WO2000004088A1 - Method for increasing transparency in blown polyethylene films - Google Patents

Method for increasing transparency in blown polyethylene films Download PDF

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Publication number
WO2000004088A1
WO2000004088A1 PCT/US1999/015555 US9915555W WO0004088A1 WO 2000004088 A1 WO2000004088 A1 WO 2000004088A1 US 9915555 W US9915555 W US 9915555W WO 0004088 A1 WO0004088 A1 WO 0004088A1
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Prior art keywords
polyethylene
nucleating agent
acrylic acid
melt
films
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Application number
PCT/US1999/015555
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French (fr)
Inventor
Arnold Lustiger
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Exxon Research And Engineering Company
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Publication date
Application filed by Exxon Research And Engineering Company filed Critical Exxon Research And Engineering Company
Priority to AU49805/99A priority Critical patent/AU4980599A/en
Publication of WO2000004088A1 publication Critical patent/WO2000004088A1/en

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    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/04Homopolymers or copolymers of ethene
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00Use of organic ingredients
    • C08K5/0008Organic ingredients according to more than one of the "one dot" groups of C08K5/01 - C08K5/59
    • C08K5/0083Nucleating agents promoting the crystallisation of the polymer matrix
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L51/00Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
    • C08L51/06Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers grafted on to homopolymers or copolymers of aliphatic hydrocarbons containing only one carbon-to-carbon double bond
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2201/00Properties
    • C08L2201/10Transparent films; Clear coatings; Transparent materials
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2205/00Polymer mixtures characterised by other features
    • C08L2205/02Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2314/00Polymer mixtures characterised by way of preparation
    • C08L2314/06Metallocene or single site catalysts

