Mutual Woven Polypropylene Fabric Safety Barricade Fence
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Polypropylene fabric is a term used to describe any textile product that is derived from the thermoplastic polymer polypropylene. This type of plastic is part of the polyolefin group, and it is non-polar and partially crystalline. Next to polyethylene, polypropylene is the second-most commonly produced plastic in the world, and it is more commonly used in packaging, straws, and other types of consumer and industrial goods than it is in textile production.
This type of plastic was originally developed by the American corporation Phillips Petroleum in . Chemists Robert Banks and J. Paul Hogan were attempting to derive gasoline from propylene, and they accidentally created polypropylene. While this experiment was deemed a failure, it was quickly recognized that this new compound has the potential to be on par with polyethylene in many applications.
It wasn't until , however, that polypropylene was made into a substance suitable for mass production. In , the Italian chemist Giulio Natta and his German colleague succeeded in forming this substance into an isotactic polymer, and the Italian corporation Montecatini quickly started producing this substance for commercial and consumer use.
Polypropylene was originally marketed under the name "Moplen," and this name is still a registered trademark of the LyondellBasell corporation. However, it is much more common to find this substance referred to as polypropylene or "polypro" for short.
Deckchair with canopy and sling in polypropylene fabric in dove grey
As the use of polypropylene became more and more popular in a number of consumer and industrial applications, it was gradually discovered that this type of plastic also showed potential as a textile. Polypropylene fabric is a nonwoven textile, which means that it is made directly from a material without any need for spinning of weaving. The main benefit of polypropylene as a fabric is its moisture transfer abilities; this textile cannot absorb any moisture, and instead, moisture passes through polypropylene fabric entirely.
This attribute allows moisture that is exuded while wearing a polypropylene garment to evaporate much more quickly than it would with a moisture-retaining garment. Therefore, this fabric is popular in textiles that are worn close to the skin. However, polypro has a tendency to absorb and retain body odors when it is used for undergarments, and it also melts at relatively low temperatures. Molten polypro fabric can cause serious burns, and this issue also makes it impossible to wash this fabric at high temperatures.
Polypropylene fabric is one of the lightest synthetic fibers in existence, and it is incredibly resistant to most acids and alkalis. In addition, the thermal conductivity of this substance is lower than that of most synthetic fibers, which means that it is ideally suited for cold weather wear.
Beige and White Basket Woven Polypropylene Upholstery Fabric
Furthermore, this fabric is highly resistant to abrasion, and it also resists insects and other pests. Due to its notable thermoplastic qualities, it's easy to mold polypro plastic into various shapes and forms, and it can be reformed through melting. This plastic is also not very susceptible to stress cracking.
However, polypro is notoriously hard to dye after it is manufactured, and it is also difficult to shape this fabric into different textures. This fabric is susceptible to UV damage, and it does not adhere well to latex or epoxies. Like every other synthetic textile, polypropylene fabric also has a significantly negative impact on the environment.
Like most types of plastics, polypro is made from substances that are derived from hydrocarbon fuels like petroleum oil. First, the monomer propylene is extracted from crude oil in gas form, and this monomer is then subjected to a process called chain-growth polymerization to create the polymer polypropylene.
Once a large number of propylene monomers are strung together, a solid plastic material is formed. To make a usable textile, polypropylene resin must be mixed with a wide variety of plasticizers, stabilizers, and fillers. These additives are introduced into molten polypro, and once the desired substance is acquired, this plastic may be allowed to cool into bricks or pellets.
These pellets or bricks are then transferred to a textile factory, and they are remelted. In most cases, this polypropylene is then formed into sheets, or it may be allowed to cool in molds. If sheets are created, these thin fibers are then cut into the desired shape and sewn or glued to create garments or diapers. A variety of different manufacturing methods are used to form polypropylene into non-apparel products.
Polypro fabric is commonly used in clothing applications in which moisture transfer is desired. For instance, this type of plastic is commonly used to make top sheets for diapers, which are the components of diapers that make direct contact with skin. By using polypropylene for this diaper component, it is assured that no moisture will remain in contact with a baby's skin, which reduces the likelihood of rashes forming.
