WO2009029476A1 - ADHESIVES MADE FROM INTERPOLYMERS OF ETHYLENE/α-OLEFINS - Google Patents

ADHESIVES MADE FROM INTERPOLYMERS OF ETHYLENE/α-OLEFINS Download PDF

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Publication number
WO2009029476A1
WO2009029476A1 PCT/US2008/073831 US2008073831W WO2009029476A1 WO 2009029476 A1 WO2009029476 A1 WO 2009029476A1 US 2008073831 W US2008073831 W US 2008073831W WO 2009029476 A1 WO2009029476 A1 WO 2009029476A1
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Prior art keywords
ethylene
composition
percent
polymer
peak
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PCT/US2008/073831
Other languages
French (fr)
Inventor
Selim Yalvac
Colin Li Pi Shan
Terri Carvagno
William Butler
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Dow Global Technologies Inc.
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Publication date
Application filed by Dow Global Technologies Inc. filed Critical Dow Global Technologies Inc.
Priority to EP08798344.1A priority Critical patent/EP2185601B1/en
Priority to CN2008801132725A priority patent/CN101835815B/en
Priority to US12/674,198 priority patent/US8222339B2/en
Priority to JP2010522017A priority patent/JP2010537002A/en
Priority to BRPI0815310-8A priority patent/BRPI0815310B1/en
Publication of WO2009029476A1 publication Critical patent/WO2009029476A1/en

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    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J123/00—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers
    • C09J123/02—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers not modified by chemical after-treatment
    • C09J123/04—Homopolymers or copolymers of ethene
    • C09J123/08—Copolymers of ethene
    • C09J123/0807—Copolymers of ethene with unsaturated hydrocarbons only containing more than three carbon atoms
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61K—PREPARATIONS FOR MEDICAL, DENTAL OR TOILETRY PURPOSES
    • A61K9/00—Medicinal preparations characterised by special physical form
    • A61K9/14—Particulate form, e.g. powders, Processes for size reducing of pure drugs or the resulting products, Pure drug nanoparticles
    • A61K9/16—Agglomerates; Granulates; Microbeadlets ; Microspheres; Pellets; Solid products obtained by spray drying, spray freeze drying, spray congealing,(multiple) emulsion solvent evaporation or extraction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • B05D5/10—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain an adhesive surface
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F210/00—Copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
    • C08F210/14—Monomers containing five or more carbon atoms
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F210/00—Copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
    • C08F210/16—Copolymers of ethene with alpha-alkenes, e.g. EP rubbers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F2500/00—Characteristics or properties of obtained polyolefins; Use thereof
    • C08F2500/03—Narrow molecular weight distribution, i.e. Mw/Mn < 3
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F2500/00—Characteristics or properties of obtained polyolefins; Use thereof
    • C08F2500/08—Low density, i.e. < 0.91 g/cm3
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F2500/00—Characteristics or properties of obtained polyolefins; Use thereof
    • C08F2500/11—Melt tension or melt strength
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F2500/00—Characteristics or properties of obtained polyolefins; Use thereof
    • C08F2500/12—Melt flow index or melt flow ratio
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F2500/00—Characteristics or properties of obtained polyolefins; Use thereof
    • C08F2500/19—Shear ratio or shear ratio index
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F2500/00—Characteristics or properties of obtained polyolefins; Use thereof
    • C08F2500/20—Activation energy or enthalpy
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2666/00—Composition of polymers characterized by a further compound in the blend, being organic macromolecular compounds, natural resins, waxes or and bituminous materials, non-macromolecular organic substances, inorganic substances or characterized by their function in the composition
    • C08L2666/02—Organic macromolecular compounds, natural resins, waxes or and bituminous materials
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J153/00—Adhesives based on block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Adhesives based on derivatives of such polymers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/28—Web or sheet containing structurally defined element or component and having an adhesive outermost layer
    • Y10T428/2852—Adhesive compositions
    • Y10T428/2878—Adhesive compositions including addition polymer from unsaturated monomer

Definitions

  • This invention relates to adhesive compositions comprising at least one ethylene/ ⁇ -olefin interpolymer, methods of making the compositions, and methods of using the compositions in applications, such as hot melt adhesives, pressure sensitive adhesives, and thermoplastic marking compositions.
  • An adhesive is a substance capable of holding solid materials (e.g., adherents or substrates) together by surface attachment. Adhesives have been widely used since ancient times. Archaeologists have found evidence of substances being used as adhesives in Arabic dating back to 4000 B.C. and in Egypt between 1500-1000 B.C. The first adhesive patent was issued in about 1750 in England for a glue made from fish. Later, patents were issued for adhesives using natural rubber, animal bones, fish, starch, milk protein or casein.
  • Hot-melt adhesives at ambient temperature are generally solid materials that can be heated to a melt to hold adherents or substrates together upon cooling and solidifying. In some applications, the bonded substrates can be detached by remelting the hot melt adhesive if the substrates can withstand the heat.
  • the hot melt adhesives can be used in paper products, packaging materials, laminated wood panels, kitchen countertops, vehicles, tapes, labels, and a variety of disposable goods, particularly in health and hygiene applications, such as disposable diapers, hospital pads, feminine sanitary napkins, and surgical drapes. These hot melt adhesives are generally based on a polymer, tackifier, and a wax.
  • hot melt adhesives are based on polymer components including ethylene based semi-crystalline polymers such as ethylene-vinyl acetate copolymer (EVA) and linear low density polyethylene (LLDPE), styrene block copolymers (SBC) such as styrene-isoprene-styrene (SIS) copolymer and styrene-butadiene-styrene (SBS) copolymer, ethylene ethyl acrylate copolymers (EEA), and polyurethane reactive adhesives (PUR).
  • EVA ethylene-vinyl acetate copolymer
  • LLDPE linear low density polyethylene
  • SBC styrene block copolymers
  • SIS styrene-isoprene-styrene
  • SBS styrene-butadiene-styrene
  • ESA ethylene ethyl acrylate copolymers
  • the invention provides an adhesive composition comprising:
  • T m melting point
  • d density
  • ⁇ T > -0.1299( ⁇ H) + 62.81 for ⁇ H greater than zero and up to 130 J/g, ⁇ T > 48°C for ⁇ H greater than 130 J/g , wherein the CRYSTAF peak is determined using at least 5 percent of the cumulative polymer, and if less than 5 percent of the polymer has an identifiable CRYSTAF peak, then the CRYSTAF temperature is 30 0 C; or
  • (e) has a storage modulus at 25°C, G'(25°C), and a storage modulus at 100 0 C, C(IOO 0 C), wherein the ratio of G'(25°C) to C(IOO 0 C) is in the range of about 1:1 to about 9:1; or (f) has a molecular fraction which elutes between 40 0 C and 130°C when fractionated using TREF, characterized in that the fraction has a block index of at least 0.5 and up to about 1 ; or
  • the invention further provides a method of applying the inventive composition to a substrate comprising: applying the composition to the substrate via spiral spray in non-contact mode at a temperature in the range of from about 100 0 C to about 150 0 C.
  • the invention further provides a method of applying the inventive composition to a substrate comprising: applying the composition to the substrate via slot die coating in contact mode at a temperature in the range of from about 100 0 C to about 150 0 C.
  • Figure 1 shows the melting point/density relationship for the inventive polymers (represented by diamonds) as compared to traditional random copolymers (represented by circles) and Ziegler-Natta copolymers (represented by triangles).
  • Figure 2 shows plots of delta DSC-CRYSTAF as a function of DSC Melt Enthalpy for various polymers.
  • the diamonds represent random ethylene/octene copolymers; the squares represent polymer examples 1-4; the triangles represent polymer examples 5-9; and the circles represent polymer examples 10-19.
  • the "X" symbols represent polymer examples A* -F*.
  • Figure 3 shows the effect of density on elastic recovery for unoriented films comprising inventive interpolymers (represented by the squares and circles) and traditional copolymers (represented by the triangles which are various AFFINITY polymers (The Dow Chemical Company)).
  • inventive interpolymers represented by the squares and circles
  • traditional copolymers represented by the triangles which are various AFFINITY polymers (The Dow Chemical Company)
  • the squares represent inventive ethylene/butene copolymers
  • the circles represent inventive ethylene/octene copolymers.
  • Figure 4 is a plot of octene content of TREF fractionated ethylene/ 1-octene copolymer fractions versus TREF elution temperature of the fraction for the polymer of Example 5 (represented by the circles) and Comparative Examples E* and F* (represented by the "X" symbols).
  • the diamonds represent traditional random ethylene/octene copolymers.
  • Figure 5 is a plot of octene content of TREF fractionated ethylene/ 1-octene copolymer fractions versus TREF elution temperature of the fraction for the polymer of Example 5 (curve 1) and for Comparative Example F* (curve T).
  • the squares represent Example F*; and the triangles represent Example 5.
  • Figure 6 is a graph of the log of storage modulus as a function of temperature for comparative ethylene/1-octene copolymer (curve 2) and propylene/ ethylene- copolymer (curve 3) and for two ethylene/1-octene block copolymers of the invention made with differing quantities of chain shuttling agent (curves 1).
  • FIG. 7 shows a plot of TMA (lmm) versus flex modulus for some inventive polymers (represented by the diamonds), as compared to some known polymers.
  • the triangles represent various VERSIFY polymers (The Dow Chemical Company); the circles represent various random ethylene/styrene copolymers; and the squares represent various AFFINITY ® polymers (The Dow Chemical Company).
  • Figure 8 is a plot of natural log ethylene mole fraction for random ethylene/ ⁇ -olefin copolymers as a function of the inverse of DSC peak melting temperature or ATREF peak temperature.
  • the filled squares represent data points obtained from random homogeneously branched ethylene/ ⁇ -olefin copolymers in ATREF; and the open squares represent data points obtained from random homogeneously branched ethylene/ ⁇ -olefin copolymers in DSC.
  • P is the ethylene mole fraction;
  • T is the temperature in Kelvin.
  • Figure 9 is a plot constructed on the basis of the Flory equation for random ethylene/ ⁇ -olefin copolymers to illustrate the definition of "block index.”
  • "A” represents the whole, perfect random copolymer;
  • “B” represents a pure "hard segment”; and
  • "C” represents the whole, perfect block copolymer having the same comonomer content as “A”.
  • A, B, and C define a triangular area within which most TREF fractions would fall.
  • Polymer means a polymeric compound prepared by polymerizing monomers, whether of the same or a different type.
  • the generic term “polymer” embraces the terms “homopolymer,” “copolymer,” “terpolymer” as well as “interpolymer.”
  • Interpolymer means a polymer prepared by the polymerization of at least two different types of monomers.
  • the generic term “interpolymer” includes the term “copolymer” (which is usually employed to refer to a polymer prepared from two different monomers) as well as the term “terpolymer” (which is usually employed to refer to a polymer prepared from three different types of monomers). It also encompasses polymers made by polymerizing four or more types of monomers.
  • ethylene/ ⁇ -olefin interpolymer generally refers to polymers comprising ethylene and an ⁇ -olefin having 3 or more carbon atoms.
  • ethylene comprises the majority mole fraction of the whole polymer, i.e., ethylene comprises at least about 50 mole percent of the whole polymer. More preferably ethylene comprises at least about 60 mole percent, at least about 70 mole percent, or at least about 80 mole percent, with the substantial remainder of the whole polymer comprising at least one other comonomer that is preferably an ⁇ -olefin having 3 or more carbon atoms.
  • the preferred composition comprises an ethylene content greater than about 80 mole percent of the whole polymer and an octene content of from about 10 to about 15, preferably from about 15 to about 20 mole percent of the whole polymer.
  • the ethylene/ ⁇ -olefin interpolymers do not include those produced in low yields or in a minor amount or as a by-product of a chemical process. While the ethylene/ ⁇ - olefin interpolymers can be blended with one or more polymers, the as-produced ethylene/ ⁇ - olefin interpolymers are substantially pure and often comprise a major component of the reaction product of a polymerization process.
  • the ethylene/ ⁇ -olefin interpolymers comprise ethylene and one or more copolymerizable ⁇ -olefin comonomers in polymerized form, characterized by multiple blocks or segments of two or more polymerized monomer units differing in chemical or physical properties. That is, the ethylene/ ⁇ -olefin interpolymers are block interpolymers, preferably multi-block interpolymers or copolymers.
  • the terms "interpolymer” and copolymer” are used interchangeably herein.
  • the multi-block copolymer can be represented by the following formula:
  • n is at least 1, preferably an integer greater than 1, such as 2, 3, 4, 5, 10, 15, 20, 30, 40, 50, 60, 70, 80, 90, 100, or higher
  • A represents a hard block or segment
  • B represents a soft block or segment.
  • As and Bs are linked in a substantially linear fashion, as opposed to a substantially branched or substantially star-shaped fashion.
  • a blocks and B blocks are randomly distributed along the polymer chain.
  • the block copolymers usually do not have a structure as follows. AAA- AA-BBB- BB
  • the block copolymers do not usually have a third type of block, which comprises different comonomer(s).
  • each of block A and block B has monomers or comonomers substantially randomly distributed within the block.
  • neither block A nor block B comprises two or more sub-segments (or sub- blocks) of distinct composition, such as a tip segment, which has a substantially different composition than the rest of the block.
  • the multi-block polymers typically comprise various amounts of "hard” and
  • “soft” segments refer to blocks of polymerized units in which ethylene is generally present in an amount greater than about 95 weight percent, and preferably greater than about 98 weight percent based on the weight of the polymer.
  • the comonomer content (content of monomers other than ethylene) in the hard segments is less than about 5 weight percent, and preferably less than about 2 weight percent based on the weight of the polymer.
  • the hard segments comprises all or substantially all ethylene.
  • Soft segments refer to blocks of polymerized units in which the comonomer content (content of monomers other than ethylene) is greater than about 5 weight percent, preferably greater than about 8 weight percent, greater than about 10 weight percent, or greater than about 15 weight percent based on the weight of the polymer.
  • the comonomer content in the soft segments can be greater than about 20 weight percent, greater than about 25 weight percent, greater than about 30 weight percent, greater than about 35 weight percent, greater than about 40 weight percent, greater than about 45 weight percent, greater than about 50 weight percent, or greater than about 60 weight percent.
  • the soft segments can often be present in a block interpolymer from about 1 weight percent to about 99 weight percent of the total weight of the block interpolymer, preferably from about 5 weight percent to about 95 weight percent, from about 10 weight percent to about 90 weight percent, from about 15 weight percent to about 85 weight percent, from about 20 weight percent to about 80 weight percent, from about 25 weight percent to about 75 weight percent, from about 30 weight percent to about 70 weight percent, from about 35 weight percent to about 65 weight percent, from about 40 weight percent to about 60 weight percent, or from about 45 weight percent to about 55 weight percent of the total weight of the block interpolymer.
  • the hard segments can be present in similar ranges.
  • the soft segment weight percentage and the hard segment weight percentage can be calculated based on data obtained from DSC or NMR.
  • Such methods and calculations are disclosed in a concurrently filed U.S. Patent Application Serial No. 11/376,835, entitled “Ethylene/ ⁇ - Olefin Block Interpolymers", filed on March 15, 2006, in the name of Colin L.P. Shan, Lonnie Hazlitt, et. al. and assigned to Dow Global Technologies Inc., the disclosure of which is incorporated by reference herein in its entirety.
  • multi-block copolymer or “segmented copolymer” refers to a polymer comprising two or more chemically distinct regions or segments (referred to as “blocks”) preferably joined in a linear manner, that is, a polymer comprising chemically differentiated units which are joined end-to-end with respect to polymerized ethylenic functionality, rather than in pendent or grafted fashion.
  • the blocks differ in the amount or type of comonomer incorporated therein, the density, the amount of crystallinity, the crystallite size attributable to a polymer of such composition, the type or degree of tacticity (isotactic or syndiotactic), regio-regularity or regio-irregularity, the amount of branching, including long chain branching or hyper-branching, the homogeneity, or any other chemical or physical property.
  • the multi -block copolymers are characterized by unique distributions of both polydispersity index (PDI or Mw/Mn), block length distribution, and/or block number distribution due to the unique process of making the copolymers.
  • the polymers when produced in a continuous process, desirably possess PDI from 1.7 to 2.9, preferably from 1.8 to 2.5, more preferably from 1.8 to 2.2, and most preferably from 1.8 to 2.1.
  • the polymers When produced in a batch or semi-batch process, the polymers possess PDI from 1.0 to 2.9, preferably from 1.3 to 2.5, more preferably from 1.4 to 2.0, and most preferably from 1.4 to 1.8.
  • R R L +k*(R u -R L ), wherein k is a variable ranging from 1 percent to 100 percent with a 1 percent increment, i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent,..., 50 percent, 51 percent, 52 percent,..., 95 percent, 96 percent, 97 percent, 98 percent, 99 percent, or 100 percent.
  • k is a variable ranging from 1 percent to 100 percent with a 1 percent increment, i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent,..., 50 percent, 51 percent, 52 percent,..., 95 percent, 96 percent, 97 percent, 98 percent, 99 percent, or 100 percent.
  • any numerical range defined by two R numbers as defined in the above is also specifically disclosed.
  • Embodiments of the invention provide compositions that comprise an ethylene/ ⁇ -olefin interpolymer, a tackifier resin and an oil or a low molecular weight polymer.
  • the compositions possess unique properties that are suitable for a variety of applications, particularly where a certain level of adhesion is required. Some non-limiting examples of suitable applications include hot melt adhesives, pressure sensitive adhesives, hot melt pressure sensitive adhesives, thermoplastic marking compositions, and the like.
  • the ethylene/ ⁇ -olefin interpolymers are a multi-block copolymer comprising at least one soft block and at least one hard block.
  • the adhesive compositions generally have a low melt viscosity so that it is easy to process the compositions .
  • the melt viscosities of the compositions can be measured by a Brookfield viscometer using appropriate spindles as by ASTM D3236 at about 350 0 F (177°C), which is incorporated herein by reference.
  • the composition has a melt viscosity of less than 4,600 cPs at about 177°C, or less than about 3,000 cPs at 177°C, or less than about 2,000 cPs at 177°C, or less than about 1,000 cPs at 177°C measured according to ASTM D3236.
  • ventive interpolymer (also referred to as “inventive interpolymer” or “inventive polymer”) comprise ethylene and one or more copolymerizable ⁇ -olefin comonomers in polymerized form, characterized by multiple blocks or segments of two or more polymerized monomer units differing in chemical or physical properties (block interpolymer), preferably a multi-block copolymer.
  • block interpolymer preferably a multi-block copolymer.
  • the ethylene/ ⁇ -olefin interpolymers are characterized by one or more of the aspects described as follows.
  • the ethylene/ ⁇ -olefin interpolymers used in embodiments of the invention have a M w /M n from about 1.7 to about 3.5 and at least one melting point, T m , in degrees Celsius and density, d, in grams/cubic centimeter, wherein the numerical values of the variables correspond to the relationship:
  • inventive interpolymers represented by diamonds
  • the melting point of such polymers are in the range of about 110 0 C to about 130 0 C when density ranges from 0.875 g/cc to about 0.945 g/cc. In some embodiments, the melting point of such polymers are in the range of about 115 0 C to about 125 0 C when density ranges from 0.875 g/cc to about 0.945 g/cc.
  • the ethylene/ ⁇ -olefin interpolymers comprise, in polymerized form, ethylene and one or more ⁇ -olefins and are characterized by a ⁇ T, in degree Celsius, defined as the temperature for the tallest Differential Scanning Calorimetry (“DSC”) peak minus the temperature for the tallest Crystallization Analysis Fractionation (“CRYSTAF”) peak and a heat of fusion in J/g, ⁇ H, and ⁇ T and ⁇ H satisfy the following relationships:
  • ⁇ T > -0.1299( ⁇ H) + 62.81, and preferably ⁇ T > -0.1299( ⁇ H) + 64.38, and more preferably ⁇ T ⁇ -0.1299( ⁇ H) + 65.95, for ⁇ H up to 130 J/g.
  • ⁇ T is equal to or greater than 48 0 C for ⁇ H greater than 130 J/g.
  • the CRYSTAF peak is determined using at least 5 percent of the cumulative polymer (that is, the peak must represent at least 5 percent of the cumulative polymer), and if less than 5 percent of the polymer has an identifiable CRYSTAF peak, then the CRYSTAF temperature is 30 0 C, and ⁇ H is the numerical value of the heat of fusion in J/g.
