WO2011141380A1 - Polypropylene with specific calcium stearate content for special capacitors - Google Patents

Polypropylene with specific calcium stearate content for special capacitors Download PDF

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Publication number
WO2011141380A1
WO2011141380A1 PCT/EP2011/057322 EP2011057322W WO2011141380A1 WO 2011141380 A1 WO2011141380 A1 WO 2011141380A1 EP 2011057322 W EP2011057322 W EP 2011057322W WO 2011141380 A1 WO2011141380 A1 WO 2011141380A1
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WO
WIPO (PCT)
Prior art keywords
capacitor film
bopp
biaxially oriented
oriented polypropylene
polypropylene
Prior art date
Application number
PCT/EP2011/057322
Other languages
French (fr)
Inventor
Franciscus Jacobs
Original Assignee
Borealis Ag
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Borealis Ag filed Critical Borealis Ag
Priority to KR1020127031725A priority Critical patent/KR20130008631A/en
Priority to MX2012012879A priority patent/MX337954B/en
Priority to EA201201532A priority patent/EA022217B1/en
Priority to BR112012028659A priority patent/BR112012028659A2/en
Priority to JP2013509519A priority patent/JP5767697B2/en
Priority to US13/697,178 priority patent/US20130115471A1/en
Priority to KR1020157001632A priority patent/KR20150027234A/en
Priority to EP11717292.4A priority patent/EP2569358B1/en
Priority to CN2011800232465A priority patent/CN102884117A/en
Publication of WO2011141380A1 publication Critical patent/WO2011141380A1/en
Priority to US15/096,030 priority patent/US20160222189A1/en

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00—Use of organic ingredients
    • C08K5/04—Oxygen-containing compounds
    • C08K5/09—Carboxylic acids; Metal salts thereof; Anhydrides thereof
    • C08K5/098—Metal salts of carboxylic acids
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B32B15/085—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyolefins
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/18—Manufacture of films or sheets
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES OR LIGHT-SENSITIVE DEVICES, OF THE ELECTROLYTIC TYPE
    • H01G2/00—Details of capacitors not covered by a single one of groups H01G4/00-H01G11/00
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES OR LIGHT-SENSITIVE DEVICES, OF THE ELECTROLYTIC TYPE
    • H01G4/00—Fixed capacitors; Processes of their manufacture
    • H01G4/002—Details
    • H01G4/018—Dielectrics
    • H01G4/06—Solid dielectrics
    • H01G4/14—Organic dielectrics
    • H01G4/18—Organic dielectrics of synthetic material, e.g. derivatives of cellulose
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES OR LIGHT-SENSITIVE DEVICES, OF THE ELECTROLYTIC TYPE
    • H01G4/00—Fixed capacitors; Processes of their manufacture
    • H01G4/33—Thin- or thick-film capacitors 
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/02—2 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2457/00—Electrical equipment
    • B32B2457/16—Capacitors
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2203/00—Applications
    • C08L2203/16—Applications used for films
    • 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
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31678—Of metal
    • Y10T428/31692—Next to addition polymer from unsaturated monomers

Definitions

  • the present invention is directed to a new capacitor film based on biaxially oriented polypropylene (BOPP).
  • BOPP biaxially oriented polypropylene
  • Polypropylene is the material of choice in the field of film capacitors as its chain lacks any kind of polar groups which orient under electrical field stress. As a result, polypropylene intrinsically possesses a low loss factor and high volume resistivity. These properties, combined with a relatively high dielectric constant and self healing character in the capacitor, make polypropylene so valuable in this technical field.
  • the dielectric strength or the breakdown voltage of polypropylene can be further increased in case it is biaxially oriented which is obtained by stretching a heated sheet of film in two opposing directions, longitudinal and transverse machine directions, inducing a more perfect crystalline formation and orientation. It is also known that additives must be added to polypropylene to make the material durable.
  • antioxidants are added to reduce the risk of degradation of the polymeric material.
  • polypropylene typically contains considerable amounts of polar residues, like chlorine, aluminium, magnesium or silicon originating from the used catalyst. These residues are unwanted as they negatively influence the dielectric properties.
  • acid scavengers are added in spite the fact that polar elements cause some extra, unfortunate dissipation in the capacitor film.
  • additives are added in lowest possible amounts, normally not exceeding 100 ppm.
  • a well accepted amount in this technical field is around 75 ppm of acid scavengers.
  • a typical problem during the preparation of biaxially oriented polypropylene (BOPP) is the die drool caused by sheer stress.
  • the winded biaxially oriented polypropylene (BOPP) is subsequently flattened in order to reduce the volume of the capacitor by pressing the round cylinder in an oval shape.
  • the flattening of the circular winding enables to increase the energy density of the capacitor further.
  • the problem of this specific capacitor design is, that the additional flattening step causes also mechanical stress and damage from which the biaxially oriented polypropylene (BOPP) suffers and the inner windings start wrinkling and rippling from the inside to the outside.
  • the object of the present invention is to provide a capacitor film which can be produced from polypropylene not getting damaged during the stretching phase and which can be winded and subsequently flattened without causing defects within the film. Further the ash content of the used polypropylene shall still in acceptable limits and shall not considerably increase the dissipation.
  • the used polypropylene must comprise an alkali earth fatty acid salt in amount exceeding 100 ppm. Accordingly the present invention is directed to a capacitor film comprising
  • additive or residues e.g. ash content
  • 1 mg additive or residues, e.g. ash content, in 1 kg composition corresponds to 1 mg additive or residues, e.g. ash content, in 1 kg composition.
  • the biaxially oriented polypropylene (BOPP) is the only polymer within the capacitor film.
  • the capacitor film may contain further additives apart from the alkali earth fatty acid salt but preferably no other polymer.
  • the remaining part up to 100.0 wt.-% may be accomplished by further additives known in the art.
  • this remaining part shall be not more than 5.0 wt.-%, preferably not more than 2.0 wt.-%, like not more than 1.0 wt.%, within the capacitor film.
  • the capacitor film preferably comprises more than 95 wt.-%, more preferably more 98 wt.-%, like more than 99.0 wt.-%, of the biaxially oriented polypropylene (BOPP).
  • the capacitor film is a biaxially oriented polypropylene (BOPP), said biaxially oriented polypropylene (BOPP) comprises more than 100 to below or equal 600 ppm of an alkali earth fatty acid salt.
  • the capacitor film of the instant invention can be produced from polypropylene without getting damaged during the processing steps and without increasing the ash content beyond unacceptable levels or increasing the dissipation. In the following the instant invention is described in more detail.
  • the capacitor film has a thickness of not more than 10.0 ⁇ , preferably not more than 5.0 ⁇ , more preferably not more than 3.0 ⁇ , yet more preferably in the range of 0.5 to 3.5 ⁇ , like in the range of 1.0 to 3.0 ⁇ .
  • the capacitor film and/or the biaxially oriented polypropylene (BOPP) is/are featured by its/their high purity. Accordingly it is preferred that the capacitor film and/or the biaxially oriented polypropylene (BOPP) has/have an ash content of equal or below 100 ppm, more preferably equal or below 50 ppm, yet more preferably equal or below 40 ppm, still yet more preferably equal or below 30 ppm.
  • this high purity is not accomplished by a washing step.
  • the polypropylene of the capacitor film is biaxially oriented.
  • the biaxially oriented polypropylene (BOPP) has a draw ratio in machine direction of at least 4.0 and a draw ratio in transverse direction of at least 4.0.
  • Such ratios are appreciated as commercial biaxially oriented polypropylene films must be stretchable at least to the above defined extent without breaking.
  • the length of the sample increases during stretching in longitudinal direction and the draw ratio in longitudinal direction calculates from the ratio of current length over original sample length. Subsequently, the sample is stretched in transverse direction where the width of the sample is increasing. Hence, the draw ratio calculates from the current width of the sample over the original width of the sample.
