The molecular weight distribution of the propylene polymer may vary.
    The ratio between the weight average Mw and the numerical average Mn is generally between 1 and 15, preferably from 2 to 10, most preferably from 2 to 6. Such a narrow molecular weight distribution of the propylene homopolymer is achieved, by For example, by peroxidic degradation or by manufacturing polypropylene by suitable metallocene catalysts.
    In a further embodiment of the invention, the propylene homopolymer used is highly isotactic. In such highly isotactic polypropylenes, the chain isotaxy index determined by RmN 13C spectroscopy of the n-heptane insoluble fraction of the polypropylene is at least 95%, preferably 96 to 99%.
    In addition, propylene copolymers, which generally contain at least 80% by weight, preferably 90 to <100% by weight, in particular 95 to 99% by weight, of propylene units are suitable as polypropylenes. The corresponding comonomer content of a maximum of 20% by weight or> 0 to 10% by weight or 1 to 5% by weight is composed, when it exists, generally of ethylene and / or butylene. The data in% by weight refer in each case to the propylene polymer. Suitable copolymers, which contain for example ethylene and / or butylene as a comonomer, are preferably statistical copolymers or block copolymers.
    According to the process according to the invention to manufacture polypropylene with an increased proportion of p-crystalline polypropylene, the preliminary mixture of polypropylene and salts of nanoscale dicarboxylic acid or the compound is melted at appropriate temperatures. This temperature is generally in a range of 160 to 300 ° C. The fusion is preferably carried out in a suitable extruder, for example in a twin screw extruder, which at the same time guarantees a good mixture of the nanoscale dicarboxylic acid salt in the polypropylene. The molten mixture is extruded and cooled to suitable temperatures.
    Both the preliminary mixture and the compounds can be used in the process according to the invention together with other polypropylenes without nucleating agents and / or possibly with additional polyolefins and / or additives. All components are then fused together in any extrusion tool or in a kneader and mixed together and extruded to give products with a proportion in p-crystalline polypropylene.
    In all variants of the process it is essential for the invention that after extrusion, the cooling of the melt, which contains salts of nanoscale dicarboxylic acids, is carried out in such a way that the nucleating action p of the salts of nanoscale dicarboxylic acids. For this, it is preferred to cool the melt slowly to a temperature in a range between 60 and 135 ° C, preferably between 80 and 130 ° C. The closer this temperature is to the crystallization temperature of the p-crystalline polypropylene, the more favorable are the conditions for the formation of the p-crystalline modification. In this way, by choosing the temperature during cooling, a greater or lesser proportion of p-polypropylene can be generated. In addition, the residence time of the melt that cools to the corresponding temperature has an influence on the p content obtained. To achieve the highest possible proportion of 13, the melt
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    the higher temperatures must be cooled very slowly, depending on the time of permanence necessary, at the given temperature in each individual case, of the conformation during extrusion.
    Depending on the application, lower proportions of p in the polypropylene may also be sufficient. The salts of p-nucleation dicarboxylic acid have a positive effect in these cases, since the cooling rate can be increased, that is, higher stretching or extrusion rates can be used. The content in p (first heating) of the polypropylene manufactured in accordance with this procedure can thus, depending on the application, vary in the range of 1-95%, preferably from 20-80%, in particular from 50-90%.
    By the process according to the invention, it is possible, under the corresponding cooling conditions, to obtain a polypropylene content p of> 80%, preferably from 85 to 95% (DSC method, first heating). For example, DSC (first heating) measurements in isotactic propylene homopolymer with 0.1% by weight of nanoscale dicarboxylic acid, a proportion of p-crystalline polypropylene of 92%, were determined.
    The process according to the invention can be used advantageously in the manufacture of sheets, shaped bodies, in particular flexible tubes and tubes, fibers and other extrusion products. The high efficiency of p-nanoscale dicarboxylic acids has a favorable effect on the most diverse extrusion applications, for example since the extrusion temperature can be reduced or the residence time can be shortened. For some applications a high proportion of p-crystalline polypropylene is advantageous, since this improves the utilization properties of polypropylene; for example, a greater resistance to shock is achieved in a fitted specimen and a greater tensile strength of polypropylene. In another application, the especially high proportion p in the polypropylene is used to generate porous sheets by converting the modification p into the alpha modification during sheet stretching or to generate rough surfaces of a stretched sheet.