  • the highest CRYSTAF peak contains at least 10 percent of the cumulative polymer.
  • the ethylene/ ⁇ -olefin interpolymers have a molecular fraction which elutes between 40 0 C and 130 0 C when fractionated using Temperature Rising Elution Fractionation ("TREF"), characterized in that said fraction has a molar comonomer content higher, preferably at least 5 percent higher, more preferably at least 10 percent higher, than that of a comparable random ethylene interpolymer fraction eluting between the same temperatures, wherein the comparable random ethylene interpolymer contains the same comonomer(s), and has a melt index, density, and molar comonomer content (based on the whole polymer) within 10 percent of that of the block interpolymer.
  • TEZ Temperature Rising Elution Fractionation
  • the Mw/Mn of the comparable interpolymer is also within 10 percent of that of the block interpolymer and/or the comparable interpolymer has a total comonomer content within 10 weight percent of that of the block interpolymer.
  • the ethylene/ ⁇ -olefin interpolymers are characterized by an elastic recovery, Re, in percent at 300 percent strain and 1 cycle measured on a compression-molded film of an ethylene/ ⁇ -olefin interpolymer, and has a density, d, in grams/cubic centimeter, wherein the numerical values of Re and d satisfy the following relationship when ethylene/ ⁇ -olefin interpolymer is substantially free of a cross-linked phase: Re >1481-1629(d); and preferably Re >1491-1629(d); and more preferably Re >1501-1629(d); and even more preferably Re ⁇ 1511-1629(d).
  • Figure 3 shows the effect of density on elastic recovery for unoriented films made from certain inventive interpolymers and traditional random copolymers.
  • inventive interpolymers For the same density, the inventive interpolymers have substantially higher elastic recoveries.
  • the ethylene/ ⁇ -olefin interpolymers have a tensile strength above 10 MPa, preferably a tensile strength > 11 MPa, more preferably a tensile strength > 13MPa and/or an elongation at break of at least 600 percent, more preferably at least 700 percent, highly preferably at least 800 percent, and most highly preferably at least 900 percent at a crosshead separation rate of 11 cm/minute.
  • the ethylene/ ⁇ -olefin interpolymers have (1) a storage modulus ratio, G'(25°C)/G'(100°C), of from 1 to 50, preferably from 1 to 20, more preferably from 1 to 10; and/or (2) a 70 0 C compression set of less than 80 percent, preferably less than 70 percent, especially less than 60 percent, less than 50 percent, or less than 40 percent, down to a compression set of 0 percent.
  • the ethylene/ ⁇ -olefin interpolymers have a 70 0 C compression set of less than 80 percent, less than 70 percent, less than 60 percent, or less than 50 percent.
  • the 70 0 C compression set of the interpolymers is less than 40 percent, less than 30 percent, less than 20 percent, and may go down to about 0 percent.
  • the ethylene/ ⁇ -olefin interpolymers have a heat of fusion of less than 85 J/g and/or a pellet blocking strength of equal to or less than 100 pounds/foot 2 (4800 Pa), preferably equal to or less than 50 lbs/ft 2 (2400 Pa), especially equal to or less than 5 lbs/ft 2 (240 Pa), and as low as 0 lbs/ft 2 (0 Pa).
  • the ethylene/ ⁇ -olefin interpolymers comprise, in polymerized form, at least 50 mole percent ethylene and have a 70 0 C compression set of less than 80 percent, preferably less than 70 percent or less than 60 percent, most preferably less than 40 to 50 percent and down to close to zero percent.
  • the multi-block copolymers possess a PDI fitting a Schultz-Flory distribution rather than a Poisson distribution.
  • the copolymers are further characterized as having both a polydisperse block distribution and a polydisperse distribution of block sizes and possessing a most probable distribution of block lengths.
  • Preferred multi- block copolymers are those containing 4 or more blocks or segments including terminal blocks. More preferably, the copolymers include at least 5, 10 or 20 blocks or segments including terminal blocks.
  • Comonomer content may be measured using any suitable technique, with techniques based on nuclear magnetic resonance ("NMR") spectroscopy preferred.
  • the polymer desirably is first fractionated using TREF into fractions each having an eluted temperature range of 10 0 C or less. That is, each eluted fraction has a collection temperature window of 10 0 C or less.
  • said block interpolymers have at least one such fraction having a higher molar comonomer content than a corresponding fraction of the comparable interpolymer.
  • the inventive polymer is an olefin interpolymer, preferably comprising ethylene and one or more copolymerizable comonomers in polymerized form, characterized by multiple blocks (i.e., at least two blocks) or segments of two or more polymerized monomer units differing in chemical or physical properties (blocked interpolymer), most preferably a multi-block copolymer, said block interpolymer having a peak (but not just a molecular fraction) which elutes between 40 0 C and 130 0 C (but without collecting and/or isolating individual fractions), characterized in that said peak, having a comonomer content estimated by infra-red spectroscopy when expanded using a full width/half maximum (FWHM) area calculation, has an average molar comonomer content higher, preferably at least 5 percent higher, more preferably at least 10 percent higher, than that of a comparable random ethylene interpolymer peak at the same elution temperature
  • the Mw/Mn of the comparable interpolymer is also within 10 percent of that of the blocked interpolymer and/or the comparable interpolymer has a total comonomer content within 10 weight percent of that of the blocked interpolymer.
  • the full width/half maximum (FWHM) calculation is based on the ratio of methyl to methylene response area [CH 3 /CH 2 ] from the ATREF infra-red detector, wherein the tallest (highest) peak is identified from the base line, and then the FWHM area is determined.
  • the FWHM area is defined as the area under the curve between T 1 and T 2 , where T 1 and T 2 are points determined, to the left and right of the ATREF peak, by dividing the peak height by two, and then drawing a line horizontal to the base line, that intersects the left and right portions of the ATREF curve.
  • a calibration curve for comonomer content is made using random ethylene/ ⁇ -olefin copolymers, plotting comonomer content from NMR versus FWHM area ratio of the TREF peak. For this infra-red method, the calibration curve is generated for the same comonomer type of interest.
  • the comonomer content of TREF peak of the inventive polymer can be determined by referencing this calibration curve using its FWHM methyl: methylene area ratio [CH3/CH 2 ] of the TREF peak.
  • Comonomer content may be measured using any suitable technique, with techniques based on nuclear magnetic resonance (NMR) spectroscopy preferred. Using this technique, said blocked interpolymers have higher molar comonomer content than a corresponding comparable interpolymer.
  • NMR nuclear magnetic resonance
  • the block interpolymer has a comonomer content of the TREF fraction eluting between 40 and 130 0 C greater than or equal to the quantity (- 0.2013) T + 20.07, more preferably greater than or equal to the quantity (-0.2013) T+ 21.07, where T is the numerical value of the peak elution temperature of the TREF fraction being compared, measured in 0 C.
  • Figure 4 graphically depicts an embodiment of the block interpolymers of ethylene and 1-octene where a plot of the comonomer content versus TREF elution temperature for several comparable ethylene/1-octene interpolymers (random copolymers) are fit to a line representing (- 0.2013) T + 20.07 (solid line). The line for the equation (-
  • T + 21.07 is depicted by a dotted line. Also depicted are the comonomer contents for fractions of several block ethylene/1-octene interpolymers of the invention (multi-block copolymers). All of the block interpolymer fractions have significantly higher 1-octene content than either line at equivalent elution temperatures. This result is characteristic of the inventive interpolymer and is believed to be due to the presence of differentiated blocks within the polymer chains, having both crystalline and amorphous nature.
  • Figure 5 graphically displays the TREF curve and comonomer contents of polymer fractions for Example 5 and Comparative Example F* to be discussed below.
  • the peak eluting from 40 to 130 0 C, preferably from 6O 0 C to 95°C for both polymers is fractionated into three parts, each part eluting over a temperature range of less than 10 0 C.
  • Example 5 Actual data for Example 5 is represented by triangles.
  • an appropriate calibration curve may be constructed for interpolymers containing different comonomers and a line used as a comparison fitted to the TREF values obtained from comparative interpolymers of the same monomers, preferably random copolymers made using a metallocene or other homogeneous catalyst composition.
  • Inventive interpolymers are characterized by a molar comonomer content greater than the value determined from the calibration curve at the same TREF elution temperature, preferably at least 5 percent greater, more preferably at least 10 percent greater.
  • the above interpolymers are interpolymers of ethylene and at least one ⁇ -olefin, especially those interpolymers having a whole polymer density from about 0.855 to about 0.935 g/cm 3 , and more especially for polymers having more than about 1 mole percent comonomer, the blocked interpolymer has a comonomer content of the TREF fraction eluting between 40 and 130 0 C greater than or equal to the quantity (- 0.1356) T + 13.89, more preferably greater than or equal to the quantity (-0.1356) T+ 14.93, and most preferably greater than or equal to the quantity (-0.2013)T + 21.07, where T is the numerical value of the peak ATREF elution temperature of the TREF fraction being compared, measured in 0 C.
  • the blocked interpolymer has a comonomer content of the TREF fraction eluting between 40 and 130 0 C greater than or equal to the quantity (- 0.2013) T + 20.07, more preferably greater than or equal to the quantity (-0.2013) T+ 21.07, where T is the numerical value of the peak elution temperature of the TREF fraction being compared, measured in °C.
  • the inventive polymer is an olefin interpolymer, preferably comprising ethylene and one or more copolymerizable comonomers in polymerized form, characterized by multiple blocks or segments of two or more polymerized monomer units differing in chemical or physical properties (blocked interpolymer), most preferably a multi-block copolymer, said block interpolymer having a molecular fraction which elutes between 40 0 C and 130 0 C, when fractionated using TREF increments, characterized in that every fraction having a comonomer content of at least about 6 mole percent, has a melting point greater than about 100 0 C.
  • every fraction has a DSC melting point of about HO 0 C or higher. More preferably, said polymer fractions, having at least 1 mol percent comonomer, has a DSC melting point that corresponds to the equation:
  • the inventive polymer is an olefin interpolymer, preferably comprising ethylene and one or more copolymerizable comonomers in polymerized form, characterized by multiple blocks or segments of two or more polymerized monomer units differing in chemical or physical properties (blocked interpolymer), most preferably a multi-block copolymer, said block interpolymer having a molecular fraction which elutes between 40 0 C and 130 0 C, when fractionated using TREF increments, characterized in that every fraction that has an ATREF elution temperature greater than or equal to about 76 0 C, has a melt enthalpy (heat of fusion) as measured by DSC, corresponding to the equation:
  • the comonomer composition of the TREF peak can be measured using an IR4 infra-red detector available from Polymer Char, Valencia, Spain (http://www.polymerchar.com/).
  • the "composition mode" of the detector is equipped with a measurement sensor (CH 2 ) and composition sensor (CH 3 ) that are fixed narrow band infra-red filters in the region of 2800-3000 cm “1 .
  • the measurement sensor detects the methylene (CH 2 ) carbons on the polymer (which directly relates to the polymer concentration in solution) while the composition sensor detects the methyl (CH 3 ) groups of the polymer.
  • the mathematical ratio of the composition signal (CH 3 ) divided by the measurement signal (CH 2 ) is sensitive to the comonomer content of the measured polymer in solution and its response is calibrated with known ethylene alpha-olefin copolymer standards.
  • the area of the peaks can be calculated using a full width/half maximum
  • FWHM FWHM calculation after applying the appropriate baselines to integrate the individual signal responses from the TREF chromatogram.
  • the full width/half maximum calculation is based on the ratio of methyl to methylene response area [CH 3 /CH 2 ] from the ATREF infra- red detector, wherein the tallest (highest) peak is identified from the base line, and then the FWHM area is determined.
  • the FWHM area is defined as the area under the curve between Tl and T2, where Tl and T2 are points determined, to the left and right of the ATREF peak, by dividing the peak height by two, and then drawing a line horizontal to the base line, that intersects the left and right portions of the ATREF curve.
  • the inventive ethylene/ ⁇ -olefin interpolymer is characterized by an average block index, ABI, which is greater than zero and up to about 1.0 and a molecular weight distribution, M w /M n , greater than about 1.3.
  • the average block index, ABI is the weight average of the block index ("BI") for each of the polymer fractions obtained in preparative TREF from 20 0 C and 110 0 C, with an increment of 5°C : where BI 1 is the block index for the ith fraction of the inventive ethylene/ ⁇ -olefin interpolymer obtained in preparative TREF, and W 1 is the weight percentage of the ith fraction.
  • BI is defined by one of the two following equations
  • T x is the preparative ATREF elution temperature for the ith fraction (preferably expressed in Kelvin)
  • P x is the ethylene mole fraction for the ith fraction, which can be measured by NMR or IR as described above.
  • P AB is the ethylene mole fraction of the whole ethylene/ ⁇ -olefin interpolymer (before fractionation), which also can be measured by NMR or IR.
  • T A and P A are the ATREF elution temperature and the ethylene mole fraction for pure "hard segments" (which refer to the crystalline segments of the interpolymer).
  • T A and P A values are set to those for high density polyethylene homopolymer, if the actual values for the "hard segments" are not available.
  • T A is 372 0 K
  • P A is 1.
  • T AB is the ATREF temperature for a random copolymer of the same composition and having an ethylene mole fraction of P AB - T AB can be calculated from the following equation:
  • ⁇ and ⁇ are two constants which can be determined by calibration using a number of known random ethylene copolymers. It should be noted that ⁇ and ⁇ may vary from instrument to instrument. Moreover, one would need to create their own calibration curve with the polymer composition of interest and also in a similar molecular weight range as the fractions. There is a slight molecular weight effect. If the calibration curve is obtained from similar molecular weight ranges, such effect would be essentially negligible.
  • random ethylene copolymers satisfy the following relationship:
  • the weight average block index, ABI for the whole polymer can be calculated.
  • ABI is greater than zero but less than about 0.3 or from about 0.1 to about 0.3. In other embodiments, ABI is greater than about 0.3 and up to about 1.0. Preferably, ABI should be in the range of from about 0.4 to about 0.7, from about 0.5 to about 0.7, or from about 0.6 to about 0.9.
  • ABI is in the range of from about 0.3 to about 0.9, from about 0.3 to about 0.8, or from about 0.3 to about 0.7, from about 0.3 to about 0.6, from about 0.3 to about 0.5, or from about 0.3 to about 0.4. In other embodiments, ABI is in the range of from about 0.4 to about 1.0, from about 0.5 to about 1.0, or from about 0.6 to about 1.0, from about 0.7 to about 1.0, from about 0.8 to about 1.0, or from about 0.9 to about 1.0.
  • the inventive ethylene/ ⁇ -olefin interpolymer comprises at least one polymer fraction which can be obtained by preparative TREF, wherein the fraction has a block index greater than about 0.1 and up to about 1.0 and a molecular weight distribution, M w /M n , greater than about 1.3.
  • the polymer fraction has a block index greater than about 0.6 and up to about 1.0, greater than about 0.7 and up to about 1.0, greater than about 0.8 and up to about 1.0, or greater than about 0.9 and up to about 1.0.
  • the polymer fraction has a block index greater than about 0.1 and up to about 1.0, greater than about 0.2 and up to about 1.0, greater than about 0.3 and up to about 1.0, greater than about 0.4 and up to about 1.0, or greater than about 0.4 and up to about 1.0. In still other embodiments, the polymer fraction has a block index greater than about 0.1 and up to about 0.5, greater than about 0.2 and up to about 0.5, greater than about 0.3 and up to about 0.5, or greater than about 0.4 and up to about 0.5.
  • the polymer fraction has a block index greater than about 0.2 and up to about 0.9, greater than about 0.3 and up to about 0.8, greater than about 0.4 and up to about 0.7, or greater than about 0.5 and up to about 0.6.
  • the inventive polymers preferably possess (1) a PDI of at least 1.3, more preferably at least 1.5, at least 1.7, or at least 2.0, and most preferably at least 2.6, up to a maximum value of 5.0, more preferably up to a maximum of 3.5, and especially up to a maximum of 2.7; (2) a heat of fusion of 80 J/g or less; (3) an ethylene content of at least 50 weight percent; (4) a glass transition temperature, T g , of less than -25°C, more preferably less than -30 0 C, and/or (5) one and only one T m .
  • the inventive interpolymers may be further characterized by a thermomechanical analysis penetration depth of 1 mm at a temperature of at least 90 0 C as well as a flexural modulus of from 3 kpsi (20 MPa) to 13 kpsi (90 MPa).
  • the inventive interpolymers can have a thermomechanical analysis penetration depth of 1 mm at a temperature of at least 104 0 C as well as a flexural modulus of at least 3 kpsi (20 MPa).
  • the ethylene/ ⁇ -olefin interpolymers have a melt index, I 2 , from 0.01 to 10 g/10 minutes, from 0.5 to 50 g/10 minutes, from 1 to 30 g/10 minutes, from 1 to 6 g/10 minutes or from 0.3 to 10 g/10 minutes.
  • the melt index for the ethylene/ ⁇ -olefin polymers is lg/10 minutes, 3 g/10 minutes or 5 g/10 minutes.
  • the polymers can have molecular weights, M w , from 1,000 g/mole to 5,000,000 g/mole, preferably from 1000 g/mole to 1,000,000, more preferably from 10,000 g/mole to 500,000 g/mole, and especially from 10,000 g/mole to 300,000 g/mole.
  • the density of the inventive polymers can be from 0.80 to 0.99 g/cm 3 and preferably for ethylene containing polymers from 0.85 g/cm 3 to 0.97 g/cm 3 .
  • the density of the ethylene/ ⁇ -olefin polymers ranges from 0.860 to 0.925 g/cm 3 or 0.867 to 0.910 g/cm 3 .
  • one such method comprises contacting ethylene and optionally one or more addition polymerizable monomers other than ethylene under addition polymerization conditions with a catalyst composition comprising: the admixture or reaction product resulting from combining: a. a first olefin polymerization catalyst having a high comonomer incorporation index, b.
  • a second olefin polymerization catalyst having a comonomer incorporation index less than 90 percent, preferably less than 50 percent, most preferably less than 5 percent of the comonomer incorporation index of catalyst (A), and c. a chain shuttling agent.
  • Representative catalysts and chain shuttling agent are as follows.
  • Catalyst (Al) is [N-(2,6-di(l-methylethyl)phenyl)amido)(2- isopropylphenyl)( ⁇ -naphthalen-2-diyl(6-pyridin-2-diyl)methane)]hafnium dimethyl, prepared according to the teachings of WO 03/40195, 2003US0204017, USSN 10/429,024, filed May 2, 2003, and WO 04/24740.
  • Catalyst (A2) is [N-(2,6-di(l-methylethyl)phenyl)amido)(2- methylphenyl)(l ,2-phenylene-(6-pyridin-2-diyl)methane)]hafnium dimethyl, prepared according to the teachings of WO 03/40195, 2003US0204017, USSN 10/429,024, filed May 2, 2003, and WO 04/24740.
  • Catalyst (A3) is bis[N,N' "-(2,4,6- tri(methylphenyl)amido)ethylenediamine]hafnium dibenzyl
  • Catalyst (A4) is bis((2-oxoyl-3-(dibenzo-lH-pyrrole-l-yl)-5-(methyl)phenyl>
  • Catalyst (Bl) is l,2-bis-(3,5-di-t-butylphenylene)(l-(N-(l- methylethyl)immino)methyl)(2-oxoyl) zirconium dibenzyl
  • Catalyst (B2) is l,2-bis-(3,5-di-t-butylphenylene)(l-(N-(2-methylcyclohexyl)- immino)methyl)(2-oxoyl) zirconium dibenzyl
  • Catalyst (Cl) is (t-butylamido)dimethyl(3-N-pyrrolyl-l,2,3,3a,7a- ⁇ -inden-l- yl)silanetitanium dimethyl prepared substantially according to the techniques of USP 6,268,444:
  • Catalyst (C2) is (t-butylamido)di(4-methylphenyl)(2-methyl-l,2,3,3a,7a- ⁇ - inden-l-yl)silanetitanium dimethyl prepared substantially according to the teachings of US- A-2003/004286:
  • Catalyst (C3) is (t-butylamido)di(4-methylphenyl)(2-methyl-l,2,3,3a,8a- ⁇ -s- indacen-l-yl)silanetitanium dimethyl prepared substantially according to the teachings of US- A-2003/004286:
  • Catalyst (Dl) is bis(dimethyldisiloxane)(indene-l-yl)zirconium dichloride available from Sigma-Aldrich:
  • shuttling agents include diethylzinc, di(i- butyl)zinc, di(n-hexyl)zinc, triethylaluminum, trioctylaluminum, triethylgallium, i- butylaluminum bis(dimethyl(t-butyl)siloxane), i-butylaluminum bis(di(trimethylsilyl)amide), n-octylaluminum di(pyridine-2-methoxide), bis(n-octadecyl)i-butylaluminum, i- butylaluminum bis(di(n-pentyl)amide), n-octylaluminum bis(2,6-di-t-butylphenoxide, n- octylaluminum di(ethyl(l-naphthyl) amide), ethylalum
  • the foregoing process takes the form of a continuous solution process for forming block copolymers, especially multi-block copolymers, preferably linear multi-block copolymers of two or more monomers, more especially ethylene and a C 3 _ 2 o olefin or cycloolefin, and most especially ethylene and a C 4 _ 2 o ⁇ -olefin, using multiple catalysts that are incapable of intercon version. That is, the catalysts are chemically distinct.
