EP1613797B1 - Monofilaments or stretched tapes from metallocene-produced polyethylene - Google Patents
Monofilaments or stretched tapes from metallocene-produced polyethylene Download PDFInfo
- Publication number
- EP1613797B1 EP1613797B1 EP04726183A EP04726183A EP1613797B1 EP 1613797 B1 EP1613797 B1 EP 1613797B1 EP 04726183 A EP04726183 A EP 04726183A EP 04726183 A EP04726183 A EP 04726183A EP 1613797 B1 EP1613797 B1 EP 1613797B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- indenyl
- metallocene
- unsubstituted
- substituted
- ind
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- -1 polyethylene Polymers 0.000 title claims description 27
- 239000004698 Polyethylene Substances 0.000 title description 12
- 229920000573 polyethylene Polymers 0.000 title description 12
- 125000003454 indenyl group Chemical group C1(C=CC2=CC=CC=C12)* 0.000 claims description 25
- 239000011347 resin Substances 0.000 claims description 25
- 229920005989 resin Polymers 0.000 claims description 25
- 125000004432 carbon atom Chemical group C* 0.000 claims description 10
- 238000000034 method Methods 0.000 claims description 10
- 229920013716 polyethylene resin Polymers 0.000 claims description 10
- YBYIRNPNPLQARY-UHFFFAOYSA-N 1H-indene Natural products C1=CC=C2CC=CC2=C1 YBYIRNPNPLQARY-UHFFFAOYSA-N 0.000 claims description 9
- 238000000137 annealing Methods 0.000 claims description 9
- 229910052736 halogen Inorganic materials 0.000 claims description 9
- 238000004519 manufacturing process Methods 0.000 claims description 9
- 238000002844 melting Methods 0.000 claims description 9
- 230000008018 melting Effects 0.000 claims description 9
- 150000002367 halogens Chemical class 0.000 claims description 8
- XYFCBTPGUUZFHI-UHFFFAOYSA-N Phosphine Natural products P XYFCBTPGUUZFHI-UHFFFAOYSA-N 0.000 claims description 7
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 7
- KPUWHANPEXNPJT-UHFFFAOYSA-N disiloxane Chemical class [SiH3]O[SiH3] KPUWHANPEXNPJT-UHFFFAOYSA-N 0.000 claims description 7
- 229910052732 germanium Inorganic materials 0.000 claims description 7
- GNPVGFCGXDBREM-UHFFFAOYSA-N germanium atom Chemical compound [Ge] GNPVGFCGXDBREM-UHFFFAOYSA-N 0.000 claims description 7
- 229910000073 phosphorus hydride Inorganic materials 0.000 claims description 7
- 229910052710 silicon Inorganic materials 0.000 claims description 7
- 239000010703 silicon Substances 0.000 claims description 7
- 229910052723 transition metal Inorganic materials 0.000 claims description 7
- 150000003624 transition metals Chemical class 0.000 claims description 7
- 229910052720 vanadium Inorganic materials 0.000 claims description 7
- 229920001179 medium density polyethylene Polymers 0.000 claims description 5
- 239000004701 medium-density polyethylene Substances 0.000 claims description 5
- 239000000155 melt Substances 0.000 claims description 5
- 238000005520 cutting process Methods 0.000 claims description 4
- 230000008569 process Effects 0.000 claims description 4
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 claims 3
- 239000004743 Polypropylene Substances 0.000 description 5
- 239000003054 catalyst Substances 0.000 description 5
- 125000000058 cyclopentadienyl group Chemical group C1(=CC=CC1)* 0.000 description 5
- 229920001903 high density polyethylene Polymers 0.000 description 5
- 239000004700 high-density polyethylene Substances 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- 229920001155 polypropylene Polymers 0.000 description 5
- 238000009826 distribution Methods 0.000 description 4
- 239000012968 metallocene catalyst Substances 0.000 description 4
- GPPXJZIENCGNKB-UHFFFAOYSA-N vanadium Chemical compound [V]#[V] GPPXJZIENCGNKB-UHFFFAOYSA-N 0.000 description 4
- 239000011954 Ziegler–Natta catalyst Substances 0.000 description 3
- 125000001183 hydrocarbyl group Chemical group 0.000 description 3
- 229920000642 polymer Polymers 0.000 description 3
- 125000001424 substituent group Chemical group 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 2
- 239000004594 Masterbatch (MB) Substances 0.000 description 2
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 2
- 125000000217 alkyl group Chemical group 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 2
- 229910052739 hydrogen Inorganic materials 0.000 description 2
- 239000001257 hydrogen Substances 0.000 description 2
- 229910052809 inorganic oxide Inorganic materials 0.000 description 2
- 229920001684 low density polyethylene Polymers 0.000 description 2
- 239000004702 low-density polyethylene Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 2
- MCULRUJILOGHCJ-UHFFFAOYSA-N triisobutylaluminium Chemical compound CC(C)C[Al](CC(C)C)CC(C)C MCULRUJILOGHCJ-UHFFFAOYSA-N 0.000 description 2
- 229910052726 zirconium Inorganic materials 0.000 description 2
- 125000004209 (C1-C8) alkyl group Chemical group 0.000 description 1
- AQZWEFBJYQSQEH-UHFFFAOYSA-N 2-methyloxaluminane Chemical compound C[Al]1CCCCO1 AQZWEFBJYQSQEH-UHFFFAOYSA-N 0.000 description 1
- 229920000089 Cyclic olefin copolymer Polymers 0.000 description 1
- 229920003299 Eltex® Polymers 0.000 description 1
- 239000005977 Ethylene Substances 0.000 description 1
- 239000006057 Non-nutritive feed additive Substances 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- QNYVNUYNGHIJEO-UHFFFAOYSA-L [Cl-].[Cl-].C(C)(C)=[Zr+2]C1CCC2CC=CC=C12 Chemical compound [Cl-].[Cl-].C(C)(C)=[Zr+2]C1CCC2CC=CC=C12 QNYVNUYNGHIJEO-UHFFFAOYSA-L 0.000 description 1