  • the draw ratio in machine direction of the biaxially oriented polypropylene (BOPP) ranges from 4.0 to 8.0, more preferably from 4.5 to 6.5.
  • the draw ratio in transverse direction of the biaxially polypropylene (BOPP) ranges preferably from 6.0 to 10.0, more preferably from 7.0 to 9.5.
  • the biaxially polypropylene (BOPP) has a draw ratio in machine direction from 4.5 to 7.0. in particular from 4.5 to 5.0, and a draw ratio in transverse direction from 6.0 to 10.0, in particular from 8.0 to 10.
  • the polypropylene which is transferred into a biaxially oriented polypropylene can be any polypropylene, however it is preferred that it is a random propylene copolymer or a propylene homopolymer, the latter is especially preferred. Accordingly wherever in the present application it is referred to properties of the biaxially oriented polypropylene (BOPP) automatically also the properties of the polypropylene used for the preparation of the biaxially oriented polypropylene (BOPP) are defined as well therewith.
  • the biaxially oriented polypropylene is a biaxially oriented random propylene copolymer.
  • the term random is understood according to IUPAC (Glossary of basic terms in polymer science; IUPAC recommendations 1996). Accordingly it is preferred that the biaxially oriented random propylene copolymer has a randomness of at least 40 %, more preferably of at least 50 %, yet more preferably at least 55 %, even more preferably of at least 60 %, and still more preferably of at least 65 %.
  • the biaxially oriented polypropylene is a biaxially oriented random propylene copolymer it comprises monomers copolymerizable with propylene, for example comonomers such as ethylene and/or C4 to C12 alpha-olefins, in particular ethylene and/or C4 to Cio alpha-olefins, e.g. 1-butene and/or 1-hexene.
  • the biaxially oriented random propylene copolymer comprises, especially consists of, monomers copolymerizable with propylene from the group consisting of ethylene, 1-butene and 1-hexene.
  • the biaxially oriented random propylene copolymer comprises - apart from propylene - units derivable from ethylene and/or 1-butene.
  • the biaxially oriented random propylene copolymer comprises units derivable from ethylene and propylene only.
  • the comonomer content in the biaxially oriented random propylene copolymer is preferably relatively low, i.e. up to 6.0 wt.-%, more preferably 0.5 to 6.0 wt.-%, still more preferably 0.5 to 4.0 wt.-%, yet more preferably 0.5 to 2.0 wt.-%.
  • biaxially oriented homopolymer used in the instant invention relates to a biaxially oriented polypropylene (BOPP) that consists substantially, i.e. of at least 99.5 wt- %, more preferably of at least 99.8 wt.-%, of propylene units. In a preferred embodiment only propylene units in the biaxially oriented propylene homopolymer are detectable.
  • the comonomer content can be determined with FT infrared spectroscopy, as described below in the examples.
  • the biaxially oriented polypropylene (BOPP) is a biaxially oriented propylene homopolymer.
  • the polypropylene is isotactic. Accordingly it is appreciated that the polypropylene is isotactic. Accordingly it is appreciated that the polypropylene is isotactic. Accordingly it is appreciated that the polypropylene is isotactic. Accordingly it is appreciated that the polypropylene is isotactic. Accordingly it is appreciated that the polypropylene is isotactic. Accordingly it is appreciated that the polypropylene is isotactic. Accordingly it is appreciated that the
  • polypropylene has a rather high pentad concentration, i.e. higher than 90 %, more preferably higher than 92 %, still more preferably higher than 93 % and yet more preferably higher than 95 %, like at least 97 %.
  • a further characteristic of the biaxially oriented polypropylene (BOPP) is the low amount of misinsertions of propylene within the polymer chain. Accordingly the biaxially oriented polypropylene (BOPP) is preferably featured by low amount of ⁇ 2,1> erythro regiodefects, i.e. of not more than 0.4 mol.-%, more preferably of not more than 0.2 mol.-%, like of not more than 0.1 mol.-%, determined by 13 C-NMR spectroscopy.
  • the capacitor film and/or the biaxially oriented polypropylene (BOPP) can have a xylene cold soluble content (XCS) in a broad range, i.e. up to 6.0 wt.-%. Accordingly the capacitor film and/or the biaxially oriented polypropylene (BOPP) may have a xylene cold soluble content (XCS) in the range of 0.3 to 6.0 wt.-%, like 0.5 to 5.5 wt.-%.
  • the capacitor film and/or the biaxially oriented polypropylene (BOPP) has/have a xylene cold soluble (XCS) content in the range of 0.5 to
  • the amount of xylene cold soluble (XCS) additionally indicates that the capacitor film and/or the biaxially oriented polypropylene (BOPP) is/are preferably free of any elastomeric polymer component, like an ethylene propylene rubber.
  • the capacitor film and/or the biaxially oriented polypropylene (BOPP) shall be not a heterophasic
  • the capacitor film and/or the biaxially oriented polypropylene (BOPP) has/have a rather high melting point. Accordingly it is appreciated that the capacitor film and/or the biaxially oriented polypropylene (BOPP) according to this invention has a melting temperature (T m ) measured according to ISO 11357-3 of at least 145.0 °C, more preferably of at least 155.0 °C, yet more preferably of at least 158 °C. Thus it is in particular appreciated that the melting temperature (T m ) measured according to ISO 11357-3 of the capacitor film and/or of the biaxially oriented
  • polypropylene is in the range of 145 to 168 °C, more preferably in the range of 155 to 164 °C, still more preferably in the range of 160 to 164 °C. Additionally it is appreciated that the capacitor film and/or the biaxially oriented polypropylene (BOPP) has/have a rather high crystallization temperature (T c ). Thus it is preferred that the capacitor film and/or the biaxially oriented polypropylene (BOPP) has/have crystallization temperature (T c ) measured according to ISO 11357-3 of at least 110 °C, more preferably of at least 111 °C.
  • the capacitor film and/or the biaxially oriented polypropylene (BOPP) has/have preferably a crystallization temperature (T c ) measured according to ISO 11357-3 in the range of 110 to 120 °C, more preferably in the range of 111 to 117 °C.
  • T c crystallization temperature
  • the molecular weight distribution is the relation between the numbers of molecules in a polymer and the individual chain length.
  • the molecular weight distribution (MWD) is expressed as the ratio of weight average molecular weight (M w ) and number average molecular weight (M n ).
  • the number average molecular weight (M n ) is an average molecular weight of a polymer expressed as the first moment of a plot of the number of molecules in each molecular weight range against the molecular weight. In effect, this is the total molecular weight of all molecules divided by the number of molecules.
  • the weight average molecular weight (M w ) is the first moment of a plot of the weight of polymer in each molecular weight range against molecular weight.
  • the number average molecular weight (M n ) and the weight average molecular weight (M w ) as well as the molecular weight distribution (MWD) are determined by size exclusion chromatography (SEC) using Waters Alliance GPCV 2000 instrument with online viscometer. The oven temperature is 140 °C. Trichlorobenzene is used as a solvent
  • the biaxially oriented polypropylene (BOPP) has a weight average molecular weight (M w ) from 100,000 to 600,000 g/mol, more preferably from 200,000 to 500,000 g/mol.
  • a broad molecular weight distribution improves the processability of the polypropylene. Accordingly it is appreciated that the molecular weight distribution (MWD) measured according to ISO 16014 is at least 2.8, more preferably at least 3.0, like at least 3.3. On the other hand a rather broad molecular weight distribution (MWD) indicates rather high amount of low molecular weight fractions which contribute to the xylene soluble content without improving the dielectrical performance. Therefore, in an alternative embodiment the molecular weight distribution (MWD) is preferably between 2.8 to 10.0, still more preferably in the range of 3.0 to 8.0.
  • the biaxially oriented polypropylene (BOPP) has a melt flow rate (MFR) given in a specific range.
  • MFR melt flow rate measured under a load of 2.16 kg at 230 °C
  • the biaxially oriented polypropylene (BOPP) has an MFR 2 (230 °C) of more than 0.5 g/lOmin, more preferably of more than 1.0 g/lOmin.
