U.S. patent application number 09/969418 was filed with the patent office on 2002-04-11 for ethylene polymer film resins.
Invention is credited to Ong, S. Christine, Schregenberger, Sandra D., Shirodkar, Pradeep P..
Application Number | 20020042472 09/969418 |
Document ID | / |
Family ID | 27099118 |
Filed Date | 2002-04-11 |
United States Patent
Application |
20020042472 |
Kind Code |
A1 |
Ong, S. Christine ; et
al. |
April 11, 2002 |
Ethylene polymer film resins
Abstract
A class of relatively high molecular weight, high density
ethylene polymers (HMW-HDPE) is disclosed capable of being formed
into thin films of high strength, such polymers having a density of
at least about 0.935 g/cc, a flow index (I.sub.21) no higher than
about 15 g/10 min., a melt flow ratio (MFR) of at least about 65,
and a dynamic elasticity at 0.1 rad./sec. of no higher than about
0.7 at a corresponding complex viscosity at 0.1 rad./sec. no higher
than about 14E5, i.e., about 14.times.10.sup.5 poises.
Inventors: |
Ong, S. Christine; (Warren,
NJ) ; Schregenberger, Sandra D.; (Bridgewater,
NJ) ; Shirodkar, Pradeep P.; (Somerset, NJ) |
Correspondence
Address: |
ExxonMobil Chemical Company
P.O. Box 2149
Baytown
TX
77522
US
|
Family ID: |
27099118 |
Appl. No.: |
09/969418 |
Filed: |
October 2, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09969418 |
Oct 2, 2001 |
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08083866 |
Jun 28, 1993 |
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6316546 |
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08083866 |
Jun 28, 1993 |
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07734989 |
Jul 24, 1991 |
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07734989 |
Jul 24, 1991 |
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07665054 |
Mar 6, 1991 |
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Current U.S.
Class: |
525/53 ; 525/240;
525/247; 525/268; 525/270; 525/320; 525/324; 526/348.1 |
Current CPC
Class: |
C08F 210/16 20130101;
C08L 23/0815 20130101; C08F 297/083 20130101; C08L 2308/00
20130101; C08L 2314/02 20130101; C08F 2500/26 20130101; C08F 2/001
20130101; C08L 2666/04 20130101; C08F 2500/12 20130101; C08F
2500/18 20130101; C08F 2500/01 20130101; C08F 2500/01 20130101;
C08F 2500/18 20130101; C08F 210/14 20130101; C08F 2500/12 20130101;
C08L 2666/04 20130101; C08L 23/06 20130101; C08F 2/002 20130101;
C08F 2/001 20130101; C08F 2500/05 20130101; C08F 210/14 20130101;
C08F 2500/05 20130101; C08F 2500/02 20130101; C08F 210/16 20130101;
B01J 8/26 20130101; C08L 23/0815 20130101; C08F 10/02 20130101;
C08F 210/16 20130101; B01J 2219/0004 20130101; C08L 23/06 20130101;
C08F 297/08 20130101; C08L 2205/02 20130101; C08F 210/16 20130101;
C08F 10/02 20130101; C08F 10/02 20130101 |
Class at
Publication: |
525/53 ; 525/240;
525/247; 525/268; 525/270; 525/320; 525/324; 526/348.1 |
International
Class: |
C08L 023/08 |
Claims
We claim:
1. A film comprising a polymer blend, the blend having: a density
of about 0.940 to 0.960 g/cc, a flow index (I.sub.21) of about 4 to
12 g/10 min, a MFR of about 75 to 180, and a dynamic elasticity of
about 0.45 to 0.65 at a corresponding complex viscosity of about
6.times.10.sup.5 to 14.times.10.sup.5 poise, wherein the blend
consists essentially of: at least about 0.5 weight fraction of a
high molecular weight (HMW) component having a density of at least
about 0.910 g/cc, a flow index (I.sub.21) of no higher than about
0.8 g/10 min, a molecular weight distribution indicated by a flow
ratio (FR) no higher than about 15, and a dynamic elasticity at 0.1
rad/s, of no higher than about 0.75 at a corresponding complex
viscosity at 0.1 rad/s of no higher than about 7.times.10.sup.6,
and a low molecular weight (LMW) component having a density of at
least about 0.940 g/cc and a melt index (I.sub.2) of at least about
100 g/10 min, wherein each of said high molecular weight (HMW)
component and said low molecular weight (LMW) component is selected
from the group consisting of a homopolymer of ethylene and at least
one copolymer of a preponderance of ethylene with a minor amount of
a 1-olefin containing 3 to about 10 carbon atoms as comonomer.
2. The film of claim 1 having a thickness up to 1.5 mil, a Dart
Drop Impact (F.sub.50) of at least about 200 g and a MD Tear of at
least about 10 g/mil.
3. The film of claim 2 having a Dart Drop Impact (F.sub.50) of
about 200 to 600 g and a MD Tear of about 15 to 60 g/mil.
4. The film of claim 3 having a Dart Drop Impact (F.sub.50) of
about 200 to 600 g and a MD Tear of about 20 to 60 g/mil.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of application
Ser. No. 07/665,054, filed Mar. 6, 1991, by A. H. Ali et al.
(Docket 6101).
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to relatively high molecular weight,
high density ethylene polymers capable of being formed with good
processability into films having improved mechanical
properties.
[0004] 2. Description of Related Art
[0005] The following information is disclosed in accordance with
the terms of 37 CFR 1.56, 1.97 and 1.98.
[0006] U.S. Pat. No. 4,307,209, issued Dec. 22, 1981, to Morita et
al., discloses a process for producing bimodal ethylene polymers in
two slurry stages in the presence of a catalyst comprising
titanium, magnesium and halogen, with the polymer of the first
stage being different in intrinsic viscosity and alpha-olefin
comonomer content, and with the second stage carried out in the
presence of the polymer of the first stage.
[0007] U.S. Pat. No. 4,352,915, issued Oct. 5, 1982, to Mashita et
al., discloses a process for producing bimodal ethylene
homopolymers or ethylene-alpha-olefin copolymers in two slurry
stages in the presence of a catalyst comprising a titanium and/or
vanadium compound supported on a specified magnesium compound, and
wherein a relatively low molecular weight component is produced in
the first stage and a relatively high molecular weight component is
produced in the second stage.
[0008] U.S. Pat. No. 4,414,369, issued Nov. 8, 1983, to Kuroda et
al., discloses a process for the production of bimodal polyolefins
wherein olefin monomers are polymerized in a first stage in the
presence of a Ziegler catalyst to produce a relatively high
molecular weight polymer which is transferred to a second stage
wherein further polymerization to a relatively low molecular weight
polymer is effected, resulting in a final polymer having a wide
molecular weight distribution.
[0009] U.S. Pat. Nos. 4,461,873, issued Jul. 24, 1984, and
4,547,551, issued Oct. 15, 1985, both to F. W. Bailey et al., each
discloses blends of high molecular weight and low molecular weights
ethylene polymers of purportedly narrow molecular weight
distribution, useful in the production of films and blow-molded
articles.
