Pipe comprising a metallocene-catalyzed polyethylene resin

Patent metadata

Field	Value
Publication number	US-9932427-B2
Application number	US-201515305683-A
Country	US
Kind code	B2
Filing date	Apr 23, 2015
Priority date	Apr 23, 2014
Publication date	Apr 3, 2018
Grant date	Apr 3, 2018

Abstract

The invention relates to a pipe comprising at least one metallocene-catalyzed polyethylene resin, wherein the polyethylene resin has a multimodal molecular weight distribution and comprises at least two metallocene-catalyzed polyethylene fractions A and B, wherein fractions A and B are prepared in different reactors of at least two reactors connected in series, wherein the polyethylene resin comprises:
at least 30% by weight and at most 50% by weight of the polyethylene fraction A, based on the total weight of the polyethylene resin, wherein fraction A has a melt index MI 2 of at least 50 g/10 min as determined on the fluff of fraction A according to ISO 1133:1997 condition D at a temperature of 190° C. and under a load of 2.16 kg;

wherein fraction B has a density of at most 0.9210 g/cm 3 ; and wherein the polyethylene resin has a melt index MI 5 of at least 0.10 g/10 min and of at most 1.0 g/10 min as determined according to ISO 1133:1997, condition T, at 190° C. and under a load of 5 kg; wherein the polyethylene resin has an HLMI of at least 4.0 g/10 min and at most 14.0 g/10 min, as measured according to the procedure of ISO 1133:1997 condition G with a temperature of 190° C. and a load of 21.6 kg; and a density of at least 0.9420 g/cm 3 and of at most 0.9460 g/cm 3 as determined according to the procedure of ASTM D-1505 at a temperature of 23° C.

First claim

The invention claimed is:

1. A pipe comprising at least one metallocene-catalyzed polyethylene resin, wherein the polyethylene resin has a multimodal molecular weight distribution and comprises at least two metallocene-catalyzed polyethylene fractions A and B, wherein fractions A and B are prepared in different reactors of at least two reactors connected in series, wherein the polyethylene resin comprises:
at least 30% by weight and at most 50% by weight of the polyethylene fraction A, based on the total weight of the polyethylene resin, wherein fraction A has a melt index MI 2 of at least 50 g/10 min as determined on the fluff of fraction A according to ISO 1133:1997 condition D at a temperature of 190° C. and under a load of 2.16 kg;
wherein the polyethylene resin has a melt index MI 5 of at least 0.10 g/10 min and of at most 1.0 g/10 min as determined according to ISO 1133:1997, condition T, at 190° C. and under a load of 5 kg; an HLMI of at least 4.0 g/10 min and at most 14.0 g/10 min, as measured according to the procedure of ISO 1133:1997 condition G with a temperature of 190° C. and a load of 21.6 kg; and a density of at least 0.9420 g/cm 3 and of at most 0.9460 g/cm 3 as determined according to the procedure of ASTM D-1505 at a temperature of 23° C.; and
wherein fraction B has a density of at most 0.9210 g/cm 3 .

2. The pipe according to claim 1 , wherein the polyethylene resin has a density of at most 0.9455 g/cm 3 as determined according to the procedure of ASTM D-1505 at a temperature of 23° C.

3. The pipe according to claim 1 , wherein fraction B has a density of at most 0.9200 g/cm 3 .

4. The pipe according to claim 1 , wherein the polyethylene resin has a molecular weight distribution Mw/Mn of at least 5.0, Mw being the weight-average molecular weight and Mn being the number-average molecular weight.

5. The pipe according to claim 1 , wherein the ratio of the HLMI of the polyethylene resin to the HLMI of the polyethylene fraction B is at most 50, the HLMI of the polyethylene resin and of fraction A being determined according to the procedure of ISO 1133:1997 condition G with a temperature of 190° C. and a load of 21.6 kg, and the HLMI of polyethylene fraction B being calculated with the formula:
HLMI=0.894*W B * Ln (HLMI B )−5.61*(W B ) 2 +0.9304 *Ln (HLMI A )−0.0877*(W B *Ln (HLMI A )) 2

wherein HLMI is the HLMI of the polyethylene resin, W A is the weight fraction of fraction A, HLMI A is the HLMI of fraction A measured on the fluff, HLMI B is the HLMI of fraction B as calculated, and wherein the sum of both fractions A and B by weight (W A +W B ) is 1.

