WO1996018679A1 - Compositions de polyethylene a aptitude de mise en ×uvre amelioree et presentant des proprietes physiques ameliorees - Google Patents
Compositions de polyethylene a aptitude de mise en ×uvre amelioree et presentant des proprietes physiques ameliorees Download PDFInfo
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- WO1996018679A1 WO1996018679A1 PCT/US1995/016534 US9516534W WO9618679A1 WO 1996018679 A1 WO1996018679 A1 WO 1996018679A1 US 9516534 W US9516534 W US 9516534W WO 9618679 A1 WO9618679 A1 WO 9618679A1
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- ethylene
- film
- polyethylene
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- 229920000573 polyethylene Polymers 0.000 title claims abstract description 26
- 239000000203 mixture Substances 0.000 title claims description 49
- 239000004698 Polyethylene Substances 0.000 title claims description 21
- -1 polyethylene Polymers 0.000 title claims description 21
- 230000000704 physical effect Effects 0.000 title abstract description 7
- 238000012545 processing Methods 0.000 title description 3
- 239000004711 α-olefin Substances 0.000 claims description 37
- 238000001125 extrusion Methods 0.000 claims description 26
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims description 24
- 229920000089 Cyclic olefin copolymer Polymers 0.000 claims description 18
- LIKMAJRDDDTEIG-UHFFFAOYSA-N 1-hexene Chemical compound CCCCC=C LIKMAJRDDDTEIG-UHFFFAOYSA-N 0.000 claims description 13
- VXNZUUAINFGPBY-UHFFFAOYSA-N 1-Butene Chemical compound CCC=C VXNZUUAINFGPBY-UHFFFAOYSA-N 0.000 claims description 11
- KWKAKUADMBZCLK-UHFFFAOYSA-N 1-octene Chemical compound CCCCCCC=C KWKAKUADMBZCLK-UHFFFAOYSA-N 0.000 claims description 11
- AFFLGGQVNFXPEV-UHFFFAOYSA-N 1-decene Chemical compound CCCCCCCCC=C AFFLGGQVNFXPEV-UHFFFAOYSA-N 0.000 claims description 10
- 239000005977 Ethylene Substances 0.000 claims description 10
- WSSSPWUEQFSQQG-UHFFFAOYSA-N 4-methyl-1-pentene Chemical compound CC(C)CC=C WSSSPWUEQFSQQG-UHFFFAOYSA-N 0.000 claims description 6
- TVMXDCGIABBOFY-UHFFFAOYSA-N n-Octanol Natural products CCCCCCCC TVMXDCGIABBOFY-UHFFFAOYSA-N 0.000 claims description 5
- 229920000098 polyolefin Polymers 0.000 abstract description 26
- 229920000642 polymer Polymers 0.000 abstract description 23
- 229920002959 polymer blend Polymers 0.000 abstract description 2
- 230000000052 comparative effect Effects 0.000 description 51
- 238000000034 method Methods 0.000 description 25
- 229920001577 copolymer Polymers 0.000 description 24
- 229920001684 low density polyethylene Polymers 0.000 description 21
- 229920000092 linear low density polyethylene Polymers 0.000 description 20
- 239000004707 linear low-density polyethylene Substances 0.000 description 17
- 238000009826 distribution Methods 0.000 description 16
- 239000004702 low-density polyethylene Substances 0.000 description 14
- 239000000463 material Substances 0.000 description 14
- 229920005989 resin Polymers 0.000 description 14
- 239000011347 resin Substances 0.000 description 14
- 230000008569 process Effects 0.000 description 13
- 239000003054 catalyst Substances 0.000 description 11
- 239000007789 gas Substances 0.000 description 10
- 239000011954 Ziegler–Natta catalyst Substances 0.000 description 7
- 229920001519 homopolymer Polymers 0.000 description 7
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 6
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 6
- 230000004913 activation Effects 0.000 description 6
- 125000004432 carbon atom Chemical group C* 0.000 description 6
- 229910052804 chromium Inorganic materials 0.000 description 6
- 239000011651 chromium Substances 0.000 description 6
- 230000007423 decrease Effects 0.000 description 6
- 239000003999 initiator Substances 0.000 description 6
- 238000004519 manufacturing process Methods 0.000 description 6
- 238000002156 mixing Methods 0.000 description 6
- 229910052719 titanium Inorganic materials 0.000 description 6
- 239000010936 titanium Substances 0.000 description 6
- AQZWEFBJYQSQEH-UHFFFAOYSA-N 2-methyloxaluminane Chemical compound C[Al]1CCCCO1 AQZWEFBJYQSQEH-UHFFFAOYSA-N 0.000 description 5
- 230000000694 effects Effects 0.000 description 5
- 150000002978 peroxides Chemical class 0.000 description 5
- CKNXPIUXGGVRME-UHFFFAOYSA-L CCCCC1(C=CC(C)=C1)[Zr](Cl)(Cl)C1(CCCC)C=CC(C)=C1 Chemical compound CCCCC1(C=CC(C)=C1)[Zr](Cl)(Cl)C1(CCCC)C=CC(C)=C1 CKNXPIUXGGVRME-UHFFFAOYSA-L 0.000 description 4
- 230000008901 benefit Effects 0.000 description 4
- 150000002976 peresters Chemical class 0.000 description 4
- 238000006116 polymerization reaction Methods 0.000 description 4
- 238000001374 small-angle light scattering Methods 0.000 description 4
- 239000004705 High-molecular-weight polyethylene Substances 0.000 description 3
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 3
- 230000001419 dependent effect Effects 0.000 description 3
- 238000011161 development Methods 0.000 description 3
- 239000005038 ethylene vinyl acetate Substances 0.000 description 3
- 238000010128 melt processing Methods 0.000 description 3
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 3
