Dilution index

Patent metadata

Field	Value
Publication number	US-10577491-B2
Application number	US-201816010542-A
Country	US
Kind code	B2
Filing date	Jun 18, 2018
Priority date	Oct 21, 2014
Publication date	Mar 3, 2020
Grant date	Mar 3, 2020

Abstract

This disclosure relates to ethylene interpolymer compositions. Specifically, ethylene interpolymer products having: a Dilution Index (Yd) greater than 0; total catalytic metal ≥3.0 ppm; ≥0.03 terminal vinyl unsaturations per 100 carbon atoms, and; optionally a Dimensionless Modulus (Xd) greater than 0. The disclosed ethylene interpolymer products have a melt index from about 0.3 to about 500 dg/minute, a density from about 0.869 to about 0.975 g/cm3, a polydispersity (Mw/Mn) from about 2 to about 25 and a CDBI50 from about 20% to about 97%. Further, the ethylene interpolymer products are a blend of at least two ethylene interpolymers; where one ethylene interpolymer is produced with a single-site catalyst formulation and at least one ethylene interpolymer is produced with a heterogeneous catalyst formulation.

First claim

What is claimed is:

1. An ethylene interpolymer product comprising:
(i) a first ethylene interpolymer;
(ii) a second ethylene interpolymer, and;
(iii) optionally a third ethylene interpolymer; wherein said ethylene interpolymer product has a Dilution Index, Y d , greater than 0; a density of from 0.910 to 0.912 g/cc, wherein density is measured according to ASTM D792 and a melt index of from 1.5 to 4.5 dg/minute, wherein said melt index is measured according to ASTM D1238 (2.16 kg load and 190° C.).

2. The ethylene interpolymer product of claim 1 synthesized using a solution polymerization process.

3. The ethylene interpolymer product of claim 1 ; wherein said interpolymer product comprises ethylene and one or more α-olefins selected from 1-hexene and 1-octene.

4. The ethylene interpolymer product of claim 1 ; wherein said first ethylene interpolymer is synthesized using a single-site catalyst formulation.

5. The ethylene interpolymer product of claim 1 ; wherein said second ethylene interpolymer is synthesized using a first heterogeneous catalyst formulation.

6. The ethylene interpolymer product of claim 1 ; wherein said third ethylene interpolymer is synthesized using a first heterogeneous catalyst formulation or a second heterogeneous catalyst formulation.

7. The ethylene interpolymer product of claim 1 wherein said second ethylene interpolymer is synthesized using a first in-line Ziegler Natta catalyst formulation or a first batch Ziegler-Natta catalyst formulation; optionally, said third ethylene interpolymer is synthesized using said first in-line Ziegler Natta catalyst formulation or said first batch Ziegler-Natta catalyst formulation.

8. The ethylene interpolymer product of claim 1 wherein said third ethylene interpolymer is synthesized using a second in-line Ziegler Natta catalyst formulation or a second batch Ziegler-Natta catalyst formulation.

9. The ethylene interpolymer product of claim 1 , having ≤1 part per million (ppm) of a metal A; wherein said metal A originates from a single site catalyst formulation used to synthesize said first ethylene interpolymer.

10. The ethylene interpolymer product of claim 9 ; wherein said metal A is titanium, zirconium or hafnium.

11. The ethylene interpolymer product of claim 1 having a metal B and optionally a metal C and the total amount of said metal B plus said metal C is from about 3 to about 11 parts per million; wherein said metal B originates from a first heterogeneous catalyst formulation used to synthesize said second ethylene interpolymer and optionally said metal C originates from a second heterogeneous catalyst formulation used to synthesize said third ethylene interpolymer; optionally said metal B and said metal C are the same metal.

12. The ethylene interpolymer product of claim 11 ; wherein said metal B and said metal C, are independently selected from titanium, zirconium, hafnium, vanadium, niobium, tantalum, chromium, molybdenum, tungsten, manganese, technetium, rhenium, iron, ruthenium or osmium.

13. The ethylene interpolymer product of claim 1 wherein said first ethylene interpolymer has a first M w /M n , said second ethylene interpolymer has a second M w /M n and said optional third ethylene interpolymer has a third M w /M n ; wherein said first M w /M n is lower than said second M w /M n and said optional third M w /M n .

14. The ethylene interpolymer product of claim 13 ; wherein the blending of said second ethylene interpolymer and said third ethylene interpolymer forms a heterogeneous ethylene interpolymer blend having a fourth M w /M n ; wherein said fourth M w /M n is not broader than said second M w /M n .

15. The ethylene interpolymer product of claim 13 wherein said second M w /M n and said optional third M w /M n are ≤4.0.

16. The ethylene interpolymer product of claim 1 ; wherein said first ethylene interpolymer has a first CDBI 50 from about 70 to about 98%, said second ethylene interpolymer has a second CDBI 50 from about 45 to about 98% and said optional third ethylene interpolymer has a third CDBI 50 from about 35 to about 98%.

17. The ethylene interpolymer product of claim 16 ; wherein said first CDBI 50 is higher than said second CDBI 50 ; optionally said first CDBI 50 is higher than said third CDBI 50 .

18. An ethylene interpolymer product comprising:
(i) a first ethylene interpolymer;
(ii) a second ethylene interpolymer, and;
(iii) optionally a third ethylene interpolymer;

wherein said ethylene interpolymer product has a Dilution Index, Y d , of from 4.5 to 5.5; a density of from 0.910 to 0.912 g/cc, wherein said density is measured according to ASTM D792 and; a melt index of from 1.5 to 4.5 dg/minute, wherein said melt index is measured according to ASTM D1238 (2.16 kg load and 190° C.).

19. The ethylene interpolymer product of claim 18 , further characterized as having ≥0.03 terminal vinyl unsaturations per 100 carbon atoms.

20. The ethylene interpolymer product of claim 18 , further characterized as having 3 parts per million (ppm) of a total catalytic metal.

Assignees

• Nova Chem Int Sa

Inventors

• Fereydoon Maryam
• Salomons Stephen
• Goyal Shivendra Kumar
• Taylor Kenneth
• Li Tieqi

Classifications

• C08F2/001

  Multistage polymerisation processes characterised by a change in reactor conditions without deactivating the intermediate polymer (C08F295/00, C08F297/00 take precedence) · CPC title

• C08F4/65904

  in combination with another component of C08F4/64 · CPC title

• C08J5/00

  Manufacture of articles or shaped materials containing macromolecular substances (manufacture of semi-permeable membranes B01D67/00 - B01D71/00) · CPC title

• B32B27/327

  comprising polyolefins obtained by a metallocene or single-site catalyst · CPC title

• B32B27/08

  of synthetic resin · CPC title