Definitions

  • the invention is directed towards increasing transparency in blown polyethylene films.
  • Polyolefin films are frequently formed as blown films.
  • Film blowing involves continuously extruding a polymer melt through a die in order to form a continuous cylinder of viscous polymer, and then expanding the diameter of the cylinder through, for example, a pressure differential between the inside and outside of the cylinders.
  • the cylinder is at a desired radius approximately equal to ⁇ times the reciprocal of the width of a take-up spool and the cylinder's wall thickness is approximately equal to the desired film thickness, the film is parted longitudinally and then wound onto the take-up spool.
  • Increased transparency can be obtained in polypropylene films by adding nucleating agents. See, for example, U.S. Patent 4,611,024. It is believed that spherulite formation in polypropylene affects film transparency. Opacity (i.e., a loss in transparency) is believed to result from the presence in the film of spherulites larger than about 1 micron because such spherulites would scatter visible light. Adding and dispersing nucleating agents into the melt from which the film is blown increases transparency because average spherulite size is reduced to below 1 micron. Visible light is therefore not strongly scattered by the film. Blown films prepared from conventional Ziegler-Natta catalyzed polyethylene can also suffer from reduced transparency.
  • the opacity in Ziegler-Natta catalyzed polyethylene is believed to result, in part, from a different mechanism than that which is believed to cause opacity in polypropylene films.
  • the opacity is believed to result in part from the presence of large spherulites, as in polypropylene, and in part from the presence of low molecular weight species such as waxes that naturally form during polymerization.
  • Metallocene-prepared polyolefin films generally provide significant improvements in physical properties, such as transparency, over their Ziegler-Natta-prepared counterparts. However, further transparency improvement is desirable.
  • the invention is a method for providing a polyethylene melt from which films of increased transparency can be formed, the method comprising forming a melt of polyethylene and a nucleating agent selected from the group consisting of ethylene copolymers containing grafted maleic anhydride, ethylene copolymers containing grafted acrylic acid, and mixtures thereof.
  • the invention is a composition comprising polyethylene and a nucleating agent selected from the group consisting of ethylene copolymers containing grafted maleic anhydride, ethylene copolymers containing grafted acrylic acid, and mixtures thereof.
  • Transparency can be increased in polyethylene films blown from a melt by forming the melt from a nucleating agent and polyethylene.
  • the preferred nucleating agents are ethylene copolymers containing grafted maleic anhydride, ethylene copolymers containing grafted acrylic acid, and mixtures thereof, with acrylic acid-ethylene copolymers being particularly preferred.
  • the additive may also be used together with sodium stearate as an acid neutralizing agent present in a concentration ranging from about 0.005 wt.% to about 0.1 wt.% based on the weight of the polyethylene and nucleating agent.
  • the preferred concentration of sodium stearate when present, ranges from about 0.01 wt.% to about 0.1 wt.% based on the weight of the copolymer and nucleating agent.
  • the nucleating agents of the present invention provide enhanced properties in blown polyethylene films, especially films blown from polyethylene formed in a process using at least one metallocene catalyst or co- catalyst.
  • An effective amount of nucleating agent, or mixtures thereof, is added to or combined with a polyethylene melt prior to film processing.
  • the effective amount generally ranges from about 0.1 wt.% to about 5 wt.% based on the added weight of the polyethylene and nucleating agent, with the range of about 0.1 wt.% to about 0.5 wt.% being preferred.
  • Polyethylene useful in the practice of the invention ranges melt index from about 0.3 dg/min to about 4 dg/min. Melts formed from the polyethylene and the nucleating agents of the invention are compatible with conventional film-blowing equipment. Methods of combining the polyethylene and nucleating agent include melt-homogenization and tumbling powdered polyethylene resin and powdered nucleating agent together in a barrel blender.
  • the graft copolymers used as nucleating agents in this invention range in density from about 0.92 to about 0.96 g/cm , with about .95 g/cm being preferred in the case of ethylene-acrylic acid and about .92 g/cm 3 preferred in the case of maleic anhydride.
  • the copolymer may also contain about 1 to about 25 butene branches per thousand carbon atoms, with about 10 to about 18 branches being preferred.
  • the acrylic acid level in the ethylene acrylic acid graft copolymers is about 2 to about 8% with about 5 to about 6% being preferred.
  • the maleic anhydride level in the ethylene maleic anhydride graft copolymer is about 0.25 to about 2%, with about 1% being preferred.
  • Copolymer nucleating agents useful in the invention range in melt index from about 0.5 dg/min to about 10 dg/min, with about 1 dg/min to about 6 dg/min being preferred.
  • Table 1 summarizes the optical properties of representative metallocene-prepared polyethylene melts that contain nucleating agents of the present invention. Films were blown from five different melts. The melts are labeled samples 1 through 5, respectively.
  • Sample 1 contained Ziegler-Natta polymerized polyethylene and none of the nucleating agents of the present invention.
  • Sample 2 contained .25 wt.% ethylene-acrylic acid copolymer with the balance being Ziegler-Natta polymerized polyethylene.
  • Sample 3 contained polyethylene prepared in the presence of a metallocene catalyst and none of the nucleating agents of the present invention.
  • Sample 4 contained polyethylene prepared in the presence of a metallocene catalyst and 0.25 wt.% ethylene- acrylic acid copolymer.
  • Sample 5 contained polyethylene prepared in the presence of a metallocene catalyst and 0.25 wt.% ethylene-butene copolymer containing maleic anhydride grafts. Polyethylene films were blown from each melt, and haze values for each sample are also recorded in the Table. Haze is a measure of opacity; higher haze values indicates lower transparency.
  • 0.001 inch thick films were extruded at a rate of about 150 lineal feet per minute. Melt temperature ranged from about 400 to about 450°C.
  • the Table shows that a factor of two improvements in film transparency is obtained when the film is formed from a melt in which the nucleating agents of the present invention are added to Ziegler-Natta polymerized polyethylene. This improvement is believed to result from the nucleating agent inhibiting spherulite formation during film blowing.
  • the Table also shows that metallocene-prepared polyethylene forms a film without nucleating agent that is as transparent as one formed from Ziegler-Natta polyethylene that contains nucleating agent. While not wishing to be bound, it is believed that the presence of the low molecular weight species such as waxes in the Ziegler-Natta polyethylene limits the ultimate transparency that can be obtained even when spherulite formation is suppressed. Metallocene-prepared polyethylene has a much narrower molecular weight distribution, and the low molecular weight species are believed to be absent or present in very small concentrations.
  • Preparing the polyethylene in a metallocene polymerization process results in the absence of such high molecular weight material, leading consequentially to large spherulite formation in the absence of an added nucleating agent.
  • adding nucleating agents of the present invention to the melt results in blown films having the greatest transparency because, it is believed, low molecular weight species that partially cause increased opacity in conventionally-prepared polyethylene films are substantially absent in the metallocene-prepared materials.