- 238000010998 test method Methods 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- 125000000484 butyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 2
- 239000012632 extractable Substances 0.000 description 2
- 238000010096 film blowing Methods 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 239000012968 metallocene catalyst Substances 0.000 description 2
- 150000003254 radicals Chemical class 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 239000002002 slurry Substances 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- 238000003856 thermoforming Methods 0.000 description 2
- RELMFMZEBKVZJC-UHFFFAOYSA-N 1,2,3-trichlorobenzene Chemical compound ClC1=CC=CC(Cl)=C1Cl RELMFMZEBKVZJC-UHFFFAOYSA-N 0.000 description 1
- VZSRBBMJRBPUNF-UHFFFAOYSA-N 2-(2,3-dihydro-1H-inden-2-ylamino)-N-[3-oxo-3-(2,4,6,7-tetrahydrotriazolo[4,5-c]pyridin-5-yl)propyl]pyrimidine-5-carboxamide Chemical compound C1C(CC2=CC=CC=C12)NC1=NC=C(C=N1)C(=O)NCCC(N1CC2=C(CC1)NN=N2)=O VZSRBBMJRBPUNF-UHFFFAOYSA-N 0.000 description 1
- AFCARXCZXQIEQB-UHFFFAOYSA-N N-[3-oxo-3-(2,4,6,7-tetrahydrotriazolo[4,5-c]pyridin-5-yl)propyl]-2-[[3-(trifluoromethoxy)phenyl]methylamino]pyrimidine-5-carboxamide Chemical compound O=C(CCNC(=O)C=1C=NC(=NC=1)NCC1=CC(=CC=C1)OC(F)(F)F)N1CC2=C(CC1)NN=N2 AFCARXCZXQIEQB-UHFFFAOYSA-N 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- 239000012190 activator Substances 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 239000002671 adjuvant Substances 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 230000003042 antagnostic effect Effects 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 238000000071 blow moulding Methods 0.000 description 1
- 238000010504 bond cleavage reaction Methods 0.000 description 1
- IAQRGUVFOMOMEM-UHFFFAOYSA-N butene Natural products CC=CC IAQRGUVFOMOMEM-UHFFFAOYSA-N 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 238000013329 compounding Methods 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000000748 compression moulding Methods 0.000 description 1
- 230000001010 compromised effect Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 125000000118 dimethyl group Chemical group [H]C([H])([H])* 0.000 description 1
- 230000003292 diminished effect Effects 0.000 description 1
- 238000010828 elution Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 125000001495 ethyl group Chemical group [H]C([H])([H])C([H])([H])* 0.000 description 1
- 229920001038 ethylene copolymer Polymers 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 230000010006 flight Effects 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 238000005194 fractionation Methods 0.000 description 1
- 239000012634 fragment Substances 0.000 description 1
- 125000004051 hexyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 229920005684 linear copolymer Polymers 0.000 description 1
- 238000012417 linear regression Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000000178 monomer Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 125000000740 n-pentyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 description 1
- 238000009828 non-uniform distribution Methods 0.000 description 1
- 230000003534 oscillatory effect Effects 0.000 description 1
- 230000004792 oxidative damage Effects 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229920006280 packaging film Polymers 0.000 description 1
- 239000012785 packaging film Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 229920005638 polyethylene monopolymer Polymers 0.000 description 1
- 229920013716 polyethylene resin Polymers 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 125000001436 propyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- 238000010526 radical polymerization reaction Methods 0.000 description 1
- 238000009877 rendering Methods 0.000 description 1
- 230000000630 rising effect Effects 0.000 description 1
- 238000001175 rotational moulding Methods 0.000 description 1
- 230000007017 scission Effects 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 229920006302 stretch film Polymers 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- ZWYDDDAMNQQZHD-UHFFFAOYSA-L titanium(ii) chloride Chemical compound [Cl-].[Cl-].[Ti+2] ZWYDDDAMNQQZHD-UHFFFAOYSA-L 0.000 description 1
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 1
- 239000003643 water by type Substances 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
- C08L23/04—Homopolymers or copolymers of ethene
- C08L23/08—Copolymers of ethene
- C08L23/0807—Copolymers of ethene with unsaturated hydrocarbons only containing four or more carbon atoms
- C08L23/0823—Copolymers of ethene with unsaturated hydrocarbons only containing four or more carbon atoms with aliphatic cyclic olefins
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2205/00—Polymer mixtures characterised by other features
- C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2314/00—Polymer mixtures characterised by way of preparation
- C08L2314/06—Metallocene or single site catalysts
Definitions
- This invention relates to metallocene catalyzed ethylene polymers which are more easily processed and exhibit superior toughness when compared to more conventional metallocene catalyzed ethylene polymers..