    It has been found that the nanoscale dicarboxylic acid salt has surprising advantages when used in a process for manufacturing a stretched porous biaxial sheet or also a stretched sheet with one or more porous layers. On the one hand, the high polypropylene contents p have a positive effect on the porosity of this sheet or the porous layer and its gas permeability. However, it has also been found that other nucleating agents p can lead to comparatively high p contents in the preliminary sheet, for example also dicarboxylic acid salts that do not undergo further grinding of the sludge during manufacturing. However, it is observed that when they are used, polypropylene cannot be stretched in the same way to form sheets or to form layers with high porosities. When nanoscale dicarboxylic acids according to the invention are used, stretching conditions, in particular high stretching factors, can be used, which results in a high porosity of the sheet or layer, resulting in safety surprisingly good blade performance.
    The invention is advantageous in the manufacture of porous monolayer and multilayer sheets. A membrane sheet is characterized in that it only has one layer or, in the case of several layers, it only includes porous layers and has high gas permeability. Eventually the invention can also be used in a multilayer sheet, which in addition to one or several porous layer / s, also comprises one or several additional layer / s / is essentially gas impermeable. The indications of this description with respect to the porous sheet are therefore suitably applied in the same way or analogously also to the porous layer or the porous layers of a multilayer sheet.
    In detail, in the manufacture of a biaxially stretched polypropylene sheet, the components of the porous layer or layers, that is, the mixture or compound of the nanoscale dicarboxylic acid salt and polypropylene, optionally mixed with additional polypropylene and / or Additional polymers and / or additional additives melt in an extruder at a temperature of at least 160 ° C. The melt of mono or multilayer polymer is co / extruded through a flat nozzle, a stretch roller is taken and cooled on the stretch roller such that the melt solidifies to form a preliminary sheet and results in desired proportion of p-crystalline polypropylene. This melting of the melt is carried out as described above in a temperature range of preferably 80 to 130 ° C, whereby a long residence time at this temperature contributes to a high proportion of p-crystalline polypropylene. For the manufacture of a porous sheet or layer, a proportion of at least 40%, preferably 60 to 95%, of polypropylene p in the preliminary sheet (measured according to DSC, first heating) and on the contrary is generally intended to generate surface roughness, lower proportions of for example 10 to 40% may be sufficient. The preliminary sheet is then heated in a manner known per se and stretched in the longitudinal direction, preferably at a temperature below 140 ° C, in particular from 80 to 125 ° C, and with a stretching factor of 2.5 : 1 to 6: 1. After longitudinal stretching, the longitudinally stretched sheet is reheated and stretched transversely, preferably at a temperature greater than 110 ° C, in particular from 120 to 145 ° C and with a stretch ratio of 3: 1 to 8: 1 . Due to the temperatures chosen during stretching, the p-crystalline polypropylene of the preliminary sheet is transformed into the alpha modification of the polypropylene and generates, depending on the process conditions and the p-content of the preliminary sheet, a continuous structure in form of porous network in the sheet or in the porous layer or at least a surface roughness due to crater-like depressions,
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    that occur during the transformation processes. Such rough surface structures are desired, for example, in sheets with a paper-like character or in capacitor sheets, which are used as a dielectric in capacitors. In order not to damage the electrical properties of such condenser sheets, it is preferred to use the nanoscale dicarboxylic acid salt only in the cover layer (s), which must have surface roughness. It was found that the nanoscale dicarboxylic acid salts do not harm or only slightly do the electrical characteristics of the condenser sheet.
    Surprisingly, it has the sheet or the layer, which is manufactured with the nanoscale dicarboxylic acid salts according to the invention, a very high and uniform porosity and a good mechanical strength. The uniform distribution of pore size is clearly visible in REM images. The average pore diameter (bubble point) is in the range of 50 to 350 nm, preferably in the range of 60 to 300 nm. In the manufacture of the porous sheet or the sheet with porous layer, only cracks occur very rarely, that is, the process has a high operational safety. The sheet can be stretched with very high factors, and exceptionally high porosities can be achieved. In principle, the Gurley value of the various embodiments of the sheet can vary over a wide range. For those sheets that include only porous layers and are used for example as membrane sheets, the Gurley value is generally in a range of 100-5000 sec; preferably 100 to 2000 sec. Surprisingly, according to the present invention, the high stretching factors also make it possible to manufacture porous sheets with very low Gurley values of 10 to <100 sec, preferably 15 to 80 sec, in particular 15 to 50 sec even with a safe procedure Such low Gurley values of less than 50 sec cannot be obtained with all methods known in the prior art. Porous films can also be obtained with Gurley values <600 sec and porosities> 50% with a thickness of less than 30 pm, preferably between 10 and 25 pm, in particular between 12 and 20 pm, even with operational safety.