  • the MFR 2 (230 °C) measured according to ISO 1133 is in the range of 0.5 to 10.0 g/lOmin, more preferably in the range of 1.0 to 6.0 g/lOmin, still more preferably in the range of 1.5 to 4.0 g/lOmin.
  • the biaxially oriented polypropylene (BOPP) is of linear structure and thus does not show (or nearly does not show) a kind of branching.
  • the biaxially oriented polypropylene (BOPP) of the instant invention has preferably a branching index g' of not less than 0.9, preferably more than 0.9, like at least 0.95.
  • the branching index g' of the biaxially oriented polypropylene (BOPP) is preferably in the range of 0.9 to 1.0, more preferably in the range of more than 0.9 to 1.0, like in the range of 0.96 to 1.0.
  • the biaxially oriented polypropylene (BOPP) shows no branching, i.e. the biaxially oriented polypropylene (BOPP) has a branching index g' of 1.0.
  • the branching index g' is defined as in which g' is the branching index, [IV] br is the intrinsic viscosity of the branched polypropylene and [IV]i; n is the intrinsic viscosity of the linear polypropylene having the same weight average molecular weight (within a range of ⁇ 3%) as the branched polypropylene.
  • a low g'-value is an indicator for a high branched polymer. In other words, if the g'-value decreases, the branching of the polypropylene increases.
  • biaxially oriented polypropylene (BOPP) As the biaxially oriented polypropylene (BOPP) according to this invention is preferably of non-branched structure it does also not show a significant amount of gel content. Gels are a typical phenomenon of polypropylenes being crosslinked. Thus the gel content is a good indicator for the chemical modification of the polypropylene. Accordingly the biaxially oriented polypropylene (BOPP) is featured by relatively moderate gel content, i.e.
  • the capacitor film must comprise in a specific range an alkali earth fatty acid salt.
  • the alkali earth fatty acid salt is present in the capacitor film in the range of more than 100 ppm to below or equal 600 ppm, more preferably in the range of 100 to 400 ppm, i.e in the range of 110 to 400 ppm, still more preferably in the range of 110 ppm to 350 ppm, yet more preferably in the range of 115 to 300 ppm, like in the range of 120 to 230 ppm.
  • a still more preferred upper limit for the amount of alkali earth fatty acid salt is 200 ppm, with 180 ppm being a particularly preferred upper limit.
  • the alkali earth fatty acid salt within the capacitor film of the present invention is used in comparatively high amounts, however the amount of alkali earth fatty acid salt preferably shall not exceed values having negative impact on the ash content.
  • the amount of the alkali earth fatty acid salt within the capacitor film does not exceed values which cause an ash content exceeding the upper limits as stated above, i.e. an ash content of not more than 100 ppm, more preferably not more than 50 ppm, yet more preferably not more than 40 ppm, still yet more preferably not more than 30 ppm.
  • the alkali earth fatty acid salt is preferably an alkali earth salt of a C u to C26 fatty acid, more preferably an alkali earth salt of a C 14 to C24 fatty acid, still more preferably an alkali earth salt of a Ci8 to C22 fatty acid, like an alkali earth salt of a Cig fatty acid. Further it is appreciated that the alkali earth fatty acid salt is an alkali earth salt of a saturated fatty acid, in particular of a saturated fatty acid as defined in this paragraph.
  • the alkali earth element of the alkali earth fatty acid salt is preferably magnesium or calcium, the latter being especially preferred.
  • the alkali earth fatty acid salt is a calcium C14 to C24 fatty acid salt, like calcium stearate.
  • the capacitor film may comprise additional additives known in the art, like antioxidants. However any additives which negatively influences the electrical breakdown behavior should be avoided.
  • the biaxially oriented polypropylene (BOPP) can be produced in a known manner.
  • the polypropylene which is used for the preparation of a biaxially oriented material is preferably prepared by polymerizing, in a slurry reactor, for example a loop reactor, propylene optionally together with at least another C2 to C12 a-olefin (comonomers), in the presence of a polymerization catalyst to produce a part of the polypropylene.
  • This part is then transferred to a subsequent gas phase reactor, wherein in the gas phase reactor propylene is reacted optionally together with comonomers as defined above in order to produce a further part in the presence of the reaction product of the first step.
  • This reaction sequence provides a reactor blend of parts (i) (fraction (A)) and (ii) (fraction (B)) constituting a polypropylene. It is of course possible by the present invention that the first reaction is carried out in a gas phase reactor while the second polymerization reaction is carried out in a slurry reactor, for example a loop reactor. It is furthermore also possible to reverse the order of producing parts (i) and (ii), which has been described above in the order of first producing part (i) and then producing part (ii).
  • the above-discussed process comprising at least two polymerization steps, is advantageous in view of the fact that it provides easily controllable reaction steps enabling the preparation of a desired reactor blend.
  • the polymerization steps may be adjusted, for example by appropriately selecting monomer feed, comonomer feed, hydrogen feed, temperature and pressure in order to suitably adjust the properties of the polymerization products obtained.
  • Such a process can be carried out using any suitable catalyst for the preparation of the polypropylene.
  • the process as discussed above is carried out using a Ziegler- Natta catalyst, in particular a high yield Ziegler-Natta catalyst (so-called fourth and fifth generation type to differentiate from low yield, so called second generation Ziegler-Natta catalysts).
  • a suitable Ziegler-Natta catalyst to be employed in accordance with the present invention comprises a catalyst component, a co-catalyst component and at least one electron donor (internal and/or external electron donor, preferably at least one external donor).
  • the catalyst component is a Ti-Mg-based catalyst component and typically the co-catalyst is an Al-alkyl based compound.
  • Suitable catalysts are in particular disclosed in US 5,234,879, WO 92/19653, WO 92/19658 and WO 99/33843.
  • Preferred external donors are the known silane-based donors, such as dicyclopentyl dimethoxy silane or cyclohexyl methyldimethoxy silane.
  • a loop-gas phase process such as developed by Borealis, known as Borstar ® technology, described for example in
  • the reaction product of the slurry polymerization which preferably is carried out in a loop reactor, is then transferred to the subsequent gas phase reactor, wherein the temperature preferably is within the range of from 50 to 130 °C, more preferably 80 to 100 °C, at a pressure in the range of from 5 to 50 bar, preferably 15 to 35 bar, again with the option of adding hydrogen in order to control the molecular weight.
  • the residence time can vary in the reactor zones identified above.
  • the residence time in the slurry reaction is in the range of from 0.5 to 5 hours, for example 0.5 to 2 hours, while the residence time in the gas phase reactor generally will be from 1 to 8 hours.
  • the properties of the polypropylene produced with the above-outlined process may be adjusted and controlled with the process conditions as known to the skilled person, for example by one or more of the following process parameters: temperature, hydrogen feed, comonomer feed, propylene feed, catalyst, type and amount of external donor, split between two or more components of a multimodal polymer. The above process enables very feasible means for obtaining the reactor-made
  • the biaxially oriented polypropylene (BOPP) and thus the capacitor film can be prepared by conventional drawing processes known in the art.
  • the process for the manufacture of a capacitor film, i.e. the biaxially oriented polypropylene (BOPP) comprises the use of the polypropylene as defined herein and its forming into a film preferably by the tenter method known in the art.
  • the tenter method is in particular a method in which the polypropylene as defined herein is melt extruded from a slit die such as a T-die and cooled on a cooling drum obtaining an undrawn sheet.
  • Said sheet is pre-heated for example with a heated metal roll and then drawn in the length direction between a plurality of rolls over which a difference in peripheral speeds is established and then both edges are gripped with grippers and the sheet is drawn in the transverse direction in an oven by means of a tenter resulting in a biaxially drawn film.
  • the temperature of said stretched sheet during the longitudinal drawing is preferably controlled in such a way as to be within the temperature range of the melting point of the polypropylene as defined herein (- 15 or + 5°C).
