U.S. patent application number 13/262554 was filed with the patent office on 2012-02-16 for heterogeneous ethylene/alpha-olefin interpolymer.
This patent application is currently assigned to Dow Global Technologies LLC. Invention is credited to Ayush A. Bafna, Mehmet Demirors, Sylvie Desjardins, Douglas S. Ginger, Terry A. Pearce, Colleen M. Tice.
Application Number | 20120041148 13/262554 |
Document ID | / |
Family ID | 42272542 |
Filed Date | 2012-02-16 |
United States Patent
Application |
20120041148 |
Kind Code |
A1 |
Bafna; Ayush A. ; et
al. |
February 16, 2012 |
HETEROGENEOUS ETHYLENE/ALPHA-OLEFIN INTERPOLYMER
Abstract
An interpolymer of ethylene and at least one alpha-olefin is
claimed, wherein the ethylene interpolymer is characterized as
having an average Mv and a valley temperature between the
interpolymer and high crystalline fraction, Thc, such that the
average Mv for a fraction above Thc from ATREF divided by average
Mv of the whole polymer from ATREF (Mhc/Mp) is less then about 1.95
and wherein the interpolymer has a CDBI of less than 60%. The
interpolymer of ethylene and at least one alpha-olefin can also be
characterized as having a high density (HD) fraction and an overall
density such that % HD fraction<-2733.3+2988.7x+144111.5
(x-0.92325)2 where x is the density in grams/cubic centimeter.
Fabricated articles comprising the novel interpolymers are also
disclosed.
Inventors: |
Bafna; Ayush A.; (Manvel,
TX) ; Demirors; Mehmet; (Pearland, TX) ;
Desjardins; Sylvie; (Lake Jackson, TX) ; Ginger;
Douglas S.; (Houston, TX) ; Tice; Colleen M.;
(Houston, TX) ; Pearce; Terry A.; (Lake Jackson,
TX) |
Assignee: |
Dow Global Technologies LLC
Midland
MI
|
Family ID: |
42272542 |
Appl. No.: |
13/262554 |
Filed: |
March 30, 2010 |
PCT Filed: |
March 30, 2010 |
PCT NO: |
PCT/US10/29214 |
371 Date: |
October 26, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61165065 |
Mar 31, 2009 |
|
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|
Current U.S.
Class: |
525/240 ;
525/333.7; 525/55; 526/123.1; 526/226; 526/348 |
Current CPC
Class: |
C08F 210/16 20130101;
Y10T 428/31913 20150401; C08L 23/06 20130101; B32B 7/02 20130101;
C08L 23/06 20130101; Y10T 428/31938 20150401; B32B 27/32 20130101;
C08L 23/0815 20130101; C08F 210/16 20130101; C08F 2500/08 20130101;
C08F 2500/03 20130101; C08F 210/14 20130101; C08L 2666/02 20130101;
C08F 2500/12 20130101; C08L 2666/06 20130101; C08L 23/0815
20130101; C08F 2500/26 20130101 |
Class at
Publication: |
525/240 ;
526/348; 525/55; 525/333.7; 526/226; 526/123.1 |
International
Class: |
C08F 210/02 20060101
C08F210/02; C08F 4/42 20060101 C08F004/42; C08F 4/12 20060101
C08F004/12; C08L 23/04 20060101 C08L023/04; C08L 23/06 20060101
C08L023/06 |
Claims
1. An interpolymer of ethylene and at least one alpha-olefin,
characterized wherein the interpolymer has an average M.sub.v and a
valley temperature between the interpolymer and high crystalline
fraction, T.sub.hc, such that the average M.sub.v for a fraction
above T.sub.hc from ATREF divided by average M.sub.v of the whole
polymer from ATREF (M.sub.hc/M.sub.p) is less than about 1.95 and
wherein the interpolymer has a CDBI of less than 60%.
2. The interpolymer of claim 1, wherein said interpolymer is
characterized by at least one of the following: a. said
interpolymer is heterogenously branched; b. said interpolymer has a
CDBI of less than 55%; or c. said interpolymer has a
M.sub.hc/M.sub.2 of less than about 1.7.
3. (canceled)
4. (canceled)
5. An interpolymer of ethylene and at least one alpha-olefin
wherein the interpolymer is characterized as having a high density
(HD) fraction and an overall density such that % HD
fraction<-2733.3+2988.7x+144111.5(x-0.92325).sup.2 where x is
the overall density in grams/cubic centimeter.
6. Film comprising the interpolymer of claim 1.
7. The film of claim 6, wherein said film is characterized by at
least one of the following: a. having a Dart A of at least 550 gm;
b. having a haze of <10%; c. having a 45 degree gloss>75
units; or d. having a Normalized MD Tear>400 gm/mil.
8. (canceled)
9. (canceled)
10. (canceled)
11. The interpolymer of claim 1 further comprising at least one
other natural or synthetic polymer.
12. The interpolymer of claim 11 where the synthetic polymer is low
density polyethylene.
13. The interpolymer of claim 1, wherein said interpolymer is
characterized by at least one of the following: a. having a melt
index from about 0.1 to about 10 g/10 min; b. having an overall
density from about 0.9 to about 0.935 g/cm.sup.3; c. having long
chain branches of less than 1 per 1000 C atoms; or d. having a
molecular weight distribution, M.sub.w/M.sub.n, of less than about
5.
14. (canceled)
15. (canceled)
16. (canceled)
17. A fabricated article comprising the interpolymer of claim
1.
18. The interpolymer of claim 1, wherein the interpolymer has been
at least partially cross-linked to at least at least 5%, by weight,
gel.
19. A process to make an interpolymer of ethylene and at least one
alpha-olefin comprising the steps of contacting ethylene with at
least one alpha-olefin under polymerizations of temperature and
pressure with a catalyst composition to form an
ethylene/alpha-olefin interpolymer having an average M.sub.v and a
valley temperature between the interpolymer and high crystalline
fraction, T.sub.hc, such that the average M.sub.v for a fraction
above T.sub.hc from ATREF divided by average M.sub.v of the whole
polymer from ATREF (M.sub.hc/M.sub.p) is less than about 1.95 and
has a CDBI of less than 60%, wherein the polymerization conditions
comprise a molar ratio of aluminum to catalyst metal atom of from
about 1:1 to about 5:1, and recovering the ethylene/alpha-olefin
interpolymer.
20. The process of claim 19 wherein said catalyst composition
comprises the product which results from combining: (A) a magnesium
halide prepared by contacting: (1) at least one hydrocarbon soluble
magnesium component represented by the general formula
R''R'Mg.xAlR'3 wherein each R'' and R' are alkyl groups (2) at
least one non-metallic or metallic halide source under conditions
such that the reaction temperature does not exceed about 60.degree.
C.; (B) at least one transition metal compound represented by the
formula Tm(OR)y Xy-x wherein Tm is a metal of Groups IVB, VB, VIB,
VIIB or VIII of the Periodic Table; R is a hydrocarbyl group having
from 1 to about 20, and (C) an additional halide source if an
insufficient quantity of component (A-2) is present to provide the
desired excess X:Mg ratio.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None.
BACKGROUND OF THE INVENTION
[0002] Ethylene alpha-olefin copolymer resins that can make films
with improved aesthetics (optical) and abuse resistance (dart)
properties create value to end-users. Heterogeneous ethylene
alpha-olefin copolymers have both high crystalline (thick crystals)
and copolymer (thin crystals) fractions.
[0003] Optical properties of a film can be defined in terms of
surface gloss, haze and clarity. Haze can depend on internal haze
(bulk scattering) and external haze (surface scattering). Both
external haze and internal haze can be a function of the high
crystalline fraction content and high crystalline fraction
molecular weight of the resin used to make the film. High
crystalline fraction can be made of thick crystals that scatter
light and hence an increase in the high crystalline fraction
content increases the haze of the film and hurts its optical
properties. Decreasing the molecular weight of the high crystalline
fraction can increase the thickness of the crystals in the high
crystalline fraction. The thicker the high crystalline fraction
crystals, the worse are the film optics. Hence a reduced content
and increased molecular weight of the high crystalline fraction
would be desirable for improved optics, although too high of a
molecular weight can cause melt fracture problems due to high melt
elasticity. Also, increasing the molecular weight of the high
crystalline fraction, for improved optics, could hurt dart
properties of the film. Higher molecular weight of the copolymer
fraction is desirable for higher film dart. For a particular resin
melt index (MI or I.sub.2), increasing the molecular weight of the
high crystalline fraction for improved optics, has to be balanced
by lowering the molecular weight of copolymer fraction so that the
MI be kept constant. This decrease in copolymer molecular weight
will hurt the dart properties. Therefore an optimum high
crystalline fraction molecular weight is desirable for balanced
dart and optical properties. Thick crystals from the high
crystalline fraction provide strength to the film improving its
tear properties. Decreasing the high crystalline fraction content
for improving optics could therefore hurt film tear. In order to
achieve a balance of tear and optical properties an optimum content
of high crystalline fraction is desirable.
[0004] Surface haze of the film can depend on the molecular weight
distribution of the ethylene alpha-olefin copolymer. Very broad
molecular weight distribution usually increases melt elasticity of
the resin leading to surface melt fracture while very narrow
molecular weight distribution can cause processing issues at the
die causing surface melt fracture. Since presence of surface melt
fracture hurts film optical properties, an optimum molecular weight
distribution is also required for improved optical properties.
[0005] Dart properties of films can depend on the molecular weight
distribution and on the copolymer fraction content. The narrower
the molecular weight distribution and more the copolymer fraction
content, the higher is the film dart. Too narrow of molecular
weight distribution could hurt optical properties and
processability (film fabrication) and hence an optimum molecular
weight distribution is required for a balance of processability,
dart and optical properties. Also, increase in copolymer fraction
content could be achieved at a cost of reduction in high
crystalline fraction content and this could hurt film tear.
Therefore in order to achieve a good balance of processability,
dart, tear and optical properties, a particular combination of
molecular weight distribution and high crystalline and copolymer
fraction content is required.
[0006] The present invention is a resin family, and a process to
make them, with this particular combination of molecular weight
distribution and high crystalline and copolymer fraction content
and molecular weight. For an equivalent density and melt index,
this combination of resin characteristics produces a film with
balanced optics, dart, tear and processability.
BRIEF SUMMARY OF THE INVENTION
[0007] In one embodiment, an interpolymer of ethylene and at least
one alpha-olefin is made, characterized wherein the interpolymer
has an average M.sub.v and a valley temperature between the
interpolymer and high crystalline fraction, T.sub.hc, such that the
average M.sub.v for a fraction above T.sub.hc from ATREF divided by
average M.sub.v of the whole polymer from ATREF (M.sub.hc/M.sub.p)
is less then about 1.95, preferably less than 1.7, and wherein the
interpolymer has a CDBI of less than 60%, preferably less than
55%.
[0008] In a second embodiment, an interpolymer of ethylene and at
least one alpha-olefin is made, wherein the interpolymer is
characterized as having a high density (HD) fraction and an overall
density such that % HD fraction<-2733.3+2988.7x+144111.5
(x-0.92325).sup.2 where x is the density in grams/cubic
centimeter.