This nonwoven fabric's moisture-transferring properties have also made it a popular textile for cold weather gear. For instance, this synthetic was used to make the underwear and undershirts that were used in the first generation of the U.S. Army's Extended Cold Weather Clothing System (ECWCS). It was found that garments made from this fabric improved the comfort of soldiers in cold-weather conditions, but problems with polypro fabrics have caused the United States military to switch to the latest generation of polyester textiles for their Generation II and Generation III ECWCS systems.
In some cases, polypropylene fabric may also be used to make sportswear, but a number of issues with this type of plastic have made newer versions of polyester more popular for this application. While this fabric's moisture-transferring properties are highly desirable for sportswear, the inability to wash this fabric with hot water makes it hard to remove odors from polypropylene sportswear. In addition, this textile's susceptibility to UV damage makes it a poor choice for any type of outerwear.
Beyond the world of apparel, polypropylene plastic is used in thousands of different applications. One of the most famous uses of this substance is in drinking straws; while straws were originally made from paper, polypropylene is now the preferred material for this application. This plastic is also used to make ropes, food labels, food packaging, sunglasses, and a variety of different types of bags.
China is currently the biggest exporter of polypropylene products. In , factories in this country produced a volume of polypro plastics valued at $5.9 billion, and it's projected that this trajectory will stay steady for the foreseeable future.
A great deal of this substance is also made in Germany; this country produced approximately $2.5 billion of polypropylene in , and Italy, France, Mexico, and Belgium are also significant producers of this substance. In , the United States produced $1.1 billion in polypro products.
The biggest player in the international polypropylene production industry is LyondellBasell. This company is incorporated in the Netherlands, and it has bases of operation in Houston and London.
The runner-up in this industry is Sinopec Group, which is based in Beijing, and PetroChina Group, which is also based in Beijing. The top 10 producers of this substance account for 55 percent of the total production of polypropylene worldwide.
Polypropylene is processed into fabrics all over the world. The biggest producer of finished polypro fabrics is China, and this type of textile is also sewn into garments and other types of fabrics in India, Pakistan, Indonesia, and a number of other countries.
Polypropylene fabric liner being installed inside a cedar raised bed
Since polypro is one of the most widely produced types of plastic, it is generally quite inexpensive in bulk. A large number of different major factories compete with each other to capture the world's plastics market, and this competition drives prices low.
However, polypropylene fabric may be relatively expensive. The main reason for this increased price is lack of demand; while polypropylene fabric used to be used to make thermal undergarments relatively frequently, recent advances in the production of polyester have made this type of fabric largely obsolete. Therefore, this type of fabric costs more to textile producers than similar synthetic fabrics, such as polyester, and this increased cost is generally passed on to the end consumer.
It's important to clarify, however, that this increased cost only applies to polypropylene fabric that is designed to be made into apparel. Various types of polypropylene fabric that are not suited for apparel are marketed at relatively low prices, and they are generally quite inexpensive. These fabrics come in a variety of different colors and textures.
A variety of different additives can be added to polypro while it's in its liquid state to alter the attributes of this material. In addition, there are two major types of this plastic:
' Homopolymer polypropylene: Polypro plastic is considered to be homopolymer when it is in its original state without any additives. This type of polypro plastic is not generally considered to be a good material for fabric.
' Copolymer polypropylene: Most types of polypropylene fabrics are copolymer. This type of polypro plastic is further split into block copolymer polypropylene and random copolymer polypropylene. The co-monomer units in the block form of this plastic are arranged in regular square patterns, but the co-monomer units in the random form are arranged in relatively random patterns. Either block or random polypropylene is suited for fabric applications, but block polypro plastic is more commonly used.
Design A Beige 100% Polypropylene Durable Powerloomed Persian Area Rug
The production and use of polypropylene has a decidedly negative impact on the environment. Since polypro plastic is derived from hydrocarbon fuels, the manufacture of this substance is inherently unsustainable; fossil fuels are limited resources, and a great deal of energy is expended to acquire these substances.
In addition, a significant amount of waste is produced in the process of making polypropylene. In some cases, the excess hydrocarbon fuels that are left over after the propylene extraction process may be reused for other purposes, but they may also be discarded, which causes a negative environmental impact.
Various toxic chemicals are also used in the polypropylene production process; the contaminated water and air that are emitted from polypro production plants enter the ecosystem and negatively affect the surrounding population, and the chemicals released in the production of this type of plastic may also affect factory workers who are exposed to it. It's also worth pointing out that a scientific study found that polypropylene plastics used in food packaging release bioactive chemicals.