- JGMRTNMKYAPNAV-UHFFFAOYSA-L [Cl-].[Cl-].C1=CC(CCCC2)=C2C1[Zr+2](=C(C)C)C1C(CCCC2)=C2C=C1 Chemical group [Cl-].[Cl-].C1=CC(CCCC2)=C2C1[Zr+2](=C(C)C)C1C(CCCC2)=C2C=C1 JGMRTNMKYAPNAV-UHFFFAOYSA-L 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 150000001336 alkenes Chemical class 0.000 description 1
- 125000003342 alkenyl group Chemical group 0.000 description 1
- 125000003545 alkoxy group Chemical group 0.000 description 1
- 125000002877 alkyl aryl group Chemical group 0.000 description 1
- 125000001118 alkylidene group Chemical group 0.000 description 1
- 125000003710 aryl alkyl group Chemical group 0.000 description 1
- 125000003118 aryl group Chemical group 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 206010061592 cardiac fibrillation Diseases 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 125000000596 cyclohexenyl group Chemical group C1(=CCCCC1)* 0.000 description 1
- 125000000219 ethylidene group Chemical group [H]C(=[*])C([H])([H])[H] 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 230000002600 fibrillogenic effect Effects 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 229910052735 hafnium Inorganic materials 0.000 description 1
- VBJZVLUMGGDVMO-UHFFFAOYSA-N hafnium atom Chemical compound [Hf] VBJZVLUMGGDVMO-UHFFFAOYSA-N 0.000 description 1
- 150000004820 halides Chemical class 0.000 description 1
- 125000005843 halogen group Chemical group 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 229910003480 inorganic solid Inorganic materials 0.000 description 1
- GWYFCOCPABKNJV-UHFFFAOYSA-N isovaleric acid Chemical compound CC(C)CC(O)=O GWYFCOCPABKNJV-UHFFFAOYSA-N 0.000 description 1
- 238000002074 melt spinning Methods 0.000 description 1
- 239000000178 monomer Substances 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 239000005022 packaging material Substances 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 238000010094 polymer processing Methods 0.000 description 1
- 238000006116 polymerization reaction Methods 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 230000006641 stabilisation Effects 0.000 description 1
- 238000011105 stabilization Methods 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 238000009941 weaving Methods 0.000 description 1
- 239000004711 α-olefin Substances 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D5/00—Formation of filaments, threads, or the like
- D01D5/42—Formation of filaments, threads, or the like by cutting films into narrow ribbons or filaments or by fibrillation of films or filaments
- D01D5/426—Formation of filaments, threads, or the like by cutting films into narrow ribbons or filaments or by fibrillation of films or filaments by cutting films
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D5/00—Formation of filaments, threads, or the like
- D01D5/42—Formation of filaments, threads, or the like by cutting films into narrow ribbons or filaments or by fibrillation of films or filaments
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
- D01F6/02—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D01F6/04—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
- D01F6/28—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D01F6/30—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds comprising olefins as the major constituent
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2913—Rod, strand, filament or fiber
- Y10T428/2933—Coated or with bond, impregnation or core
Definitions
- This invention relates to the field of monofilaments and stretched tapes prepared with metallocene-produced polyethylene.
- Monofilaments are uniaxially oriented wire-like polymer strands having a circular cross section. They are manufactured by melt spinning process and their size ranges from 0.1 to 2.5 mm in diameter, depending upon the end use application. Polyethylene, polypropylene, nylon and polyesters are commonly used as raw materials for making monofilaments.
- Stretched tapes are prepared from a primary film produced either by a blown or by a cast film process.
- the film can be cut into tapes and then oriented or reversely, oriented and then cut into tapes.
- the orientation is carried out by stretching the film or tapes while passing through an air oven or on a hot plate at a temperature below the melting point.
- the stretching is carried out by passing the film or tapes over two sets of rollers placed respectively before and after the air oven/hot plate and operating at different speeds, the speed of the second set of rellers being larger than that of the first set of rollers.
- the polymer preferably used in the market for these applications is a high density polyethylene (HDPE) prepared with a Ziegler-Natta catalyst, said HDPE having a MI2 smaller than 1 g/10min such as for example Solvay Eltex A4009MFN1325 resin or Basell Hostalen GF 7740 F1, GF7740 F2, GF7740 F3, GF7750 M2 grades or the polyethylene resins disclosed in GB-0023662 .
- the molecular weight distribution MWD of these resins is quite broad which means that the resins may include very long as well as very short chains.
- JP 11-201,176 A discloses a shrinkable packaging material obtained by weaving a flat yam comprising an ethylene- ⁇ -olefin copolymer having a 0.90 - 0.93 g/cm 3 density and produced by using a metallocene catalyst.
- PE polycrystalline polyethylene
- PP polypropylene
- raffia is defined as woven monofilaments or woven stretched tapes.