[0009] In either embodiment, the interpolymer is preferably
heterogeneously branched. Film can be made from the interpolymers
of either embodiment, especially films comprising Dart A of at
least 550 grams, or comprising haze of <10%, or comprising 45
degree gloss units of >75 units, or comprising Normalized MD
Tear >400 grams/mil. The film can comprise at least one layer
comprising the interpolymer of either the first or second
embodiment.
[0010] In either embodiment, the interpolymer can further comprise
at least one other natural or synthetic polymer, preferably low
density polyethylene. The interpolymer of either embodiment can
comprise a melt index from about 0.1 to about 10 g/10 min., or can
comprise an overall density from about 0.9 to about 0.935
g/cm.sup.3, or can comprise long chain branches of less than 1 per
1000 C atoms, or can comprise a molecular weight distribution,
M.sub.w/M.sub.n, of less than about 5.
[0011] A fabricated article can comprise the interpolymer of either
the first or second embodiment. Further the interpolymer of either
the first or second embodiment can be at least partially
cross-linked to at least 5%, by weight, gel.
[0012] A third embodiment is a process to make an interpolymer of
ethylene and at least one alpha-olefin comprising the steps of
contacting ethylene with at least one alpha-olefin under
polymerizations of temperature and pressure with a catalyst
composition to form an ethylene/alpha-olefin interpolymer having an
average M.sub.v and a valley temperature between the interpolymer
and high crystalline fraction, T.sub.hc, such that the average
M.sub.v for a fraction above T.sub.hc from ATREF divided by average
M.sub.v of the whole polymer from ATREF (M.sub.hc/M.sub.p) is less
then about 1.95 and has a CDBI of less than 60%, wherein the
polymerization conditions comprise a molar ratio of aluminum to
catalyst metal atom of from about 1:1 to about 5:1, and recovering
the ethylene/alpha-olefin interpolymer, preferably wherein said
catalyst composition comprises the product which results from
combining: [0013] (A) a magnesium halide prepared by contacting:
[0014] (1) at least one hydrocarbon soluble magnesium component
represented by the general formula R''R'Mg.xAlR'3 wherein each R''
and R' are alkyl groups [0015] (2) at least one non-metallic or
metallic halide source under conditions such that the reaction
temperature does not exceed about 60.degree. C., preferably does
not exceed about 40.degree. C., and most preferably does not exceed
about 35.degree. C.; [0016] (B) at least one transition metal
compound represented by the formula Tm(OR)y Xy-x wherein Tm is a
metal of Groups IVB, VB, VIB, VIIB or VIII of the Periodic Table; R
is a hydrocarbyl group having from 1 to about 20, preferably from 1
to about 10 carbon atoms, and [0017] (C) an additional halide
source if an insufficient quantity of component (A-2) is present to
provide the desired excess X:Mg ratio.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The foregoing summary as well as the following detailed
description will be better understood when read in conjunction with
the appended drawings. It should be understood, however, that the
invention is not limited to the precise arrangements and
instrumentalities shown. The components in the drawings are not
necessarily to scale, with emphasis instead being placed upon
clearly illustrating the principles of the present invention.
Moreover, in the drawings, like reference numerals designate
corresponding parts throughout the several views.
[0019] FIG. 1 plots Short Chain Branching Distribution and log Mv
data from ATREF for Inventive Example 1 and Comparative Example
1.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The following discussion is presented to enable a person
skilled in the art to make and use the disclosed compositions and
methods. The general principles described may be applied to
embodiments and applications other than those detailed without
departing from the spirit and scope of the disclosed compositions
and methods. The disclosed compositions and methods are not
intended to be limited to the embodiments shown, but is to be
accorded the widest scope consistent with the principles and
features disclosed.
[0021] Balance of processability, dart, tear and optical properties
was achieved by making a unique combination of resin molecular
weight distribution and high crystalline and copolymer fraction
content. Resin characteristics and film property details are listed
in Table 1, FIG. 1 and Table 2. High density fraction content was
significantly dropped and that of the copolymer fraction was
increased. Ratio of viscosity average molecular weight of the high
crystalline fraction to that of the whole polymer was lowered,
indicating lower molecular weight of the high crystalline fraction.
Ratio of viscosity average molecular weight of the copolymer
fraction to that of the whole polymer was increased indicating
higher molecular weight of the copolymer fraction. These
differences in the resin characteristics were achieved by reducing
the reactor temperature from about 160 C to about 180 C, especially
175.degree. C. and reducing the Al/Ti molar ratio from about 1:1 to
about 5:1, especially 1:1 to about 2.5:1.
[0022] Film made from the inventive resin, having unique
combination of molecular characteristics, had significantly
improved dart and optics without any sacrifice in MD Tear and
processability.
[0023] This resin can be used for applications where improvement in
optical and dart properties are required without sacrificing film
tear properties and processability during film fabrication.
[0024] Low reactor temperature is useful for narrowing the
molecular weight distribution. Reactor temperature of 175.degree.
C. yielded a product with narrow molecular weight distribution
without significantly reducing the production output (lb/hr).
Significant further reduction in temperature could further narrow
the molecular weight distribution but significantly lower the
output and also make the product hurt the processability (film
fabrication) of the resin.
[0025] Low Al/Ti ratio is useful for narrowing the molecular weight
distribution and also for reducing the high crystalline fraction
and increasing the copolymer fraction. For a HEC-3 catalyst with
3.0 Ti/40 Mg ratio, an Al/Ti ratio of 1.5 yielded a product with
narrow molecular weight distribution, less high crystalline
fraction and more copolymer fraction without significantly
affecting reactor stability.
[0026] Preferably the reactor temperature is from about 160.degree.
C. to about 180.degree. C.
[0027] Preferably the ratio of aluminum to metal atom, preferably
Al/Ti, is from about 1:1 to about 5:1.
[0028] The melt index of the disclosed ethylenic polymer can be
from about 0.01 to about 1000 g/10 minutes, as measured by ASTM
1238-04 (2.16 kg and 190.degree. C.).
[0029] Ethylene-Based Polymers
[0030] Suitable ethylene-based polymers can be prepared with
Ziegler-Natta catalysts. Examples of linear ethylene-based polymers
include high density polyethylene (HDPE) and linear low density
polyethylene (LLDPE). Suitable polyolefins include, but are not
limited to, ethylene/diene interpolymers, ethylene/.alpha.-olefin
interpolymers, ethylene homopolymers, and blends thereof.
[0031] Suitable heterogeneous linear ethylene-based polymers
include linear low density polyethylene (LLDPE), ultra low density
polyethylene (ULDPE), and very low density polyethylene (VLDPE).
For example, some interpolymers produced using a Ziegler-Natta
catalyst have a density of about 0.89 to about 0.94 g/cm.sup.3 and
have a melt index (I.sub.2) from about 0.01 to about 1,000 g/10
minutes, as measured by ASTM 1238-04 (2.16 kg and 190.degree. C.).
Preferably, the melt index (I.sub.2) can be from about 0.1 to about
50 g/10 minutes. Heterogeneous linear ethylene-based polymers may
have a molecular weight distributions, M.sub.w/M.sub.n, from about
3.5 to about 5.
[0032] The linear ethylene-based polymer may comprise units derived
from one or more .alpha.-olefin copolymers as long as there is at
least 50 mole percent polymerized ethylene monomer in the
polymer.
[0033] High density polyethylene (HDPE) may have a density in the
range of about 0.94 to about 0.97 g/cm.sup.3. HDPE is typically a
homopolymer of ethylene or an interpolymer of ethylene and low
levels of one or more .alpha.-olefin copolymers. HDPE contains
relatively few branch chains relative to the various copolymers of
ethylene and one or more .alpha.-olefin copolymers. HDPE can be
comprised of less than 5 mole % of the units derived from one or
more .alpha.-olefin comonomers
[0034] Linear ethylene-based polymers such as linear low density
polyethylene and ultra low density polyethylene (ULDPE) are
characterized by an absence of long chain branching, in contrast to
conventional low crystallinity, highly branched ethylene-based
polymers such as LDPE. Heterogeneous linear ethylene-based polymers
such as LLDPE can be prepared via solution, slurry, or gas phase
polymerization of ethylene and one or more .alpha.-olefin
comonomers in the presence of a Ziegler-Natta catalyst, by
processes such as are disclosed in U.S. Pat. No. 4,076,698
(Anderson, et al.). Relevant discussions of both of these classes
of materials, and their methods of preparation are found in U.S.
Pat. No. 4,950,541 (Tabor, et al.). Other patents and publications
to make LLDPE include WO 2008/0287634, U.S. Pat. No. 4,198,315,
U.S. Pat. No. 5,487,938, EP 0891381, and U.S. Pat. No.
5,977,251.
[0035] An .alpha.-olefin comonomer may have, for example, from 3 to
20 carbon atoms. Preferably, the .alpha.-olefin comonomer may have
3 to 8 carbon atoms. Exemplary .alpha.-olefin comonomers include,
but are not limited to, propylene, 1-butene, 3-methyl-1-butene,
1-pentene, 3-methyl-1-pentene, 4-methyl-1-pentene, 1-hexene,
1-heptene, 4,4-dimethyl-1-pentene, 3-ethyl-1-pentene, 1-octene,
1-nonene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene,
1-octadecene and 1-eicosene. Commercial examples of linear
ethylene-based polymers that are interpolymers include ATTANE.TM.
Ultra Low Density Linear Polyethylene Copolymer, DOWLEX.TM.
Polyethylene Resins, and FLEXOMER.TM. Very Low Density
Polyethylene, all available from The Dow Chemical Company.
[0036] In a further aspect, when used in reference to an ethylene
homopolymer (that is, a high density ethylene homopolymer not
containing any comonomer and thus no short chain branches), the
terms "homogeneous ethylene polymer" or "homogeneous linear
ethylene polymer" may be used to describe such a polymer.
[0037] The ethylene-based polymers described herein are relatively
inhomogeneous (or heterogeneous) ethylene polymers that possess
short chain branches and that are characterized by a relatively low
composition distribution breadth index (CDBI). That is, the
ethylene polymer has a CDBI less than or equal to about 55 percent,
preferably less than or equal to about 50 percent, more preferably
less than or equal to about 45 percent, but usually include a
measurable high density (crystalline) polymer fraction.
[0038] The CDBI is defined as the weight percent of the polymer
molecules having a co-monomer content within 50 percent of the
median total molar co-monomer content and represents a comparison
of the co-monomer distribution in the polymer to the co-monomer
distribution expected for a Bernoullian distribution. The CDBI of
polyolefins can be conveniently calculated from data obtained from
techniques known in the art, such as, for example, temperature
rising elution fractionation ("TREF") as described, for example, by
Wild, et al., Journal of Polymer Science, Poly. Phys. Ed., Vol. 20,
441 (1982); L. D. Cady, "The Role of Comonomer Type and
Distribution in LLDPE Product Performance," SPE Regional Technical
Conference, Quaker Square Hilton, Akron, Ohio, 107-119 (Oct. 1-2,
1985); or in U.S. Pat. No. 4,798,081 (Hazlitt, et al.) and U.S.