Once it is discarded by the end consumer, polypro plastic stays in the environment for a very long time. It takes hundreds of years for this substance to decompose, so it is not considered to be biodegradable. Unlike some other synthetic materials, however, most polypro introduced into the environment will break down within a thousand years or less.
Certain companies make additives for polypropylene that make this plastic biodegradable. However, these additives are not used for polypro fabrics.
This factor means that every piece of polypropylene fabric that is produced will remain in the ecosystem for hundreds of years before it is broken down. Many areas around the developed and developing world are currently encountering significant issues regarding the pollution created by plastics, and some nations are approaching this issue head-on; for instance, a variety of different businesses and cities around the United States have recently issued bans on plastic straws in an attempt to reduce pollution.
Depending on how it is made, polypro fabric may be eligible for ISO certification, which is provided by the International Organization for Standardization (ISO). This organization may also offer ISO certification for polypropylene products that are used for medical purposes.
Furthermore, ISO offers another certification program specifically for polypropylene. Known as ISO -1:, this standard tests for the tensility, impact resistance, and melt mass-flow rate of polypropylene to make sure that it is in compliance with basic criteria. This type of plastic may also be eligible for certification from the American National Standards Institute (ANSI) or NSF International.
When you think of fabric, you probably don't think it could be made of the same material as a food tray. However, polypropylene (PP) is a type of plastic with many applications, including fabric. In the following guide, we will address many of your questions about polypropylene fabric, including:
What is polypropylene fabric?
What are the types of polypropylene?
What are some applications of polypropylene fabric?
What is Polypropylene Fabric?
Polypropylene fabric is a textile made from PP, which is a thermoplastic polymer commonly used in food packaging, plastic furniture, films, automotive parts, and medical devices. This plastic is a linear hydrocarbon polymer, and it is one of the most popular plastics due to its low cost and easy manufacturability.
You can make either woven or non-woven polypropylene fabric, depending on the manufacturing process. No matter how you create it, polypropylene fabric resists staining, fading, and water absorption. Furthermore, it is flexible, lightweight, durable, breathable, moisture-wicking, recyclable, and sometimes even fire-resistant.
Common uses for polypropylene
Polypropylene fabric is used in many commercial and industrial applications. You can find it in:
Thermal insulation
Sheets
Blankets
Clothing
Mats
Carpets & carpet tiles
Reusable shopping bags
Medical face masks
Performance wear
Backpacks
Lunch bags
Upholstery
Polypropylene Fabric Material Properties
While it seems unconventional, polypropylene has excellent material properties that translate well to fabric. Some of PP's material properties include:
High heat deflection temperature (HDT)
Durability
Low cost to produce
Dimensional stability
Low density
Stiffness
Abrasion resistance
High tensile strength
Chemical resistance
Since polypropylene is a thermoplastic, you can melt it, mold it into new shapes, and cool it to the solid-state multiple times. It will degrade in quality each time due to the loss of latent heat, but you can still recycle polypropylene.
These properties make polypropylene textiles feasible for many applications. For instance, the chemical resistance makes it useful for protective clothing and gloves. Additionally, luggage benefits from its abrasion resistance.
Technically, polypropylene will never get dirty. This property is due to inactive dye sites: if something spills or soils the fabric, the stain sits between the fibers. This factor makes it extremely easy to clean with cleaners like bleach, all without the risk of changing the color. In essence, polypropylene fabrics are colorfast, resistant, and cleanable.
Recyclability of Polypropylene
Polypropylene also has the advantage of reusability and recyclability. Compared to other types of plastic, this is a significant environmental feature.
However, it is a class 5 recyclable material. This class indicates that only around 1-6% of the material will get recycled. Researchers are working on chemical recycling processes that isolate the monomers to reform the plastic.
Additionally, polypropylene is not recyclable everywhere, so it is essential to check with local waste management companies or government agencies; if they recycle polypropylene, separate it from other types of plastics before disposal.
How Is Polypropylene Fabric Made (and What Is This Material Made of?)