- the stretched tapes and monofilaments prepared with polyethylene exhibit a higher elongation at rupture, a greater flexibility and a lower tendency to fibrillation than those prepared from polypropylene. These properties are advantageous for example in the production of woven tape fabrics.
- the products prepared from polyethylene however suffer from the disadvantage their tenacity is much lower than that of the products prepared from polypropylene. Tenacity increases as a function of molecular weight, density, degree of orientation of the chains/crystallites and increases with narrowing of the molecular weight distribution. Impact strength increases with decreasing density, increasing molecular weight and decreasing molecular weight distribution.
- the present invention provides monofilaments or stretched tapes, unwoven or woven into raffia prepared from metallocene-produced polyethylene (mPE) resin having long chain branches, and a density of from 0.930 to 0.950 g/cm 3 , wherein the metallocene component is a bis-indenyl represented by the general formula R" (Ind) 2 MQ 2 (I) wherein (Ind) is an indenyl or an hydrogenated indenyl, substituted or unsubstituted, R" is a structural bridge between the two indenyls to impart stereorigidity that comprises a C 1 -C 4 alkylene radical, a dialkyl germanium or silicon or siloxane, or a alkyl phosphine or amine radical, which bridge is substituted or unsubstituted; Q is a hydrocarbyl radical having from 1 to 20 carbon atoms or a halogen, and M is a group IVb transition metal or vanadium.
- the preferred metallocene catalyst component is based on a terahydroindenyl component or on a constrained geometry component, more preferably on a terahydroindenyl component.
- the invention also provides a process for preparing the above mentioned raffia or stretched tapes with a metallocene-produced polyethylene that comprises the steps of:
- the primary film can first be cut into strips and then oriented by stretching.
- the present invention also provides a process for preparing the above mentioned raffia or stretched tapes that comprises the steps of
- the film can be either a blown film or a cast film. Film production is easier with processed material having high melt strength such as polyethylene having long chain branches and/or very long linear chains. Metallocene catalyst systems based on tetrahydroindenyl components or on constrained geometry components are particularly useful for preparing polyethylene resins having long branches.
- the resins prepared with a terahydroindenyl catalyst component provide a very stable bubble thereby leading to films having a uniform thickness and presenting no or very little creases. Uneven thickness and creases are points of weakness when the film is cut into tapes and stretched.
- the resins prepared with a terahydroindenyl catalyst component have a stable elongational viscosity leading to a stable and regular thickness.
- resins having long branches keep good mechanical properties, such as traction resistance and tenacity, at densities smaller than those of linear resins having equivalent mechanical properties.
- Working at low densities has the advantage of providing material that has improved flexibility, low fusion temperature and good processability.
- Orientation of the primary film or of the cut tapes is carried out by stretching while passing through an air oven or over a hot plate, maintained at a temperature below the melting temperature. Stretching of the primary film or of the cut tapes is done by passing said film or tapes over two sets of rollers (goddet rollers) placed respectively before and after the air oven/hot plate, and operating at different speeds.
- the stretch ratio S2/S1 is defined by the ratio of the speed of roller 2, S2 to the speed of roller 1, S1 wherein S2 is larger than S1.
- Stretching at such high temperature results in chain/crystals orientation with a simultaneous increase of crystallinity. These structural changes lead to an increase of tensile strength and concurrently to a reduction of elongation.
- the tensile strength increases with increasing stretch ratio and with increasing stretching temperature. It is preferred that the stretching temperature is as close as possible-to but smaller than the melting temperature.
- typical values for the stretch ratio are of from 5.0 to 7.0.
- the typical stretching temperatures depend upon the melting temperature of the polyethylene resins: they must be lower than but as close as possible to the melting temperature. Typically, they are from 5 to 70 °C lower than the melting temperature of the resin, preferably they are from 10 to 50 °C lower than the melting temperature of the resin.
- the drawn tapes are annealed immediately after the stretching operation in order to minimise shrinkage that could occur as a result of residual stresses in the oriented tapes.
- Annealing is done by heating the stretched tapes while they are being transferred from the second goddet rollers onto a third roller having a speed S3 that is smaller than the speed of roller 2, S2.
- speed S3 is about 95 % of speed S2.
- the annealing ratio AR is defined as (S2-S3)/S2) at a temperature slightly inferior to the stretching temperature.
- the annealing temperature is from 5 to 10 °C lower than the stretching temperature.
- Polymers that do not include either very long linear chains or long chain branched molecules have a better stretchability.
- the low density polyethylene (LDPE) having long chain branches cannot be stretched beyond a certain degree, whereas the purely linear polyethylene chains usually obtained with a Ziegler-Natta catalyst have a high degree of stretchability.
- the metallocene used to prepare the high density polyethylene is a bis-indenyl represented by the general formula: R" (Ind) 2 MQ 2 (I) wherein (Ind) is an indenyl or an hydrogenated indenyl, substituted.
- R" is a structural bridge between the two indenyls to impart stereorigidity that comprises a C 1 -C 4 alkylene radical, a dialkyl germanium or silicon or siloxane, or a alkyl phosphine or amine radical, which bridge is substituted or unsubstituted;
- Q is a hydrocarbyl radical having from 1 to 20 carbon atoms or a halogen, and M is a group IVb transition metal or Vanadium.
- each indenyl or hydrogenated indenyl compound may be substituted in the same way or differently from one another at one or more positions in the cyclopentadienyl ring, the cyclohexenyl ring and the bridge.