  • the process is ideally suited for polymerization of mixtures of monomers at high monomer conversions. Under these polymerization conditions, shuttling from the chain shuttling agent to the catalyst becomes advantaged compared to chain growth, and multi -block copolymers, especially linear multi- block copolymers are formed in high efficiency.
  • inventive interpolymers may be differentiated from conventional, random copolymers, physical blends of polymers, and block copolymers prepared via sequential monomer addition, fluxional catalysts, anionic or cationic living polymerization techniques.
  • inventive interpolymers compared to a random copolymer of the same monomers and monomer content at equivalent crystallinity or modulus, the inventive interpolymers have better (higher) heat resistance as measured by melting point, higher TMA penetration temperature, higher high- temperature tensile strength, and/or higher high-temperature torsion storage modulus as determined by dynamic mechanical analysis.
  • the inventive interpolymers Compared to a random copolymer containing the same monomers and monomer content, the inventive interpolymers have lower compression set, particularly at elevated temperatures, lower stress relaxation, higher creep resistance, higher tear strength, higher blocking resistance, faster setup due to higher crystallization (solidification) temperature, higher recovery (particularly at elevated temperatures), better abrasion resistance, higher retractive force, and better oil and filler acceptance.
  • the inventive interpolymers also exhibit a unique crystallization and branching distribution relationship.
  • the inventive interpolymers have a relatively large difference between the tallest peak temperature measured using CRYSTAF and DSC as a function of heat of fusion, especially as compared to random copolymers containing the same monomers and monomer level or physical blends of polymers, such as a blend of a high density polymer and a lower density copolymer, at equivalent overall density. It is believed that this unique feature of the inventive interpolymers is due to the unique distribution of the comonomer in blocks within the polymer backbone.
  • the inventive interpolymers may comprise alternating blocks of differing comonomer content (including homopolymer blocks).
  • inventive interpolymers may also comprise a distribution in number and/or block size of polymer blocks of differing density or comonomer content, which is a Schultz-Flory type of distribution.
  • inventive interpolymers also have a unique peak melting point and crystallization temperature profile that is substantially independent of polymer density, modulus, and morphology.
  • the microcrystalline order of the polymers demonstrates characteristic spherulites and lamellae that are distinguishable from random or block copolymers, even at PDI values that are less than 1.7, or even less than 1.5, down to less than 1.3.
  • inventive interpolymers may be prepared using techniques to influence the degree or level of blockiness. That is the amount of comonomer and length of each polymer block or segment can be altered by controlling the ratio and type of catalysts and shuttling agent as well as the temperature of the polymerization, and other polymerization variables.
  • a surprising benefit of this phenomenon is the discovery that as the degree of blockiness is increased, the optical properties, tear strength, and high temperature recovery properties of the resulting polymer are improved. In particular, haze decreases while clarity, tear strength, and high temperature recovery properties increase as the average number of blocks in the polymer increases.
  • shuttling agents and catalyst combinations having the desired chain transferring ability high rates of shuttling with low levels of chain termination
  • other forms of polymer termination are effectively suppressed. Accordingly, little if any ⁇ -hydride elimination is observed in the polymerization of ethylene/ ⁇ -olefin comonomer mixtures according to embodiments of the invention, and the resulting crystalline blocks are highly, or substantially completely, linear, possessing little or no long chain branching.
  • Polymers with highly crystalline chain ends can be selectively prepared in accordance with embodiments of the invention.
  • reducing the relative quantity of polymer that terminates with an amorphous block reduces the intermolecular dilutive effect on crystalline regions.
  • This result can be obtained by choosing chain shuttling agents and catalysts having an appropriate response to hydrogen or other chain terminating agents. Specifically, if the catalyst which produces highly crystalline polymer is more susceptible to chain termination (such as by use of hydrogen) than the catalyst responsible for producing the less crystalline polymer segment (such as through higher comonomer incorporation, regio-error, or atactic polymer formation), then the highly crystalline polymer segments will preferentially populate the terminal portions of the polymer.
  • the ethylene ⁇ -olefin interpolymers used in the embodiments of the invention are preferably interpolymers of ethylene with at least one C3-C20 ⁇ -olefin. Copolymers of ethylene and a C3-C2O ⁇ -olefin are especially preferred.
  • the interpolymers may further comprise C4-C18 diolefin and/or alkenylbenzene.
  • Suitable unsaturated comonomers useful for polymerizing with ethylene include, for example, ethylenically unsaturated monomers, conjugated or nonconjugated dienes, polyenes, alkenylbenzenes, etc. Examples of such comonomers include C3-C20 ⁇ -olefins such as propylene, isobutylene, 1-butene, 1-hexene,
  • 1- Butene and 1-octene are especially preferred.
  • Other suitable monomers include styrene, halo- or alkyl-substituted styrenes, vinylbenzocyclobutane, 1 ,4-hexadiene, 1,7-octadiene, and naphthenics (e.g., cyclopentene, cyclohexene and cyclooctene).
  • ethylene/ ⁇ -olefin interpolymers are preferred polymers, other ethylene/olefin polymers may also be used.
  • Olefins as used herein refer to a family of unsaturated hydrocarbon-based compounds with at least one carbon-carbon double bond. Depending on the selection of catalysts, any olefin may be used in embodiments of the invention.
  • suitable olefins are C3-C2O aliphatic and aromatic compounds containing vinylic unsaturation, as well as cyclic compounds, such as cyclobutene, cyclopentene, dicyclopentadiene, and norbornene, including but not limited to, norbornene substituted in the 5 and 6 position with C1-C20 hydrocarbyl or cyclohydrocarbyl groups. Also included are mixtures of such olefins as well as mixtures of such olefins with C4-C40 diolefin compounds.
  • olefin monomers include, but are not limited to propylene, isobutylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, and 1- dodecene, 1-tetradecene, 1-hexadecene, 1-octadecene, 1-eicosene, 3 -methyl- 1-butene, 3- methyl- 1-pentene, 4-methyl- 1-pentene, 4,6-dimethyl- 1-heptene, 4-vinylcyclohexene, vinylcyclohexane, norbornadiene, ethylidene norbornene, cyclopentene, cyclohexene, dicyclopentadiene, cyclooctene, C4-C40 dienes, including but not limited to 1,3 -butadiene, 1,3-pentadiene, 1,4-hexa
  • the ⁇ -olefin is propylene, 1-butene, 1- pentene, 1-hexene, 1-octene or a combination thereof.
  • any hydrocarbon containing a vinyl group potentially may be used in embodiments of the invention, practical issues such as monomer availability, cost, and the ability to conveniently remove unreacted monomer from the resulting polymer may become more problematic as the molecular weight of the monomer becomes too high.
  • polystyrene polystyrene
  • olefin polymers comprising monovinylidene aromatic monomers including styrene, o-methyl styrene, p-methyl styrene, t-butylstyrene, and the like.
  • interpolymers comprising ethylene and styrene can be prepared by following the teachings herein.
  • copolymers comprising ethylene, styrene and a C3-C20 alpha olefin, optionally comprising a C4-C2O diene, having improved properties can be prepared.
  • Suitable non-conjugated diene monomers can be a straight chain, branched chain or cyclic hydrocarbon diene having from 6 to 15 carbon atoms.
  • suitable non-conjugated dienes include, but are not limited to, straight chain acyclic dienes, such as 1,4-hexadiene, 1,6-octadiene, 1,7-octadiene, 1,9-decadiene, branched chain acyclic dienes, such as 5 -methyl- 1,4-hexadiene; 3,7-dimethyl-l,6-octadiene; 3,7-dimethyl-l,7-octadiene and mixed isomers of dihydromyricene and dihydroocinene, single ring alicyclic dienes, such as 1,3-cyclopentadiene; 1,4-cyclohexadiene; 1,5-cyclooctadiene and 1,5-cyclododecadiene, and multi-
  • the particularly preferred dienes are 1,4-hexadiene (HD), 5-ethylidene-2-norbornene (ENB), 5-vinylidene-2-norbornene (VNB), 5-methylene-2- norbornene (MNB), and dicyclopentadiene (DCPD).
  • the especially preferred dienes are 5- ethylidene-2-norbornene (ENB) and 1,4-hexadiene (HD).
  • One class of desirable polymers that can be made in accordance with embodiments of the invention are elastomeric interpolymers of ethylene, a C3-C2O ⁇ -olefin, especially propylene, and optionally one or more diene monomers.
  • suitable ⁇ -olefins include, but are not limited to, propylene, isobutylene, 1-butene, 1-pentene, 1-hexene, 4-methyl- 1-pentene, and 1-octene.
  • a particularly preferred diene is 5-ethylidene-2-norbornene.
  • the diene containing polymers comprise alternating segments or blocks containing greater or lesser quantities of the diene (including none) and ⁇ -olefin (including none)
  • the total quantity of diene and ⁇ -olefin may be reduced without loss of subsequent polymer properties. That is, because the diene and ⁇ -olefin monomers are preferentially incorporated into one type of block of the polymer rather than uniformly or randomly throughout the polymer, they are more efficiently utilized and subsequently the crosslink density of the polymer can be better controlled.
  • Such crosslinkable elastomers and the cured products have advantaged properties, including higher tensile strength and better elastic recovery.
  • the inventive interpolymers made with two catalysts incorporating differing quantities of comonomer have a weight ratio of blocks formed thereby from 95:5 to 5:95.
  • the elastomeric polymers desirably have an ethylene content of from 20 to 90 percent, a diene content of from 0.1 to 10 percent, and an ⁇ -olefin content of from 10 to 80 percent, based on the total weight of the polymer.
  • the multi-block elastomeric polymers have an ethylene content of from 60 to 90 percent, a diene content of from 0.1 to 10 percent, and an ⁇ -olefin content of from 10 to 40 percent, based on the total weight of the polymer.
  • the ethylene/ ⁇ -olefin interpolymers can be functionalized by incorporating at least one functional group in its polymer structure.
  • exemplary functional groups may include, for example, ethylenically unsaturated mono- and di-functional carboxylic acids, ethylenically unsaturated mono- and di-functional carboxylic acid anhydrides, salts thereof and esters thereof.
  • Such functional groups may be grafted to an ethylene/ ⁇ -olefin interpolymer, or it may be copolymerized with ethylene and an optional additional comonomer to form an interpolymer of ethylene, the functional comonomer and optionally other comonomer(s).
  • the amount of the functional group present in the functional interpolymer can vary.
  • the functional group can typically be present in a copolymer-type functionalized interpolymer in an amount of at least about 1.0 weight percent, preferably at least about 5 weight percent, and more preferably at least about 7 weight percent.
  • the functional group will typically be present in a copolymer-type functionalized interpolymer in an amount less than about 40 weight percent, preferably less than about 30 weight percent, and more preferably less than about 25 weight percent.
  • the composition can comprise at least two other components, in addition to the interpolymer, for the purposes of improving and/or controlling the viscosity, adhesive properties, shelf-life, stability and cost.
  • the composition comprises a tackifier and an oil or a low molecular weight polymer in addition to the interpolymer.
  • additional components include waxes, antioxidants, UV stabilizers, colorants or pigments, fillers, flow aids, coupling agents, crosslinking agents, surfactants, solvents, and combinations thereof.
  • the tackifier of the composition may modify the properties of the composition such as viscoelastic properties (e.g., storage modulus, viscous modulus, tan delta), rheological properties (e.g., viscosity), tackiness (i.e., ability to stick), pressure sensitivity, and wetting property.
  • the tackifier is used to improve the tackiness of the composition.
  • the tackifier is used to reduce the viscosity of the composition.
  • the tackifier is used to render the composition a pressure-sensitive adhesive.
  • the tackifier is used to wet out adherent surfaces and/or improve the adhesion to the adherent surfaces.
  • Tackifiers suitable for the compositions disclosed herein can be solids, semi-solids, or liquids at room temperature.
  • Non-limiting examples of tackifiers include (1) natural and modified rosins (e.g., gum rosin, wood rosin, tall oil rosin, distilled rosin, hydrogenated rosin, dimerized rosin, and polymerized rosin); (2) glycerol and pentaerythritol esters of natural and modified rosins (e.g., the glycerol ester of pale, wood rosin, the glycerol ester of hydrogenated rosin, the glycerol ester of polymerized rosin, the pentaerythritol ester of hydrogenated rosin, and the phenolic-modified pentaerythritol ester of rosin); (3) copoly
  • the tackifiers include rosin-based tackifiers (e.g.
  • the tackifiers include polyterpenes or terpene resins (e.g., SYLV ARES® terpene resins from Arizona Chemical, Jacksonville, FL).
  • the tackifiers include aliphatic hydrocarbon resins such as resins resulting from the polymerization of monomers consisting of olefins and diolefins (e.g., ESCOREZ® 1310LC, ESCOREZ® 2596 from ExxonMobil Chemical Company, Houston, Tex.
  • the tackifiers include hydrogenated cyclic hydrocarbon resins (e. g. REGALREZ® and REGALITE® resins from Eastman Chemical Company).
  • the tackifiers are modified with tackifier modifiers including aromatic compounds (e.g., ESCOREZ® 2596 from
  • the tackifier is an aliphatic hydrocarbon resin having at least five carbon atoms.
  • the tackifier has a Ring and Ball (R&B) softening point equal to or greater than 8O 0 C.
  • the Ring and Ball (R&B) softening point can be measured by the method described in ASTM E28, which is incorporated herein by reference.
  • the performance characteristics of the tackifier in the composition disclosed herein can be directly related to its compatibility with the ethylene/ ⁇ - olefin interpolymer.
  • compositions with desirable adhesive properties can be obtained with tackifiers that are compatible with the interpolymer.
  • desirable tack properties can be produced.
  • incompatible tackifiers may not produce desirable tack properties, they may be used to impact other desirable properties.
  • the properties of the composition can be fine-tuned by the addition of a tackifier having limited compatibility to reduce the tack level and/or increase the cohesive strength characteristics.
  • compositions disclosed herein comprise a plasticizer or plasticizing oil or an extender oil that may reduce viscosity and/or improve tack properties.
  • plasticizers include olefin oligomers, low molecular weight polyolefins such as liquid polybutene, low molecular weight non-aromatic polymers (e.g. REGALREZ® 1018 from Eastman Chemical Company), phthalates, mineral oils such as naphthenic, paraffinic, or hydrogenated (white) oils (e.g. Kaydol oil or ParaLuxTM oils (Chevron U.S.A.
  • Low molecular weight polyolefins may include those with Mw as low as 100, in particular, those in the range of from about 100 to 3000, in the range of from about 250 to about 2000 and in the range of from about 300 to about 1000. Paraffinic oils are especially preferred.
  • the plasticizers include polypropylene, polybutene, hydrogenated polyisoprene, hydrogenated polybutadiene, polypiperylene and copolymers of piperylene and isoprene, and the like having average molecular weights between about 350 and about 10,000.
  • the plasticizers include glyceryl esters of the usual fatty acids and polymerization products thereof.
  • a suitable insoluble plasticizer may be selected from the group which includes dipropylene glycol dibenzoate, pentaerythritol tetrabenzoate; polyethylene glycol 400-di-2-ethylhexoate; 2-ethylhexyl diphenyl phsophate; butyl benzyl phthalate, dibutyl phthalate, dioctyl phthalate, various substituted citrates, and glycerates.
  • Suitable dipropylene glycol dibenzoate and pentaerythritol tetrabenzoate may be purchased from Velsicol Chemical Company of Chicago, 111.
  • Benzoflex 9- 88 and S-552 respectively.
  • a suitable polyethylene glycol 400-di-2-ethylhexoate may be purchased from CP. Hall Company of Chicago, 111. under the trade designation “Tegmer 809”.
  • a suitable 2-ethylhexyl diphenyl phosphate, and a butyl benzyl phthalate may be purchased from Monsanto Industrial Chemical Company of St. Louis, Mo. under the trade designation "Santicizer 141 and 160", respectively.
  • Benzoflex is used as a plasticizer in an adhesive composition, it can delay the crystallization in diaper core stabilization adhesives, which are used to stabilize the thinner cores of diapers and adult incontinence products.
  • the compositions disclosed herein optionally can comprise a wax that may reduce the melt viscosity in addition to reducing costs.
  • a wax that may reduce the melt viscosity in addition to reducing costs.
  • Any wax known to a person of ordinary skill in the art can be used in the adhesion composition disclosed herein.
  • suitable waxes include petroleum waxes, polyolefin waxes such as low molecular weight polyethylene or polypropylene , synthetic waxes, paraffin and microcrystalline waxes having melting points from about 55 to about 110 0 C, Fischer- Tropsch waxes and combinations thereof.
  • the wax is a low molecular weight polyethylene homopolymer or interpolymer having a number average molecular weight of about 400 to about 6,000 g/mole.
  • the inventive interpolymer having such an average molecular weight can be used as a wax, in addition to the higher molecular weight inventive polymer being used as a polymeric component.
  • the amount of the wax in the composition can be from greater than 0 to about 50 wt %, from about 10 to about 45 wt %, or from about 25 to about 40 wt % of the total weight of the composition.
  • the tackifier to ethylene/ ⁇ -olefin block copolymer ratio is in the range of from about 3.2:1 to about 10:1, preferably about 3.5:1 to about 8:1, and more preferably about 4.0:1 to about 6.0:1.
  • the oil or low molecular weight polymer to ethylene/ ⁇ -olefin block copolymer ratio may be an amount in the range of from about 1.2: 1 to about 3.0:1, preferably about 1.3:1 to about 2.5: 1, and more preferably in the range of from about 1.5:1 to about 2.0:1.
  • compositions disclosed herein optionally can comprise an antioxidant or a stabilizer.
  • Any antioxidant known to a person of ordinary skill in the art may be used in the adhesion composition disclosed herein.
  • suitable antioxidants include amine-based antioxidants such as alkyl diphenylamines, phenyl- ⁇ - naphthylamine, alkyl or aralkyl substituted phenyl- ⁇ -naphthylamine, alkylated p- phenylene diamines, tetramethyl-diaminodiphenylamine and the like; and hindered phenol compounds such as 2,6-di-t-butyl-4-methylphenol; l,3,5-trimethyl-2,4,6-tris(3',5'-di-t-butyl- 4'-hydroxybenzyl)benzene; tetrakis[(methylene(3,5-di-t-butyl-4- hydroxyhydrocinnamate
  • the amount of the antioxidant in the composition can be from about greater than 0 to about 1 wt %, from about 0.05 to about 0.75 wt %, or from about 0.1 to about 0.5 wt % of the total weight of the composition.
  • the compositions disclosed herein optionally can comprise an UV stabilizer that may prevent or reduce the degradation of the compositions by UV radiation.
  • Any UV stabilizer known to a person of ordinary skill in the art may be used in the adhesion composition disclosed herein.
  • suitable UV stabilizers include benzophenones, benzotriazoles, aryl esters, oxanilides, acrylic esters, Formamidine carbon black, hindered amines, nickel quenchers, hindered amines, phenolic antioxidants, metallic salts, zinc compounds and combinations thereof.
  • the amount of the UV stabilizer in the composition can be from about greater than 0 to about 1 wt %, from about 0.05 to about 0.75 wt %, or from about 0.1 to about 0.5 wt % of the total weight of the composition.