[0010] U.S. Pat. No. 4,048,412, issued Sep. 13, 1977, to Caumartin
et al., discloses a process for the polymerization of olefins,
e.g., ethylene, in a series of reaction vessels each operating in
the gas phase and containing a fluidized bed of polymer and
catalyst comprising a transition metal and organometallic compound
as cocatalyst introduced into the first reactor, and wherein an
additional amount of cocatalyst is introduced into a reactor other
than the first. The patent discloses the use of different
organoaluminum compounds as cocatalysts in the reactors for the
purpose of varying the molecular weight distribution of the
polymer.
[0011] U.S. Pat. No. 4,338,424, issued Jul. 6, 1982, to Morita et
al., discloses a process for polymerizing olefins utilizing two gas
phase polymerization zones, the first employing a higher hydrogen
to olefin mole ratio to produce a low molecular weight (LMW)
polymer and the second employing a lower hydrogen to olefin mole
ratio to produce a high molecular weight (HMW) polymer. The process
also includes a dilution zone between the two polymerization zones
to which a fresh supply of olefin gas is added for feeding into the
second polymerization zone.
[0012] U.S. Pat. No. 4,390,669, issued Jun. 28, 1983, to Morita et
al., teaches the production of polyolefins utilizing two gas phase
polymerization zones with the polymer from the first zone being fed
to a suspension zone wherein it is suspended in a liquid
hydrocarbon medium and the liquid suspension is fed to the second
zone. A LMW polymer is produced in the first zone and a HMW polymer
in the second zone.
[0013] U.S. Pat. No. 4,420,592, issued Dec. 13, 1983, to Kato et
al., discloses the polymerization of olefins in the gas phase in a
multiplicity of polymerization zones wherein a gaseous stream
containing polymer from the first zone is fed to the second zone
through a transfer passage containing an inert gas zone in which
part of the gas components from the first zone is replaced by an
inert gas. The disclosure is limited to the production of LMW
polymer in the first zone and HMW polymer in the second zone.
[0014] U.S. Pat. No. 4,703,094, issued Oct. 27, 1987, to Raufast,
discloses the production of polyolefins by the polymerization of
alpha-olefins in the gas phase in several reactors, at least two of
which are interconnected by a transfer device in which the gas
mixture from the upstream reactor is subjected to decompression and
compression stages, providing for elimination of the heat of
reaction and degassing of the polymer powder.
[0015] U.S. Pat. No. 4,481,301, issued Nov. 6, 1984, to Nowlin et
al., discloses catalysts for polymerizing alpha-olefins prepared by
treating a support with an organomagnesium compound and contacting
the supported magnesium composition in a liquid medium with a
tetravalent titanium compound.
[0016] U.S. Pat. No. 4,888,318, issued Dec. 19, 1989, to Allen et
al., discloses catalysts for the polymerization of alpha-olefins
prepared by reacting a supported complex of titanium and magnesium
with trimethyl aluminum.
[0017] European Published Patent Application No. 0 369 436, of Lee
et al., published May 23, 1990, discloses a process for the
production of ethylene copolymers in the gas phase utilizing at
least two fluidized bed reactors in series under conditions such
that a high melt index copolymer is made in one reactor and a low
melt index copolymer in the other. The disclosure states that the
high and low melt index polymers can be made in any order. The
catalyst employed is a complex of magnesium, titanium, a halogen,
and an electron donor on an appropriate support such as a silica or
alumina, in combination with an organoaluminum activator and
co-catalyst.
SUMMARY OF THE INVENTION
[0018] In accordance with this invention, relatively high molecular
weight, high density ethylene polymers (HMW-HDPE) capable of being
formed into thin films of high strength are provided, such polymers
having a density of at least about 0.925 g/cc, a flow index
(I.sub.21) no higher than about 15 g/10 min., a melt flow ratio
(MFR) of at least about 65, and a dynamic elasticity (as defined
hereinafter) at 0.1 rad./sec. of no higher than about 0.70 at a
corresponding complex viscosity at 0.1 rad./sec. no higher than
about 14E5, i.e., about 14.times.10.sup.5 poises.
[0019] The ethylene polymer of this invention will in most cases
consist essentially of a bimodal blend of relatively high molecular
weight (HMW) and low molecular weight (LMW) ethylene polymers with
the HMW component present, for example, at a weight fraction of at
least about 0.5 of such ethylene polymer content and having a
density of at least about 0.910 g/cc, a flow index (I.sub.21) of,
for example, no higher than about 0.8 g/10 min., a relatively
narrow molecular weight distribution indicated by a flow ratio
(FR), for example, no higher than about 15, and a dynamic
elasticity at 0.1 rad./sec., for example, of no higher than about
0.75 at a corresponding complex viscosity at 0.1 rad./sec. of no
higher than about 7E6, i.e., 7.times.10.sup.6 poises, and the LMW
component having a density of at least about 0.940 g/cc and a melt
index (I.sub.2) of at least about 100 g/10 min.
[0020] The HMW-HDPE product of this invention having relatively low
elasticity and molecular weight distribution indicated by MFR, can
be formed with good processability into thin gauge films having
excellent mechanical properties, e.g., Dart Drop Impact and
Elmendorf Tear resistance, despite the fact that its short chain
branching, e.g., ethyl groups per 1000 C atoms, appears to be
higher in the LMW component than in the HMW component. This is
contrary to a prevailing belief that short chain branching should
be concentrated in the HMW component for optimum mechanical
properties of films.
BRIEF DESCRIPTION OF THE DRAWING
[0021] The drawing is a schematic diagram of a gas phase tandem
polymerization process which can be used to make the products of
this invention.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The ethylene polymer of this invention preferably consists
essentially of either 1) a homopolymer of ethylene; 2) at least one
copolymer of a preponderance of ethylene with a minor amount of a
1-olefin containing 3 to about 10 carbon atoms, e.g., 1-butene,
1-pentene, 1-hexene, 4-methyl-1-pentene, 1-octene, 1-decene, and
mixtures thereof; or 3) a mixture of any of the foregoing polymers.
In general, the polymer product will comprise an amount of
polymerized comonomer which is in the range, for example, of about
0 to 30 weight percent, based on the total weight of polymer.
[0023] The density of the ethylene polymer product of this
invention will generally be, for example, at least about 0.925
g/cc, preferably about 0.940 to 0.96C g/cc, and most preferably
about 0.943 to 0.952 g/cc.
[0024] The flow index or high load melt index of the ethylene
polymer of this invention (I.sub.21, measured at 190.degree. C. in
accordance with ASTM D-1238, Condition F) is generally no higher
than about 15, preferably from about 4 to 12, and most preferably
about 5 to 10 g/10 min., while the melt flow ratio (MFR), defined
as the ratio of flow index (I.sub.21) to melt index (I.sub.2),
measured at 190.degree. C. in accordance with ASTM D-1238,
Condition E, is at least about 65, preferably about 75 to 180, and
most preferably about 80 to 150.