- linear polyolefin homopolymers and copolymers have increased steadily since their introduction in the 1940's. Advances in linear polyolefin technology have enabled the polymers to be used in a wide variety of end-use applications. Processes used to convert these polymers into useful items including film blowing, film casting, sheet extrusion, profile extrusion, injection molding, rotomolding, compression molding, thermoforming, a variety of fiber producing processes, and the like. In the 1970's new, more economical processes for the production of linear polyolefins came into wide use.
- improved physical properties such as lower extractables, improved sealability, better clarity, and improved strength/toughness properties, especially impact resistance, puncture, and tensile strength as compared to the traditional Ziegler-Natta and chromium catalyzed products.
- a third processing deficiency of linear polyolefins is their relatively low melt strength which manifests itself in poor bubble stability in film blowing processes, weak parisons in blow molding processes, poor control over part thickness in thermoforming and the like when the linear polyolefins are processed at relatively high temperatures and rates.
- polydispersity index For purposes of this application, the term PDI, and lVI ⁇ /M,. (weight average molecular weight/number average molecular weight), will be used interchangeably.
- PDI polydispersity index
- lVI ⁇ /M weight average molecular weight/number average molecular weight
- Z-N and chromium catalyzed polymers generally have higher extractables, lower strength / toughness properties, higher orientation, and poorer clarity and sealabiltiy than similar metallocene-catalyzed polymers.
- European Patent Application EP 0 124 722 A2 (US 4,586,995) describes a blend of two polymers, each having a weight average molecular weight between 120,000 and 160,000.
- the first polymer which constitutes 40-95 weight percent of the blend, is an ethylene homopolymer or copolymer with a density >0.95 g/cc, an energy of activation (EJ ⁇ 20 kcal/mole, and a long-chain branching (LCB) frequency ⁇ 0.2 LCB / 1000 carbons.
- the second polymer which constitutes 5-60 percent of the blend, contains 0.5-5 LCB / 1000 carbons, ⁇ 10 short-chain branches, and has an E a >35 kcal/mole.
- Long-chain branches are defined in EP 124 722 A2 as those side branches which are sufficiently long enough to affect the molecule's hydrodynamic volume. These branches are distinguishable from “short- chain branches” which are defined in the application as containing fewer than seven carbons and do not substantially effect hydrodynamic volume. Examples of short chain branches includes groups such as methyl, ethyl, propyl, butyl, amyl, and hexyl.
- the long chain branches in the second polymer disclosed in this document are produced by irradiation of a portion of the first polymer under non-gelling conditions in the absence of oxygen. This irradiation causes molecules with vinyl end groups or fragments from molecular scission to attach themselves to the backbone of another polymer molecule, thus forming the "Y" structures referred to.
- These branched molecules are distinguishable from the branched molecules produced in high-pressure, free-radical polymerization processes (LDPE) by the relative level of short-chain branches in each.
- LDPE free-radical polymerization processes
- the Y-branched products contain fewer than one short-chain branches / 1000 carbons, the free radically polymerized products contain 10-15 short chain branches / 1000 carbons.
- Certain embodiments of the present invention are directed to a polymer or polymer blend that satisfy the need for lower extrusion energy, while maintaining or improving most end use article mechanical properties.