Polypropylene is made through addition polymerization, meaning the material is formed when you:
Break a benzoyl peroxide (BP) pi bond using heat to create BP free radicals
Initiate the breaking of the propylene monomer's pi bond using the BP free radicals and heat
Create free radicals at the breaking point of the propylene monomer
Allow electrons to react and form a covalent bond between the free radical of half of the BP and one of the radicals on the propylene to create a growing center
Let more monomer particles attach to the growing center by the free radical of the propylene
Terminate the process when the desired size is reached by combining two growing centers
Woven Polypropylene Fabric
Woven polypropylene fabric is made using an extrusion process. Polypropylene powder, activated calcium carbonate, and additives (e.g., colorants or flame-resistant additives) get poured into a mixer. The materials get blended from a low to high speed for a specific time to create a uniform mixture.
Then, the mixture goes through a feeding screw to enter a barrel in a screw-and-barrel system. Using viscous heating and external heaters, the powder undergoes melting and plasticizing. Next, it gets extruded from the system into a water tank that cools and shapes the plastic. A hygroscopic fan provides additional cooling.
A granulator cuts the plastic into strips that go through a vibrating screen. Then, a conveying fan transports the strips to a fluidized bed for treatment before sending it to a material pool for inspection. This process creates raw materials.
Once the material passes inspection, the raw material gets sent into an extruder. The polypropylene gets heated and sheared by the screw-and-barrel system so that it can get extruded from the system at a constant pressure. This material gets cooled, sliced into wires, and treated for use as a thread.
Oftentimes, the material will get extruded through a spinneret. Spinnerets have multiple small holes that create long, narrow filaments that you can spin into yarns. The spinneret uses a higher temperature than a traditional extruder to create a silk-like thread. After extrusion, this thread can undergo similar processing to traditional threads to make textiles for commercial production.
Non-Woven Polypropylene Fabric
Non-woven polypropylene fabric is made by taking polypropylene resin blocks, melting them, and pressing them into sheets of the desired thickness. You can then mold and cut the sheets into the desired shape.
The desired qualities of the fiber depend on its intended use. For example, outdoor furniture needs more durable material than a steering wheel cover. You combine the polypropylene resin with additives to produce the desired result for the intended application.
Additives include things like fillers, stabilizers, antioxidants, UV protection, and colorants, which improve many of polypropylene's physical properties. Generally, polypropylene textile features 98% polymer and 2% additives.
Polypropylene Structure Formula
Polypropylene's chemical formula is C3H6, meaning it is composed entirely of carbon and oxygen atoms. You can see the chemical formula in the repeat unit structure, as seen in parentheses in the above photo. This structure gets repeated n times to create the polymer polypropylene.
Polypropylene has a CH3 pendant group, which contributes to its strength, high heat deflection temperature, stiffness, and other material properties.
One property it exhibits is a relatively high percent crystallinity (up to 75%) for a semi-crystalline material. A high percent crystallinity indicates that the molecules are arranged in an orderly fashion, and it increases the strength.
Since polypropylene is a viscoelastic thermoplastic, it undergoes elastic and viscoelastic recovery. When you apply stress below the yield strength, it will recover its strain completely.
The melting point of polypropylene is around 160 degrees Celsius. At this temperature, it melts into a syrup-like liquid. When in the liquid state, you can mold the polypropylene and cool it to make it a solid.
However, the working range depends more on the heat deflection temperature, which ranges from 70-100 degrees Celsius. The heat deflection temperature measures the plastic's ability to bear a load at elevated temperatures.
Since the heat deflection temperature falls short of the temperature of fire, you will need to use additives to make it flame resistant when processing it into a fabric.
Types of Polypropylene Materials: Benefits & Uses
All forms of polypropylene consist of multiple propylene monomers bound together with high-strength covalent bonds. However, you can manipulate these monomers during the manufacturing process to create many different types of polypropylene materials.
Biaxially Oriented Polypropylene (BOPP) Film
BOPP film is made from polypropylene that gets film stretched along the transverse and longitudinal axes. Since it is pulled in two directions, you get biaxial molecular chain orientation. Manufacturers produce BOPP film with either a tubular or tenter frame process.
You can laminate BOPP film on other forms of polypropylene to boost their physical properties and create high-quality products, such as PP woven bags.