[0025] The dynamic elasticity of the polymer product of the
invention is no higher than about 0.7 at 0.1 rad./sec. at a
corresponding complex viscosity of no higher than about 14E5
(14.times.10.sup.5 poises) at 0.1 rad./sec., preferably about 0.45
to 0.65 at a corresponding complex viscosity of about 6E5 to 14E5,
and most preferably about 0.45 to 0.60 at a corresponding complex
viscosity of about 7E5 to 14E5.
[0026] The dynamic elasticity as used herein is defined as the
ratio of the storage modulus G'(w) to the loss modulus G"(w). The
following definitions of these moduli were adapted from those given
in J. D. Ferry, Viscoelastic Properties of Polymers, 3 rd Edition
(New York: John Wiley & Sons, 1980) 41-42. The definitions
pertain to measurements made in small strain oscillatory
measurements.
[0027] Storage Modulus, G'(w), is defined as the stress in phase
with the strain in a sinusoidal shear deformation divided by the
strain. It is a measure of the energy stored and recovered per
cycle, when different systems are compared at the same strain
amplitude. It is a function of the oscillating frequency w.
[0028] Loss Modulus, G"(w), is defined as the stress 90 degrees out
of phase with the strain divided by the strain. It is a measure of
the energy dissipated or lost per cycle of sinusoidal deformation,
when different systems are compared at the same strain amplitude.
It is also a function of the oscillating frequency w.
[0029] Complex Viscosity is derived from G'(w) and G"(w) as
hereinbefore defined using the following equation: 1 Complex
Viscosity = ( G ' ( w ) w ) 2 + ( G " ( w ) w ) 2
[0030] As stated, the ethylene polymer of this invention will in
most cases consist essentially of a bimodal blend of relatively
high molecular weight (HMW) and low molecular weight (LMW) ethylene
polymers with the HMW component being present, for example, at a
weight fraction of at least about 0.5 of the ethylene polymer
content. Such HMW component is preferably present at a weight
fraction of about 0.5 to 0.65, more preferably about 0.51 to 0.60,
with the remainder of the ethylene polymer being the LMW component.
In addition, the HMW component will generally have a density of at
least about 0.910 g/cc, preferably about 0.920 to 0.935 g/cc, and
more preferably about 0.924 to 0.935 g/cc; a flow index or high
load melt index (I.sub.21) of no higher than about 0.8, preferably
from about 0.15 to 0.7, and more preferably about 0.2 to 0.6 g/10
min.; a flow ratio (FR, defined as the ratio of flow index
(I.sub.21) to intermediate load melt index [I.sub.5], measured at
190.degree. C. under a load of 5 kilograms in accordance with ASTM
D-1238, Condition P) of no higher than about 15, preferably about 8
to 14, and more preferably about 9 to 13; and a dynamic elasticity
no higher than about 0.75 at 0.1 rad./sec. at a corresponding
complex viscosity of no higher than about 7E6 (7.times.10.sup.6
poises), at 0.1 rad./sec., preferably about 0.45 to 0.7 at a
corresponding complex viscosity of about 2E6 to 6E6, and more
preferably about 0.5 to 0.65 at a corresponding complex viscosity
of about 3E6 to 6E6.
[0031] The LMW component will generally have a density of at least
about 0.940 g/cc, preferably about 0.945 to 0.970 g/cc, and most
preferably about 0.950 to 0.970 g/cc, and a melt index (I.sub.2) of
at least about 100 g/10 min., preferably about 200 to 2000 g/10
min., and more preferably about 300 to 1500 g/10 min.
[0032] The ethylene polymer product of this invention is capable of
being formed into thin gauge films, e.g., of up to 1.5 mil., of
superior mechanical properties, e.g., an Elmendorf tear resistance
in the machine direction (MD Tear, ASTM D1922) of at least about 10
g/mil, preferably about 15 to 60 g/mil, and more preferably about
20 to 60 g/mil, and a Dart Drop Impact resistance (F.sub.50, ASTM
D1709) of at least about 200 g, preferably about 200 to 600 g, and
more preferably about 250 to 600 g.
[0033] When the ethylene polymer of this invention consists
essentially of HMW and LMW ethylene polymer components as
previously described, such components may be prepared separately
and physically blended in a conventional manner, e.g., by initially
dry blending the resin in a mixer with suitable additives, and then
melt blending it in an extruder. The relative proportions of the
HMW and LMW components are such that the blending produces an
ethylene polymer product having the desired properties of density,
flow index (I.sub.21), melt flow ratio (MFR), and dynamic
elasticity as set out hereinbefore. Preferably, however, the
desired bimodal ethylene polymer blend is directly produced by
means of a gas phase, fluidized bed, tandem reactor process as
described hereinafter in this specification and in parent
application Ser. No. 07/665,054, filed Mar. 6, 1991, by A. H. Ali
et al., the entire disclosure of which is incorporated by
reference. Whichever method is used, the described desirable
properties of the ethylene polymer obtained are dependent on the
catalyst used to polymerize both components and particularly the
HMW component, as well as the process conditions.
[0034] In utilizing a gas phase, fluidized bed, tandem reactor
process to obtain the product of this invention, bimodal ethylene
polymer blends having the described combination of good
processability and superior mechanical properties are produced by a
process including the steps of polymerizing gaseous monomeric
compositions comprising a major proportion of ethylene in at least
two gas phase, fluidized bed reactors operating in the tandem mode
under the following conditions. In the first reactor, a gas
comprising monomeric composition and, optionally, a small amount of
hydrogen, is contacted under polymerization conditions with an
appropriate Ziegler-Natta or coordination catalyst as described
more fully hereinafter, comprising a transition metal compound as
primary catalyst component and a reducing agent such as an
organometallic compound as cocatalyst, at a hydrogen/ethylene molar
ratio of no higher than about 0.3 and an ethylene partial pressure
no higher than about 100 psia such as to produce a relatively high
molecular weight (HMW) polymer powder wherein the polymer is
deposited on the catalyst particles. The HMW polymer powder
containing the catalyst is then transferred to a second reactor
with, optionally, additional cocatalyst which may be the same or
different from the cocatalyst utilized in the first reactor but
with no additional transition metal catalyst component, together
with a gaseous mixture comprising hydrogen and monomeric
composition wherein additional polymerization is carried out at a
hydrogen/ethylene molar ratio of at least about 0.9, the ratio
being sufficiently high such that it is at least about 8.0 times
that in the first reactor, and an ethylene partial pressure at
least 1.2 times that in the first reactor, to produce a relatively
low molecular weight (LMW) polymer much of which is deposited on
and within the HMW polymer/catalyst particles from the first
reactor, such that the fraction of HMW polymer in the bimodal
polymer leaving the second reactor is at least about 0.5.