- a linear polymer typically a polyolefin
- a linear polymer is given improved processability, substantial freedom from melt fracture and improved physical mechanical properties, by the inclusion of long-chain branching.
- the long chain branching is found generally only on the higher molecular weight molecules in the product distribution.
- the high molecular weight entity of the product distribution will generally have a weight average molecular weight (ML ⁇ ,) typically greater than 120,000.
- the low molecular weight entity of the product distribution will generally have an M w less than 120,000.
- a composition comprises an ethylene polymer having an extrusion torque less than 52 meters-gram (m-g) and a dart drop impact of at least 850 grams/mil.
- a film is made from the composition.
- This invention concerns certain classes of polyethylene resins, their production and articles fabricated from these resins. These resins have unique properties which make them particularly well suited for use in producing certain classes of fabricated polymeric articles. Films and blow molded articles, for instance, have combinations of properties rendering them superior to articles and films previously available for many polymeric fabricated article applications. Additionally, the resins show a surprising increase in their ability to be melt processed. Following is a detailed description of certain preferred resins within the scope of this invention, preferred methods of producing these resins, and preferred applications of these resins. Those skilled in the art will appreciate that numerous modifications to these preferred embodiments can be made without departing from the scope of the invention. For example, while the properties of resins are exemplified in film applications, they have numerous other uses. To the extent that this description is specific, this is solely for the purpose of illustrating preferred embodiments of this invention and should not be taken as limiting this invention to these specific embodiments.
- the metallocene catalyzed materials of certain embodiments of the present invention will have generally at least two components or groups of components a higher molecular weight group of components and a lower molecular weight group of components. Such combinations can be achieved by several schemes, including blending of independently produced or polymerized materials, polymerization in sequential reactors, prepolymerization of preferably the higher molecular portion or other schemes which will be known to those of ordinary skill in the art.
- the lower molecular weight component will generally have a MI greater than 1 dg/min; a molecular weight (M ⁇ ,) below 120,000, the preferred range is 30,000 to 120,000, preferably in the range of from 50,000 to 120,000, more preferably in the range of from 70,000 to 120,000; a density in the range of from 0.90 g/cm 3 to 0.97 g/cm 3 , preferably in the range of from 0.910 to 0.950, more preferably in the range of from 0.915 to 0.94, most preferably in the range of from 0.915 to 0.930 g/cm 3 ; an M ⁇ /M,, less than 6, preferably less than 5, more preferably than 4, most preferably less than 3; an energy of activation (EJ less than 10 kcal/mole, preferably in the range of from 6 to 10, more preferably in the range of from 6.5 to 9, most preferably in the range of from 6.5 to 8.5 kcal/mole; and a CDBI greater than 50 percent.
- the lower molecular weight component will generally be present in the combination in the range of from 50 to 99 weight percent, preferably in the range of from 70 to 99 weight percent, more preferably in the range of from 85 to 99 weight percent, most preferably in the range of from 90 to 99 weight percent based on the total weight of the combination.
- the higher molecular weight component will have: a MI less than 1 dg/min, preferably less than 0.5 dg/min; a molecular weight (Iv ⁇ ) greater than
- 120,000 preferably in the range of from 120,000 to 1,000,000, more preferably in the range of from 120,000 to 500,000, most preferably in the range of from 120,000 to 250,000; a density in the range of from 0.90 g/cm 3 to 0.970 g/cm 3 , preferably in the range of from 0.90 to 0.960, more preferably in the range of from 0.900 to 0.950, most preferably in the range of from 0.900 to 0.940 g/cm 3 ; an M M n less than 6, preferably less than 5, more preferably less than 4, most preferably less than 3; a CDBI greater than 50 percent; an E a greater than 12 kcal/mole, preferably in the range of from 12 to 30, more preferably in the range of from 12 to 25, most preferably in the range of from 12 to 20 kcal per mole.
- the higher molecular weight component will be present in the combination in the range of from 1 to 50 weight percent, preferably in the range of from 1 to 30 weight percent, more preferably in the range of from 1 to 15 weight percent, most preferably in the range of from 1 to 10 weight percent based on the total weight of the combination.
- Both higher and lower molecular weight components will be ethylene homopolymers, ethylene- ⁇ -olefin copolymers, or combinations of homopolymers and copolymers. If one or both components are ethylene- ⁇ -olefin copolymers, terpolymners and the like, the ⁇ -olefin or ⁇ -olefins may be the same or different in the high and low molecular weight components and the level of ⁇ -olefin or ⁇ - olefins incorporation may be the same or different.