    The porous sheet, or the porous layer (s) of the sheet, contains / n in another additional embodiment, in addition to the nanoscale dicarboxylic acid salts and polypropylenes described above, as an additional component, a copolymer in propylene block, as well as other polyolefins, which do not adversely affect the porosity. In these embodiments, it contains the sheet or porous layer generally of 50 to 85% by weight, preferably 60 to 75% by weight of propylene homopolymers and 15 to 50% by weight of propylene block copolymers, preferably of 25 to 40% by weight, and 0.001 to 5% by weight, preferably 50-1000 ppm, of the nanoscale dicarboxylic acid salt as the nucleating agent p, referred to the weight of the porous layer, or referred to the weight of the sheet . Eventually additional additives are usually included in small amounts of less than 2% by weight, for example stabilizers and neutralizing agents. In the event that additional polyolefins are contained, the proportion of the propylene homopolymer or block copolymer is correspondingly reduced. In general, the amount of additional polymers is 0 to <50% by weight, preferably 0.5 to 40% by weight, in particular 1 to 30% by weight, when these are additionally included. In these cases, the above-described proportion of polypropylenes or propylene block copolymers is correspondingly reduced. Similarly, the said proportion of propylene polymer or propylene block copolymer is reduced when amounts greater than 2% by weight of nucleating agent are used.
    The porous sheet can be single layer or multilayer. The thickness of the porous sheet is generally in a range of 10 to 200 pm, preferably 15 to 150 pm, in particular 15 to 100 pm. The density of the porous sheet is generally in a range of 0.1 to 0.6 g / cm3, preferably 0.2 to 0.5 g / cm3. The porous sheet can be provided with a corona, flame or plasma treatment to improve the filling with electrolytes. Eventually, the microporous film may comprise a disconnect layer, which reduces the permeability of the sheet at elevated temperatures.
    Porous sheets can be used advantageously as a membrane, for example in batteries, secondary batteries, in supercapacitors or similar applications.
    The following measurement methods were used to characterize raw materials and sheets:
    Flow index
    The flow rate of the propylene polymers was measured according to DIN 53 735 at 2.16 kg load and 230 ° C and at 190 ° C and 2.16 kg for polyethylenes.
    Melting points
    In the DSC measurement, a quantity of heat per unit of time is given to the polymer with a defined heating rate and the heat flux is represented as a function of temperature. The melting point is in the sense of the present invention the maximum of the DSC curve. To determine the melting point, the DSC curve is taken with a heating and cooling rate of 10K / 1min in the range of 20 to 200 ° C. To determine the melting point of the polymers, the second heating curve is evaluated as usual.
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    Density
    The density p is determined according to DIN 53 479, procedure A.
    Porosity
    The porosity is calculated from the pf density determined in the porous sheet and the density of the polypropylene starting raw material as follows:
    P [%] = 100x (1 -pp) / ppp
    A density of 0.92 g / cm3 was assumed for polypropylene.
    Permeability (Gurley value)
    The permeability of the sheets was measured with the Gurley 4110 test set, in accordance with ASTM D 726-58. In doing so, the time (in sec) needed by 100 cm3 of air to permeate the surface of a 1 inch2 (6.452 cm2) label is determined. The pressure difference across the sheet then corresponds to the pressure of a water column 12.4 cm high. The time required corresponds then to the value of Gurley.
    Ft content
    The proportion of p-crystalline polypropylene is determined by DSC. This characterization is described in J. O. Appl. Polymer Science, vol. 74, pages 2357-2368, 1999 of Varga and is carried out as follows: The sample additive with p-nucleator is first heated in the DSC up to 220 ° C with a heating rate of 20 ° C / min and melts (first heating ). It is then cooled to 100 ° C at a cooling rate of 10 ° C / min, before melting again with a heating rate of 10 ° C / min (second heating).