[0035] The foregoing conditions provide for a process wherein the
production of fines tending to foul compressors and other equipment
is kept to a relatively low level. Moreover, such conditions
provide for an inhibited level of productivity in the first reactor
with a resulting increased level of productivity in the second
reactor to produce a bimodal polymer blend having properties as
previously described and a high degree of homogeneity (indicated by
low level of gels) caused by a substantial degree of blending of
HMW and LMW polymer in each final polymer particle inherently
resulting from the process operation. The bimodal blend is capable
of being processed without undue difficulty into films having a
superior combination of mechanical properties.
[0036] The gaseous monomer entering both reactors may consist
wholly of ethylene or may comprise a preponderance of ethylene and
a minor amount of a comonomer such as a 1-olefin containing 3 to
about 10 carbon atoms. Comonomeric 1-olefins which may be employed
are, for example, 1-butene, 1-pentene, 1-hexene,
4-methyl-1-pentene, 1-octene, 1-decene, and mixtures thereof. The
comonomer may be present in the monomeric compositions entering
either or both reactors.
[0037] In many cases, the monomer composition will not be the same
in both reactors. For example, the monomer entering the first
reactor may contain a minor amount of comonomer such as 1-hexene so
that the HMW component of the bimodal product is a copolymer, while
the monomer fed to the second reactor may consist essentially of
ethylene so that the LMW component of the product is substantially
an ethylene homopolymer. The amount of comonomer may be in the
range, for example, of about 0 to 30, preferably about 0 to 20
weight percent, based on the total weight of polymer produced in
the tandem process.
[0038] Hydrogen may or may not be used to modulate the molecular
weight of the HMW polymer made in the first reactor. Thus, hydrogen
may be fed to the first reactor such that the molar ratio of
hydrogen to ethylene (H.sub.2/C.sub.2 ratio) is, for example, up to
about 0.3, preferably about 0.005 to 0.2. In the second reactor it
is necessary to produce a LMW polymer with a low enough molecular
weight and in sufficient quantity so as to produce a bimodal resin
which can be formed, with a minimum of processing difficulties,
into films having a superior combination of mechanical properties.
For this purpose, hydrogen is fed to the second reactor with the
ethylene containing monomer such that the hydrogen to ethylene mole
ratio in the gas phase is at least about 0.9, preferably in the
range of about 0.9 to 5.0 and most preferably in the range of about
1.0 to 3.5. Moreover, to provide a sufficient difference between
the molecular weights of the polymers in the first and second
reactor so as to obtain a bimodal resin product having a wide
enough molecular weight distribution necessary for the desired
levels of processability and mechanical properties, the hydrogen to
ethylene mole ratios in the two reactors should be such that the
ratio in the second reactor is at least about 8.0 times the ratio
in the first reactor, for example in the range 8.0 to 10,000 times
such ratio, and preferably 10 to 200 times the ratio in the first
reactor.
[0039] Utilizing the hydrogen to ethylene ratios set out previously
to obtain the desired molecular weights of the HMW and LMW polymers
produced in the first and second reactors respectively tends to
result in relatively high polymer productivity in the first reactor
and relatively low productivity in the second reactor. This tends
to result in turn in a bimodal polymer product containing too
little LMW polymer to maintain satisfactory processability. A
significant part of this invention lies in the discovery that this
effect can be largely overcome by employing ethylene partial
pressures in the two reactors so as to reduce the polymer
productivity in the first reactor and raise such productivity in
the second reactor. For this purpose, the ethylene partial pressure
employed in the first reactor is no higher than about 100 psia, for
example in the range of about 15 to 100 psia, preferably in the
range of about 20 to 80 psia and the ethylene partial pressure in
the second reactor is, for example in the range of about 26 to 170
psia, preferably about 55 to 120 psia, with the ethylene partial
pressures in any specific process being such that the ratio of
ethylene partial pressure in the second to that in the first
reactor is at least about 1.2, preferably about 1.25 to 7.0, and
more preferably about 1.25 to 4.0
[0040] If desired for any purpose, e.g., to control superficial gas
velocity or to absorb heat of reaction, an inert gas such as
nitrogen may also be present in one or both reactors in addition to
the monomer and hydrogen. Thus the total pressure in both reactors
may be in the range, for example, of about 100 to 600 psig,
preferably about 200 to 350 psig.
[0041] The temperature of polymerization in the first reactor may
be in the range, for example, of about 60 to 130.degree. C.,
preferably about 60 to 90.degree. C., while the temperature in the
second reactor may be in the range, for example, of about 80 to
130.degree. C., preferably about 90 to 120.degree. C. For the
purpose of controlling molecular weight and productivity in both
reactors, it is preferred that the temperature in the second
reactor be at least about 10.degree. C. higher, preferably about 20
to 60.degree. C. higher than that in the first reactor.
[0042] The residence time of the catalyst in each reactor is
controlled so that the productivity is suppressed in the first
reactor and enhanced in the second reactor, consistent with the
desired properties of the bimodal polymer product. Thus, the
residence time may be, for example, about 0.5 to 6 hours,
preferably about 1 to 3 hours in the first reactor, and, for
example, about 1 to 12 hours, preferably about 2.5 to 5 hours in
the second reactor, with the ratio of residence time in the second
reactor to that in the first reactor being in the range, for
example, of about 5 to 0.7, preferably about 2 to 0.8.
[0043] The superficial gas velocity through both reactors is
sufficiently high to disperse effectively the heat of reaction so
as to prevent the temperature from rising to levels which could
partially melt the polymer and shut the reactor down, and high
enough to maintain the integrity of the fluidized beds. Such gas
velocity may be in the range, for example, of about 40 to 120,
preferably about 50 to 90 cm/sec.
[0044] The productivity of the process in the first reactor in
terms of grams of polymer per gram atom of transition metal in the
catalyst multiplied by 10.sup.6, may be in the range, for example,
of about 1.6 to 16.0, preferably about 3.2 to 9.6; in the second
reactor, the productivity may be in the range, for example, of
about 0.6 to 9.6, preferably about 1.6 to 3.5, and in the overall
process, the productivity is in the range, for example, of about
2.2 to 25.6, preferably about 4.8 to 16.0. The foregoing ranges are
based on analysis of residual catalyst metals in the resin
product.
[0045] If it is desired to prepare the HMW and LMW components
separately and subsequently physically blend them, each component
may be produced in a single stage gas phase fluidized bed reactor
employing process conditions within the ranges described for the
two reactors utilized in the foregoing gas phase tandem reactor
process. In either case, the specific process conditions are chosen
in combination with an appropriate catalyst and weight fractions of
the two components so as to obtain a final bimodal polymer having
the desired combination of properties.
[0046] One suitable class of Ziegler-Natta catalysts for the
preparation of the polymer products of this invention
comprises:
[0047] (i) a catalyst precursor complex or mixture of complexes
consisting essentially of magnesium, titanium, a halogen, and an
electron donor as hereinafter defined supported on an inorganic
porous carrier; and
[0048] (ii) at least one hydrocarbyl aluminum cocatalyst.