Pat. No. 5,008,204 (Stehling). However, the TREF technique does not
include purge quantities in CDBI calculations. More preferably, the
co-monomer distribution of the polymer is determined using .sup.13C
NMR analysis in accordance with techniques described, for example,
in U.S. Pat. No. 5,292,845 (Kawasaki, et al.) and by J. C. Randall
in Rev. Macromol. Chem. Phys., C29, 201-317.
[0039] The presence of long chain branching can be determined in
ethylene homopolymers by using .sup.13C nuclear magnetic resonance
(NMR) spectroscopy and is quantified using the method described by
Randall (Rev. Macromol. Chem. Phys., C29, V. 2&3, 285-297).
There are other known techniques useful for determining the
presence of long chain branches in ethylene polymers, including
ethylene/1-octene interpolymers. Two such exemplary methods are gel
permeation chromatography coupled with a low angle laser light
scattering detector (GPC-LALLS) and gel permeation chromatography
coupled with a differential viscometer detector (GPC-DV). The use
of these techniques for long chain branch detection and the
underlying theories have been well documented in the literature.
See, for example, Zimm, G. H. and Stockmayer, W. H., J. Chem.
Phys., 17, 1301 (1949), and Rudin, A., Modern Methods of Polymer
Characterization, John Wiley & Sons, New York (1991)
103-112.
[0040] The terms "heterogeneous" and "heterogeneously branched"
mean that the ethylene polymer can be characterized as a mixture of
interpolymer molecules having various ethylene to comonomer molar
ratios. Heterogeneously branched linear ethylene polymers are
available from The Dow Chemical Company as DOWLEX.TM. linear low
density polyethylene and as ATTANE.TM. ultra-low density
polyethylene resins. Heterogeneously branched linear ethylene
polymers can be prepared via the solution, slurry or gas phase
polymerization of ethylene and one or more optional .alpha.-olefin
comonomers in the presence of a Ziegler Natta catalyst, by
processes such as are disclosed in U.S. Pat. No. 4,076,698
(Anderson, et al.). Heterogeneously branched ethylene polymers are
typically characterized as having molecular weight distributions,
Mw/Mn, from about 3 to about 5 and, as such, are distinct from
substantially linear ethylene polymers and homogeneously branched
linear ethylene polymers in regards to both compositional short
chain branching distribution and molecular weight distribution.
[0041] Highly Long Chain Branched Ethylene-Based Polymers
[0042] Highly long chain branched ethylene-based polymers, such as
low density polyethylene (LDPE), which can be blended with the
novel heterogeneous ethylene polymers herein, can be made using a
high-pressure process using free-radical chemistry to polymerize
ethylene monomer. Typical LDPE polymer density is from about 0.91
to about 0.94 g/cm.sup.3. The low density polyethylene may have a
melt index (I.sub.2) from about 0.01 to about 150 g/10 minutes.
Highly long chain branched ethylene-based polymers such as LDPE may
also be referred to as "high pressure ethylene polymers", meaning
that the polymer is partly or entirely homopolymerized or
copolymerized in autoclave or tubular reactors at pressures above
13,000 psig with the use of free-radical initiators, such as
peroxides (see, for example, U.S. Pat. No. 4,599,392 (McKinney, et
al.)). The process creates a polymer with significant branches,
including long chain branches.
[0043] Highly long chain branched ethylene-based polymers are
typically homopolymers of ethylene; however, the polymer may
comprise units derived from one or more .alpha.-olefin copolymers
as long as there is at least 50 mole percent polymerized ethylene
monomer in the polymer.
[0044] Comonomers that may be used in forming highly branched
ethylene-based polymer include, but are not limited to,
.alpha.-olefin comonomers, typically having no more than 20 carbon
atoms. For example, the .alpha.-olefin comonomers, for example, may
have 3 to 10 carbon atoms; or in the alternative, the
.alpha.-olefin comonomers, for example, may have 3 to 8 carbon
atoms. Exemplary .alpha.-olefin comonomers include, but are not
limited to, propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene,
1-octene, 1-nonene, 1-decene, and 4-methyl-1-pentene. In the
alternative, exemplary comonomers include, but are not limited to
.alpha.,.beta.-unsaturated C.sub.3-C.sub.8-carboxylic acids, in
particular maleic acid, fumaric acid, itaconic acid, acrylic acid,
methacrylic acid and crotonic acid derivates of the
.alpha.,.beta.-unsaturated C.sub.3-C.sub.8-carboxylic acids, for
example unsaturated C.sub.3-C.sub.15-carboxylic acid esters, in
particular ester of C.sub.1-C.sub.6-alkanols, or anhydrides, in
particular methyl methacrylate, ethyl methacrylate, n-butyl
methacrylate, ter-butyl methacrylate, methyl acrylate, ethyl
acrylate n-butyl acrylate, 2-ethylhexyl acrylate, tert-butyl
acrylate, methacrylic anhydride, maleic anhydride, and itaconic
anhydride. In another alternative, the exemplary comonomers
include, but are not limited to, vinyl carboxylates, for example
vinyl acetate. In another alternative, exemplary comonomers
include, but are not limited to, n-butyl acrylate, acrylic acid and
methacrylic acid.
[0045] Process
[0046] For producing the ethylene-based polymer of the invention, a
solution-phase polymerization process may be used. Typically such a
process occurs in a well-stirred reactor such as a loop reactor or
a sphere reactor at temperature from about 150 to about 300.degree.
C., preferably from about 160 to about 180.degree. C., and at
pressures from about 30 to about 1000 psi, preferably from about 30
to about 750 psi. The residence time in such a process is from
about 2 to about 20 minutes, preferably from about 10 to about 20
minutes. Ethylene, solvent, catalyst, and optionally one or more
comonomers are fed continuously to the reactor. Exemplary catalysts
in these embodiments include, but are not limited to, Ziegler-Natta
catalysts. Exemplary solvents include, but are not limited to,
isoparaffins. For example, such solvents are commercially available
under the name ISOPAR E (ExxonMobil Chemical Co., Houston, Tex.).
The resultant mixture of ethylene-based polymer and solvent is then
removed from the reactor and the polymer is isolated. Solvent is
typically recovered via a solvent recovery unit, that is, heat
exchangers and vapor liquid separator drum, and is recycled back
into the polymerization system.
[0047] For producing the highly long chain branched ethylene-based
polymer, a high pressure, free-radical initiated polymerization
process is typically used. Two different high pressure free-radical
initiated polymerization process types are known. In the first
type, an agitated autoclave vessel having one or more reaction
zones is used. The autoclave reactor normally has several injection
points for initiator or monomer feeds, or both. In the second type,
a jacketed tube is used as a reactor, which has one or more
reaction zones. Suitable, but not limiting, reactor lengths may be
from about 100 to about 3000 meters, preferably from about 1000 to
about 2000 meters. The beginning of a reaction zone for either type
of reactor is defined by the side injection of either initiator of
the reaction, ethylene, telomer, comonomer(s) as well as any
combination thereof. A high pressure process can be carried out in
autoclave or tubular reactors or in a combination of autoclave and
tubular reactors, each comprising one or more reaction zones.
[0048] The catalyst or initiator is injected prior to the reaction
zone where free radical polymerization is to be induced. In other
embodiment processes, the ethylene-based polymer may be fed into
the reaction system at the front of the reactor system and not
formed within the system itself. Termination of catalyst activity
may be achieved by a combination of high reactor temperatures for
the free radical polymerization portion of the reaction or by
feeding initiator into the reactor dissolved in a mixture of a
polar solvent such as isopropanol, water, or conventional initiator
solvents such as branched or unbranched alkanes.
[0049] Embodiment processes may include a process recycle loop to
improve conversion efficiency. In some embodiment processes, the
recycle loop may be treated to neutralize residues or byproducts
from the previous reaction cycle that may inhibit polymerization of
either the ethylene-based polymer or the highly long chain branched
ethylene-based polymer or inhibit the reaction forming the
disclosed ethylenic polymer. In some embodiment processes, fresh
monomer is added to this stream.
[0050] Ethylene used for the production of ethylene-based polymers
or highly long chain branched ethylene-based polymer may be
purified ethylene, which is obtained by removing polar components
from a loop recycle stream or by using a reaction system
configuration such that only fresh ethylene is used for making the
ethylene-based polymers. It is not typical that purified ethylene
is required to make highly long chain branched ethylene-based
polymer. In such cases ethylene from the recycle loop may be
used.
[0051] Chain transfer agents or telogens (CTA) are typically used
to control the melt index in a free-radical polymerization process.
Chain transfer involves the termination of growing polymer chains,
thus limiting the ultimate molecular weight of the polymer
material. Chain transfer agents are typically hydrogen atom donors
that will react with a growing polymer chain and stop the
polymerization reaction of the chain. For high pressure free
radical polymerizaton, these agents can be of many different types,
such as saturated hydrocarbons, unsaturated hydrocarbons,
aldehydes, ketones or alcohols. Typical CTAs that can be used
include, but are not limited to, propylene, isobutane, n-butane,
1-butene, methyl ethyl ketone, propionaldehyde, ISOPAR (ExxonMobil
Chemical Co.), and isopropanol. The amount of CTAs to use in the
process is about 0.03 to about 10 weight percent of the total
reaction mixture.
[0052] The melt index (MI or I.sub.2) of a polymer, which is
inversely related to the molecular weight, is controlled by
manipulating the concentration of the chain transfer agent. For
free radical polymerization, after the donation of a hydrogen atom,
the CTA forms a radical which can react with the monomers, or with
an already formed oligomers or polymers, to start a new polymer
chain. This means that any functional groups present in the chain
transfer agents will be introduced in the polymer chains. A large
number of CTAs, for example, propylene and 1-butene which have an
olefinically unsaturated bond, may also be incorporated in the
polymer chain themselves, via a copolymerization reaction. Polymers
produced in the presence of chain transfer agents are modified in a
number of physical properties such as processability, optical
properties such as haze and clarity, density, stiffness, yield
point, film draw and tear strength.
[0053] Hydrogen has been shown to be a chain transfer agent for
high pressure free radical polymerization and in the production of
the high crystallinity ethylene-based polymer. Control of the
molecular weight made in the reaction zones for disclosed processes
may be accomplished by feeding hydrogen to the reaction zones where
catalyst or initiator is injected. The final product melt index
control would be accomplished by feeding chain transfer agents to
the reaction zones where free radical polymerization takes place.
Feed of the free radical chain transfer agents could be
accomplished by direct injection into the reaction zones or by
feeding them to the front of the reactor. In some embodiment
processes, it may be necessary to remove excess CTA from the
recycle stream or limit injection so as to prevent excess buildup
of CTA in the front end of the process.
[0054] Free radical initiators that are generally used to produce
ethylene-based polymers are oxygen, which is usable in tubular
reactors in conventional amounts of between 0.0001 and 0.005 wt. %
drawn to the weight of polymerizable monomer, and peroxides.