Biaxially Oriented Polypropylene Properties & Benefits
Increased stiffness
Improved clarity
Increased toughness
Grease and oil resistance
Oxidation resistance
An improved barrier to prevent oxygen and water vapor permeation
Better impact resistance, even at low temperatures
Greater durability and longevity
Allows for high-quality graphic printing
Lightweight
Moisture and water resistance
Low cost
Typical Biaxially Oriented Polypropylene Uses
PP woven bags
Dry food packaging
Retail clothing packaging
Animal feed storage
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Grass seed storage
Soil, sand, and fertilizer storage
Snack and tobacco packaging
Shrinkwrap and heat-shrinkable films
Dielectric film on capacitors
Polypropylene Homopolymer
Polypropylene homopolymer is the most widely used type of PP. As the name suggests, it features only propylene monomers in their solid, semi-crystalline form. There can be n propylene repeat units in the structure, but there will not be any other monomers.
Polypropylene Homopolymer Properties & Benefits
High strength-to-weight ratio
Stronger and stiffer than copolymer
Greater chemical resistance
Weldability
Corrosion resistance
Processability
Impact resistance
Typical Polypropylene Homopolymer Uses
Food packaging
Medical devices
Tanks
Scrubbers
Electrical components
Fume hoods
Polypropylene Copolymer
Polypropylene copolymers can be either random or block copolymers. A copolymer is a combination of two different monomers.
Random polypropylene copolymers feature propylene and ethylene. You do not have to compare polyethylene vs. polypropylene bags if you combine the two materials into one. Generally, these copolymers have 6% polyethylene incorporated randomly throughout the polypropylene chains.
Block polypropylene copolymers use 5-15% polyethylene. The monomer units of ethylene and propylene are arranged in patterns (blocks). The regular order gives these more strength, toughness, and ductility compared to random copolymers. However, the random ones have more transparency and flexibility.
Polypropylene Copolymer Properties & Benefits
Better impact strength, toughness, and durability than homopolymer
Stress crack resistance
Toughness in low temperatures
Processability
Chemical resistance
Lightweight
Moisture resistance
Stain resistance
Typical Polypropylene Copolymer Uses
Food packaging (random copolymer only)
Stationery
Reusable containers
Textiles
Polymer banknotes
Laboratory equipment
Automotive components
Electrostatic Non-Woven Polypropylene Fibers
Creating non-woven polypropylene fibers using an electrostatic melt-blown process produces extra-fine microfibers with diameters reaching 600 nm. The electrostatic forces act with the air stream during spinning to produce fine fibers. Recently, this type of PP has gained attention for its use in N95 masks as a filter.
Electrostatic Non-Woven Polypropylene Properties & Benefits
Low cost
Moisture resistance
Stability
Color retention
Moderate tensile strength
Resistance to high temperatures
Lightweight
Insulation
Typical Electrostatic Non-Woven Polypropylene Uses
N95 and surgical masks
Hospital gowns
Medical apparel like hospital gowns, surgical covers, shoe covers, caps, and gloves
Bath wipes
Plasters
Teabags
Vacuum bags
Allergen membranes
Geotextiles
Shopping bags
Expanded Polypropylene
Expanded polypropylene is an ultra-low density closed-cell foam. For reference, Styrofoam is a closed-cell foam while a sponge is an open-cell one. You can use expanded polypropylene to make 3D foam products.
Expanded Polypropylene Properties & Benefits
High strength-to-weight ratio
Thermal insulation
Impact resistance
Water resistance
Chemical resistance
Recyclable
Durable
Sound blocking and absorption
Typical Expanded Polypropylene Uses
Coffee cups
Food packaging
Consumer goods packaging
Automobile components
Construction products
HVAC systems
Returnable packaging
UAVs
Drones
Seating components
Bumper cores
Our Key Takeaways
Polypropylene is a manufactured material that has various applications. It is strong, affordable, durable, and resistant to things like moisture, color loss, degradation, and chemicals. Whether you use it as a film coating or on its own, polypropylene works well as a textile material.
FAQs on Polypropylene Materials
Here are some clarifying questions about the benefits and applications of polypropylene and polypropylene fabrics.
Is Polypropylene Safe or Dangerous?
Polypropylene is one of the safest materials to have around people and pets. PP is non-toxic, has low reactivity, and does not corrode or degrade over time. Also, PP is inert, meaning it does not react with other chemicals.