  • compositions disclosed herein optionally can comprise a colorant or pigment.
  • a colorant or pigment Any colorant or pigment known to a person of ordinary skill in the art may be used in the adhesion composition disclosed herein.
  • suitable colorants or pigments include inorganic pigments such as titanium dioxide and carbon black, phthalocyanine pigments, and other organic pigments such as IRGAZIN®, CROMOPHT AL®, MONASTRAL®, CINQUASIA®, IRGALITE®, ORASOL®, all of which are available from Ciba Specialty Chemicals, Tarrytown, NY.
  • the amount of the colorant or pigment in the composition can be from about greater than 0 to about 10 wt %, from about 0.1 to about 5 wt %, or from about 0.5 to about 2 wt % of the total weight of the composition.
  • compositions disclosed herein may also optionally comprise a fragrance such as a perfume or other odorant.
  • a fragrance such as a perfume or other odorant.
  • Such fragrances may be contained in release agents such as microcapsules that may, for example, release fragrance upon removal of a release liner from the composition.
  • the compositions disclosed herein optionally can comprise a filler.
  • a filler Any filler known to a person of ordinary skill in the art may be used in the adhesion composition disclosed herein.
  • suitable fillers include sand, talc, dolomite, calcium carbonate, clay, silica, mica, wollastonite, feldspar, aluminum silicate, alumina, hydrated alumina, glass bead, glass microsphere, ceramic microsphere, thermoplastic microsphere, barite, wood flour, and combinations thereof.
  • the amount of the filler in the composition can be from about greater than 0 to about 60 wt %, from about 1 to about 50 wt %, or from about 5 to about 40 wt % of the total weight of the composition.
  • the Hildebrand solubility parameter for a copolymer may be calculated using a volume fraction weighting of the individual Hildebrand solubility parameters for each monomer comprising the copolymer, as described for binary copolymers in Barton A. F.
  • Hildebrand solubility parameter for polymeric materials is also known to be weakly dependent upon the molecular weight of the polymer, as noted in Barton, pages 446-448. Therefore, there will be a preferred molecular weight range for a given ethylene/ ⁇ -olefin interpolymer, and adhesive strength may be additionally controlled by manipulating the molecular weight of the ethylene/ ⁇ -olefin interpolymer or the additives such as the tackifier.
  • the cloud point is usually close to the melting point of the wax.
  • the lower the cloud point temperature the greater the compatibility.
  • the cloud point measurement is disclosed in "Adhesives and Coatings Manual” by National Distillers and Chemical Corporation (1983), which is incorporated herein by reference.
  • Dynamic mechanical analysis can be another technique to identify compatibility characteristics of the additives with the ethylene/ ⁇ -olefin interpolymer.
  • an additive such as the tackifier having a first glass transition temperature (Tg)
  • Tg first glass transition temperature
  • DMA generally reveals one single glass transition zone but with the second Tg shift to a different temperature due to the contribution of the first Tg. This indicates an intimate mix (solubility) between the tackifier and the ethylene/ ⁇ -olefin interpolymer.
  • DMA can detect a separate phase transition for each of the tackifier and the ethylene/ ⁇ -olefin interpolymer.
  • the ingredients of the compositions are melt blended by a method as described by Guerin et al. in U.S. Patent No. 4,152,189. That is, all solvent
  • Physical blending devices that provide dispersive mixing, distributive mixing, or a combination of dispersive and distributive mixing can be useful in preparing homogenous blends. Both batch and continuous methods of physical blending can be used. Non- limiting examples of batch methods include those methods using BRABENDER® mixing equipment (e.g., BRABENDER PREP CENTER®, available from C. W. Brabender Instruments, Inc., Southhackensack, N. J.), Sigma blade mixing, or B ANBURY® internal mixing and roll milling (available from Farrel Company, Ansonia, Conn.) equipment.
  • BRABENDER® mixing equipment e.g., BRABENDER PREP CENTER®, available from C. W. Brabender Instruments, Inc., Southhackensack, N. J.
  • Sigma blade mixing e.g., Sigma blade mixing, or B ANBURY® internal mixing and roll milling (available from Farrel Company, Ansonia, Conn.) equipment.
  • the mixing time required for blending the formulation is in the range of from 5 min to 20 min, and preferably in the range of from 10 min to 15 minutes.
  • continuous methods include single screw extruding, twin screw extruding, disk extruding, reciprocating single screw extruding, and pin barrel single screw extruding.
  • An aqueous dispersion of the ethylene/ ⁇ -olefin interpolymer may also be used in the formulation of various compositions.
  • U.S. Patent No. 5,574,091, incorporated by reference herein in its entirety teaches the preparation of aqueous dispersions of olefin copolymers in the presence of a stabilizing and an emulsifying amount of a suitable surfactant, such as sulfate of an ethoxylated phenol, e.g., poly(oxy-l,2-ethanediyl) ⁇ -sulfo- ⁇ (nonylphonoxy) ammonium salt.
  • a suitable surfactant such as sulfate of an ethoxylated phenol, e.g., poly(oxy-l,2-ethanediyl) ⁇ -sulfo- ⁇ (nonylphonoxy) ammonium salt.
  • Such methods can also be used to make aqueous dispersions of the ethylene/
  • compositions disclosed herein can be used as hot melt adhesives, pressure sensitive adhesives, hot melt pressure sensitive adhesives or as thermoplastic marking compositions. It can be applied to manufacture any article that requires or comprises a hot melt adhesive or a pressure sensitive adhesive.
  • suitable articles include paper products, packaging materials, laminated wood panels, kitchen countertops, vehicles, labels, disposable diapers, hospital pads, feminine sanitary napkins, surgical drapes, tapes, cases, cartons, trays, medical devices, and bandages.
  • the adhesive composition can be used in tapes, cases, cartons, trays, medical devices, and bandages.
  • the compositions are used as hot melt adhesives.
  • hot melt adhesive compositions can be used in industrial applications including packaging, particularly for low temperature use such as for dairy products or for freezer packaging of food products, and in sanitary disposable consumer articles, for example, diapers, feminine care pads, napkins, and the like. Some other suitable applications include book-binding, wood working and labeling.
  • compositions disclosed herein may be used as PSAs.
  • PSA compositions can be applied to sheeting products (e.g., decorative, reflective, and graphical), labelstock, and tape backings.
  • the substrate can be any suitable type of material depending on the desired application.
  • the substrate comprises a nonwoven, paper, polymeric film (e.g., polypropylene (e.g., biaxially oriented polypropylene (BOPP)), polyethylene, polyurea, polybutylene or a polyethylene-polypropylene copolymer, but may also be wholly or partly polyamide such as nylon, polyester such as polyethylene terephthalate, polyvinylidene fluoride, polyacrylate such as poly(methyl methacry late) (only in blends) and the like or polyester (e.g., polyethylene terephthalate (PET)), and blends thereof, or release liner (e.g., siliconized liner).
  • polypropylene e.g., biaxially oriented polypropylene (BOPP)
  • POPP biaxially oriented polypropylene
  • polyethylene polyurea
  • polyamide such as nylon
  • polyester such as polyethylene terephthalate,
  • the compositions can be utilized to form tape.
  • the PSA or hot melt adhesive composition is applied to at least one side of the backing of the tape.
  • the adhesive composition may then be crosslinked to further improve its shear strength. Any suitable crosslinking method (e.g., exposure to radiation, such as ultraviolet or electron beam) or crosslinker additive (e.g., phenolic and silane curatives) may be utilized.
  • the adhesive compositions disclosed herein may be applied to the desired substrate or adhered in any manner known in the art, particularly those methods used traditionally for making tapes, cases, cartons, trays, medical devices, health and hygiene applications and bandages.
  • the adhesive compositions can be applied by a coating head or nozzle, with associated equipment.
  • the adhesive compositions can be applied as fine lines, dots or spray coatings, in addition to other traditional forms as desired.
  • the adhesive compositions may be applied via spiral spray techniques.
  • the compositions of the present invention may be applied at lower temperatures as compared to conventional such adhesive compositions.
  • the composition may be applied at temperatures in the range of from about 110 0 C to about 150 0 C, preferably in the range of from about 115 0 C to 140 0 C, and more preferably in the range of from about
  • the substrate is a polyethylene backing sheet.
  • the method further comprises forming a laminate by applying a nonwoven sheet onto the adhesive on the substrate after applying the adhesive.
  • the nonwoven sheet comprises a spunbond polypropylene sheet.
  • the adhesive compositions can be applied using melt extrusion techniques.
  • the adhesive composition can be applied by either continuous or batch processes.
  • An example of a batch process is the placement of a portion of the adhesive composition between a substrate to which the adhesive composition is to be adhered and a surface capable of releasing the adhesive to form a composite structure.
  • An example of a continuous forming method includes drawing the adhesive composition out of a heated film die and subsequently contacting the drawn composition to a moving plastic web or other suitable substrate.
  • the adhesive compositions can be coated using a solvent-based method.
  • the solvent-based adhesive composition can be coated by such methods as knife coating, roll coating, gravure coating, rod coating, curtain coating, and air knife coating.
  • the coated solvent-based adhesive composition is then dried to remove the solvent.
  • the applied solvent-based adhesive composition is subjected to elevated temperatures, such as those supplied by an oven, to expedite drying.
  • the compositions disclosed herein are used as thermoplastic marking compositions for marking roads.
  • the filler will be provided to the thermoplastic marking composition in an amount of from 40 to 90 weight percent, preferably from 50 to 90 weight percent.
  • the filler will comprise a combination of the following: 0 to 60 weight percent sand, 0 to 100 percent dolomite or talc, 0 to 50 weight percent glass microspheres, and 1 to 20 weight percent pigment.
  • thermoplastic coating composition When it is desired that the thermoplastic coating composition have reflective attributes, a reflective inorganic filler will be employed.
  • One particularly preferred reflective inorganic filler is glass microspheres.
  • a reflective inorganic filler When a reflective inorganic filler is employed, it will typically be provided to the thermoplastic coating composition in an amount of at least 5 weight percent, preferably at least 10 weight percent, and more preferably at least 20 weight percent.
  • the reflective inorganic filler will be provided to the thermoplastic coating composition in an amount of no more than 70, preferably no more than 50 weight percent, and most preferably no more than 40 weight percent.
  • thermoplastic marking compositions are advantageous in that they may be readily designed to be applied by the various techniques used in the industry. For instance, it is now possible to develop a single formulation, which may be usefully applied by extrusion, screed, or spray techniques.
  • the thermoplastic marking compositions will preferably exhibit an adhesion, as measured in accordance with the techniques set forth in Example Two of U.S. Patent No. 6,552,110, of at least 1.0 N/mm 2 , preferably at least 1.2 N/mm 2 , more preferably at least 1.3 N/mm , and most preferably at least 1.5 N/mm .
  • U.S. Patent No. 6,552,110 is incorporated herein by reference.
  • thermoplastic marking compositions will preferably exhibit a luminance factor, as measured in accordance with the techniques set forth in Example Two of U.S. Patent No. 6,552,110, of at least 70, preferably at least 75, more preferably at least 76, and most preferably at least 78.
  • thermoplastic marking compositions further exhibit good low temperature abrasion resistance.
  • the subject formulations exhibit improved low temperature flexibility and low temperature adhesion, and exhibit improved smoke and low odor properties at high temperatures.
  • the subject formulations exhibit a broad potential range of application temperatures, particularly at temperatures of from 150 0 C to 250 0 C, which makes them suitable for application by different means. For instance, the ability of the compositions to be applied at lower application temperatures, that is, temperatures of about 150 to 170 0 C, makes them suitable for application by extrusion coating techniques; while the ability of the compositions to be applied at higher application temperatures, that is, temperatures of 200 0 C to 250 0 C makes them suitable for application by spray coating techniques.
  • the subject formulations are preferably resistant to dirt pick-up, and further preferably exhibit less viscosity variability relative to systems which lack the homogeneous ethylene polymer.
  • the subject formulations are usefully applied via spray, screed, and extrusion techniques.
  • the subject formulations may be provided as preformed tapes, which are laid upon the surface and bonded to it by heating with, for example, a gas flame, optionally under some applied pressure, as by rolling.
  • thermoplastic marking compositions are in hot melt extrusion road marking; hot melt spray road marking; hot melt hand applied road markings; colored hot melt marked bicycle lanes applied by spray or extrusion; marking of simulation/training roads for icy surface driving; preformed extruded traffic symbols (such as arrows, letters, etc.) and tapes (such as for traffic safety, information, decoration, etc.) (also called premarks or hot melt tapes); marking of flexible and soft sports/playground surfaces, such as tartan (for instance, in the marking of tennis courts, outdoor and indoor sports floorings, etc.); safety markings on ships, oil rigs, etc.; and reflecting traffic safety coatings for tunnels, concrete, metals with glass beads or other reflecting/self-glowing pigments.
  • preformed extruded traffic symbols such as arrows, letters, etc.
  • tapes such as for traffic safety, information, decoration, etc.
  • marking of flexible and soft sports/playground surfaces such as tartan (for instance, in the marking of tennis courts, outdoor and indoor sports floorings, etc
  • the subject thermoplastic marking compositions will be employed in embossed road markings.
  • Embossed road markings are formed by extrusion of a marking composition onto a surface; applying reflective particles, such as glass beads, to the extruded marking; and embossing the extruded marking such as to create channels or other ridges.
  • Such embossed markings are desirable, in that they provide enhanced water drainage and improve nighttime reflective properties, particularly in rainy weather.
  • the thermoplastic marking compositions of the invention are advantageous in embossed road marking applications, as they provide the requisite degree of flexibility, adhesion, and abrasion, even under cold temperature conditions.
  • An adhesive composition comprising:
  • (a) has a M w /M n from about 1.7 to about 3.5, at least one melting point, T m , in degrees Celsius, and a density, d, in grams/cubic centimeter, wherein the numerical values of T m and d correspond to the relationship: T m > -2002.9 + 4538.5(d) - 2422.2(d) 2 , or
  • (b) has a M w /M n from about 1.7 to about 3.5, and is characterized by a heat of fusion, ⁇ H in J/g, and a delta quantity, ⁇ T, in degrees Celsius, defined as the temperature difference between the tallest DSC peak and the tallest CRYSTAF peak, wherein the numerical values of ⁇ T and ⁇ H have the following relationships: ⁇ T > -0.1299( ⁇ H) + 62.81 for ⁇ H greater than zero and up to 130 J/g,
  • ⁇ T > 48°C for ⁇ H greater than 130 J/g , wherein the CRYSTAF peak is determined using at least 5 percent of the cumulative polymer, and if less than 5 percent of the polymer has an identifiable CRYSTAF peak, then the CRYSTAF temperature is 30 0 C; or (c) is characterized by an elastic recovery, Re, in percent at 300 percent strain and 1 cycle measured with a compression-molded film of the ethylene/ ⁇ - olefin interpolymer, and has a density, d, in grams/cubic centimeter, wherein the numerical values of Re and d satisfy the following relationship when ethylene/ ⁇ -olefin interpolymer is substantially free of a cross-linked phase: Re >1481-1629(d); or
  • (d) has a molecular fraction which elutes between 40 0 C and 130 0 C when fractionated using TREF, characterized in that the fraction has a molar comonomer content of at least 5 percent higher than that of a comparable random ethylene interpolymer fraction eluting between the same temperatures, wherein said comparable random ethylene interpolymer has the same comonomer(s) and has a melt index, density, and molar comonomer content (based on the whole polymer) within 10 percent of that of the ethylene/ ⁇ -olefin interpolymer; or
  • (e) has a storage modulus at 25°C, G'(25°C), and a storage modulus at 100 0 C, G' (100 0 C), wherein the ratio of G' (25°C) to G' (100 0 C) is in the range of about 1:1 to about 9:1; or
  • (f) has a molecular fraction which elutes between 40 0 C and 130 0 C when fractionated using TREF, characterized in that the fraction has a block index of at least 0.5 and up to about 1; or (g) has an average block index greater than zero and up to about 1.0 and a molecular weight distribution, Mw/Mn, greater than about 1.3; and,
  • composition of embodiment 1, wherein the ethylene/ ⁇ -olefin interpolymer has a M w /M n from about 1.7 to about 3.5, at least one melting point, T m , in degrees Celsius, and a density, d, in grams/cubic centimeter, wherein the numerical values of T m and d correspond to the relationship: T m > 858.91 - 1825.3(d) + 1112.8(d) 2 .
  • composition of embodiment 1, wherein the ethylene/ ⁇ -olefin interpolymer has a M w /M n from about 1.7 to about 3.5 and is characterized by a heat of fusion, ⁇ H in J/g, and a delta quantity, ⁇ T, in degrees Celsius defined as the temperature difference between the tallest DSC peak and the tallest CRYSTAF peak, wherein the numerical values of ⁇ T and ⁇ H have the following relationships: ⁇ T > -0.1299( ⁇ H) + 62.81 for ⁇ H greater than zero and up to 130 J/g, ⁇ T > 48°C for ⁇ H greater than 130 J/g , wherein the CRYSTAF peak is determined using at least 5 percent of the cumulative polymer, and if less than 5 percent of the polymer has an identifiable CRYSTAF peak, then the CRYSTAF temperature is 30 0 C.
  • composition of embodiment 1, wherein the ethylene/ ⁇ -olefin interpolymer is characterized by an elastic recovery, Re, in percent at 300 percent strain and 1 cycle measured with a compression-molded film of the ethylene/ ⁇ -olefin interpolymer, and has a density, d, in grams/cubic centimeter, wherein the numerical values of Re and d satisfy the following relationship when ethylene/ ⁇ -olefin interpolymer is substantially free of a cross-linked phase:
  • composition of embodiment 1, wherein the ethylene/ ⁇ -olefin interpolymer has a molecular fraction which elutes between 40 0 C and 130 0 C when fractionated using TREF, characterized in that the fraction has a molar comonomer content of at least 5 percent higher than that of a comparable random ethylene interpolymer fraction eluting between the same temperatures, wherein said comparable random ethylene interpolymer has the same comonomer(s) and has a melt index, density, and molar comonomer content (based on the whole polymer) within 10 percent of that of the ethylene/ ⁇ -olefin interpolymer.
  • composition of embodiment 1, wherein the ethylene/ ⁇ -olefin interpolymer has a storage modulus at 25°C, G'(25°C), and a storage modulus at 100 0 C, G'(100°C), wherein the ratio of G'(25°C) to G'(100°C) is in the range of about 1: 1 to about 9:1.
  • the composition is a hot melt adhesive composition, a pressure sensitive adhesive composition or a thermoplastic marking composition.
  • composition of embodiment 1, wherein the ⁇ -olefin is styrene, propylene, 1-butene, 1-hexene, 1-octene, 4-methyl-l-pentene, norbornene, 1-decene, 1,5-hexadiene, or a combination thereof.
  • composition of embodiment 1, wherein the tackifier has a R&B softening point equal to or greater than 8O 0 C. 14. The composition of embodiment 1, wherein the oil is present in an amount in the range of between 0 wt% to about 30 wt%, by weight of the total composition.
  • composition of embodiment 1, wherein the ethylene/ ⁇ -olefin interpolymer has a density of about 0.86 to about 0.875 g/cc.
  • composition of embodiment 1, wherein the ethylene/ ⁇ -olefin interpolymer has a melt index of about 5 to about 50 g/10 minutes.
  • a method of applying the composition of embodiment 1 to a substrate comprising: applying the composition to the substrate at a temperature in the range of from about 100 0 C to about 150 0 C.
  • T m > 858.91 - 1825.3(d) + 1112.8(d) 2 .
  • the ethylene/ ⁇ -olefin interpolymer has a M w /M n from about 1.7 to about 3.5 and is characterized by a heat of fusion, ⁇ H in J/g, and a delta quantity, ⁇ T, in degrees Celsius defined as the temperature difference between the tallest DSC peak and the tallest CRYSTAF peak, wherein the numerical values of ⁇ T and ⁇ H have the following relationships:
  • the ethylene/ ⁇ -olefin interpolymer has a molecular fraction which elutes between 40 0 C and 130 0 C when fractionated using TREF, characterized in that the fraction has a molar comonomer content of at least 5 percent higher than that of a comparable random ethylene interpolymer fraction eluting between the same temperatures, wherein said comparable random ethylene interpolymer has the same comonomer(s) and has a melt index, density, and molar comonomer content (based on the whole polymer) within 10 percent of that of the ethylene/ ⁇ -olefin interpolymer.