Preferred initiators are t-butyl peroxy pivalate, di-t-butyl
peroxide, t-butyl peroxy acetate and t-butyl peroxy-2-hexanoate or
mixtures thereof. These organic peroxy initiators are used in
conventional amounts of between 0.005 and 0.2 wt. % drawn to the
weight of polymerizable monomers.
[0055] The peroxide initiator may be, for example, an organic
peroxide. Exemplary organic peroxides include, but are not limited
to, cyclic peroxides, diacyl peroxides, dialkyl peroxides,
hydroperoxides, peroxycarbonates, peroxydicarbonates, peroxyesters,
and peroxyketals.
[0056] Exemplary cyclic peroxides include, but are not limited to,
3,6,9-triethyl-3,6,9-trimethyl-1,4,7-triperoxonane. Such cyclic
peroxides, for example, are commercially available under the
tradename TRIGONOX 301 (Akzo Nobel; Arnhem, The Netherlands).
Exemplary diacyl peroxides include, but are not limited to,
di(3,5,5-trimethylhexanoyl)peroxide. Such diacyl peroxides, for
example, are commercially available under the tradename TRIGONOX 36
(Akzo Nobel). Exemplary dialkyl peroxides include, but are not
limited to, 2,5-dimethyl-2,5-di(tert-butylperoxy)hexane;
2,5-dimethyl-2,5-di(tert-butylperoxy)hexyne-3; di-tert-amyl
peroxide; di-tert-butyl peroxide; and tert-butyl cumyl peroxide.
Such dialkyl peroxides, for example, are commercially available
under the tradenames TRIGONOX 101, TRIGONOX 145, TRIGONOX 201,
TRIGONOX B, and TRIGONOX T (Akzo Nobel). Exemplary hydroperoxides
include, but are not limited to, tert-Amyl hydroperoxide; and
1,1,3,3-tetramethylbutyl hydroperoxide. Such hydroperoxides, for
example, are commercially available under the tradenames TRIGONOX
TAHP, and TRIGONOX TMBH (Akzo Nobel). Exemplary peroxycarbonates
include, but are not limited to, tert-butylperoxy 2-ethylhexyl
carbonate; tert-amylperoxy 2-ethylhexyl carbonate; and
tert-butylperoxy isopropyl carbonate. Such peroxycarbonates, for
example, are commercially available under the tradenames TRIGONOX
117, TRIGONOX 131, and TRIGONOX BPIC (Akzo Nobel). Exemplary
peroxydicarbonates include, but are not limited to,
di(2-ethylhexyl)peroxydicarbonates; and di-sec-butyl
peroxydicarbonates. Such peroxydicarbonates, for example, are
commercially available under the tradename TRIGONOX EHP, and
TRIGONOX SBP (Akzo Nobel). Exemplary peroxyesters include, but are
not limited to, tert-amyl peroxy-2-ethylhexanoate; tert-amyl
peroxyneodecanoate; tert-amyl peroxypivalate; tert-amyl
peroxybenzoate; tert-amyl peroxyacetate;
2,5-dimethyl-2,5-di(2-ethylhexanoylperoxy)hexane; tert-butyl
peroxy-2-ethylhexanoate; tert-butyl peroxyneodecanoate; tert-butyl
peroxyneoheptanoate; tert-butyl peroxypivalate; tert-butyl
peroxydiethylacetate; tert-butyl peroxyisobutyrate;
1,1,3,3-tetramethylbutyl peroxy-2-ethylhexanoate;
1,1,3,3-tetramethylbutyl peroxyneodecanoate;
1,1,3,3-tetramethylbutyl peroxypivalate; tert-butyl
peroxy-3,5,5-trimethylhexanoate; cumyl peroxyneodecanoate;
tert-butyl peroxybenzoate; and tert-butyl peroxyacetate. Such
peroxyesters solvents, for example, are commercially available
under the tradenames TRIGONOX 121; TRIGONOX 123; TRIGONOX 125;
TRIGONOX 127; TRIGONOX 133; TRIGONOX 141; TRIGONOX 21; TRIGONOX 23;
TRIGONOX 257; TRIGONOX 25; TRIGONOX 27; TRIGONOX 41; TRIGONOX 421;
TRIGONOX 423; TRIGONOX 425; TRIGONOX 42; TRIGONOX 99; TRIGONOX C;
and TRIGONOX F (Akzo Nobel). Exemplary peroxyketals include, but
are not limited to, 1,1-di(tert-amylperoxy)cyclohexane;
1,1-di(tert-butylperoxy)cyclohexane;
1,1-di(tert-butylperoxy)-3,3,5-trimethylcyclohexane; and
2,2-di(tert-butylperoxy)butane. Such peroxyketals, for example, are
commercially available under the tradenames TRIGONOX 122, TRIGONOX
22, TRIGONOX 29, and TRIGONOX D (Akzo Nobel). The free radical
initiator system may, for example, include a mixture or combination
of any of the aforementioned peroxide initiators. The peroxide
initiator may comprise less than 60 percent by weight the free
radical initiator system.
[0057] The free radical initiator system further includes at least
one hydrocarbon solvent. The hydrocarbon solvent may, for example,
be a C.sub.5 to C.sub.30 hydrocarbon solvent. Exemplary hydrocarbon
solvents include, but are not limited to, mineral solvents, normal
paraffinic solvents, isoparaffinic solvents, cyclic solvents, and
the like. The hydrocarbon solvents may, for example, be selected
from the group consisting of n-octane, iso-octane
(2,2,4-trimethylpentane), n-dodecane, iso-dodecane
(2,2,4,6,6-pentamethylheptane), and other isoparaffinic solvents.
Exemplary hydrocarbon solvents such as isoparaffinic solvents, for
example, are commercially available under the tradenames ISOPAR C,
ISOPAR E, and ISOPAR H (ExxonMobil Chemical Co.). The hydrocarbon
solvent may comprise less than 99 percent by weight of the free
radical initiator system.
[0058] Suitable catalysts for use in embodiment processes include
any compound or combination of compounds that is adapted for
preparing polymers of the desired composition or type, either the
ethylene-based polymers or the highly long chain branched
ethylene-based polymers. Heterogeneous catalysts may be employed.
In some embodiment processes, heterogeneous catalysts, including
the well known Ziegler-Natta compositions, especially Group 4 metal
halides supported on Group 2 metal halides or mixed halides and
alkoxides and the well known chromium or vanadium based catalysts,
may be used. In some embodiment processes, the catalysts for use
may be homogeneous catalysts comprising a relatively pure
organometallic compound or metal complex, especially compounds or
complexes based on metals selected from Groups 3-10 or the
Lanthanide series. If more than one catalyst is used in a system,
it is preferred that any catalyst employed not significantly
detrimentally affect the performance of another catalyst under the
conditions of polymerization. Desirably, no catalyst is reduced in
activity by greater than 25 percent, more preferably greater than
10 percent under the conditions of the polymerization.
[0059] In embodiment processes employing a complex metal catalyst,
such a catalyst may be activated to form an active catalyst
composition by combination with a cocatalyst, preferably a cation
forming cocatalyst, a strong Lewis acid, or a combination thereof.
Suitable cocatalysts for use include polymeric or oligomeric
aluminoxanes, especially methyl aluminoxane, as well as inert,
compatible, noncoordinating, ion forming compounds. So-called
modified methyl aluminoxane (MMAO) or triethyl aluminum (TEA) is
also suitable for use as a cocatalyst. One technique for preparing
such modified aluminoxane is disclosed in U.S. Pat. No. 5,041,584
(Crapo, et al.). Aluminoxanes can also be made as disclosed in U.S.
Pat. No. 5,542,199 (Lai, et al.); U.S. Pat. No. 4,544,762
(Kaminsky, et al.); U.S. Pat. No. 5,015,749 (Schmidt, et al.); and
U.S. Pat. No. 5,041,585 (Deavenport, et al.).
[0060] In some embodiment processes, processing aids, such as
plasticizers, can also be included in the embodiment ethylenic
polymer product. These aids include, but are not limited to, the
phthalates, such as dioctyl phthalate and diisobutyl phthalate,
natural oils such as lanolin, and paraffin, naphthenic and aromatic
oils obtained from petroleum refining, and liquid resins from rosin
or petroleum feedstocks. Exemplary classes of oils useful as
processing aids include white mineral oil such as KAYDOL oil
(Chemtura Corp.; Middlebury, Conn.) and SHELLFLEX 371 naphthenic
oil (Shell Lubricants; Houston, Tex.). Another suitable oil is
TUFFLO oil (Lyondell Lubricants; Houston, Tex.).
[0061] In some embodiment processes, embodiment ethylenic polymers
are treated with one or more stabilizers, for example,
antioxidants, such as IRGANOX 1010 and IRGAFOS 168 (Ciba Specialty
Chemicals; Glattbrugg, Switzerland). In general, polymers are
treated with one or more stabilizers before an extrusion or other
melt processes. In other embodiment processes, other polymeric
additives include, but are not limited to, ultraviolet light
absorbers, antistatic agents, pigments, dyes, nucleating agents,
fillers, slip agents, fire retardants, plasticizers, processing
aids, lubricants, stabilizers, smoke inhibitors, viscosity control
agents and anti-blocking agents. The embodiment ethylenic polymer
composition may, for example, comprise less than 10 percent by the
combined weight of one or more additives, based on the weight of
the embodiment ethylenic polymer.
[0062] The embodiment ethylenic polymer may further be compounded.
In some embodiment ethylenic polymer compositions, one or more
antioxidants may further be compounded into the polymer and the
compounded polymer pelletized. The compounded ethylenic polymer may
contain any amount of one or more antioxidants. For example, the
compounded ethylenic polymer may comprise from about 200 to about
600 parts of one or more phenolic antioxidants per one million
parts of the polymer. In addition, the compounded ethylenic polymer
may comprise from about 800 to about 1200 parts of a
phosphite-based antioxidant per one million parts of polymer. The
compounded disclosed ethylenic polymer may further comprise from
about 300 to about 1250 parts of calcium stearate per one million
parts of polymer.
[0063] Cross-Linking Agents
[0064] Some suitable cross-linking agents have been disclosed in
Zweifel Hans et al., "Plastics Additives Handbook," Hanser Gardner
Publications, Cincinnati, Ohio, 5th edition, Chapter 14, pages
725-812 (2001); Encyclopedia of Chemical Technology, Vol. 17, 2nd
edition, Interscience Publishers (1968); and Daniel Seem, "Organic
Peroxides," Vol. 1, Wiley-Interscience, (1970), all of which are
incorporated herein by reference.
[0065] Non-limiting examples of suitable cross-linking agents
include peroxides, phenols, azides, aldehyde-amine reaction
products, substituted ureas, substituted guanidines; substituted
xanthates; substituted dithiocarbamates; sulfur-containing
compounds, such as thiazoles, sulfenamides, thiuramidisulfides,
paraquinonedioxime, dibenzoparaquinonedioxime, sulfur; imidazoles;
silanes and combinations thereof.