[0049] The titanium based complex or mixture of complexes is
exemplified by an empirical formula
Mg.sub.aTi(OR).sub.bX.sub.c(ED).sub.d wherein R is an aliphatic or
aromatic hydrocarbon radical having 1 to 14 carbon atoms or COR'
wherein R' is an aliphatic or aromatic hydrocarbon radical having 1
to 14 carbon atoms; each OR group is alike or different; X is Cl,
Br, or I, or mixtures thereof; ED is an electron donor, which is a
liquid Lewis base in which the precursors of the titanium based
complex are soluble; a is 0.5 to 56; b is 0, 1, or 2; c is 1 to
116, particularly 2 to 116; and d is 2 to 85. The complex is formed
by reacting appropriate titanium and magnesium compounds in the
presence of an electron donor.
[0050] A titanium compound which can be used to prepare the
foregoing complex has the formula Ti(OR).sub.ax.sub.b wherein R and
X are as defined for component (i) above; a is 0, 1 or 2; b is 1 to
4; and a+b is 3 or 4. Suitable compounds are TiCl.sub.3,
TiCl.sub.4, Ti(OC.sub.6H.sub.5)Cl.sub.3, Ti(OCOCH.sub.3)Cl.sub.3
and Ti(OCOC.sub.6H.sub.5)Cl.sub.3.
[0051] A magnesium compound which may be reacted with the foregoing
titanium compound to form the complex has the formula Mgx.sub.2
wherein X is as defined for component (i) above. Suitable examples
are MgCl.sub.2, MgBr.sub.2, and MgI.sub.2. Anhydrous MgCl.sub.2 is
a preferred compound. About 0.5 to 56, and preferably about 1 to
10, moles of the magnesium compound are used per mole of titanium
compound.
[0052] The electron donor present in the catalyst composition is an
organic compound, liquid at temperatures in the range of about
0.degree. C. to about 200.degree. C. It is also known as a Lewis
base. The titanium and magnesium compounds are both soluble in the
electron donor.
[0053] Electron donors can be selected from the group consisting of
alkyl esters of aliphatic and aromatic carboxylic acids, aliphatic
ketones, aliphatic amines, aliphatic alcohols, alkyl and cycloalkyl
ethers, and mixtures thereof, each electron donor having 2 to 20
carbon atoms. Among these electron donors, the preferred are alkyl
and cycloalkyl ethers having 2 to 20 carbon atoms, dialkyl, diaryl,
and alkyaryl ketones having 3 to 20 carbon atoms; and alkyl,
alkoxy, and alkylalkoxy esters of alkyl and aryl carboxylic acids
having 2 to 20 carbon atoms. The most preferred electron donor is
tetrahydrofuran. Other examples of suitable electron donors are
methyl formate, ethyl acetate, butyl acetate, ethyl ether, dioxane,
di-n-propyl ether, dibutyl ether, ethyl formate, methyl acetate,
ethyl anisate, ethylene carbonate, tetrahydropyran, and ethyl
propionate.
[0054] The cocatalyst may, for example, have the formula
AlR".sub.eX'.sub.fH.sub.g wherein X' is Cl or OR"'; R" and R"' are
saturated aliphatic hydrocarbon radicals having 1 to 14 carbon
atoms and are alike or different; f is 0 to 1.5; g is 0 or 1; and
e+f+g=3. Examples of suitable R, R', R", and R"radicals are:
methyl, ethyl, propyl, isopropyl, butyl, isobutyl, tert-butyl,
pentyl, neopentyl, hexyl, 2-methylpentyl, heptyl, octyl, isooctyl,
2-ethyhexyl, 5,5-dimethylhexyl, nonyl, isodecyl, undecyl, dodecyl,
cyclohexyl, cycloheptyl, and cyclooctyl. Examples of suitable R and
R' radicals are phenyl, phenethyl, methyloxyphenyl, benzyl, tolyl,
xylyl, naphthal, and methylnaphthyl. Some examples of useful
cocatalyst are triisobutylaluminum, trihexyaluminum,
di-isobutylaluminum, hydride, dihexylaluminum hydride,
di-isobutylhexylaluminum, trimethylaluminum, triethylaluminum,
diethylaluminum chloride, Al.sub.2(C.sub.2H.sub.5).sub.3C1.sub.3,
and Al (C.sub.2H.sub.5).sub.2(OC.sub.2H.sub.5).
[0055] Silica is the preferred support for the catalyst precursor.
Other suitable inorganic oxide supports are aluminum phosphate,
alumina, silica/alumina mixtures, silica pretreated with an
organoaluminum compound such as triethylaluminum, and silica
modified with diethylzinc, such modifier being used in a quantity
sufficient to react with the hydroxyl groups on the support which
otherwise tend to react with and deactivate part of the titanium in
the catalyst, but not in sufficient quantity to function as a
cocatalyst. A typical support is a solid, particulate material
essentially inert to the polymerization. It is used as a dry powder
having an average particle size of about 10 to 250 microns and
preferably about 30 to about 100 microns; a surface area of at
least about 3 square meters per gram and preferably at least about
50 square meters per gram; and a pore size of at least about 80
Angstroms and preferably at least about 100 Angstroms. Generally,
the amount of support used is that which will provide about 0.01 to
about 0.5, and preferably about 0.2 to about 0.35 millimole of
transition metal per gram of support. Impregnation of the
abovementioned catalyst precursor into, for example, silica is
accomplished by mixing the complex and silica gel in the electron
donor solvent followed by solvent removal under reduced pressure
and/or elevated temperature.
[0056] In preparing the polymer by the gas phase tandem reactor
process, it is preferred that the titanium/magnesium precursor not
be combined with the hydrocarbyl aluminum cocatalyst prior to being
fed to the first reactor, but that these components be fed to such
reactor separately, and that an additional quantity of the
hydrocarbyl aluminum cocatalyst be fed to the second reactor in an
amount sufficient to increase catalyst activity in the second
reactor. However, in such a tandem reactor process, it is not
necessary to prereduce or activate the titanium/magnesium complex
with an amount of cocatalyst prior to feeding the complex to the
first reactor. The cocatalyst is fed to each reactor neat or as a
solution in an inert solvent such as isopentane.
[0057] In preparing the HMW and LMW components separately in gas
phase reactors, the titanium/magnesium complex may be partially
activated with cocatalyst prior to being fed to the reactor. In
this case the cocatalyst used for the partial activation may be the
same or different from that fed separately to each reactor.
Preferred cocatalysts for partial activation of the
titanium/magnesium complex prior to its being fed to the reactor
are tri-n-hexylaluminum, diethylaluminum chloride, triethylaluminum
and triisobutylaluminum, or a mixture of any of these.
[0058] Broad, exemplary ranges and preferred ranges of molar ratios
of various components of the foregoing catalyst systems utilizing
titanium/magnesium complexes are as follows:
1 TABLE I Broad Catalyst Components Exemplary Range Preferred Range
1. Mg:Ti 0.5:1 to 56:1 1.5:1 to 5:1 2. Mg:X 0.005:1 to 28:1 0.075:1
to 1:1 3. Ti:X 0.01:1 to 0.5:1 0.05:1 to 0.2:1 4. Mg:ED 0.005:1 to
28:1 0.15:1 to 1.25:1 5. Ti:ED 0.01:1 to 0.5:1 0.1:1 to 0.25:1 6.