Typically, PP has a low-level contact hazard to the skin and eyes. If ingested, it can cause gastrointestinal disturbances. Many companies use polypropylene in food containers for this reason. Also, some have used the material in baby bottles due to its safety properties.
Polypropylene is less toxic than many other plastics because it does not contain bisphenol A (BPA). When in doubt, research the manufacturer of the polypropylene to see what additives they put in the product.
One of the properties of polypropylene is that it is not biodegradable; polypropylene products should be disposed of properly or recycled.
Is Polypropylene a Plastic?
Yes. Polypropylene is a flexible plastic often used to manufacture textile yarns and fibers, containers for foods and beverages, waterproofing, and all-purpose shopping bags.
Polypropylene is a commodity plastic, meaning high volume production is common for products that do not require special engineering. PP is therefore inexpensive and often disposable.
What Kind of Fabric is Polypropylene?
Polypropylene is a thermoplastic synthetic resin used for packaging, transportation, chemical fibers, and non-woven fabrics. The most widely-used fabric type is polypropylene non-woven fabrics, used in industrial and civil products.
Woven polypropylene, knitted fabric, needle-punched non-woven fabrics, and melt-blown non-woven fabric are relevant categories of polypropylene fabric.
Polypropylene fabrics are breathable but not as absorbent as other fabrics. They are easy to maintain, making them suitable for clothing of any type, with particular uses in sportswear, marine use, and protective clothing due to the fabric's resistance to staining, wrinkles, and shrinking.
Applying pigments to polypropylene is challenging since it will not accept dye when soaking in liquid. Alternative methods are challenging at a large scale, prompting the industry to research different dyes for cost-effective production.
Is Polypropylene Safe to Breathe Through?
Polypropylene fabric does not cause skin irritation or allergies when worn against the skin for an extended period. The only respiratory issues linked to polypropylene exist with textile workers who encounter large fibers.
Polypropylene is often used as a material choice for filter elements because it can form into meshes or meshes with fine pores. N95 masks contain non-woven polypropylene.
Is Polypropylene Stronger Than Steel?
When compared pound to pound, PP is stronger than steel.
The mechanical properties of polypropylene largely depend on its crystallinity. The higher the degree of crystallinity, the higher the tensile strength and stiffness in PP fabric.
PP's strength makes it a popular choice for rugs, although it is not as soft as acrylic. It is also flammable and prone to UV degradation. These durable rugs work well in outdoor and patio areas where functionality outweighs style.
Is All Polypropylene Acid-Free?
Yes. Polypropylene is chemically inert and nearly pH neutral. PP is perfect for the archival storage of sensitive documents.
Is PP Expensive?
Polypropylene is relatively low cost compared to silk, wool, and cotton. Manufacturing this fabric requires fewer steps than these other materials. Many plastic items contain polypropylene, including everything from housewares to fabric to toys.
Is Polypropylene Waterproof?
Polypropylene rates for light-duty applications involving water exposure because it has permeability to water molecules and will absorb some moisture, but it is not listed as a waterproof fabric by any manufacturers.
Although polypropylene fabric is not impenetrable, it does not absorb moisture. The material has pores too small for a liquid to penetrate but large enough to allow air and vapor to pass through.
Check out our complete 'is polypropylene waterproof' guide for more information.
Is Polypropylene Recyclable?
The answer is yes. Extruded polypropylene can produce new products.
The fabric is recyclable, which means it is reusable without losing quality. Companies can recycle clothing made from the material into new clothing or other products like carpets or insulation materials.
Polypropylene is recycled repeatedly without losing its integrity. It is the most widely recycled plastic globally, with a global recycling rate of 27%. Nevertheless, only about 1-6% gets mechanically recycled at the recycling center, with the rest going to the landfill.
Where Can I Get Polypropylene Fabric by the Yard?
You can get polypropylene fabric by the yard when you buy it as a woven polypropylene roll through the Palmetto Industries website.
By Purvis King
Bringing over 35 years of textile and flexible packaging experience to Palmetto, Mr. King earned his Bachelor's Degree in Mathematics and Physics from Augusta College in . He is skilled in all aspects of manufacturing and engineering of flexible, woven polypropylene plastics. In his free time Mr. King enjoys playing disc golf with his two sons and enjoying the outdoors.