    Starting from the DSC curve of the first heating, it is determined from the relationship between the enthalpies of fusion of the p-crystalline phase (Hp) and the sum of the enthalpies of fusion of the p-a-crystalline phase (Hp + Ha) , the degree of crystallinity Kp, dsc (fraction of p-crystalline polypropylene) present in the measured sample (unstretched sheet, injection molding part). The percentage value is calculated as follows:
    image 1
    Starting from the DSC curve of the second heating, it is determined from the relationship between the enthalpies of fusion of the p-crystalline phase (Hp) and the sum of the enthalpies of fusion of the p-a-crystalline phase (Hp + Ha) , the degree of crystallinity Kp, dsc (second heating), which indicates the maximum proportion of p that can be achieved in the corresponding polypropylene sample.
    Agglomerates and particle size
    The particle size of the dicarboxylic acid salts and the presence of agglomerates are determined by scanning electron microscopy (REM) images of the samples.
    To carry out REM imaging on a sheet sample, a custom 5 x 5 mm piece of the biaxially stretched sheet is cut and adhered to the sample holder. Next, a layer of some nanometers thick of a noble metal (Pt, Au, Pd, ...) is applied on a sputtering unit on the sheet surface.
    The cathodically sprayed sample is then introduced into the REM through a gate and there it is scanned in high vacuum with an acceleration voltage of several kV. The acceleration voltage is chosen such that a sharp image is formed without deforming the matrix of the sheet due to the thermal load to which it is subjected. The particles are so clearly visible in the image that the size of the individual particles can be measured using the measurement scale.
    The corresponding determination of the particle size of the dicarboxylic acid salts in the compound is performed on a molten sheet as a test sample. For this purpose, a non-stretched molten sheet of approximately 120 to 150 pm is manufactured from the compound. This molten sheet is processed as described above.
    The sheet, or the compound is in the sense of the present invention free of agglomerates when no particles with a size of more than 1 pm are found in the REM image or when it exists as
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    maximum one particle of> 1 | jm. The average particle size can be determined by measuring the particle size of a statistically sufficient number of particles. Correspondingly, the proportion of agglomerates of> 1 pm can also be determined on the basis of REM images.
    To determine the particle size of the dispersed dicarboxylic acid salts, a small amount of the dispersion is applied on a slide, dried and sprayed equally. In this cathodically sprayed sample, a REM can be taken and the particle size determined. On these samples thus prepared, the presence of agglomerates is checked.
    The invention will now be described in more detail on the basis of embodiments:
    Example 1
    An aqueous solution containing 40 g of pimelic acid was introduced into 1000 ml of water and heated at 83 ° C until the pimelic acid dissolved completely. To this solution was added an aqueous calcium hydroxide milk (18.4 g of Ca (OH) 2 in 200 ml of water) while stirring, the calcium pimelate precipitating as a white precipitate. The sedimented precipitate was filtered by suction and dried preliminary at 130 ° C in the drying cabinet. Finally, residual moisture and crystallization water were removed in a vacuum drying cabinet at 200 ° C for 24h. In this way a dry coarse-grained powder of calcium pimelate was obtained.
    100 g of this dry calcium pimelate in 500 ml of anhydrous (water content <1% by weight) of isopropanol were separated and the sludge was introduced into a ball mill and ground. A stable milky dispersion then resulted. REM images show a particle size of the particles in the dispersion in the 75 nm range. In the samples no agglomerates with a particle size of more than 0.8 jm were found.
    Example 1 a:
    The milky dispersion according to example 1 was dried in the exhaust air dryer at 90 ° C for 10 h, excluding moisture. A white nanoscale calcium pimelate powder was obtained. This powder was mixed in the mixer at a concentration of 0.4% by weight, based on polypropylene, with isotactic polypropylene homopolymer granules (melting point 162 ° C; MFI 3 g / 10 min). This mixture was melted in a twin screw extruder (housing temperature 240 ° C and 200 1 / min-1) and granulated into rod-shaped grains.
    The REM images of the granules (molten sheet test sample) show the finely distributed calcium pimelate without agglomerate in the PP matrix. No particles with a size> 1 pm were found in the REM images. By means of DSC analysis, the nanoscale polypropylene and calcium pimelate compound shows a p-value of 97% in the second heating.
    Example 1b
    The milky dispersion according to example 1 was mixed using a drum mixer directly on an isotactic polypropylene homopolymer granulate and this mixture was dried during mixing in the drum (or thereafter). After drying, the grains of the granulate are coated with a layer of nanoscale calcium pimelate and showed a milky white color.
