Ethylene interpolymer films

Patent metadata

Field	Value
Publication number	US-9518159-B2
Application number	US-201514919051-A
Country	US
Kind code	B2
Filing date	Oct 21, 2015
Priority date	Oct 21, 2014
Publication date	Dec 13, 2016
Grant date	Dec 13, 2016

Abstract

This disclosure relates to multilayer films having improved caulkability. These multilayer films have at least one layer containing an ethylene interpolymer product, or a blend containing an ethylene interpolymer product, where the ethylene interpolymer product has: a Dilution Index (Y d ) greater than 0; total catalytic metal ≧3.0 ppm; ≧0.03 terminal vinyl unsaturations per 100 carbon atoms, and; optionally a Dimensionless Modulus (X d ) greater than 0. The ethylene interpolymer products have a melt index from about 0.4 to about 100 dg/minute, a density from about 0.950 to about 0.970 g/cm 3 , a polydispersity (M w /M n ) from about 2 to about 25 and a CDBI 50 from about 55% 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. A film comprising at least one layer, wherein said layer comprises 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.

2. The film of claim 1 , further characterized as having ≧0.03 terminal vinyl unsaturations per 100 carbon atoms.

3. The film of claim 1 , further characterized as having ≧3 parts per million (ppm) of a total catalytic metal.

4. The film of claim 1 , further characterized as having a Dimensionless Modulus, X d , greater than 0.

5. The film of claim 1 , further characterized as having ≧0.03 terminal vinyl unsaturations per 100 carbons and ≧3 parts per million (ppm) of total catalytic metal.

6. The film of claim 1 , further characterized as having ≧3 parts per million (ppm) of total catalytic metal and a Dimensionless Modulus, X d , greater than 0.

7. The film of claim 1 , further characterized as having ≧0.03 terminal vinyl unsaturations per 100 carbons and a Dimensionless Modulus, X d , greater than 0.

8. The film of claim 1 , further characterized as having ≧0.03 terminal vinyl unsaturations per 100 carbons, ≧3 parts per million (ppm) of total catalytic metal and a Dimensionless Modulus, X d , greater than 0.

9. The film of claim 1 having a melt index from about 0.4 to about 12 dg/minute; wherein melt index is measured according to ASTM D1238 (2.16 kg load and 190° C.).

10. The film of claim 1 having a density from about 0.900 to about 0.935 g/cc; wherein density is measured according to ASTM D792.

11. The film of claim 1 having a M w /M n from about 2 to about 25.

12. The film of claim 1 having a CDBI 50 from about 20% to about 98%.

13. The film of claim 1 ; wherein
(i) said first ethylene interpolymer is from about 15 to about 60 weight percent of said ethylene interpolymer product;
(ii) said second ethylene interpolymer is from about 30 to about 85 weight percent of said ethylene interpolymer product, and;
(iii) optionally said third ethylene interpolymer is from about 0 to about 30 weight percent of said ethylene interpolymer product;
wherein weight percent is the weight of said first, said second or said optional third ethylene interpolymer divided by the weight of said ethylene interpolymer product.

14. The film of claim 1 ; wherein
(i) said first ethylene interpolymer has a melt index from about 0.01 to about 200 dg/minute;
(ii) said second ethylene interpolymer has melt index from about 0.3 to about 1000 dg/minute, and;
(iii) optionally said third ethylene interpolymer has a melt index from about 0.5 to about 2000 dg/minute;
wherein melt index is measured according to ASTM D1238 (2.16 kg load and 190° C.).

15. The film of claim 1 ; wherein
(i) said first ethylene interpolymer has a density from about 0.855 g/cm 3 to about 0.975 g/cc;
(ii) said second ethylene interpolymer has a density from about 0.89 g/cm 3 to about 0.975 g/cc, and;
(iii) optionally said third ethylene interpolymer has density from about 0.89 to about 0.975 g/cc;
wherein density is measured according to ASTM D792.

16. The film of claim 1 ; wherein said ethylene interpolymer product is synthesized using a solution polymerization process.

17. The film of claim 1 further comprising from 0.1 to about 10 mole percent of one or more α-olefin.

18. The film of claim 17 ; wherein said one or more α-olefin are C 3 to C 10 α-olefins.

19. The film of claim 17 ; wherein said one or more α-olefin is 1-hexene, 1-octene or a mixture of 1-hexene and 1-octene.

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

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

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

23. The film 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.

24. The film 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.

25. The film 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.

26. The film of claim 25 ; wherein said metal A is titanium, zirconium or hafnium.

27. The film 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.

28. The film of claim 27 ; 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.

29. The film of claim 27 ; wherein said metal B and said metal C, are independently selected from titanium, zirconium, hafnium, vanadium or chromium.

30. The film 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 .

31. The film of claim 30 ; 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 .

32. The film of claim 30 wherein said second M w /M n and said optional third M w /M n are ≦4.0.

33. The film 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%.

34. The film of claim 33 ; wherein said first CDBI 50 is higher than said second CDBI 50 ; optionally said first CDBI 50 is higher than said third CDBI 50 .

35. The film of claim 1 ; wherein said film is a multilayer film, wherein said multilayer film has a sealant layer, wherein said sealant layer comprises said ethylene interpolymer product and said multilayer film has a hole size ≧95 μm and ≦115 μm; wherein hole size is determine

Assignees

• Nova Chemicals International Sa

Inventors

• Ward Daniel
• Li Michael
• Wang Xiaochuan
• Li Tieqi
• Dobbin Christopher John Brooke
• Sibtain Fazle
• Taylor Kenneth Edward
• Khakdaman Hamidreza

Classifications

• C08L2203/10

  used for bottles · CPC title

• C08L2205/025

  containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure · CPC title

• C08L23/0815 Primary

  with aliphatic 1-olefins containing one carbon-to-carbon double bond · CPC title

• C08L2203/16

  used for films · CPC title

• C08F4/65908

  in combination with an ionising compound other than alumoxane, e.g. (C6F5)4B-X+ · CPC title