[0066] Non-limiting examples of suitable organic peroxide
cross-linking agents include alkyl peroxides, aryl peroxides,
peroxyesters, peroxycarbonates, diacylperoxides, peroxyketals,
cyclic peroxides and combinations thereof. In some embodiments, the
organic peroxide is dicumyl peroxide, t-butylisopropylidene
peroxybenzene, 1,1-di-t-butyl peroxy-3,3,5-trimethylcyclohexane,
2,5-dimethyl-2,5-di(t-butyl peroxy)hexane, t-butyl-cumyl peroxide,
di-t-butyl peroxide, 2,5-dimethyl-2,5-di-(t-butyl peroxy)hexyne or
a combination thereof. In one embodiment, the organic peroxide is
dicumyl peroxide. Additional teachings regarding organic peroxide
cross-linking agents are disclosed in C. P. Park, "Polyolefin
Foam", Chapter 9 of Handbook of Polymer Foams and Technology,
edited by D. Klempner and K. C. Frisch, Hanser Publishers, pp.
198-204, Munich (1991), which is incorporated herein by
reference.
[0067] Non-limiting examples of suitable azide cross-linking agents
include azidoformates, such as tetramethylenebis(azidoformate);
aromatic polyazides, such as 4,4'-diphenylmethane diazide; and
sulfonazides, such as p,p'-oxybis(benzene sulfonyl azide). The
disclosure of azide cross-linking agents can be found in U.S. Pat.
Nos. 3,284,421 and 3,297,674, both of which are incorporated herein
by reference.
[0068] The poly(sulfonyl azide) is any compound having at least two
sulfonyl azide groups (i.e., --SO.sub.2N.sub.3) that are reactive
towards the ethylene/.alpha.-olefin interpolymer disclosed herein.
In some embodiments, the poly(sulfonyl azide)s have a structure of
X--R--X wherein each X is --SO.sub.2N.sub.3 and R represents an
unsubstituted or inertly substituted hydrocarbyl, hydrocarbyl ether
or silicon-containing group. In some embodiments, the R group has
sufficient carbon, oxygen or silicon, preferably carbon, atoms to
separate the sulfonyl azide groups sufficiently to permit a facile
reaction between the ethylene/.alpha.-olefin interpolymer and the
sulfonyl azide groups. In other embodiments, the R group has at
least 1, at least 2, or at least 3 carbon, oxygen or silicon,
preferably carbon, atoms between the sulfonyl azide groups. The
term "inertly substituted" refers to substitution with atoms or
groups which do not undesirably interfere with the desired
reaction(s) or desired properties of the resulting cross-linked
polymers. Such groups include fluorine, aliphatic or aromatic
ethers, siloxanes and the like. Non-limiting examples of suitable
structures of R include aryl, alkyl, alkaryl, arylalkyl, silanyl,
heterocyclyl, and other inert groups. In some embodiments, the R
group includes at least one aryl group between the sulfonyl groups.
In other embodiments, the R group includes at least two aryl groups
(such as when R is 4,4' diphenylether or 4,4'-biphenyl). When R is
one aryl group, it is preferred that the group have more than one
ring, as in the case of naphthylene bis(sulfonyl azides). In some
embodiments, the poly(sulfonyl)azides include 1,5-pentane
bis(sulfonylazide), 1,8-octane bis(sulfonyl azide), 1,10-decane
bis(sulfonyl azide), 1,10-octadecane bis(sulfonyl azide),
1-octyl-2,4,6-benzene tris(sulfonyl azide), 4,4'-diphenyl ether
bis(sulfonyl azide), 1,6-bis(4'-sulfonazidophenyl)hexane,
2,7-naphthalene bis(sulfonyl azide), and mixed sulfonyl azides of
chlorinated aliphatic hydrocarbons containing an average of from 1
to 8 chlorine atoms and from about 2 to 5 sulfonyl azide groups per
molecule, and combinations thereof. In other embodiments, the
poly(sulfonyl azide)s include oxy-bis(4-sulfonylazidobenzene),
2,7-naphthalene bis(sulfonyl azido), 4,4'-bis(sulfonyl
azido)biphenyl, 4,4'-diphenyl ether bis(sulfonyl azide) and
bis(4-sulfonyl azidophenyl)methane, and combinations thereof.
[0069] Non-limiting examples of suitable aldehyde-amine reaction
products include formaldehyde-ammonia,
formaldehyde-ethylchloride-ammonia, acetaldehyde-ammonia,
formaldehyde-aniline, butyraldehyde-aniline, heptaldehyde-aniline,
and combinations thereof.
[0070] Non-limiting examples of suitable substituted ureas include
trimethylthiourea, diethylthiourea, dibutylthiourea,
tripentylthiourea, 1,3-bis(2-benzothiazolylmercaptomethyl)urea,
N,N-diphenylthiourea, and combinations thereof.
[0071] Non-limiting examples of suitable substituted guanidines
include diphenylguanidine, di-o-tolylguanidine, diphenylguanidine
phthalate, the di-o-tolylguanidine salt of dicatechol borate, and
combinations thereof.
[0072] Non-limiting examples of suitable substituted xanthates
include zinc ethylxanthate, sodium isopropylxanthate, butylxanthic
disulfide, potassium isopropylxanthate, zinc butylxanthate, and
combinations thereof.
[0073] Non-limiting examples of suitable dithiocarbamates include
copper dimethyl-, zinc dimethyl-, tellurium diethyl-, cadmium
dicyclohexyl-, lead dimethyl-, lead dimethyl-, selenium dibutyl-,
zinc pentamethylene-, zinc didecyl-, zinc
isopropyloctyl-dithiocarbamate, and combinations thereof.
[0074] Non-limiting examples of suitable thiazoles include
2-mercaptobenzothiazole, zinc mercaptothiazolyl mercaptide,
2-benzothiazolyl-N,N-diethylthiocarbamyl sulfide,
2,2'-dithiobis(benzothiazole), and combinations thereof.
[0075] Non-limiting examples of suitable imidazoles include
2-mercaptoimidazoline 2-mercapto-4,4,6-trimethyldihydropyrimidine,
and combinations thereof.
[0076] Non-limiting examples of suitable sulfenamides include
N-t-butyl-2-benzothiazole-, N-cyclohexylbenzothiazole-,
N,N-diisopropylbenzothiazole-,
N-(2,6-dimethylmorpholino)-2-benzothiazole-,
N,N-diethylbenzothiazole-sulfenamide, and combinations thereof.
[0077] Non-limiting examples of suitable thiuramidisulfides include
N,N'-diethyl-, tetrabutyl-, N,N'-diisopropyldioctyl-, tetramethyl-,
N,N'-dicyclohexyl-, N,N'-tetralaurylthiuramidisulfide, and
combinations thereof.
[0078] In some embodiments, the cross-linking agents are silanes.
Any silane that can effectively graft to and/or cross-link the
ethylene/.alpha.-olefin interpolymer or the polymer blend disclosed
herein can be used. Non-limiting examples of suitable silane
cross-linking agents include unsaturated silanes that comprise an
ethylenically unsaturated hydrocarbyl group, such as a vinyl,
allyl, isopropenyl, butenyl, cyclohexenyl or gamma-(meth)acryloxy
allyl group, and a hydrolyzable group such as a hydrocarbyloxy,
hydrocarbonyloxy, and hydrocarbylamino group. Non-limiting examples
of suitable hydrolyzable groups include methoxy, ethoxy, formyloxy,
acetoxy, proprionyloxy, alkyl and arylamino groups. In other
embodiments, the silanes are the unsaturated alkoxy silanes which
can be grafted onto the interpolymer. Some of these silanes and
their preparation methods are more fully described in U.S. Pat. No.
5,266,627, which is incorporated herein by reference. In further
embodiments, the silane cross-linking agents are
vinyltrimethoxysilane, vinyltriethoxysilane,
vinyltris(2-methoxyethoxy)silane, vinyltriacetoxysilane,
vinylmethyldimethoxysilane,
3-methacryloyloxypropyltrimethoxysilane, and combinations
thereof.
[0079] The amount of the silane cross-linking agent can vary
widely, depending upon the nature of the ethylene/.alpha.-olefin
interpolymer or the polymer blend, the silane employed, the
processing conditions, the amount of grafting initiator, the
ultimate application, and other factors. When vinyltrimethoxysilane
(VTMOS) is used, the amount of VTMOS is generally at least about
0.1 weight percent, at least about 0.5 weight percent, or at least
about 1 weight percent, based on the combined weight of the silane
cross-linking agent and the interpolymer or the polymer blend.
[0080] Uses
[0081] The embodiment ethylenic polymer may be employed in a
variety of conventional thermoplastic fabrication processes to
produce useful articles, including objects comprising at least one
film layer, such as a monolayer film, or at least one layer in a
multilayer film prepared by cast, blown, calendered, or extrusion
coating processes; molded articles, such as blow molded, injection
molded, or rotomolded articles; extrusions; fibers; and woven or
non-woven fabrics. Thermoplastic compositions comprising the
embodiment ethylenic polymer include blends with other natural or
synthetic materials, polymers, additives, reinforcing agents,
ignition resistant additives, antioxidants, stabilizers, colorants,
extenders, crosslinkers, blowing agents, and plasticizers.
[0082] The embodiment ethylenic polymer may be used in producing
fibers for other applications. Fibers that may be prepared from the
embodiment ethylenic polymer or blends thereof include staple
fibers, tow, multicomponent, sheath/core, twisted, and
monofilament. Suitable fiber forming processes include spunbonded
and melt blown techniques, as disclosed in U.S. Pat. No. 4,340,563
(Appel, et al.), U.S. Pat. No. 4,663,220 (Wisneski, et al.), U.S.
Pat. No. 4,668,566 (Nohr, et al.), and U.S. Pat. No. 4,322,027
(Reba), gel spun fibers as disclosed in U.S. Pat. No. 4,413,110
(Kavesh, et al.), woven and nonwoven fabrics, as disclosed in U.S.
Pat. No. 3,485,706 (May), or structures made from such fibers,
including blends with other fibers, such as polyester, nylon or
cotton, thermoformed articles, extruded shapes, including profile
extrusions and co-extrusions, calendared articles, and drawn,
twisted, or crimped yarns or fibers.
[0083] The embodiment ethylenic polymer may be used in a variety of
films, including but not limited to clarity shrink films, collation
shrink films, cast stretch films, silage films, stretch hooder
films, sealants, stand up pouch films, liner films, and diaper
backsheets.
[0084] The embodiment ethylenic polymer is also useful in other
direct end-use applications. The embodiment ethylenic polymer is
useful for wire and cable coating operations, in sheet extrusion
for vacuum forming operations, and forming molded articles,
including the use of injection molding, blow molding process, or
rotomolding processes. Compositions comprising the embodiment
ethylenic polymer can also be formed into fabricated articles using
conventional polyolefin processing techniques.
[0085] Other suitable applications for the embodiment ethylenic
polymer include films and fibers; soft touch goods, such as tooth
brush handles and appliance handles; gaskets and profiles;
adhesives (including hot melt adhesives and pressure sensitive
adhesives); footwear (including shoe soles and shoe liners); auto
interior parts and profiles; foam goods (both open and closed
cell); impact modifiers for other thermoplastic polymers such as
high density polyethylene, isotactic polypropylene, or other olefin
polymers; coated fabrics; hoses; tubing; weather stripping; cap
liners; flooring; and viscosity index modifiers, also known as pour
point modifiers, for lubricants.