6. The pipe according to claim 1 comprising at least 50% by weight and at most 70% by weight of polyethylene fraction B.

7. The pipe according to claim 1 , wherein the ratio of the HLMI of the polyethylene resin to the HLMI of polyethylene fraction B is at least 10 and at most 50, the HLMI of the polyethylene resin and of fraction A being determined according to the procedure of ISO 1133:1997 condition G with a temperature of 190° C. and a load of 21.6 kg, and the HLMI of polyethylene fraction B being calculated with the formula:
HLMI=0.894*W B *Ln (HLMI B )−5.61*(W B ) 2 +0.9304 *Ln ( HLMI A )−0.0877*(W B *Ln (HLMI A )) 2

wherein HLMI is the HLMI of the polyethylene resin, W A is the weight fraction of fraction A, HLMI A is the HLMI of fraction A measured on the fluff, HLMI B is the HLMI of fraction B as calculated, and wherein the sum of both fractions A and B by weight (W A +W B ) is 1.

8. The pipe according to any one of claims 1 to 7 , wherein fraction A has an MI 2 of at least 60 g/10 min and of at most 250 g/10 min.

9. The pipe according to claim 1 , wherein the polyethylene resin has a molecular weight distribution Mw/Mn of at most 14.0, Mw being the weight-average molecular weight and Mn being the number-average molecular weight.

10. The pipe according to claim 1 , wherein the polyethylene resin has a molecular weight distribution Mw/Mn of at least 5.0 and at most 12.0, preferably of at least 6.5 and at most 9.0, Mw being the weight-average molecular weight and Mn being the number-average molecular weight.

11. The pipe according to claim 1 , wherein the polyethylene resin has stress crack resistance of at least 6400 hours, preferably at least 8760 hours, preferably at least 10000 hours, as determined using the Full Notched Creep Test according to ISO 16770 performed at 80° C. under a 4.0 MPa constraint in 2% Arkopal N100.

12. The pipe according to claim 1 , wherein the polyethylene resin further comprises at least one processing aid.

13. The pipe according to claim 1 , wherein the polyethylene resin further comprises at least 100 ppm of at least one processing aid, preferably a silicon- or fluorine-based processing aid, for example a fluoroelastomer.

14. A metallocene-catalyzed polyethylene resin, wherein the polyethylene resin has a multimodal molecular weight distribution and comprises at least two metallocene-catalyzed polyethylene fractions A and B, wherein fractions A and B are prepared in different reactors of at least two reactors connected in series, wherein the polyethylene resin comprises:
at least 30% by weight and at most 50% by weight of the polyethylene fraction A, based on the total weight of the polyethylene resin, wherein fraction A has a melt index MI 2 of at least 50 g/10 min as determined on the fluff of fraction A according to ISO 1133:1997 condition D at a temperature of 190° C. and under a load of 2.16 kg;
wherein the polyethylene resin has a melt index MI 5 of at least 0.10 g/10 min and of at most 1.0 g/10 min as determined according to ISO 1133:1997, condition T, at 190° C. and under a load of 5 kg; an HLMI of at least 4.0 g/10 min and at most 14.0 g/10 min, the HLMI being determined according to the procedure of ISO 1133:1997 condition G with a temperature of 190° C. and a load of 21.6 kg; and a density of at least 0.9420 g/cm 3 and of at most 0.9460 g/cm 3 as determined according to the procedure of ASTM D-1505 at a temperature of 23° C.; and wherein fraction B has a density of at most 0.9210 g/cm 3 , preferably of at most 0.9200 g/cm 3 .

15. The metallocene-catalyzed polyethylene resin according to claim 14 , wherein the polyethylene resin has a density of at most 0.9455 g/cm 3 as determined according to the procedure of ASTM D-1505 at a temperature of 23°.

Assignees

• Total Res & Technology Feluy

Inventors

• Lhost Olivier
• Michel Jacques

Classifications

• F16L9/127 Primary

  the walls consisting of a single layer · CPC title

• C08L2314/06

  Metallocene or single site catalysts · CPC title

• C08F4/65927

  two cyclopentadienyl rings being mutually bridged · CPC title

• C08L2308/00

  Chemical blending or stepwise polymerisation process with the same catalyst · CPC title

• C08F210/02

  Ethene · CPC title