- each substituent on the indenyl may be independently chosen from those of formula XR v in which X is chosen from group IVA, oxygen and nitrogen and each R is the same or different and chosen from hydrogen or hydrocarbyl of from 1 to 20 carbon atoms and v+1 is the valence of X.
- X is preferably C.
- the cyclopentadienyl ring is substituted, its substituent groups must be so bulky as to affect coordination of the olefin monomer to the metal M.
- Substituents on the cyclopentadienyl ring preferably have R as hydrogen or CH 3 . More preferably, at least one and most preferably both cyclopentadienyl rings are unsubstituted.
- both indenyls are unsubstituted and the most preferred catalyst component is a tetrahydroindenyl.
- R" is preferably a C1-C4 alkylene radical (as used herein to describe a difunctional radical, also called alkylidene), most preferably an ethylene bridge (as used herein to describe a difunctional radical, also called ethylidene), which is substituted or unsubstituted.
- the metal M is preferably zirconium, hafnium, or titanium, most preferably zirconium.
- Each Q is the same or different and may be a hydrocarbyl or hydrocarboxy radical having 1 to 20 carbon atoms or a halogen.
- Suitable hydrocarbyls include aryl, alkyl,alkenyl,alkylaryl or arylalkyl.
- Each Q is preferably halogen.
- metallocenes used in the present invention one can cite bis tetrahydro-indenyl compounds and bis indenyl compounds as disclosed for example in WO 96/35729 or bis(cyclopentadienyl) compounds.
- the most preferred metallocene catalyst is isopropylidene-bis(4,5,6,7-tetrahydro-1-indenyl) zirconium dichloride.
- the metallocene may be supported according to any method known in the art.
- the support used in the present invention can be any organic or inorganic solids, particularly porous supports such as talc, inorganic oxides, and resinous support material such as polyolefin.
- the support material is an inorganic oxide in its finely divided form.
- alumoxane is used to ionise the catalyst during the polymerization procedure, and any alumoxane known in the art is suitable.
- the preferred alumoxanes comprise oligomeric linear and/or cyclic alkyl alumoxanes represented by the formula : And wherein n is 1-40, preferably 10-20, m is 3-40, preferably 3-20 and R is a C 1 -C 8 alkyl group and preferably methyl. Methylalumoxane is preferably used.
- aluminiumalkyl(s) can be used as cocatalyst in the reactor.
- the aluminiumalkyl is represented by the formula AlR x can be used wherein each R is the same or different and is selected from halides or from alkoxy or alkyl groups having from 1 to 12 carbon atoms and x is from 1 to 3.
- Especially suitable aluminiumalkyl are trialkylaluminium, the most preferred being triisobutylaluminium (TIBAL).
- the catalyst may be prepolymerised prior to introducing it in the reaction zone and/or prior to the stabilization of the reaction conditions in the reactor.
- the polyethylene resin of the present invention has a density ranging from 0.930 to 0.950 g/cm 3 , preferably, from 0.930 to 0.940 g/cm 3 and most preferably about 0.935 g/cm 3 .
- the melt index MI2 is within the range 0.1 to 5 g/10 min, preferably in the range 0.2 to 1.5 g/10 min.
- the density is measured following the method of standard test ASTM D 1505 at 23 °C and the melt index MI2 is measured following the method of standard test ASTM D 1238 at 190 °C and under a load of 2.16 kg.
- the metallocene-prepared polyethylenes produce very strong stretched tapes and raffia products, mainly because of their narrow molecular weight distribution and because they have long chain branches.
- the final products have improved tensile and elongation properties properties and simulteneously they have improved flexibility and processing properties.
- Resin R1 is a medium density polyethylene resin prepared with isopropylidene (tetrahydroindenyl) zirconium dichloride. It had a density of 0.934 g/cm 3 and a melt index MI2 of 0.9 g/10 min. It was additivated as follows:
- the final products, whether unwoven or woven (nets) obtained from the metallocene-produced resin R1 had a high tenacity, an excellent elongation at rupture and a very high break strength. It also had a soft touch and a high flexibility.
- the titre is measured in tex or g/km: this is a measure of the linear mass of a filament or fibre.
- the raffia products prepared according to the present invention has thus improved properties with respect to those of the prior art.
Description
- This invention relates to the field of monofilaments and stretched tapes prepared with metallocene-produced polyethylene.
- Monofilaments are uniaxially oriented wire-like polymer strands having a circular cross section. They are manufactured by melt spinning process and their size ranges from 0.1 to 2.5 mm in diameter, depending upon the end use application. Polyethylene, polypropylene, nylon and polyesters are commonly used as raw materials for making monofilaments.
- Stretched tapes are prepared from a primary film produced either by a blown or by a cast film process. The film can be cut into tapes and then oriented or reversely, oriented and then cut into tapes. The orientation is carried out by stretching the film or tapes while passing through an air oven or on a hot plate at a temperature below the melting point. The stretching is carried out by passing the film or tapes over two sets of rollers placed respectively before and after the air oven/hot plate and operating at different speeds, the speed of the second set of rellers being larger than that of the first set of rollers.
- The polymer preferably used in the market for these applications is a high density polyethylene (HDPE) prepared with a Ziegler-Natta catalyst, said HDPE having a MI2 smaller than 1 g/10min such as for example Solvay Eltex A4009MFN1325 resin or Basell Hostalen GF 7740 F1, GF7740 F2, GF7740 F3, GF7750 M2 grades or the polyethylene resins disclosed in
GB-0023662 -
JP 11-201,176 A - Semi-crystalline polyethylene (PE) and polypropylene (PP) have also been used as materials for monofilaments stretched tapes and raffia, such as disclosed for example in
FR-A-2814761 JP-2001342209 JP-2001220405 - There is thus a need for monofilaments or stretched tapes, unwoven or woven into raffia having a better balance of properties.