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  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Manufacture Of Macromolecular Shaped Articles (AREA)
  • Compositions Of Macromolecular Compounds (AREA)

Abstract

The invention is directed towards a method for improving transparency in blown polyethylene films. Accordingly, a nucleating agent and polyethylene are combined to form a melt form which the film is blown. The method comprises forming a melt of polyethylene and a nucleating agent selected form the group consisting of ethylene copolymers containing grafted maleic anhydride, ethylene copolymers containing grafted acrylic acid, and mixtures thereof. Polyethylene films having increased transparency can be blown therefrom.

Description

METHOD FOR INCREASING TRANSPARENCY IN BLOWN POLYETHYLENE FILMS
FIELD OF THE INVENTION
The invention is directed towards increasing transparency in blown polyethylene films.
BACKGROUND OF THE INVENTION
Polyolefin films, especially polyethylene films, are frequently formed as blown films. Film blowing involves continuously extruding a polymer melt through a die in order to form a continuous cylinder of viscous polymer, and then expanding the diameter of the cylinder through, for example, a pressure differential between the inside and outside of the cylinders. When the cylinder is at a desired radius approximately equal to π times the reciprocal of the width of a take-up spool and the cylinder's wall thickness is approximately equal to the desired film thickness, the film is parted longitudinally and then wound onto the take-up spool.
Increased transparency can be obtained in polypropylene films by adding nucleating agents. See, for example, U.S. Patent 4,611,024. It is believed that spherulite formation in polypropylene affects film transparency. Opacity (i.e., a loss in transparency) is believed to result from the presence in the film of spherulites larger than about 1 micron because such spherulites would scatter visible light. Adding and dispersing nucleating agents into the melt from which the film is blown increases transparency because average spherulite size is reduced to below 1 micron. Visible light is therefore not strongly scattered by the film. Blown films prepared from conventional Ziegler-Natta catalyzed polyethylene can also suffer from reduced transparency. However, the opacity in Ziegler-Natta catalyzed polyethylene is believed to result, in part, from a different mechanism than that which is believed to cause opacity in polypropylene films. In Ziegler-Natta catalyzed polyethylene the opacity is believed to result in part from the presence of large spherulites, as in polypropylene, and in part from the presence of low molecular weight species such as waxes that naturally form during polymerization.
Metallocene-prepared polyolefin films generally provide significant improvements in physical properties, such as transparency, over their Ziegler-Natta-prepared counterparts. However, further transparency improvement is desirable.
There is therefore a need for nucleating agents that are effective methods for increasing transparency in blown polyethylene films.
SUMMARY OF THE PRESENT INVENTION
In one embodiment, the invention is a method for providing a polyethylene melt from which films of increased transparency can be formed, the method comprising forming a melt of polyethylene and a nucleating agent selected from the group consisting of ethylene copolymers containing grafted maleic anhydride, ethylene copolymers containing grafted acrylic acid, and mixtures thereof.
In another embodiment, the invention is a composition comprising polyethylene and a nucleating agent selected from the group consisting of ethylene copolymers containing grafted maleic anhydride, ethylene copolymers containing grafted acrylic acid, and mixtures thereof.
DETAILED DESCRIPTION OF THE INVENTION
Transparency can be increased in polyethylene films blown from a melt by forming the melt from a nucleating agent and polyethylene. The preferred nucleating agents are ethylene copolymers containing grafted maleic anhydride, ethylene copolymers containing grafted acrylic acid, and mixtures thereof, with acrylic acid-ethylene copolymers being particularly preferred. The additive may also be used together with sodium stearate as an acid neutralizing agent present in a concentration ranging from about 0.005 wt.% to about 0.1 wt.% based on the weight of the polyethylene and nucleating agent. The preferred concentration of sodium stearate, when present, ranges from about 0.01 wt.% to about 0.1 wt.% based on the weight of the copolymer and nucleating agent.
The nucleating agents of the present invention provide enhanced properties in blown polyethylene films, especially films blown from polyethylene formed in a process using at least one metallocene catalyst or co- catalyst. An effective amount of nucleating agent, or mixtures thereof, is added to or combined with a polyethylene melt prior to film processing. The effective amount generally ranges from about 0.1 wt.% to about 5 wt.% based on the added weight of the polyethylene and nucleating agent, with the range of about 0.1 wt.% to about 0.5 wt.% being preferred.