[0086] Further treatment of the embodiment ethylenic polymer may be
performed to apply the embodiment ethylenic polymer for other end
uses. For example, dispersions (both aqueous and non-aqueous) can
also be formed using the present polymers or formulations
comprising the same. Frothed foams comprising the embodiment
ethylenic polymer can also be formed, as disclosed in PCT
Publication No. 2005/021622 (Strandburg, et al.). The embodiment
ethylenic polymer may also be crosslinked by any known means, such
as the use of peroxide, electron beam, silane, azide, or other
cross-linking technique. The embodiment ethylenic polymer can also
be chemically modified, such as by grafting (for example by use of
maleic anhydride (MAH), silanes, or other grafting agent),
halogenation, amination, sulfonation, or other chemical
modification.
[0087] Additives and adjuvants may be added to the embodiment
ethylenic polymer post-formation. Suitable additives include
fillers, such as organic or inorganic particles, including clays,
talc, titanium dioxide, zeolites, powdered metals, organic or
inorganic fibers, including carbon fibers, silicon nitride fibers,
steel wire or mesh, and nylon or polyester cording, nano-sized
particles, clays, and so forth; tackifiers, oil extenders,
including paraffinic or napthelenic oils; and other natural and
synthetic polymers, including other polymers that are or can be
made according to the embodiment methods.
[0088] Blends and mixtures of the embodiment ethylenic polymer with
other polyolefins may be performed. Suitable polymers for blending
with the embodiment ethylenic polymer include thermoplastic and
non-thermoplastic polymers including natural and synthetic
polymers. Exemplary polymers for blending include polypropylene,
(both impact modifying polypropylene, isotactic polypropylene,
atactic polypropylene, and random ethylene/propylene copolymers),
various types of polyethylene, including high pressure,
free-radical LDPE, Ziegler-Natta LLDPE, metallocene PE, including
multiple reactor PE ("in reactor" blends of Ziegler-Natta PE and
metallocene PE, such as products disclosed in U.S. Pat. No.
6,545,088 (Kolthammer, et al.); U.S. Pat. No. 6,538,070 (Cardwell,
et al.); U.S. Pat. No. 6,566,446 (Parikh, et al.); U.S. Pat. No.
5,844,045 (Kolthammer, et al.); U.S. Pat. No. 5,869,575
(Kolthammer, et al.); and U.S. Pat. No. 6,448,341 (Kolthammer, et
al.)), ethylene-vinyl acetate (EVA), ethylene/vinyl alcohol
copolymers, polystyrene, impact modified polystyrene, ABS,
styrene/butadiene block copolymers and hydrogenated derivatives
thereof (SBS and SEBS), and thermoplastic polyurethanes.
Homogeneous polymers such as olefin plastomers and elastomers,
ethylene and propylene-based copolymers (for example, polymers
available under the trade designation VERSIFY.TM. Plastomers &
Elastomers (The Dow Chemical Company) and VISTAMAXX.TM. (ExxonMobil
Chemical Co.)) can also be useful as components in blends
comprising the embodiment ethylenic polymer.
[0089] Blends and mixtures of the embodiment ethylenic polymer may
include thermoplastic polyolefin blends (TPO), thermoplastic
elastomer blends (TPE), thermoplastic vulcanizates (TPV) and
styrenic polymer blends. TPE and TPV blends may be prepared by
combining embodiment ethylenic polymers, including functionalized
or unsaturated derivatives thereof, with an optional rubber,
including conventional block copolymers, especially an SBS block
copolymer, and optionally a crosslinking or vulcanizing agent. TPO
blends are generally prepared by blending the embodiment polymers
with a polyolefin, and optionally a crosslinking or vulcanizing
agent. The foregoing blends may be used in forming a molded object,
and optionally crosslinking the resulting molded article. A similar
procedure using different components has been previously disclosed
in U.S. Pat. No. 6,797,779 (Ajbani, et al.).
[0090] Definitions
[0091] The term "composition," as used, includes a mixture of
materials which comprise the composition, as well as reaction
products and decomposition products formed from the materials of
the composition.
[0092] The terms "blend" or "polymer blend," as used, mean an
intimate physical mixture (that is, without reaction) of two or
more polymers. A blend may or may not be miscible (not phase
separated at molecular level). A blend may or may not be phase
separated. A blend may or may not contain one or more domain
configurations, as determined from transmission electron
spectroscopy, light scattering, x-ray scattering, and other methods
known in the art. The blend may be effected by physically mixing
the two or more polymers on the macro level (for example, melt
blending resins or compounding) or the micro level (for example,
simultaneous forming within the same reactor).
[0093] The term "linear" refers to polymers where the polymer
backbone of the polymer lacks measurable or demonstrable long chain
branches, for example, the polymer is substituted with an average
of less than 0.01 long branch per 1000 carbons.
[0094] The term "polymer" refers to a polymeric compound prepared
by polymerizing monomers, whether of the same or a different type.
The generic term polymer thus embraces the term "homopolymer,"
usually employed to refer to polymers prepared from only one type
of monomer, and the term "interpolymer" as defined. The terms
"ethylene/.alpha.-olefin polymer" is indicative of interpolymers as
described.
[0095] The term "interpolymer" refers to polymers prepared by the
polymerization of at least two different types of monomers. The
generic term interpolymer includes copolymers, usually employed to
refer to polymers prepared from two different monomers, and
polymers prepared from more than two different types of
monomers.
[0096] The term "ethylene-based polymer" refers to a polymer that
contains more than 50 mole percent polymerized ethylene monomer
(based on the total amount of polymerizable monomers) and,
optionally, may contain at least one comonomer.
[0097] The term "ethylene/.alpha.-olefin interpolymer" refers to an
interpolymer that contains more than 50 mole percent polymerized
ethylene monomer (based on the total amount of polymerizable
monomers) and at least one .alpha.-olefin.
[0098] The term "ethylenic polymer" refers to a polymer resulting
from the bonding of an ethylene-based polymer and at least one
highly long chain branched ethylene-based polymer.
Test Methods
[0099] Density
[0100] Density (g/cm.sup.3) is measured according to ASTM-D 792-03,
Method B, in isopropanol. Specimens are measured within 1 hour of
molding after conditioning in the isopropanol bath at 23.degree. C.
for 8 min to achieve thermal equilibrium prior to measurement. The
specimens are compression molded according to ASTM D-4703-00 Annex
A with a 5 min initial heating period at about 190.degree. C. and a
15.degree. C./min cooling rate per Procedure C. The specimen is
cooled to 45.degree. C. in the press with continued cooling until
"cool to the touch."
[0101] Melt Index
[0102] Melt index, or I.sub.2, is measured in accordance with ASTM
D 1238, Condition 190.degree. C./2.16 kg, and is reported in grams
eluted per 10 minutes. I.sub.10 is measured in accordance with ASTM
D 1238, Condition 190.degree. C./10 kg, and is reported in grams
eluted per 10 minutes.
[0103] DSC Crystallinity
[0104] Differential Scanning calorimetry (DSC) can be used to
measure the melting and crystallization behavior of a polymer over
a wide range of temperature. For example, the TA Instruments Q1000
DSC, equipped with an RCS (refrigerated cooling system) and an
autosampler is used to perform this analysis. During testing, a
nitrogen purge gas flow of 50 ml/min is used. Each sample is melt
pressed into a thin film at about 175.degree. C.; the melted sample
is then air-cooled to room temperature (.about.25.degree. C.). A
3-10 mg, 6 mm diameter specimen is extracted from the cooled
polymer, weighed, placed in a light aluminum pan (ca 50 mg), and
crimped shut. Analysis is then performed to determine its thermal
properties.
[0105] The thermal behavior of the sample is determined by ramping
the sample temperature up and down to create a heat flow versus
temperature profile. First, the sample is rapidly heated to
180.degree. C. and held isothermal for 3 minutes in order to remove
its thermal history. Next, the sample is cooled to -40.degree. C.
at a 10.degree. C./minute cooling rate and held isothermal at
-40.degree. C. for 3 minutes. The sample is then heated to
150.degree. C. (this is the "second heat" ramp) at a 10.degree.
C./minute heating rate. The cooling and second heating curves are
recorded. The cool curve is analyzed by setting baseline endpoints
from the beginning of crystallization to -20.degree. C. The heat
curve is analyzed by setting baseline endpoints from -20.degree. C.
to the end of melt. The values determined are peak melting
temperature (T.sub.m), peak crystallization temperature (T.sub.c),
heat of fusion (H.sub.f) (in Joules per gram), and the calculated %
crystallinity for polyethylene samples using:
% Crystallinity=((H.sub.f)/(292 J/g)).times.100.
[0106] The heat of fusion (H.sub.f) and the peak melting
temperature are reported from the second heat curve. Peak
crystallization temperature is determined from the cooling
curve.
[0107] Gel Permeation Chromatography (GPC)
[0108] The GPC system consists of a Waters (Milford, Mass.) 150 C
high temperature chromatograph (other suitable high temperatures
GPC instruments include Polymer Laboratories (Shropshire, UK) Model
210 and Model 220) equipped with an on-board differential
refractometer (RI). Additional detectors can include an IR4
infra-red detector from Polymer ChAR (Valencia, Spain), Precision
Detectors (Amherst, Mass.) 2-angle laser light scattering detector
Model 2040, and a Viscotek (Houston, Tex.) 150R 4-capillary
solution viscometer. A GPC with the last two independent detectors
and at least one of the first detectors is sometimes referred to as
"3D-GPC", while the term "GPC" alone generally refers to
conventional GPC. Depending on the sample, either the 15-degree
angle or the 90-degree angle of the light scattering detector is
used for calculation purposes. Data collection is performed using
Viscotek TriSEC software, Version 3, and a 4-channel Viscotek Data
Manager DM400. The system is also equipped with an on-line solvent
degassing device from Polymer Laboratories (Shropshire, UK).
Suitable high temperature GPC columns can be used such as four 30
cm long Shodex HT803 13 micron columns or four 30 cm Polymer Labs
columns of 20-micron mixed-pore-size packing (MixA LS, Polymer
Labs). The sample carousel compartment is operated at 140.degree.
C. and the column compartment is operated at 150.degree. C. The
samples are prepared at a concentration of 0.1 grams of polymer in
50 milliliters of solvent. The chromatographic solvent and the
sample preparation solvent contain 200 ppm of butylated
hydroxytoluene (BHT). Both solvents are sparged with nitrogen. The
polyethylene samples are gently stirred at 160.degree. C. for four
hours. The injection volume is 200 microliters. The flow rate
through the GPC is set at 1 ml/minute.
[0109] The GPC column set is calibrated before running the Examples
by running twenty-one narrow molecular weight distribution
polystyrene standards. The molecular weight (MW) of the standards
ranges from 580 to 8,400,000 grams per mole, and the standards are
contained in 6 "cocktail" mixtures. Each standard mixture has at
least a decade of separation between individual molecular weights.