  • composition is a hot melt adhesive composition, a pressure sensitive adhesive composition or a thermoplastic marking composition.
  • ⁇ -olefin is styrene, propylene, 1-butene, 1-hexene, 1-octene, 4-methyl-l-pentene, norbornene, 1-decene, 1,5- hexadiene, or a combination thereof.
  • the tackifier is present in the range from about 15 wt% to about 75 wt %, by weight of the total composition.
  • An automated liquid-handling robot equipped with a heated needle set to 16O 0 C is used to add enough 1,2,4-trichlorobenzene stabilized with 300 ppm Ionol to each dried polymer sample to give a final concentration of 30 mg/mL.
  • a small glass stir rod is placed into each tube and the samples are heated to 16O 0 C for 2 hours on a heated, orbital- shaker rotating at 250 rpm.
  • the concentrated polymer solution is then diluted to 1 mg/ml using the automated liquid-handling robot and the heated needle set to 16O 0 C.
  • a Symyx Rapid GPC system is used to determine the molecular weight data for each sample.
  • a Gilson 350 pump set at 2.0 ml/min flow rate is used to pump helium- purged 1,2-dichlorobenzene stabilized with 300 ppm Ionol as the mobile phase through three Plgel 10 micrometer ( ⁇ m) Mixed B 300mm x 7.5mm columns placed in series and heated to 16O 0 C.
  • a Polymer Labs ELS 1000 Detector is used with the Evaporator set to 25O 0 C, the Nebulizer set to 165 0 C, and the nitrogen flow rate set to 1.8 SLM at a pressure of 60-80 psi (400-600 kPa) N 2 .
  • the polymer samples are heated to 16O 0 C and each sample injected into a 250 ⁇ l loop using the liquid-handling robot and a heated needle. Serial analysis of the polymer samples using two switched loops and overlapping injections are used. The sample data is collected and analyzed using Symyx EpochTM software. Peaks are manually integrated and the molecular weight information reported uncorrected against a polystyrene standard calibration curve.
  • Branching distributions are determined by crystallization analysis fractionation (CRYSTAF) using a CRYSTAF 200 unit commercially available from
  • PolymerChar Valencia, Spain.
  • the samples are dissolved in 1,2,4 trichlorobenzene at 160 0 C (0.66 mg/mL) for 1 hr and stabilized at 95 0 C for 45 minutes.
  • the sampling temperatures range from 95 to 30 0 C at a cooling rate of 0.2°C/min.
  • An infrared detector is used to measure the polymer solution concentrations.
  • the cumulative soluble concentration is measured as the polymer crystallizes while the temperature is decreased.
  • the analytical derivative of the cumulative profile reflects the short chain branching distribution of the polymer.
  • the CRYSTAF peak temperature and area are identified by the peak analysis module included in the CRYSTAF Software (Version 200 Lb, PolymerChar, Valencia, Spain).
  • the CRYSTAF peak finding routine identifies a peak temperature as a maximum in the dW/dT curve and the area between the largest positive inflections on either side of the identified peak in the derivative curve.
  • the preferred processing parameters are with a temperature limit of 70 0 C and with smoothing parameters above the temperature limit of 0.1, and below the temperature limit of 0.3.
  • DSC Standard Method Excluding Samples 1-4 and A-C
  • the DSC melting peak is measured as the maximum in heat flow rate (W/g) with respect to the linear baseline drawn between -30 0 C and end of melting.
  • the heat of fusion is measured as the area under the melting curve between -30 0 C and the end of melting using a linear baseline.
  • the gel permeation chromatographic system consists of either a Polymer Laboratories Model PL-210 or a Polymer Laboratories Model PL-220 instrument.
  • the column and carousel compartments are operated at 140 0 C.
  • Three Polymer Laboratories 10- micron Mixed-B columns are used.
  • the solvent is 1,2,4 trichlorobenzene.
  • the samples are prepared at a concentration of 0.1 grams of polymer in 50 milliliters of solvent containing 200 ppm of butylated hydroxy toluene (BHT). Samples are prepared by agitating lightly for 2 hours at 160 0 C.
  • the injection volume used is 100 microliters and the flow rate is 1.0 ml/minute.
  • 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 molecular weights using the following equation (as described in Williams and Ward, L Polvm. ScL, Polvm. Let., 6, 621 (1968)):
  • Samples for density measurement are prepared according to ASTM D 1928. Measurements are made within one hour of sample pressing using ASTM D792, Method B. Flexural/Secant Modulus/ Storage Modulus
  • Clarity is measured using BYK Gardner Haze-gard as specified in ASTM D 1746.
  • E f is the strain taken for cyclic loading
  • ⁇ s is the strain where the load returns to the baseline during the 1 st unloading cycle.
  • L 0 is the load at 50% strain at 0 time and L 12 is the load at 50 percent strain after 12 hours.
  • DMA Dynamic Mechanical Analysis
  • a 1.5mm plaque is pressed and cut in a bar of dimensions 32xl2mm.
  • the sample is clamped at both ends between fixtures separated by 10mm (grip separation ⁇ L) and subjected to successive temperature steps from -100 0 C to 200 0 C (5 0 C per step).
  • the torsion modulus G' is measured at an angular frequency of 10 rad/s, the strain amplitude being maintained between 0.1 percent and 4 percent to ensure that the torque is sufficient and that the measurement remains in the linear regime.
  • Analytical temperature rising elution fractionation (ATREF) analysis is conducted according to the method described in USP 4,798,081 and Wilde, L.; RyIe, T.R.; Knobeloch, D.C.; Peat, LR. ; Determination of Branching Distributions in Polyethylene and Ethylene Copolymers, J. Polym. ScL, 20, 441-455 (1982), which are incorporated by reference herein in their entirety..
  • 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 0 C at a cooling rate of 0.1°C/min.
  • the samples are prepared by adding approximately 3g of a 50/50 mixture of tetrachloroethane-d2/orthodichlorobenzene to 0.4 g sample in a 10 mm NMR tube.
  • the samples are dissolved and homogenized by heating the tube and its contents to 15O 0 C.
  • the data are collected using a JEOL EclipseTM 400MHz spectrometer or a Varian Unity PlusTM 400MHz spectrometer, corresponding to a 13C resonance frequency of 100.5 MHz.
  • the data are acquired using 4000 transients per data file with a 6 second pulse repetition delay. To achieve minimum signal-to-noise for quantitative analysis, multiple data files are added together.
  • the spectral width is 25,000 Hz with a minimum file size of 32K data points.
  • the samples are analyzed at 130 0 C in a 10 mm broad band probe.
  • the comonomer incorporation is determined using Randall's triad method (Randall, J.C.; JMS-Rev. Macromol. Chem. Phys., C29, 201-317 (1989), which is incorporated by reference herein in its entirety.
  • TREF fractionation is carried by dissolving 15-20 g of polymer in 2 liters of 1 ,2,4-trichlorobenzene (TCB) by stirring for 4 hours at 16O 0 C.
  • the polymer solution is forced by 15 psig (100 kPa) nitrogen onto a 3 inch by 4 foot (7.6 cm x 12 cm) steel column packed with a 60:40 (v:v) mix of 30-40 mesh (600-425 ⁇ m) spherical, technical quality glass beads (available from Potters Industries, HC 30 Box 20, Brownwood, TX, 76801) and stainless steel, 0.028" (0.7mm) diameter cut wire shot (available from Pellets, Inc., 63 Industrial Drive, North Tonawanda, NY, 14120).
  • the column is immersed in a thermally controlled oil jacket, set initially to 160 0 C.
  • the column is first cooled ballistically to 125 0 C, then slow cooled to 20 0 C at 0.04 0 C per minute and held for one hour.
  • Fresh TCB is introduced at about 65 ml/min while the temperature is increased at 0.167 0 C per minute.
  • Approximately 2000 ml portions of eluant from the preparative TREF column are collected in a 16 station, heated fraction collector.
  • the polymer is concentrated in each fraction using a rotary evaporator until about 50 to 100 ml of the polymer solution remains.
  • the concentrated solutions are allowed to stand overnight before adding excess methanol, filtering, and rinsing (approx. 300-500 ml of methanol including the final rinse).
  • the filtration step is performed on a 3 position vacuum assisted filtering station using 5.0 ⁇ m polytetrafluoroethylene coated filter paper (available from Osmonics Inc., Cat
  • Melt Strength is measured by using a capillary rheometer fitted with a 2.1 mm diameter, 20:1 die with an entrance angle of approximately 45 degrees. After equilibrating the samples at 190 0 C for 10 minutes, the piston is run at a speed of 1 inch/minute (2.54 cm/minute). The standard test temperature is 190 0 C. The sample is drawn uniaxially to a set of accelerating nips located 100 mm below the die with an acceleration of 2.4 mm/sec 2 . The required tensile force is recorded as a function of the take-up speed of the nip rolls. The maximum tensile force attained during the test is defined as the melt strength. In the case of polymer melt exhibiting draw resonance, the tensile force before the onset of draw resonance was taken as melt strength. The melt strength is recorded in centiNewtons ("cN").
  • catalyst (Bl) is conducted as follows. a) Preparation of (l-methylethyl)(2-hvdroxy-3,5-di(t-butyl)phenyl)methylimine
  • catalyst (B 2) is conducted as follows. a) Preparation of (l-(2-methylcvclohexyl)ethyl)(2-oxoyl-3,5-di(t-butyl)phenyl)imine [166] 2-Methylcyclohexylamine (8.44 mL, 64.0 mmol) is dissolved in methanol (90 mL), and di-t-butylsalicaldehyde (10.00 g, 42.67 mmol) is added. The reaction mixture is stirred for three hours and then cooled to -25°C for 12 hrs.
  • shuttling agents include diethylzinc (DEZ, SAl), di(i-butyl)zinc (SA2), di(n-hexyl)zinc (SA3), triethylaluminum (TEA, SA4), trioctylaluminum (SA5), triethylgallium (SA6), i-butylaluminum bis(dimethyl(t- butyl)siloxane) (SA7), i-butylaluminum bis(di(trimethylsilyl)amide) (SA8), n-octylaluminum di(pyridine-2-methoxide) (SA9), bis(n-octadecyl)i-butylaluminum (SAlO), i-butylaluminum bis (di(n-pentyl) amide) (SAI l), n-octylaluminum bis(2,6-di
  • a series of polymerizations are conducted in a parallel pressure reactor (PPR) contained of 48 individual reactor cells in a 6 x 8 array that are fitted with a pre-weighed glass tube.
  • the working volume in each reactor cell is 6000 ⁇ L.
  • Each cell is temperature and pressure controlled with stirring provided by individual stirring paddles.
  • the monomer gas and quench gas are plumbed directly into the PPR unit and controlled by automatic valves.
  • Liquid reagents are robotically added to each reactor cell by syringes and the reservoir solvent is mixed alkanes.
  • the order of addition is mixed alkanes solvent (4 ml), ethylene, 1-octene comonomer (1 ml), cocatalyst 1 or cocatalyst 1/MMAO mixture, shuttling agent, and catalyst or catalyst mixture.
  • the reagents are premixed in a small vial immediately prior to addition to the reactor.
  • a reagent is omitted in an experiment, the above order of addition is otherwise maintained. Polymerizations are conducted for approximately 1-2 minutes, until predetermined ethylene consumptions are reached. After quenching with CO, the reactors are cooled and the glass tubes are unloaded.
  • Examples 1-4 demonstrate the synthesis of linear block copolymers by the present invention as evidenced by the formation of a very narrow MWD, essentially monomodal copolymer when DEZ is present and a bimodal, broad molecular weight distribution product (a mixture of separately produced polymers) in the absence of DEZ. Due to the fact that Catalyst (Al) is known to incorporate more octene than Catalyst (Bl), the different blocks or segments of the resulting copolymers of the invention are distinguishable based on branching or density. Table 1
  • the DSC curve for the polymer of example 1 shows a 115.7°C melting point (Tm) with a heat of fusion of 158.1 J/g.
  • the corresponding CRYSTAF curve shows the tallest peak at 34.5°C with a peak area of 52.9 percent.
  • the difference between the DSC Tm and the Tcrystaf is 81.2°C.
  • the DSC curve for the polymer of example 2 shows a peak with a 109.7 0 C melting point (Tm) with a heat of fusion of 214.0 J/g.
  • the corresponding CRYSTAF curve shows the tallest peak at 46.2°C with a peak area of 57.0 percent.
  • the difference between the DSC Tm and the Tcrystaf is 63.5 0 C.
  • the DSC curve for the polymer of example 3 shows a peak with a 120.7 0 C melting point (Tm) with a heat of fusion of 160.1 J/g.
  • the corresponding CRYSTAF curve shows the tallest peak at 66.1°C with a peak area of 71.8 percent.
  • the difference between the DSC Tm and the Tcrystaf is 54.6°C.
  • the DSC curve for the polymer of example 4 shows a peak with a 104.5 0 C melting point (Tm) with a heat of fusion of 170.7 J/g.
  • the corresponding CRYSTAF ⁇ curve shows the tallest peak at 30 0 C with a peak area of 18.2 percent.
  • the difference between the DSC Tm and the Tcrystaf is 74.5 0 C.
  • the DSC curve for Comparative Example A* shows a 90.0 0 C melting point (Tm) with a heat of fusion of 86.7 J/g.
  • the corresponding CRYSTAF curve shows the tallest peak at 48.5°C with a peak area of 29.4 percent. Both of these values are consistent with a resin that is low in density.
  • the difference between the DSC Tm and the Tcrystaf is 41.8°C.
  • the DSC curve for Comparative Example B* shows a 129.8°C melting point (Tm) with a heat of fusion of 237.0 J/g.
  • the corresponding CRYSTAF curve shows the tallest peak at 82.4°C with a peak area of 83.7 percent. Both of these values are consistent with a resin that is high in density.
  • the difference between the DSC Tm and the Tcrystaf is 47.4°C.
  • the DSC curve for Comparative Example C* shows a 125.3°C melting point (Tm) with a heat of fusion of 143.0 J/g.
  • the corresponding CRYSTAF curve shows the tallest peak at 81.8 0 C with a peak area of 34.7 percent as well as a lower crystalline peak at 52.4 0 C.
  • the separation between the two peaks is consistent with the presence of a high crystalline and a low crystalline polymer.
  • the difference between the DSC Tm and the Tcrystaf is 43.5 0 C.
  • the DSC curve for the polymer of example 5 shows a peak with a 119.6 0 C melting point (Tm) with a heat of fusion of 60.0 J/g.
  • the corresponding CRYSTAF curve shows the tallest peak at 47.6°C with a peak area of 59.5 percent.
  • the delta between the DSC Tm and the Tcrystaf is 72.0 0 C.
  • the DSC curve for the polymer of example 6 shows a peak with a 115.2 0 C melting point (Tm) with a heat of fusion of 60.4 J/g.
  • the corresponding CRYSTAF curve shows the tallest peak at 44.2°C with a peak area of 62.7 percent.
  • the delta between the DSC Tm and the Tcrystaf is 71.0 0 C.
  • the DSC curve for the polymer of example 7 shows a peak with a 121.3 0 C melting point with a heat of fusion of 69.1 J/g.
  • the corresponding CRYSTAF curve shows the tallest peak at 49.2°C with a peak area of 29.4 percent.
  • the delta between the DSC Tm and the Tcrystaf is 72.1 0 C.
  • the DSC curve for the polymer of example 8 shows a peak with a 123.5 0 C melting point (Tm) with a heat of fusion of 67.9 J/g.
  • the corresponding CRYSTAF curve shows the tallest peak at 80.1 0 C with a peak area of 12.7 percent.
  • the delta between the DSC Tm and the Tcrystaf is 43.4°C.
  • the DSC curve for the polymer of example 9 shows a peak with a 124.6 0 C melting point (Tm) with a heat of fusion of 73.5 J/g.
  • the corresponding CRYSTAF curve shows the tallest peak at 80.8 0 C with a peak area of 16.0 percent.
  • the delta between the DSC Tm and the Tcrystaf is 43.8°C.
  • the delta between the DSC Tm and the Tcrystaf is 83.2°C.
  • the DSC curve for the polymer of example 13 shows a peak with a 114.4 0 C melting point (Tm) with a heat of fusion of 49.4 J/g.
  • the corresponding CRYSTAF curve shows the tallest peak at 33.8 0 C with a peak area of 7.7 percent.
  • the delta between the DSC Tm and the Tcrystaf is 84.4°C.
  • the DSC for the polymer of example 14 shows a peak with a 120.8 0 C melting point (Tm) with a heat of fusion of 127.9 J/g.
  • the corresponding CRYSTAF curve shows the tallest peak at 72.9 0 C with a peak area of 92.2 percent.
  • the delta between the DSC Tm and the Tcrystaf is 47.9°C.
  • the DSC curve for the polymer of example 15 shows a peak with a 114.3 0 C melting point (Tm) with a heat of fusion of 36.2 J/g.
  • the corresponding CRYSTAF curve shows the tallest peak at 32.3 0 C with a peak area of 9.8 percent.
  • the delta between the DSC Tm and the Tcrystaf is 82.0 0 C.
  • the DSC curve for the polymer of example 17 shows a peak with a 116.0 0 C melting point (Tm) with a heat of fusion of 47.0 J/g.
  • the corresponding CRYSTAF curve shows the tallest peak at 43.1 0 C with a peak area of 56.8 percent.
  • the delta between the DSC Tm and the Tcrystaf is 72.9°C.
  • the DSC curve for the polymer of example 18 shows a peak with a 120.5 0 C melting point (Tm) with a heat of fusion of 141.8 J/g.
  • the corresponding CRYSTAF curve shows the tallest peak at 70.0 0 C with a peak area of 94.0 percent.
  • the delta between the DSC Tm and the Tcrystaf is 50.5 0 C.
  • the DSC curve for the polymer of example 19 shows a peak with a 124.8 0 C melting point (Tm) with a heat of fusion of 174.8 J/g.
  • the corresponding CRYSTAF curve shows the tallest peak at 79.9 0 C with a peak area of 87.9 percent.
  • the delta between the DSC Tm and the Tcrystaf is 45.0 0 C.
  • the DSC curve for the polymer of Comparative Example E* shows a peak with a 124.0 0 C melting point (Tm) with a heat of fusion of 179.3 J/g.
  • the corresponding CRYSTAF curve shows the tallest peak at 79.3°C with a peak area of 94.6 percent. Both of these values are consistent with a resin that is high in density.
  • the delta between the DSC Tm and the Tcrystaf is 44.6°C.
  • the DSC curve for the polymer of Comparative Example F* shows a peak with a 124.8 0 C melting point (Tm) with a heat of fusion of 90.4 J/g.
  • the corresponding CRYSTAF curve shows the tallest peak at 77.6°C with a peak area of 19.5 percent. The separation between the two peaks is consistent with the presence of both a high crystalline and a low crystalline polymer.
  • the delta between the DSC Tm and the Tcrystaf is 47.2°C.
  • Comparative Example G* is a substantially linear ethylene/1-octene copolymer (AFFINITY®, available from The Dow Chemical Company)
  • Comparative Example H* is an elastomeric, substantially linear ethylene/ 1-octene copolymer (AFFINITYOEG8100, available from The Dow Chemical Company)
  • Comparative Example I* is a substantially linear ethylene/1-octene copolymer (AFFINIT Yd)PL 1840, available from The Dow Chemical Company)
  • Comparative Example J* is a hydrogenated styrene/butadiene/styrene triblock copolymer (KRATONTM G1652, available from KRATON Polymers LLC)
  • Comparative Example K* is a thermoplastic vulcanizate (TPV, a polyolefin blend containing dispersed therein a crosslinked elastomer). Results are presented in Table 4. Table 4 High Temperature Mechanical Properties
  • Comparative Example F* (which is a physical blend of the two polymers resulting from simultaneous polymerizations using catalyst Al and Bl) has a 1 mm penetration temperature of about 70 0 C, while Examples 5-9 have a 1 mm penetration temperature of 100 0 C or greater. Further, examples 10-19 all have a 1 mm penetration temperature of greater than 85°C, with most having 1 mm TMA temperature of greater than 90 0 C or even greater than 100 0 C. This shows that the novel polymers have better dimensional stability at higher temperatures compared to a physical blend.