Cocatalyst used as 0:1 to 50:1 0:1 to 5:1 Partial Activator:Ti 7.
Total Cocatalyst:Ti 0.6:1 to 250:1 11:1 to 105:1 8. ED:Al 0.05:1 to
25:1 0.2:1 to 5:1
[0059] Specific examples of the described catalysts comprising a
titanium/magnesium complex, and methods for their preparation are
disclosed, for example, in U.S. Pat. Nos. 3,989,881; 4,124,532,
4,174,429; 4,349,648; 4,379,759; 4,719,193; and 4,888,318; and
European Patent application Publication Nos. 0 012 148; 0 091 135;
0 120 503; and 0,369,436; and the entire disclosures of these
patents and publications pertaining to catalysts are incorporated
herein by reference.
[0060] Another class of catalysts which may be used in the process
of this invention is prepared by treating a previously dried,
solid, inorganic, porous carrier containing OH groups, e.g.,
silica, with a liquid, e.g., tetrahydrofuran, containing a
hydrocarbyl magnesium, e.g. ethylmagnesium chloride, evaporating
liquid from the so-treated carrier leaving a magnesium precipitate
on the carrier surface, and contacting the resulting powder with a
solution of transition metal compound, e.g., a tetravalent titanium
compound such as titanium tetrachloride, to form a transition
metal/Mg complex or mixture of complexes on the surface of the
carrier. The carrier may be initially dried in the presence of an
oxygen-containing gas such as air rather than an inert gas such as
nitrogen. The resulting supported transition metal/Mg complex may
be utilized with a hydrocarbyl aluminum cocatalyst as disclosed
previously with other Ti/Mg complexes, added to the first or both
reactors. If hydrocarbyl aluminum cocatalysts are added to both
reactors, they may be the same or different. Various catalysts of
this type and methods of preparing them are described in U.S. Pat.
Nos. 4,481,301 and 4,562,169, the entire disclosures of which are
incorporated herein by reference.
[0061] The amount of cocatalyst utilized in the Ziegler-Natta
catalyst employed in the process of making the products of this
invention whether for pre-reduction or activation of the catalyst
prior to polymerization or added to the sole reactor or the first
reactor of a tandem reactor process or both, is generally in the
range, for example, of about 2 to 100 gram atoms of cocatalyst
metal, e.g., aluminum, per gram atom of transition metal, e.g.,
titanium, preferably about 5 to 50 gram atoms of cocatalyst metal
per gram atom of transition metal. Any amount of cocatalyst added
to the second reactor is not included in the foregoing ranges.
However, it is preferred that additional cocatalyst be fed to the
second reactor to increase catalyst activity.
[0062] Referring now to the drawing, catalyst component containing
transition metal, e.g. titanium, is fed into first reactor 1
through line 2. Ethylene, comonomer, e.g., 1-hexene, if used,
hydrogen, if used, inert gas such as nitrogen, if used, and
cocatalyst, e.g. triethylaluminum (TEAL), are fed through line 3
into recycle line 4 where they are combined with recycle gas and
fed into the bottom of reactor 1. The gas velocity is high enough
and the size and density of the particles in reactor 1 are such as
to form a fluidized or dense bed 5 comprising catalyst particles
associated with polymer formed by the polymerization of ethylene
and, if present, comonomer within reactor 1. The conditions in
reactor 1, e.g. partial pressure of ethylene, hydrogen/ethylene
molar ratio, temperature, total pressure, etc. are controlled such
that the polymer which forms is of relatively high molecular weight
(HMW). Recycle gas leaving the top of reactor 1 through line 4 is
recompressed in compressor 6, cooled in heat exchanger 7 after
passing through valve 8 and are fed to the bottom of reactor 1
after being optionally combined with make-up gases and cocatalyst
from line 3 as described.
[0063] Periodically, when sufficient HMW polymer has formed in
reactor 1, the polymer and catalyst 1 are transferred to discharge
tank 9 by opening valve 10 while valves 11, 12 and 13 remain
closed. When an amount of the HMW polymer and catalyst from reactor
1 which is desired to be transferred has been fed to discharge tank
9, the transfer system to second reactor 14 is activated by opening
valve 13 to force the HMW polymer and catalyst into transfer hose
15. Valve 13 is then closed to isolate transfer hose 15 from
discharge tank 9 and valve 11 is opened, ensuring that any gases
leaking through valve 13 are vented and do not back-leak across
valve 10 into reactor 1. Transfer hose 15 is then pressurized with
reactor-cycle gas from reactor 14 by opening valve 16. To minimize
upsets in reactor 14, surge vessel 17 is used to store gas for
pressuring transfer hose 15. With valve 16 still in the open
position, valve 18 is opened to convey HMW polymer and catalyst
into reactor 14. Both valves 16 and 18 are left open for a period
to sweep transfer .hose 15. Valves 18 and 16 are then closed
sequentially. Transfer hose 15 is then vented by opening valve 13,
valve 11 having remained open during the transfer operation.
Discharge tank 9 is then purged with purified nitrogen through line
18A by opening valve 12.
[0064] During the transfer, cycle gas comprising hydrocarbons and
hydrogen leaves reactor 14 through line 19, is compressed by
compressor 20, flows through valves 21, 22 and 23 in line 24 and
through surge tank 17, valve 16 and pressurized transfer hose 15 as
described, thus effecting the transfer of HMW polymer and catalyst
to reactor 14.
[0065] After the transfer to reactor 14 is effected, the flow of
gas from reactor 14 to transfer hose 15 is stopped by closing
valves 21, 22, 23 and 16. Ethylene, hydrogen, comonomer, e.g.,
1-hexene, if used, inert gas such as nitrogen, if used, and
cocatalyst or catalyst component, e.g., TEAL, are fed to reactor 14
through line 25 after being combined with unreacted cycle gas
leaving the top of reactor 14 through line 19 which is compressed
in compressor 20, cooled in heat exchanger 26 and enters the bottom
of reactor 14 through line 27. The gas velocity and size and
density of the particles in reactor 14 are such as to form
fluidized or dense bed 28 of bimodal polymer particles associated
with the catalyst, including the transition metal primary catalyst
component added to reactor 1. The conditions in reactor 14, e.g.,
partial pressure of ethylene, hydrogen/ethylene ratio and
temperature, are controlled such that a relatively low molecular
weight (LMW) polymer forms primarily on and within the HMW
polymer/catalyst particles transferred from reactor 1. After a
sufficient amount of LMW polymer has formed resulting in a bimodal
polymer having a desirable molecular weight distribution and other
properties, the polymer is transferred to discharge tank 29 by
opening valve 30 while keeping valve 31 closed. After substantially
all the polymer has been transferred to discharge tank 29, it is
collected by closing valve 30 and opening valve 31, resulting in
the pressure discharge of the final polymer product through line
32.
