Homopolymer Polypropylene for Packaging Materials

Recyclable stand-up pouch for beverages made entirely of polypropylene that can be hot filled, sealed, and recycled. The pouch has a thin outer layer for printing and a thicker sealing layer. The outer layer is extruded and glued to the sealing layer. The pouch is formed by connecting the front, back, and base sections using a sealing structure. The sealing layer is thicker than the outer layer to provide sealing properties. The pouch can be hot filled, sealed, and recycled as a single-material polypropylene structure.

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Recyclable stand-up pouch for beverages that is made entirely of polypropylene, is easier to recycle compared to traditional multi-material pouches, and has improved barrier properties. The pouch has separate outer, inner, and base layers all made of polypropylene. The inner layer is thicker than the outer layer to provide sealing. This allows the pouch to be sealed and filled without needing a separate sealing layer. The barrier properties of the polypropylene layers prevent spoilage and evaporation. The pouch can be recycled as a single material instead of separating layers.

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Preparing wide molecular weight distribution polypropylene using a supported catalyst in combination with molecular weight control agents. The method involves using a rare earth metal-containing catalyst and different molecular weight control agents at different stages of continuous propylene polymerization. This allows tuning chain transfer rates to create a wide polypropylene molecular weight distribution.

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Packaging material with improved recyclability and a method to predict recyclability of packaging containing printing inks, adhesives, and additives. The packaging material contains only propylene-based plastics like polypropylene (PP) and ethylene-propylene copolymers (EPP) to enhance recyclability. The printing ink, adhesive, and additives are selected to decompose at temperatures above 320°C, preventing gas bubbles in recycled material. The decomposition profile is analyzed to predict recyclability.

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Soft polypropylene with low hardness and flexural modulus for applications like packaging, automotive interiors, and medical devices where traditional polypropylene is too stiff. The softness is achieved by a specific polymerization process using high ethylene content, high specific surface area catalysts, and multi-stage reactors. The process involves bulk polymerizing propylene with a small amount of ethylene in two loop reactors to destroy stereoregularity, then gas phase copolymerizing propylene and ethylene in a third reactor to generate high ethylene content ethylene-propylene copolymers with low modulus and hardness.

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Propylene polymerization method to narrow powder particle size distribution without prepolymerization steps. The method involves adding the propylene catalyst containing a polymer nucleating agent, cocatalyst, and optional electron donor separately to the main polymerization reactor instead of precontacting them. This prevents excessive activation of the catalyst before polymerization and allows better control over particle size. The catalysts are introduced sequentially instead of contacting before the reactor. This improves the morphology and narrows the particle size distribution of the polypropylene powder compared to precontact methods.

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A method and device for preparing metallocene polypropylene (mPP) using bulk polymerization. The method involves reacting propylene and hydrogen in the presence of a metallocene catalyst. The catalyst contains a specific metallocene compound, support, and optional cocatalyst. The device has a reactor with separate catalyst and propylene inlets. This allows accurate catalyst metering and prevents impurity breaker contamination. It also has a bottom discharge pipeline with a valve for product removal. The device design enables controlled catalyst addition and impurity mitigation for high quality mPP production.

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Producing ultra-high molecular weight polypropylene (UHMW-PP) without using hydrogen as a molecular weight regulator during polymerization. The method involves controlling the ratios of the main catalyst, co-catalyst, and co-catalyst, as well as the polymerization temperature and pressure, to achieve UHMW-PP with viscosity average molecular weight above 1 million g/mol. This allows producing UHMW-PP with lower inorganic content and smaller particle size compared to conventional methods.

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A method for producing high molecular weight polypropylene with a narrow molecular weight distribution using a specific catalyst system. The catalyst contains a transition metal compound represented by Formula 1, with the metal M, groups Q1 and Q2, and ligands R1-R12. The catalyst may also include cocatalysts like aluminoxanes. Polymerizing propylene with this catalyst system yields polypropylene with weight average molecular weight (Mw) of 90,000 to 300,000 g/mol and molecular weight distribution (Mw/Mn) of 1 to 15.

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Easily recyclable oxygen and moisture barrier packaging material made of polypropylene (PP) that provides superior barrier properties while enabling easy recycling. The packaging has a base film, a multi-layer barrier layer on it containing at least one barrier, and an outer layer on the barrier layer. The barrier layers are formed using deposition and wet coating techniques to combine metal adherence and barrier agents. This allows improved barrier properties by supplementing single barrier materials and merging functions. The use of PP throughout provides recyclability.