    The REM images of these granules (molten sheet test sample) show finely distributed calcium pimelate without agglomerate on the surface of the granules. These coated granules were melted in a twin screw extruder (housing temperature 240 ° C and 200 1 / min-1) and granulated to form grains in the form of a bar. This nanoscale polypropylene and calcium pimelate compound also shows a DS value of 97% in the second heating by DSC analysis. The REM images of these granulate grains show finely distributed calcium pimelate particles with a size of <100 nm. In REM images no particles with a size of> 1pm were found.
    Comparative Example 1
    An aqueous solution containing 40 g of pimelic acid was introduced into 1000 ml of water and heated at 83 ° C until the pimelic acid dissolved completely. To this solution was added an aqueous solution of calcium hydroxide (18.4 g of Ca (OH) 2 in 200 ml) with stirring, the calcium pimelate precipitating as a white precipitate. The sedimented precipitate was filtered by suction and dried preliminary at 130 ° C in the drying cabinet. Finally, residual moisture and crystallization water were removed in a vacuum drying cabinet at 200 ° C for 24h. In this way a dry coarse-grained powder of calcium pimelate was obtained.
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    100 g of this dry calcium pimelate was introduced into a ball mill and ground dry. Then a white powder of calcium pimelate resulted. REM images show a particle size of the powder in the 50o nm range with agglomerates with a particle size of up to 2 pm.
    Comparative Example 1a:
    The powder according to comparative example 1 was mixed in the mixer at a concentration of 0.4% by weight with granulation of isotactic polypropylene homopolymer (melting point 162 ° C, MFI 3 g / 10 min). This mixture was melted in a twin screw extruder (housing temperature 240 ° C and 200 1 / min-1) and granulated to form rod-shaped grains.
    The REM images of the granules (molten sheet test sample) show the finely distributed calcium pimelate in the PP matrix, but there are also agglomerates with a particle size of 1 to 10 pm. By means of DSC analysis, the mixture of polypropylene and nanoscale calcium pimelate shows a p-value of 97% in the second heating.
    Example of sheet 1
    In a mixer, the compound according to example 1a was mixed with propylene homopolymer and propylene block copolymer. This mixture was melted in an extruder and further homogenized. According to the extrusion process, the melt was extruded from a wide groove nozzle at an extrusion temperature of 245 ° C to form a single layer sheet. This sheet had the following composition:
    Approx. 50% by weight of propylene homopolymer (PP) with a n-heptane soluble content of 4.5% by weight (based on 100 PP) and a melting point of 165 ° C; and a flow rate of 3.2 g / 10 min at 230 ° C and 2.16 kg of load (DIN 53 735) and
    approx. 49.96% by weight of propylene-ethylene block copolymer with an ethylene content of approx. 5% by weight based on the block copolymer and a flow rate (230 ° C and 2.16 kg) of 6 g / 10 min
    0. 04% by weight of N-scale Ca pimelate as a nucleating agent p.
    The sheet additionally contained stabilizer and neutralizing agent in usual amounts.
    After extrusion, the polymer mixture was passed through a first stretching roller and an additional trio of rollers, cooled and solidified and then stretched longitudinally, stretched transversely and fixed, the following having been chosen in detail terms:
    Extrusion: extrusion temperature 245 ° C
    Cooling roller: temperature 125 ° C,
    Extraction speed: 1.5 m / min (residence time on the stretch roller: 55 sec)
    Longitudinal stretching: stretching roller T = 90 ° C Longitudinal stretching in factor 4
    Cross stretch: heating panels T = 145 ° C Stretch panels T = 145 ° C Cross stretch in factor 4
    The porous sheet thus produced had a thickness of approx. 30 pm and had a density of 0.30 g / cm3 and showed a uniform opaque white appearance. The porosity was 66% and the Gurley value of 340 sec. During the manufacture of the sheets no cracks were produced for several hours. The rEm image (figure 1) shows a uniform distribution of the Ca pimelate without agglomerates in the porous sheet. The dicarboxylic acid salts are easily recognizable as bright spots on the polymer chains of the polypropylene net.