[0066] The following examples further illustrate the invention. The
elasticity and viscosity values were all determined at 0.1
rad./sec.
Example 1
[0067] A catalyst was prepared by reacting MgCl.sub.2,
tetrahydrofuran (THF) and TiCl.sub.3 .0.33 AlCl.sub.3 adding the
resulting complex to dehydrated silica treated with sufficient
triethylaluminum to react with the OH groups in the silica but not
enough to function significantly as partial activator or
cocatalyst, and drying the resulting silica supported catalyst
precursor. The procedure used to prepare the catalyst was
substantially that of Example 4 of U.S. Pat. No. 4,888,318 except
that the partial activation of the supported magnesium and titanium
precursor with tri-n-hexyaluminum and diethylaluminum chloride, as
shown in the patent, was omitted. The free flowing catalyst powder
contained the following weight percentages of components: Ti, 1.13;
Mg, 1.95; Cl, 8.22; THF, 15.4; and Al, 1.41.
[0068] Using the foregoing catalyst, a gas phase, fluidized bed
polymerization process was carried out using two reactors operating
in the tandem mode as shown in the drawing. The process included
the feeding of 1-hexene as comonomer and triethylaluminum (TEAL) as
cocatalyst to both reactors. Nitrogen was used to control the total
pressure in both reactors at about 300 psig. Averages of other
conditions in both reactors, which were controlled to produce a
HMW-HDPE bimodal resin suitable for being blown extruded into low
gauge films with superior mechanical properties, are shown in Table
I, wherein "PC.sub.2=" is the partial pressure of the ethylene,
"H.sub.2/C.sub.2" is the molar ratio of hydrogen to ethylene, and
"C.sub.6/C.sub.2" is the molar ratio of 1-hexene to ethylene in the
gas phase.
2 TABLE I Reactor 1 (HMW) Reactor 14 (LMW) Temp. (.degree. C.) 75
105 PC.sub.2 = (psi) 55-65 84-90 H.sub.2/C.sub.2 0.03 2.0
C.sub.6/C.sub.2 0.035-0.045 0.03 TEAL (ppmw) 290 190 Resid. Time
(hrs) 2.8 3.6
[0069] The HMW polymer leaving reactor 1 was found by direct
measurement to have a flow index (I.sub.21) of 0.35 g/10 min., a
flow ratio (FR) of 11, a dynamic elasticity of 0.56 at a complex
viscosity of 4.1E6 (4.1.times.10.sup.6 ) poises, and a density of
0.931 g/cc, while the LMW polymer produced in reactor 14 was
calculated from a single reactor process model to have a melt index
(I.sub.2) of about 400 g/10 min. and a density of 0.966 g/cc.
[0070] The granular bimodal polymer obtained from reactor 14 had a
fraction of HMW component of 0.57. In this example and in Examples
2, and 4 to 7, the final polymer contained about 4 to 7 ppm of
titanium ash. This is an indication of the amount of titanium
precursor used in the process since substantially all the titanium
in such precursor is present in the final polymer.
[0071] Using standard procedures and a Banbury mixer and Sterling
extruder, the granular bimodal polymer from reactor 14 was
compounded into pellets having a flow index (I.sub.21) of 6.1 g/10
min., a MFR of 116, a density of 0.946 g/cc, and a dynamic
elasticity of 0.598 at a corresponding complex viscosity of 1.1E6
poises. The rheological properties, i.e., of elasticity and
viscosity, of the HMW component and the bimodal polymer blend were
measured in the Rheometric System IV at 200.degree. C. under
dynamic oscillatory mode in parallel plate geometry.
[0072] The bimodal polymer pellets were blown extruded into films
on a 50 mm Alpine extruder equipped with a grooved barrel extruder,
a 100 mm die and 1 mm die gap. The other extruder conditions were:
melt temp=416.degree. F.; frost line height=36 inches; blow-up
ratio=4.0; nominal film gauge=0.5 mil; output=120 lbs./hr. The
films were found to have a Dart Drop Impact (F.sub.50) of 400 g and
a MD Tear of 26 g/mil. Contrary to what is expected in the art,
these properties were achieved despite the fact that the bimodal
polymer was found to have a higher degree of short chain branching
in the LMW component than in the HMW component.
Example 2
[0073] The procedure of Example 1 was followed using slightly
different process conditions as shown in Table II:
3 TABLE II Reactor 1 (HMW) Reactor 14 (LMW) Temp. (.degree. C.) 75
105 PC.sub.2 = (psi) 68 86 H.sub.2/C.sub.2 0.03 1.7 C.sub.6/C.sub.2
0.04 0.04 TEAL (ppmw) 300 300 Resid. Time (hrs) 3.0 4.0
[0074] The HMW component leaving reactor 1 was found by direct
measurement to have the following properties: I.sub.21=0.45 g/10
min.; FR=10; dynamic elasticity=0.59 at a complex viscosity of
4.0E6; and density=0.931 g/cc; the LMW was calculated to have a
melt index (I.sub.2) of 450 (estimated from GPC) and a density of
0.964 g/cc; and the pellets prepared from the granular bimodal
blend polymer from reactor 14 had the following properties: HMW
weight fraction=0.57; I.sub.21=6.7 g/10min.; MFR=106; dynamic
elasticity=0.60 at a complex viscosity of 9.3E5 poises; and
density=0.945 g/cc. Films prepared from the bimodal polymer blend
as described in Example 1 had a Dart Drop Impact (F.sub.50) of 406
g and an MD Tear of 28 g/mil.
Example 3
[0075] A catalyst was prepared as follows: In part A of the
preparation, 289.5 grams of Davison 955-800 silica having a nominal
average particle size of 50 microns were transferred into a 4-neck
3-liter round bottom flask fitted with an overhead stirrer and
under a slow purge of nitrogen. About 1500 ml of dry
tetrahydrofuran (THF) were added to the flask which was placed into
an oil bath set at 60-65.degree. C. Next 184 ml of a 2.0 molar
solution of ethylmagnesium chloride in THF was added dropwise using
an addition funnel to the silica/THF slurry. After 10 minutes, the
THF was removed by distillation to yield a white free flowing
powder. The powder was dried for 16 hours under a slow nitrogen
purge with the oil bath set at 80-85.degree. C., and, except for 2
grams which were removed from the flask, constitute the part A
product. The powder was found to contain 6.0 wt. % of THF.
[0076] In part B of the preparation, 1500 mls of heptane as
received was placed into a 3-liter round bottom flask, and 162 ml
of neat titanium tetrachloride was added dropwise to the heptane
using an addition funnel. This solution was then siphoned into the
part A product. The slurry was stirred for 1.5 hours with the oil
bath at 80-85.degree. C. after which the silica was allowed to
settle and the reaction solution was decanted through a gas
dispersion tube under a slight nitrogen pressure. The silica was
then washed six times with about 1500 mls of dry hexane. After the
last wash, the silica was dried with a nitrogen purge to yield 370
grams of a very light tan catalyst precursor. Analysis: Mg=2.52 wt.