  • Comparative Example J* (a commercial SEBS) has a good 1 mm TMA temperature of about 107 0 C, but it has very poor (high temperature 70 0 C) compression set of about 100 percent and it also failed to recover (sample broke) during a high temperature (80 0 C) 300 percent strain recovery.
  • the exemplified polymers have a unique combination of properties unavailable even in some commercially available, high performance thermoplastic elastomers.
  • Table 4 shows a low (good) storage modulus ratio
  • Example 5 has a pellet blocking strength of 0 MPa, meaning it is free flowing under the conditions tested, compared to Comparatives F and G which show considerable blocking. Blocking strength is important since bulk shipment of polymers having large blocking strengths can result in product clumping or sticking together upon storage or shipping, resulting in poor handling properties.
  • High temperature (70 0 C) compression set for the inventive polymers is generally good, meaning generally less than about 80 percent, preferably less than about 70 percent and especially less than about 60 percent.
  • Comparatives F, G, H and J all have a 70 0 C compression set of 100 percent (the maximum possible value, indicating no recovery). Good high temperature compression set (low numerical values) is especially needed for applications such as gaskets, window profiles, o-rings, and the like.
  • Table 5 shows results for mechanical properties for the new polymers as well as for various comparison polymers at ambient temperatures. It may be seen that the inventive polymers have very good abrasion resistance when tested according to ISO 4649, generally showing a volume loss of less than about 90 mm 3 , preferably less than about 80 mm 3 , and especially less than about 50 mm 3 . In this test, higher numbers indicate higher volume loss and consequently lower abrasion resistance.
  • Tear strength as measured by tensile notched tear strength of the inventive polymers is generally 1000 mJ or higher, as shown in Table 5. Tear strength for the inventive polymers can be as high as 3000 mJ, or even as high as 5000 mJ. Comparative polymers generally have tear strengths no higher than 750 mJ.
  • Table 5 also shows that the polymers of the invention have better retractive stress at 150 percent strain (demonstrated by higher retractive stress values) than some of the comparative samples.
  • Comparative Examples F*, G* and H* have retractive stress value at 150 percent strain of 400 kPa or less, while the inventive polymers have retractive stress values at 150 percent strain of 500 kPa (Ex. 11) to as high as about 1100 kPa (Ex. 17).
  • Polymers having higher than 150 percent retractive stress values would be quite useful for elastic applications, such as elastic fibers and fabrics, especially nonwoven fabrics. Other applications include diaper, hygiene, and medical garment waistband applications, such as tabs and elastic bands.
  • Table 5 also shows that stress relaxation (at 50 percent strain) is also improved (less) for the inventive polymers as compared to, for example, Comparative Example G*.
  • Lower stress relaxation means that the polymer retains its force better in applications such as diapers and other garments where retention of elastic properties over long time periods at body temperatures is desired.
  • optical properties reported in Table 6 are based on compression molded films substantially lacking in orientation. Optical properties of the polymers may be varied over wide ranges, due to variation in crystallite size, resulting from variation in the quantity of chain shuttling agent employed in the polymerization. Extractions of Multi-Block Copolymers
  • the ether in the flask is evaporated under vacuum at ambient temperature, and the resulting solids are purged dry with nitrogen. Any residue is transferred to a weighed bottle using successive washes of hexane. The combined hexane washes are then evaporated with another nitrogen 66202
  • a second clean round bottom flask charged with 350 mL of hexane is then connected to the extractor.
  • the hexane is heated to reflux with stirring and maintained at reflux for 24 hours after hexane is first noticed condensing into the thimble. Heating is then stopped and the flask is allowed to cool. Any hexane remaining in the extractor is transferred back to the flask.
  • the hexane is removed by evaporation under vacuum at ambient temperature, and any residue remaining in the flask is transferred to a weighed bottle using successive hexane washes.
  • the hexane in the flask is evaporated by a nitrogen purge, and the residue is vacuum dried overnight at 40 0 C.
  • Continuous solution polymerizations are carried out in a computer controlled well-mixed reactor.
  • Purified mixed alkanes solvent IsoparTM E available from ExxonMobil Chemical Company
  • ethylene, 1-octene, and hydrogen where used
  • the feeds to the reactor are measured by mass-flow controllers.
  • the temperature of the feed stream is controlled by use of a glycol cooled heat exchanger before entering the reactor.
  • the catalyst component solutions are metered using pumps and mass flow meters.
  • the reactor is run liquid-full at approximately 550 psig pressure.
  • water and additive are injected in the polymer solution.
  • the water hydrolyzes the catalysts, and terminates the polymerization reactions.
  • the post reactor solution is then heated in preparation for a two- stage devolatization.
  • the polymer melt is pumped to a die for underwater pellet cutting.
  • Zn/C 2 *1000 (Zn feed flow*Zn concentration/1000000/Mw of Zn)/(Total Ethylene feed flow*(l-fractional ethylene conversion rate)/Mw of Ethylene)* 1000.
  • Zn in “Zn/C 2 *1000” refers to the amount of zinc in diethyl zinc (“DEZ”) used in the polymerization process
  • C2 refers to the amount of ethylene used in the polymerization process.
  • Continuous solution polymerization is carried out in a computer controlled well-mixed reactor.
  • Purified mixed alkanes solvent (ISOPARTM E available from ExxonMobil Chemical Company), ethylene, 1-octene, and hydrogen (if applicable) is combined and fed to a 102 L reactor.
  • the feeds to the reactor are measured by mass-flow controllers.
  • the temperature of the feed stream is controlled by use of a glycol cooled heat exchanger before entering the reactor.
  • the catalyst component solutions are metered using pumps and mass flow meters.
  • the reactor is run liquid-full at approximately 550 psig pressure.
  • water and additive are injected in the polymer solution. The water hydrolyzes the catalysts, and terminates the polymerization reactions.
  • Example 20 The post reactor solution is then heated in preparation for a two-stage devolatilization. The solvent and unreacted monomers are removed during the devolatilization process. The polymer melt is pumped to a die for underwater pellet cutting. Process details and results are contained in Tables 8 and 9. Testing of Example 20
  • the CRYSTAF peak temperature and area were identified by the peak analysis module included in the CRYSTAF Software (Version 2001. b, PolymerChar, Valencia, Spain).
  • the CRYSTAF peak finding routine identified a peak temperature as a maximum in the dW/dT curve and the area between the largest positive inflections on either side of the identified peak in the derivative curve.
  • the preferred processing parameters were with a temperature limit of 70 0 C and with smoothing parameters above the temperature limit of 0.1 , and below the temperature limit of 0.3.
  • the CRYSTAF peak temperature and the peak area of each example are listed in Table 9 below. 66202
  • the sample was then cooled to -4O 0 C at 10°C/min cooling rate and held at -4O 0 C for 3 minutes.
  • the sample was then heated to 150 0 C at 10°C/minute heating rate.
  • the cooling and second heating curves were recorded.
  • the melting peak (T m ) and cooling peak (T c ) were determined.
  • T m2 or T c2 The heat of fusion, T m and T c of each example are listed in Table 9 below.
  • the gel permeation chromatographic system consisted of either a Polymer Laboratories Model PL-210 or a Polymer Laboratories Model PL- 220 instrument. The column and carousel compartments were operated at 140 0 C. Three Polymer Laboratories 10-micron Mixed-B columns were used. The solvent was 1 ,2,4-trichlorobenzene. The samples were prepared at a concentration of 0.1 grams of polymer in 50 milliliters of solvent containing 200 ppm of butylated hydroxytoluene (BHT). Samples were prepared by agitating lightly for 2 hours at 160 0 C. The injection volume used was 100 microliters and the flow rate was 1.0 ml/minute.
  • Example 20 Various Physical Properties of Example 20
  • the sample is placed in the chamber, which is in turn inserted into a Brookfield Thermosel and locked into place with bent needle-nose pliers.
  • the sample chamber has a notch on the bottom that fits in the bottom of the Brookfield Thermosel to ensure that the chamber is not allowed to turn when the spindle is inserted and spinning.
  • the sample is heated to the desired temperature (170°C/338°F).
  • the viscometer apparatus is lowered and the spindle submerged into the sample chamber. Lowering is continued until brackets on the viscometer align on the Thermosel.
  • the viscometer is turned on, and set to a shear rate which leads to a torque reading in the range of 40 to 70 percent. Readings are taken every minute for about 15 minutes, or until the values stabilize, and then the final reading is recorded.
  • Formulation 1 may be applied at a significantly lower temperature with equal or better results than that of Formulation A, which could not be applied at 250 0 F.
  • the initial peel strength of Formulation 1 is 5.5 pounds per linear inch and increases with aging to 15.2 pli and 14.2 pli. All of which would be useful in a diaper construction or similar such personal hygiene article.
  • compositions or methods may include numerous compounds or steps not mentioned herein. In other embodiments, the compositions or methods do not include, or are substantially free of, any compounds or steps not enumerated herein. Variations and modifications from the described embodiments exist. Finally, any number disclosed herein should be construed to mean approximate, regardless of whether the word "about” or “approximately” is used in describing the number. The appended claims intend to cover all those modifications and variations as falling within the scope of the invention.

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Abstract

An adhesive composition comprises: (i) at least one ethylene/α-olefin interpolymer, (ii) at least one tackifier; and (iii) an oil or a low molecular weight polymer. Preferably, the ethylene/α-olefin interpolymer has a Mw/Mn from about 1.7 to about 3.5, at least one melting point, Tm, in degrees Celsius, and a density, d, in grams/cubic centimeter, wherein the numerical values of Tm and d correspond to the relationship: Tm ≥ 858.91 - 1825.3(d) + 1112.8(d)2. The composition can be used in hot melt adhesives, pressure sensitive adhesives, hot melt pressure sensitive adhesives and thermoplastic marking paints.

Description

_ADHESIVES MADE FROM INTERPOL YMERS OF ETH YLENE/α- OLEFINS
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is related to U.S. Patent Application Serial No. 11/376,957, filed on March 15, 2006, the disclosure of which is herein incorporated by reference in its entirety.
FIELD OF THE INVENTION
[1] This invention relates to adhesive compositions comprising at least one ethylene/α-olefin interpolymer, methods of making the compositions, and methods of using the compositions in applications, such as hot melt adhesives, pressure sensitive adhesives, and thermoplastic marking compositions.
BACKGROUND OF THE INVENTION
[2] An adhesive is a substance capable of holding solid materials (e.g., adherents or substrates) together by surface attachment. Adhesives have been widely used since ancient times. Archaeologists have found evidence of substances being used as adhesives in Babylon dating back to 4000 B.C. and in Egypt between 1500-1000 B.C. The first adhesive patent was issued in about 1750 in Britain for a glue made from fish. Later, patents were issued for adhesives using natural rubber, animal bones, fish, starch, milk protein or casein. The development of synthetic adhesives from the late 19th century has led to many synthetic adhesives, such as nitrocellulose, phenol-formaldehyde resins, urea-formaldehyde resins, epoxy resins, bismaleimide resins, polysiloxanes, polychloroprene, polyacrylates, polymethacrylates, polyurethanes, polycyanoacrylates, hot melt adhesives and pressure sensitive adhesives.
[3] Pressure sensitive adhesives (PSAs) generally are adhesive materials which bond to adherents when a required pressure is applied to effect an adhesion to the adherents. PSAs can be permanent or removable. Removable PSAs have been widely used in re- positionable applications, such as Post-it® notes. Pressure sensitive adhesives are generally based on a polymer, a tackifier and an oil. Some common PSAs are based on polymers such as natural rubbers, synthetic rubbers (e.g., styrene-butadiene rubber (SBR) and styrene- isoprene-styrene (SIS), polyacrylates, polymethacrylates, and poly-alpha-olefins. The PSAs can be solvent-based, water-based, or hot melt systems. The PSAs may also be hot melt adhesives.
[4] Hot-melt adhesives at ambient temperature are generally solid materials that can be heated to a melt to hold adherents or substrates together upon cooling and solidifying. In some applications, the bonded substrates can be detached by remelting the hot melt adhesive if the substrates can withstand the heat. The hot melt adhesives can be used in paper products, packaging materials, laminated wood panels, kitchen countertops, vehicles, tapes, labels, and a variety of disposable goods, particularly in health and hygiene applications, such as disposable diapers, hospital pads, feminine sanitary napkins, and surgical drapes. These hot melt adhesives are generally based on a polymer, tackifier, and a wax. Some common hot melt adhesives are based on polymer components including ethylene based semi-crystalline polymers such as ethylene-vinyl acetate copolymer (EVA) and linear low density polyethylene (LLDPE), styrene block copolymers (SBC) such as styrene-isoprene-styrene (SIS) copolymer and styrene-butadiene-styrene (SBS) copolymer, ethylene ethyl acrylate copolymers (EEA), and polyurethane reactive adhesives (PUR). One desirable property of hot melt adhesives is the absence of a liquid carrier, thereby eliminating the costly process associated with solvent removal.
[5] Some compositions that contain a polymer, a tackifier and optionally at least a filler or a pigment may be used as thermoplastic marking compositions. The polymer can be a silane-modified petroleum resin, an ethylene-vinyl acetate copolymer, an atactic polypropylene; a carboxy-modified hydrocarbon resin, an ester-modified hydrocarbon resin, a polyolefin copolymer, or a combination thereof.
[6] Despite the availability of a variety of hot melt adhesives, pressure sensitive adhesives, and road paints, there are still needs for new adhesive compositions with improved properties.
SUMMARY OF INVENTION
The invention provides an adhesive composition comprising:
(i) about 10 wt% to about 40 wt%, based on total weight of the adhesive composition, of at least one ethylene/α-olefin block copolymer, wherein the ethylene/α- olefin block copolymer comprises greater than 50 mol% ethylene based on total weight of the copolymer and:
- ? - (a) has a Mw/Mn from about 1.7 to about 3.5, at least one melting point, Tm, in degrees Celsius, and a density, d, in grams/cubic centimeter, wherein the numerical values of Tm and d correspond to the relationship:
Tm > -2002.9 + 4538.5(d) - 2422.2(d)2, or (b) has a Mw/Mn from about 1.7 to about 3.5, and is characterized by a heat of fusion, ΔH in J/g, and a delta quantity, ΔT, in degrees Celsius, defined as the temperature difference between the tallest DSC peak and the tallest CRYSTAF peak, wherein the numerical values of ΔT and ΔH have the following relationships:
ΔT > -0.1299(ΔH) + 62.81 for ΔH greater than zero and up to 130 J/g, ΔT > 48°C for ΔH greater than 130 J/g , wherein the CRYSTAF peak is determined using at least 5 percent of the cumulative polymer, and if less than 5 percent of the polymer has an identifiable CRYSTAF peak, then the CRYSTAF temperature is 300C; or
(c) is characterized by an elastic recovery, Re, in percent at 300 percent strain and 1 cycle measured with a compression- molded film of the ethylene/α- olefin interpolymer, and has a density, d, in grams/cubic centimeter, wherein the numerical values of Re and d satisfy the following relationship when ethylene/α-olefin interpolymer is substantially free of a cross-linked phase:
Re >1481-1629(d); or (d) has a molecular fraction which elutes between 400C and 1300C when fractionated using TREF, characterized in that the fraction has a molar comonomer content of at least 5 percent higher than that of a comparable random ethylene interpolymer fraction eluting between the same temperatures, wherein said comparable random ethylene interpolymer has the same comonomer(s) and has a melt index, density, and molar comonomer content (based on the whole polymer) within 10 percent of that of the ethylene/α-olefin interpolymer; or
(e) has a storage modulus at 25°C, G'(25°C), and a storage modulus at 1000C, C(IOO0C), wherein the ratio of G'(25°C) to C(IOO0C) is in the range of about 1:1 to about 9:1; or (f) has a molecular fraction which elutes between 400C and 130°C when fractionated using TREF, characterized in that the fraction has a block index of at least 0.5 and up to about 1 ; or
(g) has an average block index greater than zero and up to about 1.0 and a molecular weight distribution, Mw/Mn, greater than about 1.3; and,
(ii) about 30 wt% to about 70 wt%, based on total weight of the adhesive composition, of at least one tackifier; and,
(iii) about 10 wt% to about 30 wt%, based on total weight of the adhesive composition, of an oil or a low molecular weight polymer.
The invention further provides a method of applying the inventive composition to a substrate comprising: applying the composition to the substrate via spiral spray in non-contact mode at a temperature in the range of from about 100 0C to about 150 0C. The invention further provides a method of applying the inventive composition to a substrate comprising: applying the composition to the substrate via slot die coating in contact mode at a temperature in the range of from about 1000C to about 1500C.
The invention further provides an article comprising the inventive composition. [7] Additional aspects of the invention and characteristics and properties of various embodiments of the invention become apparent with the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[1] Figure 1 shows the melting point/density relationship for the inventive polymers (represented by diamonds) as compared to traditional random copolymers (represented by circles) and Ziegler-Natta copolymers (represented by triangles).
[2] Figure 2 shows plots of delta DSC-CRYSTAF as a function of DSC Melt Enthalpy for various polymers. The diamonds represent random ethylene/octene copolymers; the squares represent polymer examples 1-4; the triangles represent polymer examples 5-9; and the circles represent polymer examples 10-19. The "X" symbols represent polymer examples A* -F*.
[3] Figure 3 shows the effect of density on elastic recovery for unoriented films comprising inventive interpolymers (represented by the squares and circles) and traditional copolymers (represented by the triangles which are various AFFINITY polymers (The Dow Chemical Company)). The squares represent inventive ethylene/butene copolymers; and the circles represent inventive ethylene/octene copolymers.
[4] Figure 4 is a plot of octene content of TREF fractionated ethylene/ 1-octene copolymer fractions versus TREF elution temperature of the fraction for the polymer of Example 5 (represented by the circles) and Comparative Examples E* and F* (represented by the "X" symbols). The diamonds represent traditional random ethylene/octene copolymers.
[5] Figure 5 is a plot of octene content of TREF fractionated ethylene/ 1-octene copolymer fractions versus TREF elution temperature of the fraction for the polymer of Example 5 (curve 1) and for Comparative Example F* (curve T). The squares represent Example F*; and the triangles represent Example 5.
[6] Figure 6 is a graph of the log of storage modulus as a function of temperature for comparative ethylene/1-octene copolymer (curve 2) and propylene/ ethylene- copolymer (curve 3) and for two ethylene/1-octene block copolymers of the invention made with differing quantities of chain shuttling agent (curves 1).
[7] Figure 7 shows a plot of TMA (lmm) versus flex modulus for some inventive polymers (represented by the diamonds), as compared to some known polymers. The triangles represent various VERSIFY polymers (The Dow Chemical Company); the circles represent various random ethylene/styrene copolymers; and the squares represent various AFFINITY® polymers (The Dow Chemical Company).
[8] Figure 8 is a plot of natural log ethylene mole fraction for random ethylene/α-olefin copolymers as a function of the inverse of DSC peak melting temperature or ATREF peak temperature. The filled squares represent data points obtained from random homogeneously branched ethylene/α-olefin copolymers in ATREF; and the open squares represent data points obtained from random homogeneously branched ethylene/α-olefin copolymers in DSC. "P" is the ethylene mole fraction; "T" is the temperature in Kelvin. [9] Figure 9 is a plot constructed on the basis of the Flory equation for random ethylene/α-olefin copolymers to illustrate the definition of "block index." "A" represents the whole, perfect random copolymer; "B" represents a pure "hard segment"; and "C" represents the whole, perfect block copolymer having the same comonomer content as "A". A, B, and C define a triangular area within which most TREF fractions would fall.
DETAILED DESCRIPTION OF THE INVENTION
General Definitions
[8] "Polymer" means a polymeric compound prepared by polymerizing monomers, whether of the same or a different type. The generic term "polymer" embraces the terms "homopolymer," "copolymer," "terpolymer" as well as "interpolymer."
[9] "Interpolymer" means a polymer prepared by the polymerization of at least two different types of monomers. The generic term "interpolymer" includes the term "copolymer" (which is usually employed to refer to a polymer prepared from two different monomers) as well as the term "terpolymer" (which is usually employed to refer to a polymer prepared from three different types of monomers). It also encompasses polymers made by polymerizing four or more types of monomers.