The standard mixtures are purchased from Polymer Laboratories
(Shropshire, UK). The polystyrene standards are prepared at 0.025 g
in 50 mL of solvent for molecular weights equal to or greater than
1,000,000 grams per mole and 0.05 g in 50 ml of solvent for
molecular weights less than 1,000,000 grams per mole. The
polystyrene standards were dissolved at 80.degree. C. with gentle
agitation for 30 minutes. The narrow standards mixtures are run
first and in order of decreasing highest molecular weight component
to minimize degradation. The polystyrene standard peak molecular
weights are converted to polyethylene M.sub.w using the
Mark-Houwink K and a (sometimes referred to as .alpha.) values
mentioned later for polystyrene and polyethylene. See the Examples
section for a demonstration of this procedure.
[0110] With 3D-GPC absolute weight average molecular weight
("M.sub.w, Abs") and intrinsic viscosity are also obtained
independently from suitable narrow polyethylene standards using the
same conditions mentioned previously. These narrow linear
polyethylene standards may be obtained from Polymer Laboratories
(Shropshire, UK; Part No.'s PL2650-0101 and PL2650-0102).
[0111] The systematic approach for the determination of
multi-detector offsets is performed in a manner consistent with
that published by Balke, Mourey, et al. (Mourey and Balke,
Chromatography Polym., Chapter 12, (1992)) (Balke, Thitiratsakul,
Lew, Cheung, Mourey, Chromatography Polym., Chapter 13, (1992)),
optimizing triple detector log (M.sub.w and intrinsic viscosity)
results from Dow 1683 broad polystyrene (American Polymer Standards
Corp.; Mentor, Ohio) or its equivalent to the narrow standard
column calibration results from the narrow polystyrene standards
calibration curve. The molecular weight data, accounting for
detector volume off-set determination, are obtained in a manner
consistent with that published by Zimm (Zimm, B. H., J. Chem.
Phys., 16, 1099 (1948)) and Kratochvil (Kratochvil, P., Classical
Light Scattering from Polymer Solutions, Elsevier, Oxford, N.Y.
(1987)). The overall injected concentration used in the
determination of the molecular weight is obtained from the mass
detector area and the mass detector constant derived from a
suitable linear polyethylene homopolymer, or one of the
polyethylene standards. The calculated molecular weights are
obtained using a light scattering constant derived from one or more
of the polyethylene standards mentioned and a refractive index
concentration coefficient, do/dc, of 0.104. Generally, the mass
detector response and the light scattering constant should be
determined from a linear standard with a molecular weight in excess
of about 50,000 daltons. The viscometer calibration can be
accomplished using the methods described by the manufacturer or
alternatively by using the published values of suitable linear
standards such as Standard Reference Materials (SRM) 1475a, 1482a,
1483, or 1484a. The chromatographic concentrations are assumed low
enough to eliminate addressing 2.sup.nd viral coefficient effects
(concentration effects on molecular weight).
[0112] Analytical Temperature Rising Elution Fractionation
(ATREF)
[0113] High Density Fraction (percent) is measured via analytical
temperature rising elution fractionation analysis (ATREF). ATREF
analysis is conducted according to the method described in U.S.
Pat. No. 4,798,081 and Wilde, L.; Ryle, T. R.; Knobeloch, D. C.;
Peat, I. R.; Determination of Branching Distributions in
Polyethylene and Ethylene Copolymers, Journal of Polymer Science,
20, 441-455 (1982). The composition to be analyzed is dissolved in
trichlorobenzene and allowed to crystallize in a column containing
an inert support (stainless steel shot) by slowly reducing the
temperature to 20.degree. C. at a cooling rate of 0.1.degree.
C./min. The column is equipped with an infrared detector. An ATREF
chromatogram curve is then generated by eluting the crystallized
polymer sample from the column by slowly increasing the temperature
of the eluting solvent (trichlorobenzene) from 20 to 120.degree. C.
at a rate of 1.5.degree. C./min. Viscosity average molecular weight
(Mv) of the eluting polymer is measured and reported. An ATREF plot
has the short chain branching distribution (SCBD) plot and a
molecular weight plot. The SCBD plot has 3 peaks, one for the high
crystalline fraction (typically above 90.degree. C.), one for
copolymer fraction (typically in between 30-90.degree. C.) and one
for purge fraction (typically below 30.degree. C.). The curve also
has a valley in between the copolymer and the high crystalline
fraction. Thc is the lowest temperature in this valley. % High
density (HD) fraction is the area under the curve above Thc. Mv is
the viscosity average molecular weight from ATREF. Mhc is the
average Mv for fraction above Thc. Mc is the average Mv of
copolymer between 60-90.degree. C. Mp is the average Mv of whole
polymer.
[0114] Fast Temperature Rising Elution Fractionation (F-TREF)
[0115] The fast-TREF can be performed with a Crystex instrument by
Polymer ChAR (Valencia, Spain) in orthodichlorobenzene (ODCB) with
IR-4 infrared detector in compositional mode (Polymer ChAR, Spain)
and light scattering (LS) detector (Precision Detector Inc.,
Amherst, Mass.).
[0116] When testing F-TREF, 120 mg of the sample is added into a
Crystex reactor vessel with 40 ml of ODCB held at 160.degree. C.
for 60 minutes with mechanical stirring to achieve sample
dissolution. The sample is loaded onto TREF column. The sample
solution is then cooled down in two stages: (1) from 160.degree. C.
to 100.degree. C. at 40.degree. C./minute, and (2) the polymer
crystallization process started from 100.degree. C. to 30.degree.
C. at 0.4.degree. C./minute. Next, the sample solution is held
isothermally at 30.degree. C. for 30 minutes. The
temperature-rising elution process starts from 30.degree. C. to
160.degree. C. at 1.5.degree. C./minute with flow rate of 0.6
ml/minute. The sample loading volume is 0.8 ml. Sample molecular
weight (M.sub.w) is calculated as the ratio of the 15.degree. or
90.degree. LS signal over the signal from measuring sensor of IR-4
detector. The LS-MW calibration constant is obtained by using
polyethylene national bureau of standards SRM 1484a. The elution
temperature is reported as the actual oven temperature. The tubing
delay volume between the TREF and detector is accounted for in the
reported TREF elution temperature.
[0117] Preparative Temperature Rising Elution Fractionation
(P-TREF)
[0118] The temperature rising elution fractionation method (TREF)
can be used to preparatively fractionate the polymers (P-TREF) and
is derived from Wilde, L.; Ryle, T. R.; Knobeloch, D. C.; Peat, I.
R.; "Determination of Branching Distributions in Polyethylene and
Ethylene Copolymers", J. Polym. Sci., 20, 441-455 (1982), including
column dimensions, solvent, flow and temperature program. An
infrared (IR) absorbance detector is used to monitor the elution of
the polymer from the column. Separate temperature programmed liquid
baths--one for column loading and one for column elution--are also
used.
[0119] Samples are prepared by dissolution in trichlorobenzene
(TCB) containing approximately 0.5%
2,6-di-tert-butyl-4-methylphenol at 160.degree. C. with a magnetic
stir bar providing agitation. Sample load is approximately 150 mg
per column. After loading at 125.degree. C., the column and sample
are cooled to 25.degree. C. over approximately 72 hours. The cooled
sample and column are then transferred to the second temperature
programmable bath and equilibrated at 25.degree. C. with a 4
ml/minute constant flow of TCB. A linear temperature program is
initiated to raise the temperature approximately 0.33.degree.
C./minute, achieving a maximum temperature of 102.degree. C. in
approximately 4 hours.
[0120] Fractions are collected manually by placing a collection
bottle at the outlet of the IR detector. Based upon earlier ATREF
analysis, the first fraction is collected from 56 to 60.degree. C.
Subsequent small fractions, called subfractions, are collected
every 4.degree. C. up to 92.degree. C., and then every 2.degree. C.
up to 102.degree. C. Subfractions are referred to by the midpoint
elution temperature at which the subfraction is collected.
[0121] Subfractions are often aggregated into larger fractions by
ranges of midpoint temperature to perform testing. Fractions may be
further combined into larger fractions for testing purposes.
[0122] A weight-average elution temperature is determined for each
Fraction based upon the average of the elution temperature range
for each subfraction and the weight of the subfraction versus the
total weight of the sample. Weight average temperature is defined
as:
T w = T T ( f ) * A ( f ) / T A ( f ) , ##EQU00001##
where T(f) is the mid-point temperature of a narrow slice or
segment and A(f) is the area of the segment, proportional to the
amount of polymer, in the segment.
[0123] Data are stored digitally and processed using an EXCEL
(Microsoft Corp.; Redmond, Wash.) spreadsheet. The TREF plot, peak
maximum temperatures, fraction weight percentages, and fraction
weight average temperatures were calculated with the spreadsheet
program.
[0124] Haze is determined according to ASTM-D 1003.
[0125] Gloss 45.degree. is determined according to ASTM-2457.
[0126] Elmendorf Tear Resistance is measured according to ASTM-D
1922.
[0127] Dart Impact Strength is measured according to ASTM-D
1709-04, Method A.
[0128] C13 NMR Comonomer Content
[0129] It is well known to use NMR spectroscopic methods for
determining polymer composition. ASTM D 5017-96, J. C. Randall et
al., in "NMR and Macromolecules" ACS Symposium series 247, J. C.
Randall, Ed., Am. Chem. Soc., Washington, D.C., 1984, Ch. 9, and J.
C. Randall in "Polymer Sequence Determination", Academic Press, New
York (1977) provide general methods of polymer analysis by NMR
spectroscopy.
[0130] Gel Content Measurement
[0131] When the ethylene interpolymer, either alone or contained in
a composition is at least partially crosslinked, the degree of
crosslinking may be measured by dissolving the composition in a
solvent for specified duration, and calculating the percent gel or
unextractable component. The percent gel normally increases with
increasing crosslinking levels. For cured articles according to the
invention, the percent gel content is desirably in the range from
at least about 5 to 100 percent as measured according to ASTM
D-2765.
EXAMPLES
[0132] Preparation of Ethylene-Based Polymers
[0133] Multi-Constituent Catalyst
[0134] An exemplary multi-constituent catalyst system includes a
Ziegler-Natta catalyst composition including a magnesium and
titanium containing procatalyst and a cocatalyst. The procatalyst
is a titanium supported MgCl.sub.2 Ziegler Natta catalyst
characterized by a Mg:Ti molar ratio of 40:1.0. The cocatalyst is a
triethylaluminum. The procatalyst may have a Ti:Mg ratio between
1.0:40 to 5.0:40, preferably 3.0:40. The procatalyst and the
cocatalyst components can be contacted either before entering the
reactor or in the reactor. The procatalyst may, for example, be any
other titanium based Ziegler Natta catalyst. The Al:Ti molar ratio
of cocatalyst component to procatalyst component can be from about
1:1 to about 5:1.