- It is an object of the present invention to prepare monofilament or stretched tape products having high tenacity.
- It is another object of the present invention to prepare monofilament or stretched tape-products having high impact strength.
- It is also an object of the present invention to prepare monofilament or stretched tape products having high elongation at rupture.
- It is a further object of the present invention to prepare monofilament or stretched tape products having a soft touch.
- It is yet another object of the present invention to prepare monofilament or stretched tape products having great flexibility.
- Accordingly the present invention provides monofilaments or stretched tapes, unwoven or woven into raffia prepared from metallocene-produced polyethylene (mPE) resin having long chain branches, and a density of from 0.930 to 0.950 g/cm3, wherein the metallocene component is a bis-indenyl represented by the general formula
R" (Ind)2 MQ2 (I)
wherein (Ind) is an indenyl or an hydrogenated indenyl, substituted or unsubstituted, R" is a structural bridge between the two indenyls to impart stereorigidity that comprises a C1-C4 alkylene radical, a dialkyl germanium or silicon or siloxane, or a alkyl phosphine or amine radical, which bridge is substituted or unsubstituted; Q is a hydrocarbyl radical having from 1 to 20 carbon atoms or a halogen, and M is a group IVb transition metal or vanadium. - The preferred metallocene catalyst component is based on a terahydroindenyl component or on a constrained geometry component, more preferably on a terahydroindenyl component.
- The invention also provides a process for preparing the above mentioned raffia or stretched tapes with a metallocene-produced polyethylene that comprises the steps of:
- a) providing a metallocene-produced medium density polyethylene resin having long chain branches, wherein the metallocene component is a bis-indenyl represented by the general formula
R" (Ind)2 MQ2 (I)
wherein (Ind) is an indenyl or an hydrogenated indenyl, substituted or unsubstituted, R" is a structural bridge between the two indenyls to impart stereorigidity that comprises a C1-C4 alkylene radical, a dialkyl germanium or silicon or siloxane, or a alkyl phosphine or amine radical, which bridge is substituted or unsubstituted; Q is a hydrocarbyl radical having from 1 to 20 carbon atoms or a halogen, and M is a group IVb transition metal or vanadium; - b) producing a film from the polyethylene resin of step a)
- c) orienting the film obtained from step b) by stretching;
- d) cutting the stretched film of step c) into strips;
- e) optionally, annealing the stretched tapes.
- Alternatively, the primary film can first be cut into strips and then oriented by stretching.
- The present invention also provides a process for preparing the above mentioned raffia or stretched tapes that comprises the steps of
- a) providing a metallocene-produced medium density polyethylene resin having long chain branches wherein the metallocene component is a tetrahydroindenyl bis-indenyl represented by the general formula
R"(Ind)2MQ2 (I)
wherein (Ind) is an indenyl or a hydrogenated indenyl, substituted or unsubstituted, R" is a structural bridge between the two indenyls to impart stereorigidity that comprises a C1-C4 alkylene radical, a dialkyl germanium or silicon or siloxane, or a alkyl phosphine or amine radical, which bridge is substituted or unsubstituted; Q is a hydrocarbyl radical having from 1 to 20 carbon atoms or a halogen, and M is a group IVb transition metal or vanadium; - b) producing a film from the polyethylene resin of step a)
- c) cutting the film obtained from step b) into strips;
- d) orienting the strips of film of step c) by stretching;
- e) optionally annealing the stretched tapes.
- The film can be either a blown film or a cast film. Film production is easier with processed material having high melt strength such as polyethylene having long chain branches and/or very long linear chains. Metallocene catalyst systems based on tetrahydroindenyl components or on constrained geometry components are particularly useful for preparing polyethylene resins having long branches.
- In the production of blown films, the resins prepared with a terahydroindenyl catalyst component provide a very stable bubble thereby leading to films having a uniform thickness and presenting no or very little creases. Uneven thickness and creases are points of weakness when the film is cut into tapes and stretched.
- In the production of cast films, the resins prepared with a terahydroindenyl catalyst component have a stable elongational viscosity leading to a stable and regular thickness.
- It is further observed that resins having long branches keep good mechanical properties, such as traction resistance and tenacity, at densities smaller than those of linear resins having equivalent mechanical properties. Working at low densities has the advantage of providing material that has improved flexibility, low fusion temperature and good processability.
- Orientation of the primary film or of the cut tapes is carried out by stretching while passing through an air oven or over a hot plate, maintained at a temperature below the melting temperature. Stretching of the primary film or of the cut tapes is done by passing said film or tapes over two sets of rollers (goddet rollers) placed respectively before and after the air oven/hot plate, and operating at different speeds. The stretch ratio S2/S1 is defined by the ratio of the speed of roller 2, S2 to the speed of roller 1, S1 wherein S2 is larger than S1.