  • the uniformity of the film thickness on transverse drawing can be evaluated with the method in which a fixed region on the film is masked after drawing in the length direction and measuring the actual drawing factor by measuring the spacing of the said masking after transverse drawing.
  • the film can treated by corona discharge in air, nitrogen, carbon dioxide gas or any of the mixtures on the surface to be metalized, to improve the adhesive strength to the metal to be deposited, and wound by a winder.
  • the obtained film can set in a vacuum metalizer, and the film is preferably coated with an oil to form an insulation groove suitable for the purpose concerned, using a gravure coater, etc. Then, the metal suitable for the purpose concerned is deposited to achieve a predetermined layer resistance. Furthermore, as required, metallization is carried out through a comb- shaped deposition preventive plate to continuously change the resistance value in the transverse direction of the film.
  • the metalized film is slit, to make two metalized reels as a pair for making a capacitor device.
  • the reels are wound to form a device and the device is formed to be flat by a thermal press, being followed by metal spraying at the ends, attaching of leads, as required impregnation with an insulating oil, and packaging to make a capacitor.
  • the present invention is directed to the use of a polypropylene, preferably of a biaxially oriented polypropylene (BOPP), comprising more than 100 ppm to below or equal 600 ppm, more preferably in the range of 110 to 400 ppm, still more preferably in the range of 110 ppm to 350 ppm, yet more preferably in the range of 115 to 300 ppm, like in the range of 120 to 230 ppm, even more preferably 120 to 200 ppm, especially preferably 120 to 180 ppm of an alkali earth fatty acid salt, preferably of an alkali earth fatty acid salt as defined above, for the preparation of a biaxially oriented polypropylene (BOPP) and a capacitor film, respectively. Further the present invention is directed to the use of the capacitor film as defined herein in a capacitor.
  • BOPP biaxially oriented polypropylene
  • the present invention is directed to a capacitor comprising at least one layer comprising a capacitor film as defined herein. Additionally it is preferred that the capacitor comprises a metal layer, in particular a metal layer obtained by the above described process.
  • the isotacticity is determined by quantitative 13 C nuclear magnetic resonance (NMR) spectroscopy after basic assignment as e.g. in: V. Busico and R. Cipullo, Progress in Polymer Science, 2001, 26, 443-533. Experimental parameters are adjusted to ensure measurement of quantitative spectra for this specific task as e.g. in: S. Berger and S. Braun, 200 and More NMR Experiments: A Practical Course, 2004, Wiley- VCH, Weinheim. Quantities are calculated using simple corrected ratios of the signal integrals of
  • the isotacticity is determined at the pentad level i.e. mmmm fraction of the pentad distribution.
  • the relative amount of 2,1 -insertions of propylene monomers in the chain is determined by
  • Randomness random ethylene (-P-E-P-) content / the total ethylene content x 100%.
  • Mw/Mn/MWD are measured by Gel Permeation Chromatography (GPC) according to the following method:
  • a Waters Alliance GPCV 2000 instrument, equipped with refractive index detector and online viscosimeter is used with 3 x TSK-gel columns (GMHXL-HT) from TosoHaas and 1 ,2,4-trichlorobenzene (TCB, stabilized with 200 mg/L 2,6-Di tert butyl-4-methyl-phenol) as solvent at 145 °C and at a constant flow rate of 1 mL/min. 216.5 ⁇ of sample solution are injected per analysis.
  • the column set is calibrated using relative calibration with 19 narrow MWD polystyrene (PS) standards in the range of 0.5 kg/mol to 11 500 kg/mol and a set of well characterized broad polypropylene standards. All samples are prepared by dissolving 5 to 10 mg of polymer in 10 mL (at 160 °C) of stabilized TCB (same as mobile phase) and keeping for 3 hours with continuous shaking prior sampling in into the GPC instrument.
  • PS polystyrene
  • melt flow rates are measured with a load of 2.16 kg (MFR 2 ) at 230 °C.
  • the melt flow rate is that quantity of polymer in grams which the test apparatus standardised to ISO 1133 extrudes within 10 minutes at a temperature of 230 °C under a load of 2.16 kg.
  • Comonomer content (wt%) is determined in a known manner based on Fourier transform infrared spectroscopy (FTIR) determination calibrated with C 13 -NMR.
  • FTIR Fourier transform infrared spectroscopy
  • the xylene cold soluble fraction (XCS) is determined at 23 °C according to ISO 6427.
  • the gel content is assumed to be identical to the xylene hot insoluble (XHI) fraction, which is determined by extracting 1 g of finely cut polymer sample with 350 ml xylene in a Soxhlet extractor for 48 hours at the boiling temperature. The remaining solid amount is dried at
  • crystallinity measured with Mettler TA820 differential scanning calorimetry (DSC) on 5- 10 mg samples. Both crystallization and melting curves were obtained during 10 °C/min cooling and heating scans between 30 °C and 225 °C. Melting and crystallization temperatures were taken as the peaks of endotherms and exotherms.
  • Ash content Ash content is measured according to ISO 3451-1 standard.
  • the propylene homopolymer (PP-H) has been additivated with calcium stearate (CAS-No. 1592-23-0) so that the content of the calcium stearate within the propylene homopolymer (PP-H) was 75 ppm.
  • the resulting composition had an ash content of 15 ppm. Comparative Example (CE2)
  • the propylene homopolymer (PP-H) has been additivated with calcium stearate (CAS-No. 1592-23-0) so that the content of the calcium stearate within the propylene homopolymer (PP-H) was 600 ppm.
  • the resulting composition had an ash content of 63 ppm.
  • the propylene homopolymer (PP-H) has been additivated with calcium stearate (CAS-No. 1592-23-0) so that the content of the calcium stearate within the propylene homopolymer (PP-H) was 150 ppm.
  • the resulting composition had an ash content of 29 ppm.
  • CE and IE were subjected to the following work flow to create cast films: The materials were extruded and cast onto a chill roll to generate quenched film sheets. Settings used were according to table 1

Abstract

Capacitor film comprising a biaxially oriented polypropylene (BOPP) and more than 100 to below or equal 400 ppm of an alkali earth fatty acid salt.

Description

Polypropylene with specific calcium stearate content for special capacitors
The present invention is directed to a new capacitor film based on biaxially oriented polypropylene (BOPP).
Polypropylene is the material of choice in the field of film capacitors as its chain lacks any kind of polar groups which orient under electrical field stress. As a result, polypropylene intrinsically possesses a low loss factor and high volume resistivity. These properties, combined with a relatively high dielectric constant and self healing character in the capacitor, make polypropylene so valuable in this technical field. The dielectric strength or the breakdown voltage of polypropylene can be further increased in case it is biaxially oriented which is obtained by stretching a heated sheet of film in two opposing directions, longitudinal and transverse machine directions, inducing a more perfect crystalline formation and orientation. It is also known that additives must be added to polypropylene to make the material durable. For instance antioxidants are added to reduce the risk of degradation of the polymeric material. Further the polypropylene typically contains considerable amounts of polar residues, like chlorine, aluminium, magnesium or silicon originating from the used catalyst. These residues are unwanted as they negatively influence the dielectric properties. Thus also acid scavengers are added in spite the fact that polar elements cause some extra, unfortunate dissipation in the capacitor film. Of course such additives are added in lowest possible amounts, normally not exceeding 100 ppm. A well accepted amount in this technical field is around 75 ppm of acid scavengers. However, a typical problem during the preparation of biaxially oriented polypropylene (BOPP) is the die drool caused by sheer stress. Further nowadays the winded biaxially oriented polypropylene (BOPP) is subsequently flattened in order to reduce the volume of the capacitor by pressing the round cylinder in an oval shape. The flattening of the circular winding enables to increase the energy density of the capacitor further. The problem of this specific capacitor design is, that the additional flattening step causes also mechanical stress and damage from which the biaxially oriented polypropylene (BOPP) suffers and the inner windings start wrinkling and rippling from the inside to the outside. Accordingly the object of the present invention is to provide a capacitor film which can be produced from polypropylene not getting damaged during the stretching phase and which can be winded and subsequently flattened without causing defects within the film. Further the ash content of the used polypropylene shall still in acceptable limits and shall not considerably increase the dissipation.