    Example of sheet 2
    A sheet was manufactured as described in the example of sheet 1. Unlike the example of sheet 1, the compound according to example 1b is now used. A sheet with the same characteristics as according to the example was obtained
    1. Nor did cracks appear during manufacturing.
    Example of sheet 3
    A sheet was manufactured as described in the example of sheet 2. The composition was not modified. In contrast to the example of sheet 1, a stretch with a longitudinal stretch factor of 4.8 was performed during fabrication and in cross stretch with a factor of 5.8. The porous sheet thus manufactured had a thickness of approx. twenty
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    pm and had a density of 0.25 g / cm3 and showed a uniform opaque white appearance. The porosity was 60% and the Gurley value of 200 sec. Nor did cracks appear during manufacturing.
    Example of sheet 4
    A sheet was manufactured as described in the example of sheet 3. The composition was not modified. Unlike the example of sheet 1, a lower extraction speed of 1 m / min was chosen for manufacturing (residence time in the stretch roller: 80 sec). The other conditions of the procedure were not modified. The porous sheet thus manufactured had a thickness of approximately 25 pm and had a density of 0.25 g / cm 3 and showed a uniform opaque white appearance. The porosity was 70% and the value of Gurley was 60 sec. This sheet could also be surprisingly manufactured with a safe manufacturing process.
    Comparative Example 1 (Plate)
    A sheet was manufactured as described in the example of sheet 1. However, unlike the example of sheet 1, a compound manufactured according to comparative example 1a was used. A sheet with a similar profile of characteristics was obtained. But in the course of 4 hours of manufacturing there were 5 cracks. The REM images of the biaxially stretched sheet show agglomerated particles with a size of up to 5 pm.
    Comparative Example 2:
    A sheet was manufactured as described in the example of sheet 3. However, unlike the example of sheet 3 a compound manufactured according to comparative example 1a was used. A sheet with a characteristic profile similar to that of the sheet 3 example was obtained. But in the course of 4 hours of manufacture 10 cracks were produced. De facto the sheet could not be manufactured with a safe procedure nor was it cost effective. REM images (Figure 2) show agglomerated particles with a size of up to 5 pm. In particular in Figure 2 it can be seen how these agglomerates generate tears during stretching, which cause cracks during manufacturing.
    Comparative Example 3:
    A sheet was manufactured as described in the example of sheet 4. However, unlike the example of sheet 4, a compound manufactured according to comparative example 1a was used. Under these conditions of the process no sheet could be manufactured, due to the continuous cracks.
    Example 2
    An aqueous solution containing 40 g of subic acid was introduced into 1000 ml of water and heated to 85 ° C until the subic acid dissolved completely. To this solution was added an aqueous calcium hydroxide milk (17.02 g of Ca (OH) 2 in 200 ml of water) with stirring, the calcium suberate precipitating as a white precipitate. The sedimented precipitate was filtered by suction and dried preliminary at 130 ° C in the drying cabinet. Finally, residual moisture and crystallization water were removed in a vacuum drying cabinet at 200 ° C for 24h. In this way a dry coarse-grained powder of calcium suberate was obtained.
    100 g of this dry calcium suberate in 300 ml of isopropanol anhydrous were separated by gravity and the sludge was introduced into a ball mill and ground. A stable milky dispersion then resulted. REM images show a particle size of the particles in the dispersion in the 75 nm range. In the samples no agglomerates with a particle size of more than 1 pm were found.
    Example 2a: Powder
    The milky dispersion according to example 2 was dried in the exhaust air dryer at 90 ° C for 10 h, excluding moisture. A white powder of nanoscale calcium suberate was obtained.
    This powder was mixed in the mixer at a concentration of 0.4% by weight, based on polypropylene, with isotactic polypropylene homopolymer granules (melting point 162 ° C; MFI 3 g / 10 min). This mixture was melted in a twin screw extruder (housing temperature 240 ° C and 200 1 / min-1) and granulated into rod-shaped grains.
    The REM images of the granules (molten sheet test sample) show the finely distributed calcium suberate without agglomerate in the PP matrix. By means of DSC analysis, the mixture of polypropylene and nanoscale calcium suberate shows a 99% p-value in the second heating.
    Example 2b
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    The milky dispersion according to example 2 was mixed using a drum mixer directly on an isotactic polypropylene homopolymer granulate and this mixture was dried during mixing in the drum (or thereafter). After drying, the grains of the granulate are coated with a layer of nanoscale calcium suberate and show a milky white color.