- the ⁇ -olefin or ⁇ -olefins may be selected from those having 3 to 20 carbon atoms, preferably 4 to 10 carbon atoms, more preferably 6 to 8 carbon atoms. Most preferred ⁇ -olefins are 1-butene, 4-methyl-l-pentene, 1-hexene, 1-octene, 1-decene and mixtures thereof.
- the ⁇ -olefin when present, will be present in the ethylene- ⁇ - olefin copolymer or copolymers in the range of from 0.2 to 10 mole percent based on the total moles of monomer and comonomer incorporated into the copolymer, preferably in the range of 0.2 to 7.5 mole percent, more preferably in the range of from 0.2 to 6.5 mole percent, most preferably in the range of from 0.2 to 5.5 mole percent.
- Melt processing of polymers represented by certain embodiments of the present invention will generally be characterized by reduced torque or power in a given piece of extrusion equipment, at a constant output (unit of weight/unit of time) compared to other metallocene catalyzed polyolefins, and Z-N catalyzed polyolefins. While the effects will be seen in larger equipment, routine laboratory testing can exhibit the effects, for instance, in a Haake Torque Rheometer. In such a piece of equipment the torque at the conditions discussed below, the compositions will exhibit torque less than 52 m-g preferably less than 50 m-g, more preferably less than 48 m-g, most preferably less than 46 m-g.
- Films, molded articles and the like made from these components may also include, in addition to the two aforementioned polyolefin components, other adjuvants and blend components that will be understood by those of ordinary skill in the art to be components and/or additives that may aid melt processing, prevent oxidative damage, improve specific end use properties, and the like, all without substantial negative effect on either melt processability or physical properties of the fabricated article.
- Such films may be used as stretch films (single or multi-layer), general packaging films, bags made from such films, and the like.
- fabricated articles include extrusion blow-molded articles, injection molded articles, thermoformed articles and the like.
- the dart drop impact will be at least 850 g/mil, preferably at least 950 g/mil, preferably at least 1,100 g/mil, more preferably at least 1,200 g/mil, most preferably at least 1,300 g/mil.
- One technique predicted to verify that the long chain branches are present only on the larger molecules of the invention is to first fractionate the material according to the procedure described by J. J. Watkins, et. al., in The Journal of Supercritical Fluids, 1991, 4, 24-31, and then determine the Flow Activation Energy on each fraction.
- the fractions containing very low or no long chain branching should have the same E a as linear molecules with the same short-chain branching frequency.
- the fractions containing long-chain branching should have a much higher E a , after correcting the data for short-chain branching frequency.
- the molecular weight distribution of a polymer can be determined with a Waters Gel Permeation Chromatograph equipped with Ultrastyrogel columns and a refractive index detector.
- the operating temperature of the instrument was set at 145°C, and the eluting solvent was trichlorobenzene.
- the calibration standards included sixteen polystyrenes of precisely known molecular weight, ranging from a molecular weight of 500 to a molecular weight of 5.2 million, and a polyethylene standard, NBS 1475.
- the refractive index detector detects polymeric molecules in the GPC effluent which have been separated based on hydrodynamic volume. The assumption is that those molecules eluting through the detector at time T x have the same molecular weight as those molecules in the linear calibration standard that elute at time T x .
- long chain branches do not increase the hydrodynamic volume of linear molecules by an amount proportional to the length of these branches. It is believed that their contribution is only a fraction of the branch length. Therefore, if a long chain branched sample is analyzed with a refractive index detector calibrated with linear standards, the reported GPC moments will be low.
- a low angle laser light scattering detector (LALLS), on the other hand, produces a signal which is proportional to molecular weight, rather than hydrodynamic volume. Therefore, if the long chain branched sample is analyzed with both detectors, and M ⁇ (DRI) ⁇ M ⁇ (LALLS) then than the difference between the two ML ⁇ 's is attributed to, and provides addition evidence of long chain branching. The difference in the M w 's should indicate a minimum estimate of the average branch length.
- E a energy of activation for viscous flow.
- the E a of linear ethylene homopolymers is approximately 6.5 kcal/mole.
- the E a of LDPEs is typically in the range of 11-15 kcal/mole.
- E a is independent of molecular weight and polydispersity index, but does increase with increasing comonomer content and with increasing short chain branching length.
- Ethylene-hexene copolymers with densities greater than 0.900 contain less than 20 weight percent hexene-derived polymer units.
- the E a of ethylene-hexene copolymers which contain less than 20 weight percent hexene-derived units is less than 8 kcal/mole. Therefore, an E a greater than 8 kcal/mole is considered indicative of long chain branching in ethylene-hexene copolymers with densities greater than 0.900 g cc.