The finding of the present invention is that the used polypropylene must comprise an alkali earth fatty acid salt in amount exceeding 100 ppm. Accordingly the present invention is directed to a capacitor film comprising
(a) more than 90 wt.-% of a biaxially oriented polypropylene (BOPP) and
(b) more than 100 to below or equal 600 ppm of an alkali earth fatty acid salt.
As usual 1 ppm of additive or residues, e.g. ash content, corresponds to 1 mg additive or residues, e.g. ash content, in 1 kg composition.
Preferably the biaxially oriented polypropylene (BOPP) is the only polymer within the capacitor film. Accordingly the capacitor film may contain further additives apart from the alkali earth fatty acid salt but preferably no other polymer. Thus the remaining part up to 100.0 wt.-% may be accomplished by further additives known in the art. However this remaining part shall be not more than 5.0 wt.-%, preferably not more than 2.0 wt.-%, like not more than 1.0 wt.%, within the capacitor film. Accordingly the capacitor film preferably comprises more than 95 wt.-%, more preferably more 98 wt.-%, like more than 99.0 wt.-%, of the biaxially oriented polypropylene (BOPP). Accordingly in one preferred embodiment the capacitor film is a biaxially oriented polypropylene (BOPP), said biaxially oriented polypropylene (BOPP) comprises more than 100 to below or equal 600 ppm of an alkali earth fatty acid salt.
It has been surprisingly found out that the capacitor film of the instant invention can be produced from polypropylene without getting damaged during the processing steps and without increasing the ash content beyond unacceptable levels or increasing the dissipation. In the following the instant invention is described in more detail.
Typically the capacitor film has a thickness of not more than 10.0 μηι, preferably not more than 5.0 μηι, more preferably not more than 3.0 μηι, yet more preferably in the range of 0.5 to 3.5 μιη, like in the range of 1.0 to 3.0 μιη.
Further the capacitor film and/or the biaxially oriented polypropylene (BOPP) is/are featured by its/their high purity. Accordingly it is preferred that the capacitor film and/or the biaxially oriented polypropylene (BOPP) has/have an ash content of equal or below 100 ppm, more preferably equal or below 50 ppm, yet more preferably equal or below 40 ppm, still yet more preferably equal or below 30 ppm.
According to an embodiment of the present invention, this high purity is not accomplished by a washing step.
As stated above the polypropylene of the capacitor film is biaxially oriented. Preferably the biaxially oriented polypropylene (BOPP) has a draw ratio in machine direction of at least 4.0 and a draw ratio in transverse direction of at least 4.0. Such ratios are appreciated as commercial biaxially oriented polypropylene films must be stretchable at least to the above defined extent without breaking. The length of the sample increases during stretching in longitudinal direction and the draw ratio in longitudinal direction calculates from the ratio of current length over original sample length. Subsequently, the sample is stretched in transverse direction where the width of the sample is increasing. Hence, the draw ratio calculates from the current width of the sample over the original width of the sample.
Preferably the draw ratio in machine direction of the biaxially oriented polypropylene (BOPP) ranges from 4.0 to 8.0, more preferably from 4.5 to 6.5. The draw ratio in transverse direction of the biaxially polypropylene (BOPP) ranges preferably from 6.0 to 10.0, more preferably from 7.0 to 9.5. In a preferred embodiment the biaxially polypropylene (BOPP) has a draw ratio in machine direction from 4.5 to 7.0. in particular from 4.5 to 5.0, and a draw ratio in transverse direction from 6.0 to 10.0, in particular from 8.0 to 10. The polypropylene which is transferred into a biaxially oriented polypropylene (BOPP) can be any polypropylene, however it is preferred that it is a random propylene copolymer or a propylene homopolymer, the latter is especially preferred. Accordingly wherever in the present application it is referred to properties of the biaxially oriented polypropylene (BOPP) automatically also the properties of the polypropylene used for the preparation of the biaxially oriented polypropylene (BOPP) are defined as well therewith.
According to an embodiment of the present invention the biaxially oriented polypropylene (BOPP) is a biaxially oriented random propylene copolymer. The term random is understood according to IUPAC (Glossary of basic terms in polymer science; IUPAC recommendations 1996). Accordingly it is preferred that the biaxially oriented random propylene copolymer has a randomness of at least 40 %, more preferably of at least 50 %, yet more preferably at least 55 %, even more preferably of at least 60 %, and still more preferably of at least 65 %.
In case the biaxially oriented polypropylene (BOPP) is a biaxially oriented random propylene copolymer it comprises monomers copolymerizable with propylene, for example comonomers such as ethylene and/or C4 to C12 alpha-olefins, in particular ethylene and/or C4 to Cio alpha-olefins, e.g. 1-butene and/or 1-hexene. Preferably the biaxially oriented random propylene copolymer comprises, especially consists of, monomers copolymerizable with propylene from the group consisting of ethylene, 1-butene and 1-hexene. More specifically the biaxially oriented random propylene copolymer comprises - apart from propylene - units derivable from ethylene and/or 1-butene. In a preferred embodiment the biaxially oriented random propylene copolymer comprises units derivable from ethylene and propylene only. The comonomer content in the biaxially oriented random propylene copolymer is preferably relatively low, i.e. up to 6.0 wt.-%, more preferably 0.5 to 6.0 wt.-%, still more preferably 0.5 to 4.0 wt.-%, yet more preferably 0.5 to 2.0 wt.-%.
The expression biaxially oriented homopolymer used in the instant invention relates to a biaxially oriented polypropylene (BOPP) that consists substantially, i.e. of at least 99.5 wt- %, more preferably of at least 99.8 wt.-%, of propylene units. In a preferred embodiment only propylene units in the biaxially oriented propylene homopolymer are detectable. The comonomer content can be determined with FT infrared spectroscopy, as described below in the examples. As stated above it is in particular appreciated that the biaxially oriented polypropylene (BOPP) is a biaxially oriented propylene homopolymer.
Preferably the polypropylene is isotactic. Accordingly it is appreciated that the
polypropylene has a rather high pentad concentration, i.e. higher than 90 %, more preferably higher than 92 %, still more preferably higher than 93 % and yet more preferably higher than 95 %, like at least 97 %.
A further characteristic of the biaxially oriented polypropylene (BOPP) is the low amount of misinsertions of propylene within the polymer chain. Accordingly the biaxially oriented polypropylene (BOPP) is preferably featured by low amount of <2,1> erythro regiodefects, i.e. of not more than 0.4 mol.-%, more preferably of not more than 0.2 mol.-%, like of not more than 0.1 mol.-%, determined by 13C-NMR spectroscopy.
The capacitor film and/or the biaxially oriented polypropylene (BOPP) can have a xylene cold soluble content (XCS) in a broad range, i.e. up to 6.0 wt.-%. Accordingly the capacitor film and/or the biaxially oriented polypropylene (BOPP) may have a xylene cold soluble content (XCS) in the range of 0.3 to 6.0 wt.-%, like 0.5 to 5.5 wt.-%.
However in preferred embodiments the capacitor film and/or the biaxially oriented polypropylene (BOPP) has/have a xylene cold soluble (XCS) content in the range of 0.5 to
4.0 wt.-%, more preferably in the range of 0.5 to 3.0 wt.-%, still more preferably of 0.5 to 2.0 wt.-%.