Polyethylene useful in the practice of the invention ranges melt index from about 0.3 dg/min to about 4 dg/min. Melts formed from the polyethylene and the nucleating agents of the invention are compatible with conventional film-blowing equipment. Methods of combining the polyethylene and nucleating agent include melt-homogenization and tumbling powdered polyethylene resin and powdered nucleating agent together in a barrel blender.
The graft copolymers used as nucleating agents in this invention range in density from about 0.92 to about 0.96 g/cm , with about .95 g/cm being preferred in the case of ethylene-acrylic acid and about .92 g/cm3 preferred in the case of maleic anhydride. In the case of ethylene-maleic anhydride graft copolymers, the copolymer may also contain about 1 to about 25 butene branches per thousand carbon atoms, with about 10 to about 18 branches being preferred. The acrylic acid level in the ethylene acrylic acid graft copolymers is about 2 to about 8% with about 5 to about 6% being preferred. The maleic anhydride level in the ethylene maleic anhydride graft copolymer is about 0.25 to about 2%, with about 1% being preferred. Copolymer nucleating agents useful in the invention range in melt index from about 0.5 dg/min to about 10 dg/min, with about 1 dg/min to about 6 dg/min being preferred.
Table 1 summarizes the optical properties of representative metallocene-prepared polyethylene melts that contain nucleating agents of the present invention. Films were blown from five different melts. The melts are labeled samples 1 through 5, respectively. Sample 1 contained Ziegler-Natta polymerized polyethylene and none of the nucleating agents of the present invention. Sample 2 contained .25 wt.% ethylene-acrylic acid copolymer with the balance being Ziegler-Natta polymerized polyethylene. Sample 3 contained polyethylene prepared in the presence of a metallocene catalyst and none of the nucleating agents of the present invention. Sample 4 contained polyethylene prepared in the presence of a metallocene catalyst and 0.25 wt.% ethylene- acrylic acid copolymer. Sample 5 contained polyethylene prepared in the presence of a metallocene catalyst and 0.25 wt.% ethylene-butene copolymer containing maleic anhydride grafts. Polyethylene films were blown from each melt, and haze values for each sample are also recorded in the Table. Haze is a measure of opacity; higher haze values indicates lower transparency.
0.001 inch thick films were extruded at a rate of about 150 lineal feet per minute. Melt temperature ranged from about 400 to about 450°C.
TABLE 1
POLYMER SAMPLE 1 SAMPLE 2 SAMPLE 3 SAMPLE 4 SAMPLE 5
Measured Haze 20% 9.20% 9.90% 3.70% 5%
The Table shows that a factor of two improvements in film transparency is obtained when the film is formed from a melt in which the nucleating agents of the present invention are added to Ziegler-Natta polymerized polyethylene. This improvement is believed to result from the nucleating agent inhibiting spherulite formation during film blowing.
The Table also shows that metallocene-prepared polyethylene forms a film without nucleating agent that is as transparent as one formed from Ziegler-Natta polyethylene that contains nucleating agent. While not wishing to be bound, it is believed that the presence of the low molecular weight species such as waxes in the Ziegler-Natta polyethylene limits the ultimate transparency that can be obtained even when spherulite formation is suppressed. Metallocene-prepared polyethylene has a much narrower molecular weight distribution, and the low molecular weight species are believed to be absent or present in very small concentrations. When the nucleating agents of the present invention are added to metallocene-prepared polyethylene, as in Samples 4 and 5, still further reductions in haze are obtained compared to the Ziegler-Natta-prepared polyethylene films formed with or without nucleating agent. It is believed that this additional improvement is due to the inhibition of spherulite formation, films formed from the metallocene-prepared polyethylene being already substantially free of low molecular weight species.
In summary, it has been discovered that combining a nucleating agent with a polyethylene melt when forming blown films formed from either metallocene-prepared or Ziegler-Natta-prepared polyethylene causes a substantial increase in film transparency.
It is believed that the opacity in metallocene-prepared polyethylene films results from the presence of large spherulites in the films. Spherulite growth is inhibited when nucleating agents are present in the melt from which the film is blown. Although spherulite growth is somewhat suppressed in conventionally-prepared (i.e., Ziegler-Natta-prepared) polyethylene because the high molecular weight species present in that material function as a nucleating agent, adding the nucleating agents of the present invention to conventionally- prepared polyethylene melts results in greater spherulite growth suppression, and films blown therefrom exhibit increased transparency.
Preparing the polyethylene in a metallocene polymerization process results in the absence of such high molecular weight material, leading consequentially to large spherulite formation in the absence of an added nucleating agent. However, adding nucleating agents of the present invention to the melt results in blown films having the greatest transparency because, it is believed, low molecular weight species that partially cause increased opacity in conventionally-prepared polyethylene films are substantially absent in the metallocene-prepared materials.