- Stretching at such high temperature results in chain/crystals orientation with a simultaneous increase of crystallinity. These structural changes lead to an increase of tensile strength and concurrently to a reduction of elongation. The tensile strength increases with increasing stretch ratio and with increasing stretching temperature. It is preferred that the stretching temperature is as close as possible-to but smaller than the melting temperature. For high density polyethylene, typical values for the stretch ratio are of from 5.0 to 7.0. The typical stretching temperatures depend upon the melting temperature of the polyethylene resins: they must be lower than but as close as possible to the melting temperature. Typically, they are from 5 to 70 °C lower than the melting temperature of the resin, preferably they are from 10 to 50 °C lower than the melting temperature of the resin.
- Preferably, the drawn tapes are annealed immediately after the stretching operation in order to minimise shrinkage that could occur as a result of residual stresses in the oriented tapes. Annealing is done by heating the stretched tapes while they are being transferred from the second goddet rollers onto a third roller having a speed S3 that is smaller than the speed of roller 2, S2. Preferably, speed S3 is about 95 % of speed S2. The annealing ratio AR is defined as (S2-S3)/S2) at a temperature slightly inferior to the stretching temperature. Typically, the annealing temperature is from 5 to 10 °C lower than the stretching temperature.
- Polymers that do not include either very long linear chains or long chain branched molecules have a better stretchability. For example, the low density polyethylene (LDPE) having long chain branches cannot be stretched beyond a certain degree, whereas the purely linear polyethylene chains usually obtained with a Ziegler-Natta catalyst have a high degree of stretchability.
- The metallocene used to prepare the high density polyethylene is a bis-indenyl represented by the general formula:
R" (Ind)2 MQ2 (I)
wherein (Ind) is an indenyl or an hydrogenated indenyl, substituted. or unsubstituted, R" is a structural bridge between the two indenyls to impart stereorigidity that comprises a C1-C4 alkylene radical, a dialkyl germanium or silicon or siloxane, or a alkyl phosphine or amine radical, which bridge is substituted or unsubstituted; Q is a hydrocarbyl radical having from 1 to 20 carbon atoms or a halogen, and M is a group IVb transition metal or Vanadium. - In formula (I), each indenyl or hydrogenated indenyl compound may be substituted in the same way or differently from one another at one or more positions in the cyclopentadienyl ring, the cyclohexenyl ring and the bridge.
- In formula (I), each substituent on the indenyl may be independently chosen from those of formula XRv in which X is chosen from group IVA, oxygen and nitrogen and each R is the same or different and chosen from hydrogen or hydrocarbyl of from 1 to 20 carbon atoms and v+1 is the valence of X. X is preferably C. If the cyclopentadienyl ring is substituted, its substituent groups must be so bulky as to affect coordination of the olefin monomer to the metal M. Substituents on the cyclopentadienyl ring preferably have R as hydrogen or CH3. More preferably, at least one and most preferably both cyclopentadienyl rings are unsubstituted.
- In a preferred embodiment, both indenyls are unsubstituted and the most preferred catalyst component is a tetrahydroindenyl.
- R" is preferably a C1-C4 alkylene radical (as used herein to describe a difunctional radical, also called alkylidene), most preferably an ethylene bridge (as used herein to describe a difunctional radical, also called ethylidene), which is substituted or unsubstituted.
- The metal M is preferably zirconium, hafnium, or titanium, most preferably zirconium.
- Each Q is the same or different and may be a hydrocarbyl or hydrocarboxy radical having 1 to 20 carbon atoms or a halogen. Suitable hydrocarbyls include aryl, alkyl,alkenyl,alkylaryl or arylalkyl. Each Q is preferably halogen.
- Among the preferred metallocenes used in the present invention, one can cite bis tetrahydro-indenyl compounds and bis indenyl compounds as disclosed for example in
WO 96/35729 - The metallocene may be supported according to any method known in the art. In the event it is supported, the support used in the present invention can be any organic or inorganic solids, particularly porous supports such as talc, inorganic oxides, and resinous support material such as polyolefin. Preferably, the support material is an inorganic oxide in its finely divided form.
- The addition on the support, of an agent that reacts with the support and has an ionising action, creates an active site.
- Preferably, alumoxane is used to ionise the catalyst during the polymerization procedure, and any alumoxane known in the art is suitable.
-
- One or more aluminiumalkyl(s) can be used as cocatalyst in the reactor. The aluminiumalkyl is represented by the formula AlRx can be used wherein each R is the same or different and is selected from halides or from alkoxy or alkyl groups having from 1 to 12 carbon atoms and x is from 1 to 3. Especially suitable aluminiumalkyl are trialkylaluminium, the most preferred being triisobutylaluminium (TIBAL).
- Further, the catalyst may be prepolymerised prior to introducing it in the reaction zone and/or prior to the stabilization of the reaction conditions in the reactor.
- The polyethylene resin of the present invention has a density ranging from 0.930 to 0.950 g/cm3, preferably, from 0.930 to 0.940 g/cm3 and most preferably about 0.935 g/cm3. The melt index MI2 is within the range 0.1 to 5 g/10 min, preferably in the range 0.2 to 1.5 g/10 min.
- The density is measured following the method of standard test ASTM D 1505 at 23 °C and the melt index MI2 is measured following the method of standard test ASTM D 1238 at 190 °C and under a load of 2.16 kg.
- The metallocene-prepared polyethylenes produce very strong stretched tapes and raffia products, mainly because of their narrow molecular weight distribution and because they have long chain branches. The final products have improved tensile and elongation properties properties and simulteneously they have improved flexibility and processing properties.
- Several resins have been tested for preparing raffia products.