- E a can be determined from parallel plate oscillatory shear melt viscoelastic measurements at four different temperatures. Zero shear viscosity at each temperature is plotted vs. the reciprocal of temperature. The slope of the linear regression of this plot is equal to E a / R, where R is the gas constant, 1.987 cal/deg-mole.
- Composition distribution is a measure of how uniformly a comonomer is distributed in a linear ethylene-based copolymer.
- Comonomer uniformity can be determined with a Temperature Rising Elution Fractionation (TREF) procedure similar to the one described in Wild, et al., J. Poly. Sci., Poly. Phys. Ed., Vol. 20, p. 441 (1982).
- the test result is a distribution curve which illustrates the soluble fraction (weight percent) vs. temperature.
- the temperature scale is transformed to comonomer content using TREF data obtained with calibration standards which have very narrowly distributed, known comonomer levels.
- compositional attribute used in this development to distinguish between polymers is the breadth of the comonomer distribution, as indicated by its Composition Distribution Breadth Index (CDBI).
- CDBI is defined as the weight percent of the polymer molecules having a comonomer content within ⁇ 50 percent of the median total molar comonomer content.
- Extrusion energy i.e., the energy required to extrude a polyethylene product at a standard set of conditions, is expressed either as amps or torque.
- Screw type Single flighted, blunt tip
- Torque requirements were determined for comparative examples 7, 9, and 12-19 at 190°C and 128 Table 2. Results are summarized in following table, and are illustrated in Figure 1.
- Comparative Example 1 is a linear ethylene-hexene copolymer produced in a gas phase process with a silica-supported, bis(l-methyl-3-n-butyl- cyclopentadienyl) zirconium dichloride / methyl alumoxane catalyst (not available commercially).
- M ⁇ , MI, density, and melt flow ratio are 131,000, 0.6, 0.921, and 15.9, respectively. Comparative Example 2
- Comparative Example 2 is a blend composed of 7 weight percent Escorene
- Escorene LD-113 is a commercially available long-chain branched ethylene homopolymer produced in a high-pressure, tubular reactor with a peroxide initiator.
- LD-113 are 2.3 and 0.921, respectively.
- Comparative Example 3 is a linear ethylene-hexene copolymer produced in a gas phase process with a silica-supported, bis(l-methyl-3-n-butyl- cyclopentadienyl) zirconium dichloride / methyl alumoxane catalyst (not available commercially).
- M ⁇ ,, MI and density are 119,000, 0.83 and 0.920, respectively.
- Comparative Example 4 is a blend composed of 3 weight percent Escorene
- HD-7000F and 97 weight percent Comparative Example 3.
- Escorene HD-7000F is a commercially available linear ethylene-butene copolymer produced in a series slurry process with a titanium-based Ziegler-Natta catalyst.
- Target MI and density of the HD-7000F are 0.045 and 0.952, respectively.
- Typical M,, of HD 7000F is > 200,000.
- Comparative Example 5 is a blend composed of 3 weight percent Escorene HD-9856B and 97 weight percent Comparative Example 3.
- Escorene HD-9856B is a commercially available linear ethylene-butene copolymer produced in a series slurry process with a titanium-based Ziegler-Natta catalyst.
- Target MI and density of the HD-9856B are 0.46 and 0.956, respectively.
- Typical M of HD 9856 B is 140,000.
- Comparative Example 6 is a blend composed of 6 weight percent Escorene HD-9856B and 94 weight percent Comparative Example 3. Escorene HD-9856B is described in Comparative Example 5. Comparative Example 7
- Comparative Example 7 is Escorene LL-3001.63, a commercially available linear ethylene-hexene copolymer produced in a gas phase reactor with a titanium- based Ziegler-Natta catalyst.
- Typical M ⁇ , MI, density, and melt flow ratio are 110,000, 1.9,0.922, and 27, respectively.
- Comparative Example 8 is a blend composed of 30 weight percent LD-113 and 70 weight percent of the resin described in Comparative Example 7. LD-113 is described in Comparative Example 2.
- Comparative Example 9 is a linear ethylene-hexene copolymer produced in a gas phase process with a silica-supported, bis(l-methyl-3-n-butyl- cyclopentadienyl) zirconium dichloride / methyl alumoxane catalyst (not available commercially).
- M ⁇ MI, density, and melt flow ratio are 80,000, 3.04, 0.919, and
- Comparative Example 10 is a linear ethylene-hexene copolymer produced in a gas phase process with a silica-supported, bis(l-methyl-3-n-butyl- cyclopentadienyl) zirconium dichloride/methyl alumoxane catalyst (not available commercially).