The amount of xylene cold soluble (XCS) additionally indicates that the capacitor film and/or the biaxially oriented polypropylene (BOPP) is/are preferably free of any elastomeric polymer component, like an ethylene propylene rubber. In other words the capacitor film and/or the biaxially oriented polypropylene (BOPP) shall be not a heterophasic
polypropylene, i.e. a system consisting of a polypropylene matrix in which an elastomeric phase is dispersed. Such systems are featured by a rather high xylene cold soluble content. A further aspect of the instant invention is that the capacitor film and/or the biaxially oriented polypropylene (BOPP) has/have a rather high melting point. Accordingly it is appreciated that the capacitor film and/or the biaxially oriented polypropylene (BOPP) according to this invention has a melting temperature (Tm) measured according to ISO 11357-3 of at least 145.0 °C, more preferably of at least 155.0 °C, yet more preferably of at least 158 °C. Thus it is in particular appreciated that the melting temperature (Tm) measured according to ISO 11357-3 of the capacitor film and/or of the biaxially oriented
polypropylene (BOPP) is in the range of 145 to 168 °C, more preferably in the range of 155 to 164 °C, still more preferably in the range of 160 to 164 °C. Additionally it is appreciated that the capacitor film and/or the biaxially oriented polypropylene (BOPP) has/have a rather high crystallization temperature (Tc). Thus it is preferred that the capacitor film and/or the biaxially oriented polypropylene (BOPP) has/have crystallization temperature (Tc) measured according to ISO 11357-3 of at least 110 °C, more preferably of at least 111 °C. Accordingly the capacitor film and/or the biaxially oriented polypropylene (BOPP) has/have preferably a crystallization temperature (Tc) measured according to ISO 11357-3 in the range of 110 to 120 °C, more preferably in the range of 111 to 117 °C.
The molecular weight distribution (MWD) is the relation between the numbers of molecules in a polymer and the individual chain length. The molecular weight distribution (MWD) is expressed as the ratio of weight average molecular weight (Mw) and number average molecular weight (Mn). The number average molecular weight (Mn) is an average molecular weight of a polymer expressed as the first moment of a plot of the number of molecules in each molecular weight range against the molecular weight. In effect, this is the total molecular weight of all molecules divided by the number of molecules. In turn, the weight average molecular weight (Mw) is the first moment of a plot of the weight of polymer in each molecular weight range against molecular weight.
The number average molecular weight (Mn) and the weight average molecular weight (Mw) as well as the molecular weight distribution (MWD) are determined by size exclusion chromatography (SEC) using Waters Alliance GPCV 2000 instrument with online viscometer. The oven temperature is 140 °C. Trichlorobenzene is used as a solvent
(ISO 16014). Accordingly it is preferred that the biaxially oriented polypropylene (BOPP) has a weight average molecular weight (Mw) from 100,000 to 600,000 g/mol, more preferably from 200,000 to 500,000 g/mol.
A broad molecular weight distribution (MWD) improves the processability of the polypropylene. Accordingly it is appreciated that the molecular weight distribution (MWD) measured according to ISO 16014 is at least 2.8, more preferably at least 3.0, like at least 3.3. On the other hand a rather broad molecular weight distribution (MWD) indicates rather high amount of low molecular weight fractions which contribute to the xylene soluble content without improving the dielectrical performance. Therefore, in an alternative embodiment the molecular weight distribution (MWD) is preferably between 2.8 to 10.0, still more preferably in the range of 3.0 to 8.0.
Furthermore, it is preferred that the biaxially oriented polypropylene (BOPP) has a melt flow rate (MFR) given in a specific range. The melt flow rate measured under a load of 2.16 kg at 230 °C (ISO 1133) is denoted as MFR2 (230 °C). Accordingly, it is preferred that the biaxially oriented polypropylene (BOPP) has an MFR2 (230 °C) of more than 0.5 g/lOmin, more preferably of more than 1.0 g/lOmin. Accordingly it is appreciated that the MFR2 (230 °C) measured according to ISO 1133 is in the range of 0.5 to 10.0 g/lOmin, more preferably in the range of 1.0 to 6.0 g/lOmin, still more preferably in the range of 1.5 to 4.0 g/lOmin. Further it is appreciated that the biaxially oriented polypropylene (BOPP) is of linear structure and thus does not show (or nearly does not show) a kind of branching. Accordingly it is appreciated that the biaxially oriented polypropylene (BOPP) of the instant invention has preferably a branching index g' of not less than 0.9, preferably more than 0.9, like at least 0.95. In other words if the biaxially oriented polypropylene (BOPP) has some kind of branching it shall be rather moderate. Accordingly the branching index g' of the biaxially oriented polypropylene (BOPP) is preferably in the range of 0.9 to 1.0, more preferably in the range of more than 0.9 to 1.0, like in the range of 0.96 to 1.0. In an especially preferred embodiment the biaxially oriented polypropylene (BOPP) shows no branching, i.e. the biaxially oriented polypropylene (BOPP) has a branching index g' of 1.0. The branching index g' is defined as
Figure imgf000009_0001
in which g' is the branching index, [IV]br is the intrinsic viscosity of the branched polypropylene and [IV]i;n is the intrinsic viscosity of the linear polypropylene having the same weight average molecular weight (within a range of ± 3%) as the branched polypropylene. Thereby, a low g'-value is an indicator for a high branched polymer. In other words, if the g'-value decreases, the branching of the polypropylene increases. Reference is made in this context to B.H. Zimm and W.H. Stockmeyer, J. Chem. Phys. 17,1301 (1949). This document is herewith included by reference.
As the biaxially oriented polypropylene (BOPP) according to this invention is preferably of non-branched structure it does also not show a significant amount of gel content. Gels are a typical phenomenon of polypropylenes being crosslinked. Thus the gel content is a good indicator for the chemical modification of the polypropylene. Accordingly the biaxially oriented polypropylene (BOPP) is featured by relatively moderate gel content, i.e. of not more than 0.50 wt.-%, more preferably of not more than 0.25 wt.-%, still more preferably of not more than 0.15 wt.-%, like below 0.15 wt.-%, yet more preferably not more than 0.10 wt.-%, determined as the relative amount of polymer insoluble in boiling xylene (xylene hot insoluble fraction, XHI). In an especially preferred embodiment no gel content is detectable.
As stated above a further essential finding of the present invention is that the capacitor film must comprise in a specific range an alkali earth fatty acid salt. Accordingly one requirement of the present invention is that the alkali earth fatty acid salt is present in the capacitor film in the range of more than 100 ppm to below or equal 600 ppm, more preferably in the range of 100 to 400 ppm, i.e in the range of 110 to 400 ppm, still more preferably in the range of 110 ppm to 350 ppm, yet more preferably in the range of 115 to 300 ppm, like in the range of 120 to 230 ppm. A still more preferred upper limit for the amount of alkali earth fatty acid salt is 200 ppm, with 180 ppm being a particularly preferred upper limit.
As stated above the alkali earth fatty acid salt within the capacitor film of the present invention is used in comparatively high amounts, however the amount of alkali earth fatty acid salt preferably shall not exceed values having negative impact on the ash content. Thus it is preferred that the amount of the alkali earth fatty acid salt within the capacitor film does not exceed values which cause an ash content exceeding the upper limits as stated above, i.e. an ash content of not more than 100 ppm, more preferably not more than 50 ppm, yet more preferably not more than 40 ppm, still yet more preferably not more than 30 ppm. The alkali earth fatty acid salt is preferably an alkali earth salt of a C u to C26 fatty acid, more preferably an alkali earth salt of a C 14 to C24 fatty acid, still more preferably an alkali earth salt of a Ci8 to C22 fatty acid, like an alkali earth salt of a Cig fatty acid. Further it is appreciated that the alkali earth fatty acid salt is an alkali earth salt of a saturated fatty acid, in particular of a saturated fatty acid as defined in this paragraph.
The alkali earth element of the alkali earth fatty acid salt is preferably magnesium or calcium, the latter being especially preferred.
Accordingly in a specific embodiment the alkali earth fatty acid salt is a calcium C14 to C24 fatty acid salt, like calcium stearate.