- Resin R1 is a medium density polyethylene resin prepared with isopropylidene (tetrahydroindenyl) zirconium dichloride. It had a density of 0.934 g/cm3 and a melt index MI2 of 0.9 g/10 min. It was additivated as follows:
- 94.5 wt% of resin R1;
- 4 % red masterbatch PE 44930 from Clariant;
- 1 % polymer processing aid AMF 702 from Schuman;
- 0.5 % antibloc masterbatch B1981 from Clariant. Resin R2 was a commercial resin prepared with a Ziegler-Natta catalyst system: (GF7740 F1 from Hostalen). It had a density of 0.946 g/cm3 and a melt index MI2 of 0.5 g/10min.
- These two resins were treated under the same conditions for blown film production, and for stretching.
- Melt die temperature: 220 °C.
- Thickness of primary film: 60 microns;
- Orientation temperature: varied progressively from 80 to 120 °C.
- Stretch ratio: 7:1
- The final products, whether unwoven or woven (nets) obtained from the metallocene-produced resin R1 had a high tenacity, an excellent elongation at rupture and a very high break strength. It also had a soft touch and a high flexibility.
- The properties of the stretched tapes obtained from resins R1 and R2 are summarised in Table I.
TABLE I. R1 R2 Tenacity at rupture cN/Tex 24.9 22.1 Elongation at rupture % 33.2 29.3 Strength at rupture cN 593 525 Titre Tex 23.8 20.8 - The elongation, the strength and the tenacity at rupture of the stretched tapes have been measured following the method of standard test ISO-2062 (1993).
- The titre is measured in tex or g/km: this is a measure of the linear mass of a filament or fibre.
- The properties of the woven stretched tapes or raffia are displayed in Table II.
TABLE II. R1 R2 Elongation at rupture % 30.6 29.4 Strength at rupture cN 997 811 - The raffia products prepared according to the present invention has thus improved properties with respect to those of the prior art.
- The elongation and strength at rupture of the raffia have been measured following the method of standard test ISO-5081 (1977).
Claims (7)
- Monofilaments or stretched tapes, unwoven or woven into raffia prepared from a metallocene-produced polyethylene resin having long chain branches and a density of from 0.930 to 0.950 g/cm3, wherein the metallocene component is a bis-indenyl represented by the general formula
R"(Ind)2MQ2 (I)
wherein (Ind) is an indenyl or a hydrogenated indenyl, substituted or unsubstituted, R" is a structural bridge between the two indenyls to impart stereorigidity that comprises a C1-C4 alkylene radical, a dialkyl germanium or silicon or siloxane, or a alkyl phosphine or amine radical, which bridge is substituted or unsubstituted; Q is a hydrocarbyl radical having from 1 to 20 carbon atoms or a halogen, and M is a group IVb transition metal or vanadium. - The monofilaments or stretched tapes of claim 1 wherein the density of the polyethylene resin is of from 0.930 to 0.940 g/cm3 and preferably of about 0.935 g/cm3 and the melt index MI2 is within the range 0.1 to 5 g/10 min, preferably in the range 0.2 to 1.5 g/10 min.
- A process for preparing the stretched tapes of claim 1 or claim 2 that comprises the steps of:a) providing a metallocene-produced medium density polyethylene resin having long chain branches wherein the metallocene component is a bis-indenyl represented by the general formula
R"(Ind)2MQ2 (I)
wherein (Ind) is an indenyl or a hydrogenated indenyl, substituted or unsubstituted, R" is a structural bridge between the two indenyls to impart stereorigidity that comprises a C1-C4 alkylene radical, a dialkyl germanium or silicon or siloxane, or a alkyl phosphine or amine radical, which bridge is substituted or unsubstituted; Q is a hydrocarbyl radical having from 1 to 20 carbon atoms or a halogen, and M is a group IVb transition metal or vanadium;b) producing a film from the polyethylene resin of step a)c) orienting the film obtained from step b) by stretching;d) cutting the stretched film of step c) into stripse) optionally, annealing the stretched tapes. - A process for preparing the stretched tapes of claim 1 or claim 2 that comprises the steps of:a) providing a metallocene-produced medium density polyethylene resin having long chain branches wherein the metallocene component is a bis-indenyl represented by the general formula
R"(Ind)2MQ2 (I)
wherein (Ind) is an indenyl or a hydrogenated indenyl, substituted or unsubstituted, R" is a structural bridge between the two indenyls to impart stereorigidity that comprises a C1-C4 alkylene radical, a dialkyl germanium or silicon or siloxane, or a alkyl phosphine or amine radical, which bridge is substituted or unsubstituted; Q is a hydrocarbyl radical having from 1 to 20 carbon atoms or a halogen, and M is a group IVb transition metal or vanadium;b) producing a film from the polyethylene resin of step a)c) cutting the film obtained from step b) into strips;d) orienting the strips of film of step c) by stretching;e) optionally, annealing the stretched tapes. - The process of claim 3 or 4 wherein the stretching temperature is of from 10 to 70 °C lower than the melting temperature of the resin.
- The process of claim 5 wherein the stretching temperature is of from 15 to 50 °C lower than the melting temperature of the resin
- The process of any one of claims 3 to 6 wherein the annealing temperature, if annealing is performed, is of from 5 to 10 °C lower than the stretching temperature.