    The REM images of these granulate grains (molten sheet test sample) show finely distributed calcium suberate without agglomerate on the surface of the granulate grains. These coated granulate grains were melted in a twin screw extruder (housing temperature 240 ° C and 200 1 / min-1) and granulated to form rod-shaped grains. This nano-scale polypropylene and calcium suberate compound also shows a 99% p value in the second heating by DSC analysis. The REM images of the granulate grains (molten sheet test sample) show the finely distributed calcium suberate particles with a size of <100 nm. No agglomerates with a particle size of> 1 pm were found.
    Plate Example 5
    In a mixer, the compound according to example 2a was mixed with propylene homopolymer and propylene block copolymer. This mixture was melted in an extruder and further homogenized. According to the extrusion process, the melt was extruded from a wide groove nozzle at an extrusion temperature of 245 ° C to form a single layer sheet. This sheet had the following composition:
    Approx. 50% by weight of propylene homopolymer (PP) with a soluble n-heptane content of 4.5% by weight
    (referred to 100% pP) and a melting point of 165 ° C; and a flow rate of 3.2 g / 10 min at 230 ° C and 2.16 kg of load (DIN 53 735) and
    approx. 49.96% by weight of propylene-ethylene block copolymer with an ethylene content of approx. 5% by weight based on the block copolymer and a flow rate (230 ° C and 2.16 kg) of 6 g / 10 min
    0.04% by weight of N-scale Ca subarate as nucleating agent p.
    The sheet additionally contained stabilizer and neutralizing agent in usual amounts.
    After extrusion, the polymer mixture was passed through a first stretching roller and an additional trio of rollers, cooled and solidified and then stretched longitudinally, stretched transversely and fixed, the following having been chosen in detail terms:
    Extrusion: extrusion temperature 245 ° C
    Cooling roller: temperature 125 ° C,
    Extraction speed: 1.5 m / min (residence time on the stretch roller: 55 sec)
    Longitudinal stretching: stretching roller T = 90 ° C Longitudinal stretching in factor 4
    Cross stretch: heating panels T = 145 ° C Stretch panels T = 145 ° C Cross stretch in factor 4
    The porous film thus manufactured had a thickness of approx. 30 pm and had a density of 0.30 g / cm3 and showed a uniform opaque white appearance. The porosity was 66% and the Gurley value of 340 sec. During the manufacture of the sheets no cracks were produced for several hours.
    Plate Example 6
    A sheet was manufactured as described in the example of sheet 5. Unlike the example of sheet 5, the compound according to example 2b was now used. A sheet with the same characteristics as in the example of sheet 5 was obtained. Nor did cracks appear during manufacturing.
    权利要求:
    Claims (15)
    [1]
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    1. Process for manufacturing a stable dispersion formed by an anhydrous liquid phase and dispersed dicarboxylic acid salts, in which an aliphatic dicarboxylic acid reacts with a divalent metal salt in an aqueous solution to form a dicarboxylic acid salt and the acid salt dicarboxylic is then separated and dried,
    characterized in that the salt of dried dicarboxylic acid in an anhydrous liquid phase is then separated by gravity and crushed until a stable dispersion is formed, the dispersion containing <1% salts of dicarboxylic acid having a particle size of> 1 | jm, determining the size of the particles and the presence of agglomerates in images of the samples in the scanning electron microscope.
    [2]
    2. Method according to claim 1,
    characterized in that the dicarboxylic acid is an aliphatic dicarboxylic acid with 4 to 15 C atoms and the anhydrous liquid phase is an alcohol.
    [3]
    3. Method according to claim 1 or 2,
    characterized in that the dicarboxylic acid is pimelic acid or suberic acid and the metal salt is an alkaline earth salt.
    [4]
    4. Process according to one of claims 1 to 3, characterized in that the metal salt is a hydroxide, a carbonate or a chloride.
    [5]
    5. Polypropylene compound, which can be obtained by a process in which the anhydrous liquid phase is removed from the dispersion manufactured according to one of claims 1 to 4, the remaining powder of dicarboxylic acid salt is mixed with polypropylene already The preliminary mixture thus obtained is melted and extruded to form a granulated compound.
    [6]
    6. Polypropylene compound, which can be obtained by a process in which a dispersion, manufactured
    according to one of claims 1 to 4, it is mixed with polypropylene, the anhydrous liquid phase of this mixture is removed and then the preliminary mixture thus obtained is melted and extruded to form a granulated compound.