- M ⁇ ,, MI, density, and melt flow ratio are 80,000, 3.31, 0.919, and 17.3, respectively.
- Examples 1, 3, 9, and 10 are prepared according to a process disclosed in WO 94/26816 inco ⁇ orated herein by reference for pu ⁇ oses of U. S. Patent practice.
- Example 11 is a blend composed of 95 weight percent Comparative
- Example 10 and 5 weight percent Bl which is a high molecular weight, linear ethylene-hexene copolymer and which contains linear long chain branching.
- Bl was prepared by adding 180 psig ethylene, 8 ml hexene-1, and a mono-Cp catalyst (dimethyl(tetramethylcyclopentadienyl)cyclododecylamidosilyl titanium dichloride) with a methyl-alumoxane activator to 500 ml toluene in a 2-liter autoclave reactor.
- the reactor temperature was relatively controlled at 90°C, and the polymerization was terminated after 15 minutes.
- the resulting product had a density of 0.912 g/cc, an E a of 14.1 kcal mole, an M w of 206,000 (DRI detector) and 231,000 (LALLS detector), a polydispersity of 2.56 (DRI detector, uncorrected for long chain branching); and a average butyl branching content of 22 br/1000 carbons.
- Comparative Example 12 is Escorene LL-1001,30, a commercially available linear ethylene-butene copolymer produced in a gas phase reactor with a titanium-based Ziegler-Natta catalyst. MI is 1.06 dg/min., typical density is 0.918 g/cc.
- Comparative Example 13 is Escorene LL-3002.37, a commercially available linear ethylene-hexene copolymer produced in a gas phase reactor with a titanium-based Ziegler-Natta catalyst. MI is 1.92 dg min., typical density is 0.918 g cc.
- Comparative Example 14 is Escorene LL- 1002.09, a commercially available linear ethylene-butene copolymer produced in a gas phase reactor with a titanium-based Ziegler-Natta catalyst. MI is 2.16 dg min., typical density is 0.918 g/cc.
- Comparative Example 15 is Escorene LL-3003.32, a commercially available linear ethylene-hexene copolymer produced in a gas phase reactor with a titanium-based Ziegler-Natta catalyst. MI is 3.06 dg/min., typical density is 0.918 g/cc.
- Comparative Example 16 is LD-141.87, a commercially available long- chain branched ethylene-vinyl acetate copolymer produced in a high-pressure, tubular reactor with a peroxide initiator.
- Target MI, density, and VA content are 2.3 dg/min, 0.921 g/cc, and 2%, respectively.
- Comparative Example 17 is LD-312.09, a commercially available long- chain branched ethylene-vinyl acetate copolymer produced in a high-pressure, tubular reactor with a peroxide initiator. MI is 1.00 dg/min., typical density and VA content are 0.927 g/cc and 4.6 weight percent, respectively.
- Comparative Example 18 is LD-105.30, a commercially available long- chain branched polyethylene-homopolymer produced in a high-pressure, tubular reactor with a peroxide initiator. MI is 2.00 dg/min., typical density is 0.925 g/cc.
- Comparative Example 19 is LD-306.09, a commercially available long- chain branched ethylene-vinyl acetate copolymer produced in a high-pressure, tubular reactor with a peroxide initiator. MI is 2.00 dg/min., typical density and VA content are 0.926 g/cc and 5.5 weight percent, respectively.
- Polyethylene products may be distinguished from each other by, for instance, their processability and their end-use properties. These attributes may be predicted by, among other things, the catalyst and process used to produce the product, (which define the product's molecular weight and comonomer distributions), and on the product's melt index, density, and comonomer type. Blending different products together allows converters to combine certain advantages of the individual blend components.
- One combination which has been quite popular since linear polyethylenes (Z-N and/or chromium catalyzed) were first introduced is LLDPE plus LDPE, with the LLDPE content generally >70 weight percent.
- LLDPEs can be drawn down to relatively thin gauges, and have higher modulus and significantly better strength/toughness properties than LDPEs.
- LLDPEs have lower melt strength, require more extrusion energy, and are hazier than LDPEs.
- LDPEs on the other hand, have higher melt strength and good clarity. The combination succeeds in improving LLDPE's melt strength and clarity, while retaining LLDPE's good drawability, but generally does not improve LLDPE's extrusion energy or mechanical properties.
- Certain blend ratios e.g., 70- 80 percent LLDPE / 20-30 percent LDPE, are antagonistic relative to dart impact and tear resistance, i.e., the dart and tear of the blend is generally poorer than either the blend components by themselves.