[10] The term "ethylene/α-olefin interpolymer" generally refers to polymers comprising ethylene and an α-olefin having 3 or more carbon atoms. Preferably, ethylene comprises the majority mole fraction of the whole polymer, i.e., ethylene comprises at least about 50 mole percent of the whole polymer. More preferably ethylene comprises at least about 60 mole percent, at least about 70 mole percent, or at least about 80 mole percent, with the substantial remainder of the whole polymer comprising at least one other comonomer that is preferably an α-olefin having 3 or more carbon atoms. For many ethylene/octene copolymers, the preferred composition comprises an ethylene content greater than about 80 mole percent of the whole polymer and an octene content of from about 10 to about 15, preferably from about 15 to about 20 mole percent of the whole polymer. In some embodiments, the ethylene/α-olefin interpolymers do not include those produced in low yields or in a minor amount or as a by-product of a chemical process. While the ethylene/α- olefin interpolymers can be blended with one or more polymers, the as-produced ethylene/α- olefin interpolymers are substantially pure and often comprise a major component of the reaction product of a polymerization process. [11] The ethylene/α-olefin interpolymers comprise ethylene and one or more copolymerizable α-olefin comonomers in polymerized form, characterized by multiple blocks or segments of two or more polymerized monomer units differing in chemical or physical properties. That is, the ethylene/α-olefin interpolymers are block interpolymers, preferably multi-block interpolymers or copolymers. The terms "interpolymer" and copolymer" are used interchangeably herein. In some embodiments, the multi-block copolymer can be represented by the following formula:
(AB)n where n is at least 1, preferably an integer greater than 1, such as 2, 3, 4, 5, 10, 15, 20, 30, 40, 50, 60, 70, 80, 90, 100, or higher, "A" represents a hard block or segment and "B" represents a soft block or segment. Preferably, As and Bs are linked in a substantially linear fashion, as opposed to a substantially branched or substantially star-shaped fashion. In other embodiments, A blocks and B blocks are randomly distributed along the polymer chain. In other words, the block copolymers usually do not have a structure as follows. AAA- AA-BBB- BB
In still other embodiments, the block copolymers do not usually have a third type of block, which comprises different comonomer(s). In yet other embodiments, each of block A and block B has monomers or comonomers substantially randomly distributed within the block. In other words, neither block A nor block B comprises two or more sub-segments (or sub- blocks) of distinct composition, such as a tip segment, which has a substantially different composition than the rest of the block.
[12] The multi-block polymers typically comprise various amounts of "hard" and
"soft" segments. "Hard" segments refer to blocks of polymerized units in which ethylene is generally present in an amount greater than about 95 weight percent, and preferably greater than about 98 weight percent based on the weight of the polymer. In other words, the comonomer content (content of monomers other than ethylene) in the hard segments is less than about 5 weight percent, and preferably less than about 2 weight percent based on the weight of the polymer. In some embodiments, the hard segments comprises all or substantially all ethylene. "Soft" segments, on the other hand, refer to blocks of polymerized units in which the comonomer content (content of monomers other than ethylene) is greater than about 5 weight percent, preferably greater than about 8 weight percent, greater than about 10 weight percent, or greater than about 15 weight percent based on the weight of the polymer. In some embodiments, the comonomer content in the soft segments can be greater than about 20 weight percent, greater than about 25 weight percent, greater than about 30 weight percent, greater than about 35 weight percent, greater than about 40 weight percent, greater than about 45 weight percent, greater than about 50 weight percent, or greater than about 60 weight percent.
[13] The soft segments can often be present in a block interpolymer from about 1 weight percent to about 99 weight percent of the total weight of the block interpolymer, preferably from about 5 weight percent to about 95 weight percent, from about 10 weight percent to about 90 weight percent, from about 15 weight percent to about 85 weight percent, from about 20 weight percent to about 80 weight percent, from about 25 weight percent to about 75 weight percent, from about 30 weight percent to about 70 weight percent, from about 35 weight percent to about 65 weight percent, from about 40 weight percent to about 60 weight percent, or from about 45 weight percent to about 55 weight percent of the total weight of the block interpolymer. Conversely, the hard segments can be present in similar ranges. The soft segment weight percentage and the hard segment weight percentage can be calculated based on data obtained from DSC or NMR. Such methods and calculations are disclosed in a concurrently filed U.S. Patent Application Serial No. 11/376,835, entitled "Ethylene/α- Olefin Block Interpolymers", filed on March 15, 2006, in the name of Colin L.P. Shan, Lonnie Hazlitt, et. al. and assigned to Dow Global Technologies Inc., the disclosure of which is incorporated by reference herein in its entirety.
[14] The term "crystalline" if employed, refers to a polymer that possesses a first order transition or crystalline melting point (Tm) as determined by differential scanning calorimetry (DSC) or equivalent technique. The term may be used interchangeably with the term "semicrystalline". The term "amorphous" refers to a polymer lacking a crystalline melting point as determined by differential scanning calorimetry (DSC) or equivalent technique.
[15] The term "multi-block copolymer" or "segmented copolymer" refers to a polymer comprising two or more chemically distinct regions or segments (referred to as "blocks") preferably joined in a linear manner, that is, a polymer comprising chemically differentiated units which are joined end-to-end with respect to polymerized ethylenic functionality, rather than in pendent or grafted fashion. In a preferred embodiment, the blocks differ in the amount or type of comonomer incorporated therein, the density, the amount of crystallinity, the crystallite size attributable to a polymer of such composition, the type or degree of tacticity (isotactic or syndiotactic), regio-regularity or regio-irregularity, the amount of branching, including long chain branching or hyper-branching, the homogeneity, or any other chemical or physical property. The multi -block copolymers are characterized by unique distributions of both polydispersity index (PDI or Mw/Mn), block length distribution, and/or block number distribution due to the unique process of making the copolymers. More specifically, when produced in a continuous process, the polymers desirably possess PDI from 1.7 to 2.9, preferably from 1.8 to 2.5, more preferably from 1.8 to 2.2, and most preferably from 1.8 to 2.1. When produced in a batch or semi-batch process, the polymers possess PDI from 1.0 to 2.9, preferably from 1.3 to 2.5, more preferably from 1.4 to 2.0, and most preferably from 1.4 to 1.8.
[16] In the following description, all numbers disclosed herein are approximate values, regardless whether the word "about" or "approximate" is used in connection therewith. They 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 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 1 percent to 100 percent with a 1 percent increment, i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent,..., 50 percent, 51 percent, 52 percent,..., 95 percent, 96 percent, 97 percent, 98 percent, 99 percent, or 100 percent. Moreover, any numerical range defined by two R numbers as defined in the above is also specifically disclosed.
[17] Embodiments of the invention provide compositions that comprise an ethylene/α-olefin interpolymer, a tackifier resin and an oil or a low molecular weight polymer. The compositions possess unique properties that are suitable for a variety of applications, particularly where a certain level of adhesion is required. Some non-limiting examples of suitable applications include hot melt adhesives, pressure sensitive adhesives, hot melt pressure sensitive adhesives, thermoplastic marking compositions, and the like. Preferably, the ethylene/α-olefin interpolymers are a multi-block copolymer comprising at least one soft block and at least one hard block. [18] The adhesive compositions generally have a low melt viscosity so that it is easy to process the compositions . The melt viscosities of the compositions can be measured by a Brookfield viscometer using appropriate spindles as by ASTM D3236 at about 3500F (177°C), which is incorporated herein by reference. In some embodiments, the composition has a melt viscosity of less than 4,600 cPs at about 177°C, or less than about 3,000 cPs at 177°C, or less than about 2,000 cPs at 177°C, or less than about 1,000 cPs at 177°C measured according to ASTM D3236. Ethylene/α- Olefin Interpolymers
[19] The ethylene/α-olefin interpolymers used in embodiments of the invention
(also referred to as "inventive interpolymer" or "inventive polymer") comprise ethylene and one or more copolymerizable α-olefin comonomers in polymerized form, characterized by multiple blocks or segments of two or more polymerized monomer units differing in chemical or physical properties (block interpolymer), preferably a multi-block copolymer. The ethylene/α-olefin interpolymers are characterized by one or more of the aspects described as follows.
[20] In one aspect, the ethylene/α-olefin interpolymers used in embodiments of the invention have a Mw/Mn from about 1.7 to about 3.5 and at least one melting point, Tm, in degrees Celsius and density, d, in grams/cubic centimeter, wherein the numerical values of the variables correspond to the relationship:
Tm > -2002.9 + 4538.5(d) - 2422.2(d)2, and preferably Tm > -6288.1 + 13141(d) - 6720.3(d)2, and more preferably Tm > 858.91 - 1825.3(d) + 1112.8(d)2. [21] Such melting point/density relationship is illustrated in Figure 1. Unlike the traditional random copolymers of ethylene/α-olefins whose melting points decrease with decreasing densities, the inventive interpolymers (represented by diamonds) exhibit melting points substantially independent of the density, particularly when density is between about 0.87 g/cc to about 0.95 g/cc. For example, the melting point of such polymers are in the range of about 110 0C to about 130 0C when density ranges from 0.875 g/cc to about 0.945 g/cc. In some embodiments, the melting point of such polymers are in the range of about 115 0C to about 125 0C when density ranges from 0.875 g/cc to about 0.945 g/cc.
[22] In another aspect, the ethylene/α-olefin interpolymers comprise, in polymerized form, ethylene and one or more α-olefins and are characterized by a ΔT, in degree Celsius, defined as the temperature for the tallest Differential Scanning Calorimetry ("DSC") peak minus the temperature for the tallest Crystallization Analysis Fractionation ("CRYSTAF") peak and a heat of fusion in J/g, ΔH, and ΔT and ΔH satisfy the following relationships:
ΔT > -0.1299(ΔH) + 62.81, and preferably ΔT > -0.1299(ΔH) + 64.38, and more preferably ΔT ≥ -0.1299(ΔH) + 65.95, for ΔH up to 130 J/g. Moreover, ΔT is equal to or greater than 48 0C for ΔH greater than 130 J/g. The CRYSTAF peak is determined using at least 5 percent of the cumulative polymer (that is, the peak must represent at least 5 percent of the cumulative polymer), and if less than 5 percent of the polymer has an identifiable CRYSTAF peak, then the CRYSTAF temperature is 300C, and ΔH is the numerical value of the heat of fusion in J/g. More preferably, the highest CRYSTAF peak contains at least 10 percent of the cumulative polymer. Figure 2 shows plotted data for inventive polymers as well as comparative examples. Integrated peak areas and peak temperatures are calculated by the computerized drawing program supplied by the instrument maker. The diagonal line shown for the random ethylene octene comparative polymers corresponds to the equation ΔT = -0.1299 (ΔH) + 62.81.
[23] In yet another aspect, the ethylene/α-olefin interpolymers have a molecular fraction which elutes between 400C and 1300C when fractionated using Temperature Rising Elution Fractionation ("TREF"), characterized in that said fraction has a molar comonomer content higher, preferably at least 5 percent higher, more preferably at least 10 percent higher, than that of a comparable random ethylene interpolymer fraction eluting between the same temperatures, wherein the comparable random ethylene interpolymer contains the same comonomer(s), and has a melt index, density, and molar comonomer content (based on the whole polymer) within 10 percent of that of the block interpolymer. Preferably, the Mw/Mn of the comparable interpolymer is also within 10 percent of that of the block interpolymer and/or the comparable interpolymer has a total comonomer content within 10 weight percent of that of the block interpolymer.
[24] In still another aspect, the ethylene/α-olefin interpolymers are characterized by an elastic recovery, Re, in percent at 300 percent strain and 1 cycle measured on a compression-molded film of an ethylene/α-olefin interpolymer, and has a density, d, in grams/cubic centimeter, wherein the numerical values of Re and d satisfy the following relationship when ethylene/α-olefin interpolymer is substantially free of a cross-linked phase: Re >1481-1629(d); and preferably Re >1491-1629(d); and more preferably Re >1501-1629(d); and even more preferably Re ≥1511-1629(d).
[25] Figure 3 shows the effect of density on elastic recovery for unoriented films made from certain inventive interpolymers and traditional random copolymers. For the same density, the inventive interpolymers have substantially higher elastic recoveries.
[26] In some embodiments, the ethylene/α-olefin interpolymers have a tensile strength above 10 MPa, preferably a tensile strength > 11 MPa, more preferably a tensile strength > 13MPa and/or an elongation at break of at least 600 percent, more preferably at least 700 percent, highly preferably at least 800 percent, and most highly preferably at least 900 percent at a crosshead separation rate of 11 cm/minute.
[27] In other embodiments, the ethylene/α-olefin interpolymers have (1) a storage modulus ratio, G'(25°C)/G'(100°C), of from 1 to 50, preferably from 1 to 20, more preferably from 1 to 10; and/or (2) a 700C compression set of less than 80 percent, preferably less than 70 percent, especially less than 60 percent, less than 50 percent, or less than 40 percent, down to a compression set of 0 percent.
[28] In still other embodiments, the ethylene/α-olefin interpolymers have a 700C compression set of less than 80 percent, less than 70 percent, less than 60 percent, or less than 50 percent. Preferably, the 700C compression set of the interpolymers is less than 40 percent, less than 30 percent, less than 20 percent, and may go down to about 0 percent.
[29] In some embodiments, the ethylene/α-olefin interpolymers have a heat of fusion of less than 85 J/g and/or a pellet blocking strength of equal to or less than 100 pounds/foot2 (4800 Pa), preferably equal to or less than 50 lbs/ft2 (2400 Pa), especially equal to or less than 5 lbs/ft2 (240 Pa), and as low as 0 lbs/ft2 (0 Pa). [30] In other embodiments, the ethylene/α-olefin interpolymers comprise, in polymerized form, at least 50 mole percent ethylene and have a 700C compression set of less than 80 percent, preferably less than 70 percent or less than 60 percent, most preferably less than 40 to 50 percent and down to close to zero percent.
[31] In some embodiments, the multi-block copolymers possess a PDI fitting a Schultz-Flory distribution rather than a Poisson distribution. The copolymers are further characterized as having both a polydisperse block distribution and a polydisperse distribution of block sizes and possessing a most probable distribution of block lengths. Preferred multi- block copolymers are those containing 4 or more blocks or segments including terminal blocks. More preferably, the copolymers include at least 5, 10 or 20 blocks or segments including terminal blocks.
[32] Comonomer content may be measured using any suitable technique, with techniques based on nuclear magnetic resonance ("NMR") spectroscopy preferred. Moreover, for polymers or blends of polymers having relatively broad TREF curves, the polymer desirably is first fractionated using TREF into fractions each having an eluted temperature range of 100C or less. That is, each eluted fraction has a collection temperature window of 100C or less. Using this technique, said block interpolymers have at least one such fraction having a higher molar comonomer content than a corresponding fraction of the comparable interpolymer.
[33] In another aspect, the inventive polymer is an olefin interpolymer, preferably comprising ethylene and one or more copolymerizable comonomers in polymerized form, characterized by multiple blocks (i.e., at least two blocks) or segments of two or more polymerized monomer units differing in chemical or physical properties (blocked interpolymer), most preferably a multi-block copolymer, said block interpolymer having a peak (but not just a molecular fraction) which elutes between 400C and 1300C (but without collecting and/or isolating individual fractions), characterized in that said peak, having a comonomer content estimated by infra-red spectroscopy when expanded using a full width/half maximum (FWHM) area calculation, has an average molar comonomer content higher, preferably at least 5 percent higher, more preferably at least 10 percent higher, than that of a comparable random ethylene interpolymer peak at the same elution temperature and expanded using a full width/half maximum (FWHM) area calculation, wherein said comparable random ethylene interpolymer has the same comonomer(s) and has a melt index, density, and molar comonomer content (based on the whole polymer) within 10 percent of that of the blocked interpolymer. Preferably, the Mw/Mn of the comparable interpolymer is also within 10 percent of that of the blocked interpolymer and/or the comparable interpolymer has a total comonomer content within 10 weight percent of that of the blocked interpolymer. The full width/half maximum (FWHM) calculation is based on the ratio of methyl to methylene response area [CH3/CH2] from the ATREF infra-red detector, wherein the tallest (highest) peak is identified from the base line, and then the FWHM area is determined. For a distribution measured using an ATREF peak, the FWHM area is defined as the area under the curve between T1 and T2, where T1 and T2 are points determined, to the left and right of the ATREF peak, by dividing the peak height by two, and then drawing a line horizontal to the base line, that intersects the left and right portions of the ATREF curve. A calibration curve for comonomer content is made using random ethylene/α-olefin copolymers, plotting comonomer content from NMR versus FWHM area ratio of the TREF peak. For this infra-red method, the calibration curve is generated for the same comonomer type of interest. The comonomer content of TREF peak of the inventive polymer can be determined by referencing this calibration curve using its FWHM methyl: methylene area ratio [CH3/CH2] of the TREF peak.
[34] Comonomer content may be measured using any suitable technique, with techniques based on nuclear magnetic resonance (NMR) spectroscopy preferred. Using this technique, said blocked interpolymers have higher molar comonomer content than a corresponding comparable interpolymer.
[35] Preferably, for interpolymers of ethylene and 1-octene, the block interpolymer has a comonomer content of the TREF fraction eluting between 40 and 1300C greater than or equal to the quantity (- 0.2013) T + 20.07, more preferably greater than or equal to the quantity (-0.2013) T+ 21.07, where T is the numerical value of the peak elution temperature of the TREF fraction being compared, measured in 0C.
[36] Figure 4 graphically depicts an embodiment of the block interpolymers of ethylene and 1-octene where a plot of the comonomer content versus TREF elution temperature for several comparable ethylene/1-octene interpolymers (random copolymers) are fit to a line representing (- 0.2013) T + 20.07 (solid line). The line for the equation (-
0.2013) T + 21.07 is depicted by a dotted line. Also depicted are the comonomer contents for fractions of several block ethylene/1-octene interpolymers of the invention (multi-block copolymers). All of the block interpolymer fractions have significantly higher 1-octene content than either line at equivalent elution temperatures. This result is characteristic of the inventive interpolymer and is believed to be due to the presence of differentiated blocks within the polymer chains, having both crystalline and amorphous nature.
[37] Figure 5 graphically displays the TREF curve and comonomer contents of polymer fractions for Example 5 and Comparative Example F* to be discussed below. The peak eluting from 40 to 1300C, preferably from 6O0C to 95°C for both polymers is fractionated into three parts, each part eluting over a temperature range of less than 100C.
Actual data for Example 5 is represented by triangles. The skilled artisan can appreciate that an appropriate calibration curve may be constructed for interpolymers containing different comonomers and a line used as a comparison fitted to the TREF values obtained from comparative interpolymers of the same monomers, preferably random copolymers made using a metallocene or other homogeneous catalyst composition. Inventive interpolymers are characterized by a molar comonomer content greater than the value determined from the calibration curve at the same TREF elution temperature, preferably at least 5 percent greater, more preferably at least 10 percent greater.
[38] In addition to the above aspects and properties described herein, the inventive polymers can be characterized by one or more additional characteristics. In one aspect, the inventive polymer is an olefin interpolymer, preferably comprising ethylene and one or more copolymerizable comonomers in polymerized form, characterized by multiple blocks or segments of two or more polymerized monomer units differing in chemical or physical properties (blocked interpolymer), most preferably a multi -block copolymer, said block interpolymer having a molecular fraction which elutes between 400C and 1300C, when fractionated using TREF increments, characterized in that said fraction has a molar comonomer content higher, preferably at least 5 percent higher, more preferably at least 10, 15, 20 or 25 percent higher, than that of a comparable random ethylene interpolymer fraction eluting between the same temperatures, wherein said comparable random ethylene interpolymer comprises the same comonomer(s), preferably it is the same comonomer(s), and a melt index, density, and molar comonomer content (based on the whole polymer) within 10 percent of that of the blocked interpolymer. Preferably, the Mw/Mn of the comparable interpolymer is also within 10 percent of that of the blocked interpolymer and/or the comparable interpolymer has a total comonomer content within 10 weight percent of that of the blocked interpolymer.