[0135] General Description of the Multi-Constituent Catalyst
System
[0136] The multi-constituent catalyst system, as used herein,
refers to a Ziegler-Natta catalyst composition including a
magnesium and titanium containing procatalyst and a cocatalyst. The
procatalyst may, for example, comprise the reaction product of
magnesium dichloride, an alkylaluminum dihalide, and a titanium
alkoxide.
[0137] The olefin polymerization procatalyst precursors comprise
the product which results from combining:
[0138] (A) a magnesium halide prepared by contacting:
[0139] (1) at least one hydrocarbon soluble magnesium component
represented by the general formula R''R'Mg.xAlR'3 wherein each R''
and R' are alkyl groups
[0140] (2) at least one non-metallic or metallic halide source
under conditions such that the reaction temperature does not exceed
about 60.degree. C., preferably does not exceed about 40.degree.
C., and most preferably does not exceed about 35.degree. C.;
[0141] (B) at least one transition metal compound represented by
the formula Tm(OR)y Xy-x wherein Tm is a metal of Groups IVB, VB,
VIB, VIIB or VIII of the Periodic Table; R is a hydrocarbyl group
having from 1 to about 20, preferably from 1 to about 10 carbon
atoms.
[0142] (C) an additional halide source if an insufficient quantity
of component (A-2) is present to provide the desired excess X:Mg
ratio;
[0143] Particularly suitable transition metal compounds include,
for example, titanium tetrachloride, titanium trichloride, vanadium
tetrachloride, zirconium tetrachloride, tetra(isopropoxy)-titanium,
tetrabutoxytitanium, diethoxytitanium dibromide, dibutoxytitanium
dichloride, tetraphenoxytitanium, tri-isopropoxy vanadium oxide,
zirconium tetra-n-propoxide, mixtures thereof and the like.
[0144] Other suitable titanium compounds which can be employed as
the transition metal component herein include those titanium
complexes and/or compounds resulting from reacting:
[0145] (A) at least one titanium compound represented by the
formula Ti(OR)x X4-x wherein each R is independently a hydrocarbyl
group having from 1 to about 20, preferably from about 1 to about
10, most preferably from about 2 to about 4 carbon atoms; X is a
halogen and x has a value from zero to 4; with
[0146] (B) at least one compound containing at least one aromatic
hydroxyl group.
[0147] The foregoing procatalyst components are combined in
proportions sufficient to provide atomic ratios as previously
mentioned.
[0148] The foregoing pro-catalytic reaction product is preferably
prepared in the presence of an inert diluent. The concentrations of
catalyst components are preferably such that when the essential
components of the catalytic reaction product are combined, the
resultant slurry is from about 0.005 to about 1.0 molar
(moles/liter) with respect to magnesium. By way of an example of
suitable inert organic diluents can be mentioned liquified ethane,
propane, isobutane, n-butane, n-hexane, the various isomeric
hexanes, isooctane, paraffinic mixtures of alkanes having from 8 to
12 carbon atoms, cyclohexane, methylcyclopentane,
dimethylcyclohexane, dodecane, industrial solvents composed of
saturated or aromatic hydrocarbons such as kerosene, naphthas,
etc., especially when freed of any olefin compounds and other
impurities, and especially those having boiling points in the range
from about -50.degree. C. to about 200.degree. C. Mixing of the
procatalyst components to provide the desired catalytic reaction
product is advantageously prepared under an inert atmosphere such
as nitrogen, argon or other inert gas at temperatures in the range
from about -100.degree. C. to about 200.degree. C., preferably from
about -20.degree. C. to about 100.degree. C., provided that the
magnesium halide support is prepared such that the reaction
temperature does not exceed about 60.degree. C. In the preparation
of the catalytic reaction product, it is not necessary to separate
hydrocarbon soluble components from hydrocarbon insoluble
components of the reaction product.
[0149] The procatalyst composition serves as one component of a
Ziegler-Natta catalyst composition, in combination with a
cocatalyst. The cocatalyst is preferably employed in a molar ratio
based on titanium in the procatalyst of from 1:1 to 100:1, but more
preferably in a molar ratio of from 1:1 to 5:1.
Inventive Example 1
[0150] Inventive Example 1 is made according to the following
procedures: A heterogeneously branched ethylene/a-olefin copolymer
is prepared using a multi-constituent catalyst system, as described
hereinabove, suitable for (co)polymerizing ethylene and one or more
.alpha.-olefin comonomers, e.g. 1-octene, in two adiabatic
spherical reactors, linked together in series, operating under a
solution condition. The ethylene monomer, 1-octene comonomer, and
hydrogen were combined with a solvent, e.g. Isopar.RTM. E,
commercially available from ExxonMobil. The feed streams are
purified from polar impurities such as water, carbon monoxide,
sulfurous compounds, and unsaturated compounds such as acetylene
and cooled to 13.degree. C. before entering the reactor. The
majority (85-90%) of the reaction occurs in the first sphere
reactor that is 10-foot diameter. The mixing is achieved via
circulating the
polymer/catalyst/cocatalyst/solvent/ethylene/co-monomer/hydrogen
solution with agitator equipped with mixing blades. The feed
(ethylene/comonomer/solvent/hydrogen) enters the reactor from the
bottom and the catalyst/cocatalyst enters the reactor separately
from the feed and also from the bottom. The first reactor
temperature is about 175.degree. C., and the reactor pressure is
about 500 psi. The temperature of the second reactor, in series
with the first, increases to 202.degree. C. with approximately
10-15% of the remaining reaction occurring and no additional
streams added. Catalyst/Co-catalyst Al/Ti molar feed ratio is set
at 1.5. The average reactor residence time is about 8 minutes per
sphere reactor prior to termination post-reactor by a fluid
specially designed for that purpose. After the polymer solution
leaves the reactor, the solvent with unconverted ethylene monomer
and 1-octene comonomer is removed from the polymer solution via a
two stage devolatilizer system, and then recycled. The recycled
stream is purified before entering the reactor again. The polymer
melt is pumped through a die specially designed for underwater
pelletization. The pellets are transferred to classifier screens to
remove over and undersize particles. The finished pellets are then
transferred to rail cars. The properties of the heterogeneously
branched ethylene/.alpha.-olefin copolymer are listed in Table 1.
FIG. 1 is an ATREF of Inventive Example 1.
[0151] The heterogeneously branched ethylene/.alpha.-olefin
copolymer is further processed via blown film extrusion process on
Gloucester line with a 6-inch diameter Sano die. The die has a gap
of 70 mils. The film is blown with a blow up ratio of about 2.5 and
a frost-line height of about 30 inches. The layflat width of the
film is about 23.5 inches, while the thickness of the films is
about 2 mils. The heterogeneously branched ethylene/.alpha.-olefin
copolymer is melt extruded through an annular circular die. The hot
melt emerges from the die thereby forming a tube. The tube is
expanded by air, and at the same time, the cooled air chills the
web to a solid state. The film tube is then collapsed within a
V-shaped frame of rollers and is nipped at the end of the frame to
trap the air within the bubble. The nip rolls also draw the film
away from the die. The tube is slit and wound as a single-film
layer onto a roll. The properties of the inventive film 1 are
listed in Table 2.
Comparative Example 1
[0152] Comparative Example 1, a linear low density polyethylene, is
made at 190 C reactor temperature and 3.5:1 Al/Ti ratio. All other
conditions remain the same as the Inventive Example 1. The
properties of Comparative Example 1 are listed in Table 1. FIG. 1
is an ATREF of Comparative Example 1. The Comparative Example 1 is
processed via blown film extrusion process, as described above. The
Comparative Example 1 is melt extruded through an annular circular
die. The hot melt emerges from the die thereby forming a tube. The
tube is expanded by air, and at the same time, the cooled air
chills the web to a solid state. The film tube is then collapsed
within a V-shaped frame of rollers and is nipped at the end of the
frame to trap the air within the bubble. The nip rolls also draw
the film away from the die. The tube is slit and wound as a
single-film layer onto a roll. The properties of the comparative
film 1 are listed in Table 2.
Figures & Tables
TABLE-US-00001 [0153] TABLE 1 Resin production and characterization
data for inventive and comparative example 1. Inventive Comparative
Description Example 1 Example 1 Resin MI (g/10 minutes) 0.80 0.80
Resin density (g/cc) 0.917 0.917 Catalyst HEC-3 HEC-3 Ti/40 Mg 3 3
Al/Ti 1.5 3.5 Rx. Temp (.degree. C.) 175 190 M.sub.hc 103000 143000
M.sub.c 64234 54815 M.sub.p 76542 71007 M.sub.hc/M.sub.p 1.35 2.01
M.sub.c/M.sub.p 0.84 0.77 % HD fraction - ATREF 10.6 15.4 T.sub.hc,
lowest temperature in the valley between copolymer and high
crystalline fraction M.sub.v, viscosity average molecular weight
from ATREF M.sub.hc, Average Mv for fraction above T.sub.hc from
ATREF M.sub.c, Avg Mv of copolymer between 60-90.degree. C. - ATREF
M.sub.p, Average Mv of whole polymer from ATREF % HD fraction, area
under the curve above T.sub.hc
TABLE-US-00002 TABLE 2 Properties of films made from Inventive
example 1 and Comparative example 1. Inventive Comparative
Description Example 1 Example 1 Target thickness mil 2 2 Dart A g
724 533 Gloss 45.degree. 91 70 Haze % 5.6 10.6 Normalized MD Tear
g/mil 477 469
[0154] While the embodiments have been described with
particularity, it will be understood that various other
modifications will be apparent to and can be readily made by those
skilled in the art without departing from the spirit and scope of
the invention. Accordingly, it is not intended that the scope of
the claims to be limited to the examples and descriptions set forth
but rather that the claims be construed as encompassing all the
features of patentable novelty which reside in the present
invention, including all features which would be treated as
equivalents by those skilled in the art to which the invention
pertains.
[0155] It is intended that the disclosure of preferred or desired,
more preferred or more desired, highly preferred or highly desired,
or most preferred or most desired substituents, ranges, end uses,
processes, or combinations with respect to any one of the disclosed
compositions and methods is applicable as well to any other of the
preceding or succeeding embodiments of the disclosed compositions
and methods, independently of the identity of any other specific
substituent, range, use, process, or combination.
[0156] Unless otherwise stated, implicit from the context or
conventional in the art, all parts and percentages are based on
weight.
[0157] All applications, publications, patents, test procedures,
and other documents cited, including priority documents, are fully
incorporated by reference to the extent such disclosure is not
inconsistent with the disclosed compositions and methods and for
all jurisdictions in which such incorporation is permitted.
[0158] Depending upon the context in which such values are
described, and unless specifically stated otherwise, such values
may vary by 1 percent, 2 percent, 5 percent, or, sometimes, 10 to
20 percent. Whenever a numerical range with a lower limit, RL, and
an upper limit, RU, is disclosed, any number falling within the
range, including the limits themselves is specifically disclosed.
In particular, the following numbers within the range are
specifically disclosed: R=RL+k*(RU-RL), wherein k is a variable
ranging from 0.01 to 1.00 with a 0.01 increment, that is, k is 0.01
or 0.02 to 0.99 or 1.00. Moreover, any numerical range defined by
two R numbers as defined is also specifically disclosed.
* * * * *