Claims

CLAIMS:
1. A composition comprising polyethylene and a nucleating agent selected from the group consisting of ethylene copolymers containing grafted maleic anhydride, ethylene copolymers containing grafted acrylic acid, and mixtures thereof.
2. The composition of claim 1 wherein the polyethylene ranges in number average melt index from about .3 dg/min to about 4 dg/min.
3. The composition of claim 2 wherein the nucleating agent is present in an amount ranging from about 0.1 wt.% to about 5 wt.% based on the added weight of the polyethylene and nucleating agent.
4. The composition of claim 3 wherein the nucleating agent is an ethylene copolymer containing grafted acrylic acid having a density ranging from about 0.92 to about 0.96 g/cm and an acrylic acid concentration ranging from about 2 wt.% to about 8 wt.% based on the weight of the copolymer.
5. The composition of claim 4 wherein the polyethylene is formed in a polymerization process using at least one metallocene catalyst or cocatalyst.
6. A method for providing a melt from which polyethylene films of increased transparency can be formed, the method comprising combining polyethylene and a nucleating agent selected from the group consisting of ethylene copolymers containing grafted maleic anhydride, ethylene copolymers containing grafted acrylic acid, and mixtures thereof, and forming the melt therefrom.
7. The method of claim 6 wherein the polyethylene ranges in melt index from about 0.3 to about 4.
8. The method of claim 7 wherein the nucleating agent is present in an amount ranging from about 0.1 wt.% to about 5 wt.% based on the added weight of the polyethylene and nucleating agent.
9. The method of claim 8 wherein the nucleating agent is an ethylene copolymer containing grafted acrylic acid having a density ranging from about 0.92 to about 0.96 g/cm3 and an acrylic acid concentration ranging from about 2 wt.% to about 8 wt.% based on the weight of the copolymer.
10. The method of claim 9 wherein the polyethylene is formed in a polymerization process using at least one metallocene catalyst or cocatalyst.
PCT/US1999/015555 1998-07-14 1999-07-09 Method for increasing transparency in blown polyethylene films WO2000004088A1 (en)

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US09/115,075 1998-07-14

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6649694B2 (en) 2001-12-21 2003-11-18 Eastman Chemical Company Process for producing ethylene-α-olefin interpolymer films
US7786203B2 (en) 2005-09-16 2010-08-31 Milliken & Company Polymer compositions comprising nucleating or clarifying agents and articles made using such compositions
CN103627072A (en) * 2012-08-23 2014-03-12 中国石油天然气股份有限公司 High-transparency polyolefin film master batch
CN103627070A (en) * 2012-08-23 2014-03-12 中国石油天然气股份有限公司 Low-haze polyethylene film resin composition
CN103627069A (en) * 2012-08-23 2014-03-12 中国石油天然气股份有限公司 High-transparency polyethylene film master batch

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0598626A2 (en) * 1992-11-19 1994-05-25 Mitsui Petrochemical Industries, Ltd. Ethylene copolymer composition

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0598626A2 (en) * 1992-11-19 1994-05-25 Mitsui Petrochemical Industries, Ltd. Ethylene copolymer composition

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6649694B2 (en) 2001-12-21 2003-11-18 Eastman Chemical Company Process for producing ethylene-α-olefin interpolymer films
US7786203B2 (en) 2005-09-16 2010-08-31 Milliken & Company Polymer compositions comprising nucleating or clarifying agents and articles made using such compositions
CN103627072A (en) * 2012-08-23 2014-03-12 中国石油天然气股份有限公司 High-transparency polyolefin film master batch
CN103627070A (en) * 2012-08-23 2014-03-12 中国石油天然气股份有限公司 Low-haze polyethylene film resin composition
CN103627069A (en) * 2012-08-23 2014-03-12 中国石油天然气股份有限公司 High-transparency polyethylene film master batch
CN103627072B (en) * 2012-08-23 2016-04-06 中国石油天然气股份有限公司 High-transparency polyolefin film master batch

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