%, Ti=3.36 wt. %, THF=3.2 wt. %.
[0077] The foregoing catalyst was used to carry out a two stage,
HMW first, gas phase fluidized bed process in the tandem mode as
illustrated in the drawing and similar to that described in Example
1, under conditions such as to produce a high molecular weight,
high density ethylene polymer film resin in accordance with this
invention. As cocatalyst, triethylaluminum (TEAL) was fed to the
first (HMW) reactor and trimethylaluminum (TMA) to the second (LMW)
reactor. Ranges of reaction conditions employed are shown in Table
III.
4 TABLE III Reactor 1 (HMW) Reactor 14 (LMW) Temp. (.degree. C.) 75
98 PC.sub.2 = (psi) 30 60 H.sub.2/C.sub.2 0.03 2.4 C.sub.6/C.sub.2
0.04 0.042 TEAL (ppmw) 330 0 TMA (ppmw) 0 660 Resid. Time (hrs) 5.0
4.0
[0078] The HMW polymer leaving reactor 1 was found by direct
measurement to have the following properties: I.sub.21=0.30 g/10
min.; FR=15: dynamic elasticity=0.66 at a complex viscosity of
4.2E6; and density=0.930 g/cc; the LMW component was calculated to
have a melt index (I.sub.2) of 550 (estimated from GPC) and an
estimated density of 0.965 g/cc; and pellets prepared from the
granular bimodal polymer from reactor 14 had the following
properties: HMW weight fraction=0.57; I.sub.21=8.8 g/10 min.;
MFR=140; dynamic elasticity=0.587 at a complex viscosity of 9.5E5
poises; and density=0.945 g/cc. In addition, the polymer had a
titanium ash content of about 12 to 18 ppm. Films prepared from the
bimodal polymer blend as described in Example 1 had a Dart Drop
Impact (F.sub.50) of 387 g and a MD Tear of 22 g/mil.
Example 4
[0079] HMW and LMW components intended to be physically blended in
producing an HMW-HDPE bimodal polymer in accordance with this
invention were separately prepared in a single stage gas phase
reactor. The catalyst used to prepare the HMW component was the
same as that described in Example 1. The catalyst used to prepare
the LMW component was the catalyst of Example 1 subjected to
prereduction or partial activation with tri-n-hexylaluminum, as
cocatalyst. The procedure used to prepare the catalyst was
substantially that of Example 4 of U.S. Pat. No. 4,888,318 except
that the partial activation of the supported magnesium and titanium
precursor was carried out with tri-n-hexylaluminum alone as partial
activator rather than the latter together with diethylaluminum
chloride as shown in the patent. The free flowing catalyst powder
contained the following weight percentages of components: Ti, 1.07;
Mg, 1.7; Cl, 7.5; THF, 14.3; and Al, 1.98.
[0080] Reactor conditions employed in the preparation of the two
components are shown in Table IV.
5 TABLE IV HMW LMW Temp. (.degree. C.) 80 98 PC.sub.2 = (psi) 84 78
H.sub.2/C.sub.2 0.02 1.72 C.sub.6/C.sub.2 0.008 0.085 TEAL (ppmw)
400 400 Resid. Time (hrs) 2.0 2.0
[0081] The HMW component had the following properties: I.sub.21
=0.3 g/10 min.; FR=10; dynamic elasticity=0.64 at a complex
viscosity of 5.0E6 poises; and density=0.935 g/cc; while the LMW
component had a melt index (I.sub.2) of 300 g/10 min. and a density
of 0.950 g/cc.
[0082] A blend of the HMW and LMW components was prepared by melt
mixing in a Banbury mixer with a conventional stabilizer package to
prevent degradation. The blend had the following properties: HMW
weight fraction=0.55; I.sub.21=5.8 g/10 min.; MFR=90; density=0.942
g/cc; and dynamic elasticity=0.577 at a complex viscosity of 11.4E5
poises. A film prepared from the blend as described in Example 1
had a Dart Drop Impact (F.sub.50) of 330 g and a MD Tear of 21
g/mil.
Example 5
[0083] The procedure of Example 4 was followed except that the
blend contained a weight fraction of 0.50 of the HMW fraction
prepared in a 3/4 inch Brabender twin screw extruder. The blend of
HMW and LMW components had the following properties: I.sub.21=7.7
g/10 min.; MFR=101; density=0.9624 g/cc; and dynamic
elasticity=0.516 at a complex viscosity of 9.3E5 poises. The
bimodal polymer blend could be formed into low gauge films as
described in Example 1 having excellent mechanical properties,
e.g., Dart Drop Impact and MD Tear.
Example 6
[0084] The procedure of Example 5 was generally followed except
that the catalyst of Example 1, which was not partially activated,
was used to prepare both the HMW and LMW polymers, and the
conditions in the HMW and LMW reactors were as shown in Table
V.
6 TABLE V HMW LMW Temp. (.degree. C.) 74 105 PC.sub.2 = (psi) 24 87
H.sub.2/C.sub.2 0.018 1.44 C.sub.6/C.sub.2 0.098 0.0002 TEAL (ppmw)
320 400 Resid. Time (hrs) 2.8 2.4
[0085] The HMW component had the following properties:
I.sub.21=0.38 g/10 min.; FR=11; dynamic elasticity=0.615 at a
complex viscosity of 4.16E6 poises; and density=0.926 g/cc; while
the LMW component had a melt index (I.sub.2) of 250 g/10 min.and a
density of 0.960 g/cc.
[0086] A blend of the HMW and LMW components prepared as described
in Example 4 had the following properties: HMW weight
fraction=0.52; I.sub.21=9.9 g/10 min.; MFR=115; density=0.942 g/cc;
and dynamic elasticity=0.517 g/10 min. at a complex viscosity of
8.0E5 poises. A 1 mil film prepared from the blend as described in
Example 1 had a Dart Drop Impact (F.sub.50) of 387 g, a MD Tear of
26 g/mil., and a TD Tear (Elmendorf tear resistance in the
transverse direction) of 57 g/mil.
Example 7
[0087] The procedure of Example 6 was followed using the same HMW
and LMW components except that such components were blended in a
different proportion. The blend had the following properties: HMW
weight fraction=0.58; I.sub.21=5.7 g/10 min.; MFR=94; density=0.940
g/cc; and dynamic elasticity=0.522 at a complex viscosity of 10.2E5
poises. A 1 mil film prepared from the blend as described in
Example 1 had a Dart Drop Impact (F.sub.50) of 305 g, a MD Tear of
23 g/mil. and a TD Tear of 375 g/mil.
[0088] The results of the foregoing examples indicate that HMW-HDPE
resins of this invention can be blown extruded into low gauge films
having superior mechanical properties.
[0089] Before being formulated into films, the polymers of this
invention may be compounded with various additives utilized in
relatively minor amounts, e.g., other polymers such as conventional
low-density polyethylene (LDPE) and recycled polyethylene,
stabilizers, anti-oxidants, plasticizers, fillers, etc., as are
well known in the art.
* * * * *