As stated above, the capacitor film may comprise additional additives known in the art, like antioxidants. However any additives which negatively influences the electrical breakdown behavior should be avoided. The biaxially oriented polypropylene (BOPP) can be produced in a known manner. In a first step the polypropylene which is used for the preparation of a biaxially oriented material is preferably prepared by polymerizing, in a slurry reactor, for example a loop reactor, propylene optionally together with at least another C2 to C12 a-olefin (comonomers), in the presence of a polymerization catalyst to produce a part of the polypropylene. This part is then transferred to a subsequent gas phase reactor, wherein in the gas phase reactor propylene is reacted optionally together with comonomers as defined above in order to produce a further part in the presence of the reaction product of the first step. This reaction sequence provides a reactor blend of parts (i) (fraction (A)) and (ii) (fraction (B)) constituting a polypropylene. It is of course possible by the present invention that the first reaction is carried out in a gas phase reactor while the second polymerization reaction is carried out in a slurry reactor, for example a loop reactor. It is furthermore also possible to reverse the order of producing parts (i) and (ii), which has been described above in the order of first producing part (i) and then producing part (ii). The above-discussed process, comprising at least two polymerization steps, is advantageous in view of the fact that it provides easily controllable reaction steps enabling the preparation of a desired reactor blend. The polymerization steps may be adjusted, for example by appropriately selecting monomer feed, comonomer feed, hydrogen feed, temperature and pressure in order to suitably adjust the properties of the polymerization products obtained.
Such a process can be carried out using any suitable catalyst for the preparation of the polypropylene. Preferably, the process as discussed above is carried out using a Ziegler- Natta catalyst, in particular a high yield Ziegler-Natta catalyst (so-called fourth and fifth generation type to differentiate from low yield, so called second generation Ziegler-Natta catalysts). A suitable Ziegler-Natta catalyst to be employed in accordance with the present invention comprises a catalyst component, a co-catalyst component and at least one electron donor (internal and/or external electron donor, preferably at least one external donor). Preferably, the catalyst component is a Ti-Mg-based catalyst component and typically the co-catalyst is an Al-alkyl based compound. Suitable catalysts are in particular disclosed in US 5,234,879, WO 92/19653, WO 92/19658 and WO 99/33843. Preferred external donors are the known silane-based donors, such as dicyclopentyl dimethoxy silane or cyclohexyl methyldimethoxy silane.
One embodiment of a process as discussed above is a loop-gas phase process, such as developed by Borealis, known as Borstar® technology, described for example in
EP 0 887 379 Al and WO 92/12182.
With respect to the above-mentioned preferred slurry-gas phase process, the following general information can be provided with respect to the process conditions.
Temperature of from 40 to 110 °C, preferably between 60 and 100 °C, in particular between 80 and 90 °C, with a pressure in the range of from 20 to 80 bar, preferably 30 to 60 bar, with the option of adding hydrogen in order to control the molecular weight. The reaction product of the slurry polymerization, which preferably is carried out in a loop reactor, is then transferred to the subsequent gas phase reactor, wherein the temperature preferably is within the range of from 50 to 130 °C, more preferably 80 to 100 °C, at a pressure in the range of from 5 to 50 bar, preferably 15 to 35 bar, again with the option of adding hydrogen in order to control the molecular weight. The residence time can vary in the reactor zones identified above. In embodiments, the residence time in the slurry reaction, for example the loop reactor, is in the range of from 0.5 to 5 hours, for example 0.5 to 2 hours, while the residence time in the gas phase reactor generally will be from 1 to 8 hours. The properties of the polypropylene produced with the above-outlined process may be adjusted and controlled with the process conditions as known to the skilled person, for example by one or more of the following process parameters: temperature, hydrogen feed, comonomer feed, propylene feed, catalyst, type and amount of external donor, split between two or more components of a multimodal polymer. The above process enables very feasible means for obtaining the reactor-made
polypropylene.
The biaxially oriented polypropylene (BOPP) and thus the capacitor film can be prepared by conventional drawing processes known in the art. Accordingly the process for the manufacture of a capacitor film, i.e. the biaxially oriented polypropylene (BOPP), according to this invention comprises the use of the polypropylene as defined herein and its forming into a film preferably by the tenter method known in the art. The tenter method is in particular a method in which the polypropylene as defined herein is melt extruded from a slit die such as a T-die and cooled on a cooling drum obtaining an undrawn sheet. Said sheet is pre-heated for example with a heated metal roll and then drawn in the length direction between a plurality of rolls over which a difference in peripheral speeds is established and then both edges are gripped with grippers and the sheet is drawn in the transverse direction in an oven by means of a tenter resulting in a biaxially drawn film. The temperature of said stretched sheet during the longitudinal drawing is preferably controlled in such a way as to be within the temperature range of the melting point of the polypropylene as defined herein (- 15 or + 5°C). The uniformity of the film thickness on transverse drawing can be evaluated with the method in which a fixed region on the film is masked after drawing in the length direction and measuring the actual drawing factor by measuring the spacing of the said masking after transverse drawing.
Subsequently, the film can treated by corona discharge in air, nitrogen, carbon dioxide gas or any of the mixtures on the surface to be metalized, to improve the adhesive strength to the metal to be deposited, and wound by a winder.
The obtained film can set in a vacuum metalizer, and the film is preferably coated with an oil to form an insulation groove suitable for the purpose concerned, using a gravure coater, etc. Then, the metal suitable for the purpose concerned is deposited to achieve a predetermined layer resistance. Furthermore, as required, metallization is carried out through a comb- shaped deposition preventive plate to continuously change the resistance value in the transverse direction of the film. The metalized film is slit, to make two metalized reels as a pair for making a capacitor device. Then, the reels are wound to form a device and the device is formed to be flat by a thermal press, being followed by metal spraying at the ends, attaching of leads, as required impregnation with an insulating oil, and packaging to make a capacitor.
Moreover the present invention is directed to the use of a polypropylene, preferably of a biaxially oriented polypropylene (BOPP), comprising more than 100 ppm to below or equal 600 ppm, more preferably in the range of 110 to 400 ppm, still more preferably in the range of 110 ppm to 350 ppm, yet more preferably in the range of 115 to 300 ppm, like in the range of 120 to 230 ppm, even more preferably 120 to 200 ppm, especially preferably 120 to 180 ppm of an alkali earth fatty acid salt, preferably of an alkali earth fatty acid salt as defined above, for the preparation of a biaxially oriented polypropylene (BOPP) and a capacitor film, respectively. Further the present invention is directed to the use of the capacitor film as defined herein in a capacitor.
In addition, the present invention is directed to a capacitor comprising at least one layer comprising a capacitor film as defined herein. Additionally it is preferred that the capacitor comprises a metal layer, in particular a metal layer obtained by the above described process.
The present invention will now be described in further detail by the following examples.
E X A M P L E S A. Measuring methods
The following definitions of terms and determination methods apply for the above general description of the invention as well as to the below examples unless otherwise defined. Quantification of isotacticity in polypropylene by 13C NMR spectroscopy
The isotacticity is determined by quantitative 13C nuclear magnetic resonance (NMR) spectroscopy after basic assignment as e.g. in: V. Busico and R. Cipullo, Progress in Polymer Science, 2001, 26, 443-533. Experimental parameters are adjusted to ensure measurement of quantitative spectra for this specific task as e.g. in: S. Berger and S. Braun, 200 and More NMR Experiments: A Practical Course, 2004, Wiley- VCH, Weinheim. Quantities are calculated using simple corrected ratios of the signal integrals of
representative sites in a manner known in the art. The isotacticity is determined at the pentad level i.e. mmmm fraction of the pentad distribution.
<2,l>-propylene insertions ( <2,1> erythro regiodefects)
The relative amount of 2,1 -insertions of propylene monomers in the chain is determined by
13C-NMPv spectroscopy and calculated as described in EP 0 629 632 Bl .