- Bl is a 0.912 g/cc density, linear ethylene-hexene copolymer with a relatively high molecular weight and an E a of 14 kcal/mole. Details of its preparation appear in Example 1 1.
- the present invention is distinguishable from known polyethylenes on the basis of the nature and positioning of the long chain branches, and on the combination of reduced extrusion energy and substantially enhanced film impact resistance.
- the long chain branches are of sufficient length, frequency, and intramolecular position to produce a component with an E a greater than 12 kcal/mole. They are more compatible with the linear blend component, and produces the appropriate solid state thermoplastic networks to deliver enhanced mechanical properties.
- the ethylene copolymers described herein may be made from ethylene and an alpha-olefin where the alpha-olefin has in the range of from 4 to 20 carbon atoms, preferably in the range of from 4 to 10 carbon atoms, most preferably in the range of from 4 to 8 carbon atoms.
- the choice of comonomer for the lower molecular weight component and the higher molecular weight component can be based on having the same alpha-olefin as the comonomer or different alpha-olefins as comonomers (for instance, lower molecular weight material may have a butene comonomer, the higher molecular weight material may have an octene comonomer).
- the level of comonomer inco ⁇ oration in the members of the combination may be same or may be different. In general the range of comonomer inco ⁇ oration in copolymers described by an embodiment of the present invention are dependent on the type of comonomer.
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Abstract
Cette invention concerne des polyoléfines linéaires et plus spécifiquement des polymères d'éthylène qui possèdent des propriétés de mise en ÷uvre améliorées par rapport aux polyéthylènes linéaires connus jusqu'à présent. Pour améliorer l'aptitude de mise en ÷uvre, on introduit un constituant présentant une masse molaire (Mw) élevée, à savoir, supérieure à 120 000 dans un constituant à masse molaire (Mw) plus faible, à savoir, inférieure à 120 000. Le constituant à masse molaire élevée possède une ramification à chaîne longue. L'aptitude de mise en ÷uvre améliorée se manifeste par une plus grande sensibilité au cisaillement du polymère ou du mélange polymère, ce qui a pour effet de réduire la puissance et le couple nécessaire pour extruder ces polymères. En outre les propriétés physiques telles que la résistance à l'impact d'une flèchette ne sont pas négativement modifiées par l'incorporation du constituant à masse molaire plus élevée et peuvent donc être améliorées.
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US35812594A | 1994-12-16 | 1994-12-16 | |
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PCT/US1995/016534 WO1996018679A1 (fr) | 1994-12-16 | 1995-12-18 | Compositions de polyethylene a aptitude de mise en ×uvre amelioree et presentant des proprietes physiques ameliorees |
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Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO1998026000A1 (fr) * | 1996-12-12 | 1998-06-18 | The Dow Chemical Company | Compositions interpolymeres et film etirable coule produit a partir de celles-ci |
US6812289B2 (en) | 1996-12-12 | 2004-11-02 | Dow Global Technologies Inc. | Cast stretch film of interpolymer compositions |
WO2007008361A1 (fr) * | 2005-07-11 | 2007-01-18 | Equistar Chemicals, Lp | Compositions de polyethylene |
CN116063598A (zh) * | 2018-09-17 | 2023-05-05 | 切弗朗菲利浦化学公司 | 改性负载型铬催化剂和由其生产的基于乙烯的聚合物 |
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EP0274536A1 (fr) * | 1986-07-04 | 1988-07-20 | Mitsui Petrochemical Industries, Ltd. | Composition a base de polyolefine pour le moulage par injection |
US5210142A (en) * | 1992-02-13 | 1993-05-11 | The Dow Chemical Company | Reduction of melt fracture in linear polyethylene |
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EP0274536A1 (fr) * | 1986-07-04 | 1988-07-20 | Mitsui Petrochemical Industries, Ltd. | Composition a base de polyolefine pour le moulage par injection |
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Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO1998026000A1 (fr) * | 1996-12-12 | 1998-06-18 | The Dow Chemical Company | Compositions interpolymeres et film etirable coule produit a partir de celles-ci |
US6812289B2 (en) | 1996-12-12 | 2004-11-02 | Dow Global Technologies Inc. | Cast stretch film of interpolymer compositions |
WO2007008361A1 (fr) * | 2005-07-11 | 2007-01-18 | Equistar Chemicals, Lp | Compositions de polyethylene |
CN116063598A (zh) * | 2018-09-17 | 2023-05-05 | 切弗朗菲利浦化学公司 | 改性负载型铬催化剂和由其生产的基于乙烯的聚合物 |
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