    [7]
    7. Polypropylene with a proportion of p-crystalline polypropylene, which can be obtained by a process in
    that the anhydrous liquid phase is removed from the dispersion manufactured according to one of claims 1 to 4, the remaining powder of dicarboxylic acid salt is mixed with polypropylene and melted at a temperature of at least 150 ° C and the The melt is then slowly cooled to a temperature in the range of 60 to 135 ° C and the cooled polypropylene melt has a proportion of p-crystalline polypropylene of 10 to 95%, this proportion of p-crystalline polypropylene being determined by means DSC measurement, as described in the description under the corresponding title.
    [8]
    8. Polypropylene with a proportion of p-crystalline polypropylene, which can be obtained by a process in which a compound according to claim 5 or 6, if necessary mixed with polypropylene without nucleating agents and / or other polyolefins and / or Additional additives melt at a temperature of at least 150 ° C and then the melt is cooled slowly to a temperature in the range of 60 to 135 ° C and the cooled polypropylene melt contains a proportion of p-crystalline polypropylene of 10 to 95%, said proportion of p-crystalline polypropylene being determined by DSC measurement, as described in the description under the corresponding heading.
    [9]
    9. Biaxially stretched polypropylene sheet with at least one porous layer, which can be obtained by a process in which a compound according to claim 5 or 6, if necessary mixed with additional polypropylene and / or other polymers and / or additives additional, it melts at a temperature of at least 160 ° C and is extruded through a flat nozzle and cooled on cooling rollers at a temperature in the range of 80 to 130 ° C, with a long stay at this temperature and the cooled preliminary sheet has at least 40% p-crystalline polypropylene, this proportion of p-crystalline polypropylene being determined by DSC measurement, as described in the description under the corresponding title and the preliminary sheet is then heated and stretched in the longitudinal direction and in the transverse direction and in which the temperature during stretching is chosen so that the p-crystalline polypropylene of the sheet Preliminary mine becomes the modification of polypropylene.
    [10]
    10. Polypropylene sheet according to claim 9,
    characterized in that the nanoscale dicarboxylic acid salt has a particle size of less than 100 nm in the porous sheet and there is no agglomerate with a particle size of> 1 jm.
    [11]
    11. Polypropylene sheet according to claim 9 or 10,
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    characterized in that the sheet has a Gurley value of <500 sec, measured according to ASTM D 726-58.
    [12]
    12. Polypropylene sheet according to one of claims 9 to 11,
    characterized in that the porosity of the sheet is> 50%, the porosity P being determined by measuring the density according to DIN 53 479, procedure A, as described in the description under the corresponding title.
    [13]
    13. Use of a porous sheet according to one of claims 9 to 12, as a membrane in batteries, secondary batteries or in supercapacitors.
    [14]
    14. Biaxially stretched polypropylene sheet with at least one layer, which can be obtained by a process in which for the layer a compound according to one of claims 5 to 6, if necessary mixed with additional polypropylene and / or other polymers and / or additional additives, melts at a temperature of at least 160 ° C and is extruded through a flat nozzle and cooled on cooling rollers at a temperature in the range of 80 to 130 ° C, with a long permanence at this temperature and the cooled preliminary sheet has 10 to 40% p-crystalline polypropylene in the layer, this proportion of p-crystalline polypropylene being determined by DSC measurement, as described in the description under the corresponding title and sheet Preliminary is then heated and stretched in the longitudinal direction and in the transverse direction and in which the temperature during stretching is chosen so that the polypropylene The non-p-crystalline of the preliminary sheet becomes the modification a of the polypropylene and the layer forms an outer layer of the sheet and this layer has a surface roughness on the outer surface due to crater-like depressions.
    [15]
    15. Use of a sheet according to claim 14 as a dielectric in capacitors or as a sheet with properties similar to paper.
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    法律状态:
    优先权:
    申请号 | 申请日 | 专利标题
    DE102009050439|2009-10-20|
    DE102009050439A|DE102009050439A1|2009-10-20|2009-10-20|Nanoscale ß-nucleating agent for polypropylene|
    PCT/EP2010/006240|WO2011047797A1|2009-10-20|2010-10-13|NANOSCALE β-NUCLEATING AGENT FOR POLYPROPYLENE|
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