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Recyclable multilayer packaging material with improved chemical resistance for applications like pharmaceuticals and personal care products. The material is made of multiple polypropylene (PP) layers bonded together using different adhesives. This allows recyclability since it uses a single plastic type. The PP layers are preferably biaxially oriented PP (BOPP) for strength. The use of PP instead of other plastics like PE provides better chemical resistance against aggressive fillers. The packaging material can be made by adhesive lamination or extrusion lamination.

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A catalyst system for gas-phase polypropylene production that allows preparation of polypropylene with broad molecular weight distribution in a single reactor. The catalyst system comprises ZN (Ziegler-Natta) catalyst, triethylaluminum, and two or more external electron donor composites. The electron donors can be silanes like diisopropyldimethoxysilane and tetraethoxysilane. The ratio of the donors is 0.1-75% for the first donor and 99.9-25% for the second donor. This catalyst system improves hydrogen sensitivity and enables preparation of polypropylene with composite properties in a single reactor, avoiding the need for multiple reactors for product development.

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A method to prepare impact-resistant polypropylene with improved properties compared to traditional multi-stage reactor methods. The method involves removing entrained light components like hydrogen from the polypropylene powder between stages. This is done by separating the gas and solid phases in a dedicated gas-solid separator before introducing the powder into the next reactor. This prevents the light components from participating in the copolymerization reaction and improves the impact resistance of the final polypropylene.

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Producing polypropylene with high melt flow index for applications like meltblown fiber fabrics, by using a specific electron donor with the catalyst and slurry polymerization to prevent catalyst deactivation from hydrogen gas. The electron donor is amino silane compounds. This allows higher melt flow index polypropylene above 500 g/10min without catalyst deactivation issues. The polymerization is in a slurry reaction system.

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A catalyst composition and method for producing high-strength polypropylene with improved mechanical properties and high crystallinity in a shorter time compared to conventional Ziegler-Natta catalysts. The catalyst composition contains a Ziegler-Natta catalyst, an external electron donor, diisobutylaluminum hydride, and trialkyl aluminum. The composition allows producing polypropylene with Xylene Cold Soluble content of 3 wt% or less in a shorter time. The catalyst composition ratio ranges are: 0.005-0.1 wt% Ziegler-Natta catalyst, 5-20 wt% electron donor, 0.05-3 wt% diisobutylaluminum hydride, and 10-94 wt% trialkyl aluminum. The catalyst

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A multilayer polypropylene fabric for making bagged products that allows hot sealing like heat-sealable PE films while maintaining mechanical strength like woven PP fabrics. The fabric consists of two layers: an outer layer made of woven PP (WWP) for mechanical strength, and an inner layer made of heat-sealable PP (CPP) for sealing. The fabric can be extruded into PP bags that can be closed using heat sealing like PE bags. The heat sealing temperature is between 110-120°C. The fabric allows hot sealing the bag mouth without affecting the mechanical properties. This provides a 100% PP bag that can be sealed like PE bags but has better recyclability and reusability compared to mixed material bags.

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A multilayer polypropylene fabric for making bagged packaging that can be sealed shut using heat welding instead of sewing. The fabric consists of multiple layers including an outer woven polypropylene layer for strength and an inner thermo-weldable layer for sealing. The outer layer provides mechanical rigidity while the inner layer allows heat sealing to create a watertight closure. The multilayer fabric allows making 100% PP bags that can be sealed shut using existing heat sealing equipment without compromising strength or waterproofing.

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A method to prepare polypropylene using a metallocene catalyst that reduces fragmentation of the catalyst particles during polymerization. The method involves continuously transporting the catalyst to a prepolymerization reactor using two inert solvents. The first solvent (A) transports the catalyst and propylene, while the second solvent (B) transports just the catalyst. By adjusting the solvent ratios, it enables efficient and safe catalyst transportation and controllable prepolymerization activity. The prepolymerization coats the catalyst particles, increasing strength. This reduces fragmentation in main polymerization.

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A process for making high melt index propylene polymers with improved rigidity. The process involves a two-stage polymerization. In stage 1, prepolymerization is done at low temperature and pressure to generate a propylene prepolymer. In stage 2, homopolymerization or copolymerization is done at higher temperature and pressure using the prepolymer. The lower temperature and pressure stage improves polymer properties like isotacticity and hydrogen sensitivity. The higher temperature and pressure stage allows higher melt index. The weight ratio of polymers in stages 2 and 3 can be adjusted for optimal balance.

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A process for making highly isotactic polypropylene with low decalin solubility using a Ziegler-Natta catalyst and specific diluent composition. The process involves suspension polymerization with a Ziegler-Natta catalyst, propylene, and a diluent containing a donor agent. The donor agent improves isotacticity while preventing ether compounds from decreasing it. The polypropylene has a soluble decalin fraction of 2.5% or less, with high isotacticity and catalyst activity. The recovered diluent is purified and reused with added donor agent.

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