Priority Applications (1)
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EP04726183A EP1613797B1 (en) | 2003-04-16 | 2004-04-07 | Monofilaments or stretched tapes from metallocene-produced polyethylene |
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EP03076128A EP1469104A1 (en) | 2003-04-16 | 2003-04-16 | Metallocene produced polyethylene for fibres applications |
PCT/EP2004/050479 WO2004092459A1 (en) | 2003-04-16 | 2004-04-07 | Metallocene produced polyethylene for fibres applications |
EP04726183A EP1613797B1 (en) | 2003-04-16 | 2004-04-07 | Monofilaments or stretched tapes from metallocene-produced polyethylene |
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EP1613797A1 EP1613797A1 (en) | 2006-01-11 |
EP1613797B1 true EP1613797B1 (en) | 2013-03-06 |
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EP03076128A Withdrawn EP1469104A1 (en) | 2003-04-16 | 2003-04-16 | Metallocene produced polyethylene for fibres applications |
EP04726183A Expired - Lifetime EP1613797B1 (en) | 2003-04-16 | 2004-04-07 | Monofilaments or stretched tapes from metallocene-produced polyethylene |
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US (1) | US20070178303A1 (en) |
EP (2) | EP1469104A1 (en) |
JP (1) | JP4767839B2 (en) |
KR (1) | KR101333394B1 (en) |
CN (1) | CN100434575C (en) |
WO (1) | WO2004092459A1 (en) |
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GB0320690D0 (en) * | 2003-09-03 | 2003-10-01 | Solvay | Polyethylene composition for nets |
EP1659136A1 (en) * | 2004-11-19 | 2006-05-24 | Total Petrochemicals Research Feluy | Solid state properties of polyethylene prepared with tetrahydroindenyl-based catalyst system |
EP1674523A1 (en) * | 2004-12-22 | 2006-06-28 | Total Petrochemicals Research Feluy | Caps and closures |
ATE501850T1 (en) * | 2006-01-19 | 2011-04-15 | Basell Polyolefine Gmbh | POLYETHYLENE COMPOSITION FOR STRETCHED BAND PRODUCTS |
WO2007082817A1 (en) * | 2006-01-19 | 2007-07-26 | Basell Polyolefine Gmbh | Polyethylene composition for stretched tape products |
MX2009005315A (en) * | 2006-11-21 | 2009-05-28 | Fina Technology | Polyethylene useful for producing film and molded articles in a process which uses solid state stretching. |
BRPI0700676F1 (en) * | 2007-03-01 | 2019-01-15 | Forte Tecnologia & Consultoria Ltda | pallet |
EP1972704A1 (en) * | 2007-03-22 | 2008-09-24 | Borealis Technology Oy | Fibre, tapes or filaments comprising a polyethylene composition |
GB0802550D0 (en) | 2008-02-12 | 2008-03-19 | Ineos Mfg Belguim Nv | Polymers and articles thereof |
EP2216367A1 (en) * | 2009-02-09 | 2010-08-11 | Total Petrochemicals Research Feluy | High impact resistance polyethylene |
JP5668689B2 (en) | 2009-11-09 | 2015-02-12 | 旭硝子株式会社 | Polytetrafluoroethylene aqueous emulsion and method for producing the same, polytetrafluoroethylene aqueous dispersion obtained by using the aqueous emulsion, polytetrafluoroethylene fine powder, and stretched porous body |
KR101401370B1 (en) | 2010-09-23 | 2014-05-29 | 토탈 리서치 앤드 테크놀로지 펠루이 | Artificial grass |
JP5972887B2 (en) * | 2010-10-29 | 2016-08-17 | ダウ グローバル テクノロジーズ エルエルシー | Polyethylene-based drawn monofilaments and drawn strips and methods for their preparation |
JP5794737B2 (en) * | 2012-07-02 | 2015-10-14 | 住友ゴム工業株式会社 | Artificial grass |
EP3201243B1 (en) * | 2014-10-03 | 2022-05-18 | ExxonMobil Chemical Patents Inc. | Polyethylene polymers, films made therefrom, and methods of making the same |
KR20190062433A (en) | 2016-09-27 | 2019-06-05 | 디에스엠 아이피 어셋츠 비.브이. | Transparent stretch article |
CN112368434B (en) | 2018-07-26 | 2023-05-09 | 陶氏环球技术有限责任公司 | Heat-shrinkable knit raffle fabric and method of using such fabric |
CN110820058B (en) * | 2019-11-05 | 2021-02-23 | 上海化工研究院有限公司 | Preparation method of civil high-performance polyethylene fiber |
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EP0205960B1 (en) * | 1985-06-17 | 1990-10-24 | AlliedSignal Inc. | Very low creep, ultra high moduls, low shrink, high tenacity polyolefin fiber having good strength retention at high temperatures and method to produce such fiber |
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- 2004-04-07 CN CNB200480009870XA patent/CN100434575C/en not_active Expired - Fee Related
- 2004-04-07 EP EP04726183A patent/EP1613797B1/en not_active Expired - Lifetime
- 2004-04-07 JP JP2006505533A patent/JP4767839B2/en not_active Expired - Fee Related
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Publication number | Publication date |
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EP1469104A1 (en) | 2004-10-20 |
KR20060010750A (en) | 2006-02-02 |
CN100434575C (en) | 2008-11-19 |
US20070178303A1 (en) | 2007-08-02 |
JP4767839B2 (en) | 2011-09-07 |
WO2004092459A1 (en) | 2004-10-28 |
CN1774528A (en) | 2006-05-17 |
JP2006523784A (en) | 2006-10-19 |
EP1613797A1 (en) | 2006-01-11 |
KR101333394B1 (en) | 2013-11-28 |
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