Randomness
In the FTIR measurements, films of 250 -mm thickness were compression moulded at 225 °C and investigated on a Perkin-Elmer System 2000 FTIR instrument. The ethylene peak area (760-700 cm4) was used as a measure of total ethylene content. The absorption band for the structure -P-E-P- (one ethylene unit between propylene units), occurs at 733 cm"1' This band characterizes the random ethylene content. For longer ethylene sequences (more than two units), an absorption band occurs at 720 cm"1. Generally, a shoulder corresponding to longer ethylene runs is observed for the random copolymers. The calibration for total ethylene content based on the area and random ethylene (PEP) content based on peak height at 733 cm"1 was made by 13C"NMR. (Thermochimica Acta, 66 (1990) 53-68 ).
Randomness = random ethylene (-P-E-P-) content / the total ethylene content x 100%. Mw, Mn, MWD
Mw/Mn/MWD are measured by Gel Permeation Chromatography (GPC) according to the following method:
The weight average molecular weight (Mw), the number average molecular weight (Mn), and the molecular weight distribution (MWD = Mw/Mn) is measured by a method based on ISO 16014-1 :2003 and ISO 16014-4:2003. A Waters Alliance GPCV 2000 instrument, equipped with refractive index detector and online viscosimeter is used with 3 x TSK-gel columns (GMHXL-HT) from TosoHaas and 1 ,2,4-trichlorobenzene (TCB, stabilized with 200 mg/L 2,6-Di tert butyl-4-methyl-phenol) as solvent at 145 °C and at a constant flow rate of 1 mL/min. 216.5 μΕ of sample solution are injected per analysis. The column set is calibrated using relative calibration with 19 narrow MWD polystyrene (PS) standards in the range of 0.5 kg/mol to 11 500 kg/mol and a set of well characterized broad polypropylene standards. All samples are prepared by dissolving 5 to 10 mg of polymer in 10 mL (at 160 °C) of stabilized TCB (same as mobile phase) and keeping for 3 hours with continuous shaking prior sampling in into the GPC instrument.
Melt Flow Rate (MFR)
The melt flow rates are measured with a load of 2.16 kg (MFR2) at 230 °C. The melt flow rate is that quantity of polymer in grams which the test apparatus standardised to ISO 1133 extrudes within 10 minutes at a temperature of 230 °C under a load of 2.16 kg.
Comonomer content
Comonomer content (wt%) is determined in a known manner based on Fourier transform infrared spectroscopy (FTIR) determination calibrated with C13-NMR.
Xylene cold soluble fraction (XCS wt%)
The xylene cold soluble fraction (XCS) is determined at 23 °C according to ISO 6427.
The gel content is assumed to be identical to the xylene hot insoluble (XHI) fraction, which is determined by extracting 1 g of finely cut polymer sample with 350 ml xylene in a Soxhlet extractor for 48 hours at the boiling temperature. The remaining solid amount is dried at
90°C and weighed for determining the insolubles amount.
Melting temperature Tm, crystallization temperature Tc, and the degree of
crystallinity: measured with Mettler TA820 differential scanning calorimetry (DSC) on 5- 10 mg samples. Both crystallization and melting curves were obtained during 10 °C/min cooling and heating scans between 30 °C and 225 °C. Melting and crystallization temperatures were taken as the peaks of endotherms and exotherms.
Ash content Ash content is measured according to ISO 3451-1 standard.
B. Examples
In the examples a propylene homopolymer (PP-H) with a MFR2 (230 °C) of 3.3 g/lOmin, a melting temperature of 163 °C, and a pentad concentration of 97.4 % has been used. No 2,1- insertions of propylene monomers in the chain were detectable by 13C-NMR spectroscopy. Comparative Example (CE1)
The propylene homopolymer (PP-H) has been additivated with calcium stearate (CAS-No. 1592-23-0) so that the content of the calcium stearate within the propylene homopolymer (PP-H) was 75 ppm. The resulting composition had an ash content of 15 ppm. Comparative Example (CE2)
The propylene homopolymer (PP-H) has been additivated with calcium stearate (CAS-No. 1592-23-0) so that the content of the calcium stearate within the propylene homopolymer (PP-H) was 600 ppm. The resulting composition had an ash content of 63 ppm.
Inventive Example (IE)
The propylene homopolymer (PP-H) has been additivated with calcium stearate (CAS-No. 1592-23-0) so that the content of the calcium stearate within the propylene homopolymer (PP-H) was 150 ppm. The resulting composition had an ash content of 29 ppm.
CE and IE were subjected to the following work flow to create cast films: The materials were extruded and cast onto a chill roll to generate quenched film sheets. Settings used were according to table 1
Table 1 : Cast Film process parameters
Figure imgf000017_0001
The frictional behaviour of cast films based on comparative and inventive examples were measured according to ISO 8295 (1995)
The friction of the cast film (1) based on comparative example (CEl) was more pronounced compared to the cast film (2) prepared from the inventive example (IE). According to experience, this indicates that the inventive example (IE) from which the cast film (2) was made is more suitable for being converted into flattened capacitors compared to the cast film (1).

Claims

C L A I M S
Capacitor film comprising
(a) at least 90 wt.-% of a biaxially oriented polypropylene (BOPP) and
(b) more than 100 to below or equal 400 ppm of an alkali earth fatty acid salt.
Capacitor film according to claim 1 , wherein the biaxially oriented polypropylene (BOPP) has a draw ratio in machine direction of at least 4.0 and a draw ration in transverse direction of at least 4.0.
Capacitor film according to claim 1 or 2, wherein the biaxially oriented polypropylene (BOPP) is the only polymer component within the capacitor film.
4. Capacitor film according to any one of the preceding claims, wherein the biaxially oriented polypropylene (BOPP) is a propylene homopolymer.
5. Capacitor film according to any one of the preceding claims, wherein the capacitor film and/or the biaxially oriented polypropylene (BOPP) has/have an ash content below 100 ppm.
6. Capacitor film according to any one of the preceding claims, wherein the biaxially oriented polypropylene (BOPP) has
(a) <2,1> erythro regiodefects of not more than 0.4 mol.-% determined by 13C- spectroscopy
and/or
(b) a branching index g' of at least 0.9.
7. Capacitor film according to any one of the preceding claims, wherein the biaxially oriented polypropylene (BOPP) has
(a) a molecular weight distribution (MWD) measured according to ISO 16014 of at least 2.8,
and/or
(b) a melt flow rate MFR2 (230 °C) measured according to ISO 1133 in the range of 1.0 to 6.0 g/lOmin. Capacitor film according to any one of the preceding claims, wherein the capacitor film and/or the biaxially oriented polypropylene (BOPP) has/have
(a) a melting temperature (Tm) measured according to ISO 11357-3 of at least 145.0 °C,
and/or
(b) crystallization temperature (Tc) measured according to ISO 11357-3 of at least 113 °C.
Capacitor film according to any one of the preceding claims, wherein the capacitor film and/or the biaxially oriented polypropylene (BOPP) has/have a xylene cold soluble fraction (XCS) of up to 6.0 wt.-%.
Capacitor film according to any one of the preceding claims, wherein the amount of alkali earth fatty acid salt within the capacitor film is in the range of 120 to 230 ppm.
Capacitor film according to any one of the preceding claims, wherein the alkali earth fatty acid salt is an alkali earth salt of a saturated fatty acid.
Capacitor film according to any one of the preceding claims, wherein the alkali earth fatty acid salt is an alkali earth salt of a C u to C26 fatty acid.
Capacitor film according to any one of the preceding claims, wherein the alkali earth fatty acid salt is calcium stearate.
Capacitor comprising a capacitor film according to any one of the preceding claims.
Capacitor according to claim 14, wherein the capacitor comprises additionally a metal layer.
16. Use of a polypropylene comprising more than 100 to below or equal 600 ppm of an alkali earth fatty acid salt for the preparation of a biaxially oriented polypropylene (BOPP) and/or a capacitor film.
PCT/EP2011/057322 2010-05-12 2011-05-06 Polypropylene with specific calcium stearate content for special capacitors WO2011141380A1 (en)

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