[39] Preferably, the above interpolymers are interpolymers of ethylene and at least one α-olefin, especially those interpolymers having a whole polymer density from about 0.855 to about 0.935 g/cm3, and more especially for polymers having more than about 1 mole percent comonomer, the blocked interpolymer has a comonomer content of the TREF fraction eluting between 40 and 1300C greater than or equal to the quantity (- 0.1356) T + 13.89, more preferably greater than or equal to the quantity (-0.1356) T+ 14.93, and most preferably greater than or equal to the quantity (-0.2013)T + 21.07, where T is the numerical value of the peak ATREF elution temperature of the TREF fraction being compared, measured in 0C.
[40] Preferably, for the above interpolymers of ethylene and at least one alpha- olefin especially those interpolymers having a whole polymer density from about 0.855 to about 0.935 g/cm3, and more especially for polymers having more than about 1 mole percent comonomer, the blocked interpolymer has a comonomer content of the TREF fraction eluting between 40 and 1300C greater than or equal to the quantity (- 0.2013) T + 20.07, more preferably greater than or equal to the quantity (-0.2013) T+ 21.07, where T is the numerical value of the peak elution temperature of the TREF fraction being compared, measured in °C.
[41] In still another aspect, the inventive polymer is an olefin interpolymer, preferably comprising ethylene and one or more copolymerizable comonomers in polymerized form, characterized by multiple blocks or segments of two or more polymerized monomer units differing in chemical or physical properties (blocked interpolymer), most preferably a multi-block copolymer, said block interpolymer having a molecular fraction which elutes between 400C and 1300C, when fractionated using TREF increments, characterized in that every fraction having a comonomer content of at least about 6 mole percent, has a melting point greater than about 1000C. For those fractions having a comonomer content from about 3 mole percent to about 6 mole percent, every fraction has a DSC melting point of about HO0C or higher. More preferably, said polymer fractions, having at least 1 mol percent comonomer, has a DSC melting point that corresponds to the equation:
Tm > (-5.5926)(mol percent comonomer in the fraction) + 135.90. [42] In yet another aspect, the inventive polymer is an olefin interpolymer, preferably comprising ethylene and one or more copolymerizable comonomers in polymerized form, characterized by multiple blocks or segments of two or more polymerized monomer units differing in chemical or physical properties (blocked interpolymer), most preferably a multi-block copolymer, said block interpolymer having a molecular fraction which elutes between 400C and 1300C, when fractionated using TREF increments, characterized in that every fraction that has an ATREF elution temperature greater than or equal to about 760C, has a melt enthalpy (heat of fusion) as measured by DSC, corresponding to the equation:
Heat of fusion (J/gm) < (3.1718)(ATREF elution temperature in Celsius) - 136.58, [43] The inventive block interpolymers have a molecular fraction which elutes between 400C and 1300C, when fractionated using TREF increments, characterized in that every fraction that has an ATREF elution temperature between 4O0C and less than about 760C, has a melt enthalpy (heat of fusion) as measured by DSC, corresponding to the equation: Heat of fusion (J/gm) < (1.1312)(ATREF elution temperature in Celsius) + 22.97. ATREF Peak Comonomer Composition Measurement by Infra-Red Detector
[44] The comonomer composition of the TREF peak can be measured using an IR4 infra-red detector available from Polymer Char, Valencia, Spain (http://www.polymerchar.com/).
[45] The "composition mode" of the detector is equipped with a measurement sensor (CH2) and composition sensor (CH3) that are fixed narrow band infra-red filters in the region of 2800-3000 cm"1. The measurement sensor detects the methylene (CH2) carbons on the polymer (which directly relates to the polymer concentration in solution) while the composition sensor detects the methyl (CH3) groups of the polymer. The mathematical ratio of the composition signal (CH3) divided by the measurement signal (CH2) is sensitive to the comonomer content of the measured polymer in solution and its response is calibrated with known ethylene alpha-olefin copolymer standards.
[46] The detector when used with an ATREF instrument provides both a concentration (CH2) and composition (CH3) signal response of the eluted polymer during the TREF process. A polymer specific calibration can be created by measuring the area ratio of the CH3 to CH2 for polymers with known comonomer content (preferably measured by NMR). The comonomer content of an ATREF peak of a polymer can be estimated by applying the reference calibration of the ratio of the areas for the individual CH3 and CH2 response (i.e. area ratio CH3/CH2 versus comonomer content).
[47] The area of the peaks can be calculated using a full width/half maximum
(FWHM) calculation after applying the appropriate baselines to integrate the individual signal responses from the TREF chromatogram. The full width/half maximum calculation is based on the ratio of methyl to methylene response area [CH3/CH2] from the ATREF infra- red detector, wherein the tallest (highest) peak is identified from the base line, and then the FWHM area is determined. For a distribution measured using an ATREF peak, the FWHM area is defined as the area under the curve between Tl and T2, where Tl and T2 are points determined, to the left and right of the ATREF peak, by dividing the peak height by two, and then drawing a line horizontal to the base line, that intersects the left and right portions of the ATREF curve.
[48] The application of infra-red spectroscopy to measure the comonomer content of polymers in this ATREF-infra-red method is, in principle, similar to that of GPC/FTIR systems as described in the following references: Markovich, Ronald P.; Hazlitt, Lonnie G.; Smith, Linley; "Development of gel-permeation chromatography-Fourier transform infrared spectroscopy for characterization of ethylene-based polyolefin copolymers", Polymeric Materials Science and Engineering (1991), 65, 98-100; and Deslauriers, PJ. ; Rohlfing, D. C; Shieh, E.T.; "Quantifying short chain branching microstructures in ethylene- 1 -olefin copolymers using size exclusion chromatography and Fourier transform infrared spectroscopy (SEC-FTIR)", Polymer (2002), 43, 59-170, both of which are incorporated by reference herein in their entirety.
[49] In other embodiments, the inventive ethylene/α-olefin interpolymer is characterized by an average block index, ABI, which is greater than zero and up to about 1.0 and a molecular weight distribution, Mw/Mn, greater than about 1.3. The average block index, ABI, is the weight average of the block index ("BI") for each of the polymer fractions obtained in preparative TREF from 200C and 1100C, with an increment of 5°C :
Figure imgf000019_0001
where BI1 is the block index for the ith fraction of the inventive ethylene/α-olefin interpolymer obtained in preparative TREF, and W1 is the weight percentage of the ith fraction. [50] For each polymer fraction, BI is defined by one of the two following equations
(both of which give the same BI value):
BI J' Tx -V Txo or Bi = _ LnPx - LnPX0
\ITA -IITAB LnPA - LnPAB where Tx is the preparative ATREF elution temperature for the ith fraction (preferably expressed in Kelvin), Px is the ethylene mole fraction for the ith fraction, which can be measured by NMR or IR as described above. PAB is the ethylene mole fraction of the whole ethylene/α-olefin interpolymer (before fractionation), which also can be measured by NMR or IR. TA and PA are the ATREF elution temperature and the ethylene mole fraction for pure "hard segments" (which refer to the crystalline segments of the interpolymer). As a first order approximation, the TA and PA values are set to those for high density polyethylene homopolymer, if the actual values for the "hard segments" are not available. For calculations performed herein, TA is 3720K, PA is 1.
[51] TAB is the ATREF temperature for a random copolymer of the same composition and having an ethylene mole fraction of PAB- TAB can be calculated from the following equation:
Ln PAB = α/TAB + β [52] where α and β are two constants which can be determined by calibration using a number of known random ethylene copolymers. It should be noted that α and β may vary from instrument to instrument. Moreover, one would need to create their own calibration curve with the polymer composition of interest and also in a similar molecular weight range as the fractions. There is a slight molecular weight effect. If the calibration curve is obtained from similar molecular weight ranges, such effect would be essentially negligible. In some embodiments, random ethylene copolymers satisfy the following relationship:
Ln P = -237.83/TATREF + 0.639 Txo is the ATREF temperature for a random copolymer of the same composition and having an ethylene mole fraction of Px. Txo can be calculated from LnPx = α/Txo + β. Conversely, PXo is the ethylene mole fraction for a random copolymer of the same composition and having an ATREF temperature of Tx, which can be calculated from Ln PXo = α/Tx + β.
[53] Once the block index (BI) for each preparative TREF fraction is obtained, the weight average block index, ABI, for the whole polymer can be calculated. In some embodiments, ABI is greater than zero but less than about 0.3 or from about 0.1 to about 0.3. In other embodiments, ABI is greater than about 0.3 and up to about 1.0. Preferably, ABI should be in the range of from about 0.4 to about 0.7, from about 0.5 to about 0.7, or from about 0.6 to about 0.9. In some embodiments, ABI is in the range of from about 0.3 to about 0.9, from about 0.3 to about 0.8, or from about 0.3 to about 0.7, from about 0.3 to about 0.6, from about 0.3 to about 0.5, or from about 0.3 to about 0.4. In other embodiments, ABI is in the range of from about 0.4 to about 1.0, from about 0.5 to about 1.0, or from about 0.6 to about 1.0, from about 0.7 to about 1.0, from about 0.8 to about 1.0, or from about 0.9 to about 1.0.
[54] Another characteristic of the inventive ethylene/α-olefin interpolymer is that the inventive ethylene/α-olefin interpolymer comprises at least one polymer fraction which can be obtained by preparative TREF, wherein the fraction has a block index greater than about 0.1 and up to about 1.0 and a molecular weight distribution, Mw/Mn, greater than about 1.3. In some embodiments, the polymer fraction has a block index greater than about 0.6 and up to about 1.0, greater than about 0.7 and up to about 1.0, greater than about 0.8 and up to about 1.0, or greater than about 0.9 and up to about 1.0. In other embodiments, the polymer fraction has a block index greater than about 0.1 and up to about 1.0, greater than about 0.2 and up to about 1.0, greater than about 0.3 and up to about 1.0, greater than about 0.4 and up to about 1.0, or greater than about 0.4 and up to about 1.0. In still other embodiments, the polymer fraction has a block index greater than about 0.1 and up to about 0.5, greater than about 0.2 and up to about 0.5, greater than about 0.3 and up to about 0.5, or greater than about 0.4 and up to about 0.5. In yet other embodiments, the polymer fraction has a block index greater than about 0.2 and up to about 0.9, greater than about 0.3 and up to about 0.8, greater than about 0.4 and up to about 0.7, or greater than about 0.5 and up to about 0.6.
[55] For copolymers of ethylene and an α-olefin, the inventive polymers preferably possess (1) a PDI of at least 1.3, more preferably at least 1.5, at least 1.7, or at least 2.0, and most preferably at least 2.6, up to a maximum value of 5.0, more preferably up to a maximum of 3.5, and especially up to a maximum of 2.7; (2) a heat of fusion of 80 J/g or less; (3) an ethylene content of at least 50 weight percent; (4) a glass transition temperature, Tg, of less than -25°C, more preferably less than -300C, and/or (5) one and only one Tm.
[56] Further, the inventive polymers can have, alone or in combination with any other properties disclosed herein, a storage modulus, G', such that log (G') is greater than or equal to 400 kPa, preferably greater than or equal to 1.0 MPa, at a temperature of 1000C. Moreover, the inventive polymers possess a relatively flat storage modulus as a function of temperature in the range from 0 to 1000C (illustrated in Figure 6) that is characteristic of block copolymers, and heretofore unknown for an olefin copolymer, especially a copolymer of ethylene and one or more C3-8 aliphatic α-olefins. (By the term "relatively flat" in this context is meant that log G' (in Pascals) decreases by less than one order of magnitude between 50 and 1000C, preferably between 0 and 1000C).
[57] The inventive interpolymers may be further characterized by a thermomechanical analysis penetration depth of 1 mm at a temperature of at least 900C as well as a flexural modulus of from 3 kpsi (20 MPa) to 13 kpsi (90 MPa). Alternatively, the inventive interpolymers can have a thermomechanical analysis penetration depth of 1 mm at a temperature of at least 1040C as well as a flexural modulus of at least 3 kpsi (20 MPa).
They may be characterized as having an abrasion resistance (or volume loss) of less than 90 mm3. Figure 7 shows the TMA (1 mm) versus flex modulus for the inventive polymers, as compared to other known polymers. The inventive polymers have significantly better flexibility-heat resistance balance than the other polymers. [58] Additionally, the ethylene/α-olefin interpolymers can have a melt index, I2, from 0.01 to 2000 g/10 minutes, preferably from 0.01 to 1000 g/10 minutes, more preferably from 0.01 to 500 g/10 minutes, and especially from 0.01 to 100 g/10 minutes. In certain embodiments, the ethylene/α-olefin interpolymers have a melt index, I2, from 0.01 to 10 g/10 minutes, from 0.5 to 50 g/10 minutes, from 1 to 30 g/10 minutes, from 1 to 6 g/10 minutes or from 0.3 to 10 g/10 minutes. In certain embodiments, the melt index for the ethylene/α-olefin polymers is lg/10 minutes, 3 g/10 minutes or 5 g/10 minutes.
[59] The polymers can have molecular weights, Mw, from 1,000 g/mole to 5,000,000 g/mole, preferably from 1000 g/mole to 1,000,000, more preferably from 10,000 g/mole to 500,000 g/mole, and especially from 10,000 g/mole to 300,000 g/mole. The density of the inventive polymers can be from 0.80 to 0.99 g/cm3 and preferably for ethylene containing polymers from 0.85 g/cm3 to 0.97 g/cm3. In certain embodiments, the density of the ethylene/α-olefin polymers ranges from 0.860 to 0.925 g/cm3 or 0.867 to 0.910 g/cm3. [60] The process of making the polymers has been disclosed in the following patent applications and publications: U.S. Provisional Application No. 60/553,906, filed March 17, 2004; U.S. Provisional Application No. 60/662,937, filed March 17, 2005; U.S. Provisional Application No. 60/662,939, filed March 17, 2005; U.S. Provisional Application No. 60/5662938, filed March 17, 2005; PCT Application No. PCT/US2005/008916, filed March 17, 2005; PCT Application No. PCT/US2005/008915, filed March 17, 2005; PCT
Application No. PCT/US2005/008917, filed March 17, 2005; PCT Publication No. WO 2005/090425, published September 29, 2005; PCT Publication No. WO 2005/090426, published September 29, 2005; and, PCT Publication No. WO 2005/090427, published September 29, 2005, all of which are incorporated by reference herein in their entirety. For example, one such method comprises contacting ethylene and optionally one or more addition polymerizable monomers other than ethylene under addition polymerization conditions with a catalyst composition comprising: the admixture or reaction product resulting from combining: a. a first olefin polymerization catalyst having a high comonomer incorporation index, b. a second olefin polymerization catalyst having a comonomer incorporation index less than 90 percent, preferably less than 50 percent, most preferably less than 5 percent of the comonomer incorporation index of catalyst (A), and c. a chain shuttling agent. Representative catalysts and chain shuttling agent are as follows.
[61] Catalyst (Al) is [N-(2,6-di(l-methylethyl)phenyl)amido)(2- isopropylphenyl)(α-naphthalen-2-diyl(6-pyridin-2-diyl)methane)]hafnium dimethyl, prepared according to the teachings of WO 03/40195, 2003US0204017, USSN 10/429,024, filed May 2, 2003, and WO 04/24740.
Figure imgf000023_0001
[62] Catalyst (A2) is [N-(2,6-di(l-methylethyl)phenyl)amido)(2- methylphenyl)(l ,2-phenylene-(6-pyridin-2-diyl)methane)]hafnium dimethyl, prepared according to the teachings of WO 03/40195, 2003US0204017, USSN 10/429,024, filed May 2, 2003, and WO 04/24740.
Figure imgf000023_0002
[63] Catalyst (A3) is bis[N,N' "-(2,4,6- tri(methylphenyl)amido)ethylenediamine]hafnium dibenzyl
Figure imgf000023_0003
[64] Catalyst (A4) is bis((2-oxoyl-3-(dibenzo-lH-pyrrole-l-yl)-5-(methyl)phenyl>
2-phenoxymethyl)cyclohexane-l,2-diyl zirconium (IV) dibenzyl, prepared substantially according to the teachings of US-A-2004/0010103.
- 99 -
Figure imgf000024_0001
[65] Catalyst (Bl) is l,2-bis-(3,5-di-t-butylphenylene)(l-(N-(l- methylethyl)immino)methyl)(2-oxoyl) zirconium dibenzyl
Figure imgf000024_0002
[66] Catalyst (B2) is l,2-bis-(3,5-di-t-butylphenylene)(l-(N-(2-methylcyclohexyl)- immino)methyl)(2-oxoyl) zirconium dibenzyl
Figure imgf000024_0003
[67] Catalyst (Cl) is (t-butylamido)dimethyl(3-N-pyrrolyl-l,2,3,3a,7a-η-inden-l- yl)silanetitanium dimethyl prepared substantially according to the techniques of USP 6,268,444:
Figure imgf000025_0001
C(CH3)3
[68] Catalyst (C2) is (t-butylamido)di(4-methylphenyl)(2-methyl-l,2,3,3a,7a-η- inden-l-yl)silanetitanium dimethyl prepared substantially according to the teachings of US- A-2003/004286:
Figure imgf000025_0002
[69] Catalyst (C3) is (t-butylamido)di(4-methylphenyl)(2-methyl-l,2,3,3a,8a-η-s- indacen-l-yl)silanetitanium dimethyl prepared substantially according to the teachings of US- A-2003/004286:
Figure imgf000025_0003
[70] Catalyst (Dl) is bis(dimethyldisiloxane)(indene-l-yl)zirconium dichloride available from Sigma-Aldrich:
Figure imgf000026_0001
[71] Shuttling Agents The shuttling agents employed include diethylzinc, di(i- butyl)zinc, di(n-hexyl)zinc, triethylaluminum, trioctylaluminum, triethylgallium, i- butylaluminum bis(dimethyl(t-butyl)siloxane), i-butylaluminum bis(di(trimethylsilyl)amide), n-octylaluminum di(pyridine-2-methoxide), bis(n-octadecyl)i-butylaluminum, i- butylaluminum bis(di(n-pentyl)amide), n-octylaluminum bis(2,6-di-t-butylphenoxide, n- octylaluminum di(ethyl(l-naphthyl) amide), ethylaluminum bis(t-butyldimethylsiloxide), ethylaluminum di(bis(trimethylsilyl)amide), ethylaluminum bis(2,3,6,7-dibenzo-l- azacycloheptaneamide), n-octylaluminum bis(2,3,6,7-dibenzo-l-azacycloheptaneamide), n- octylaluminum bis(dimethyl(t-butyl)siloxide, ethylzinc (2,6-diphenylphenoxide), and ethylzinc (t-butoxide).
[72] Preferably, the foregoing process takes the form of a continuous solution process for forming block copolymers, especially multi-block copolymers, preferably linear multi-block copolymers of two or more monomers, more especially ethylene and a C3_2o olefin or cycloolefin, and most especially ethylene and a C4_2o α-olefin, using multiple catalysts that are incapable of intercon version. That is, the catalysts are chemically distinct. Under continuous solution polymerization conditions, the process is ideally suited for polymerization of mixtures of monomers at high monomer conversions. Under these polymerization conditions, shuttling from the chain shuttling agent to the catalyst becomes advantaged compared to chain growth, and multi -block copolymers, especially linear multi- block copolymers are formed in high efficiency.
[73] The inventive interpolymers may be differentiated from conventional, random copolymers, physical blends of polymers, and block copolymers prepared via sequential monomer addition, fluxional catalysts, anionic or cationic living polymerization techniques. In particular, compared to a random copolymer of the same monomers and monomer content at equivalent crystallinity or modulus, the inventive interpolymers have better (higher) heat resistance as measured by melting point, higher TMA penetration temperature, higher high- temperature tensile strength, and/or higher high-temperature torsion storage modulus as determined by dynamic mechanical analysis. Compared to a random copolymer containing the same monomers and monomer content, the inventive interpolymers have lower compression set, particularly at elevated temperatures, lower stress relaxation, higher creep resistance, higher tear strength, higher blocking resistance, faster setup due to higher crystallization (solidification) temperature, higher recovery (particularly at elevated temperatures), better abrasion resistance, higher retractive force, and better oil and filler acceptance. [74] The inventive interpolymers also exhibit a unique crystallization and branching distribution relationship. That is, the inventive interpolymers have a relatively large difference between the tallest peak temperature measured using CRYSTAF and DSC as a function of heat of fusion, especially as compared to random copolymers containing the same monomers and monomer level or physical blends of polymers, such as a blend of a high density polymer and a lower density copolymer, at equivalent overall density. It is believed that this unique feature of the inventive interpolymers is due to the unique distribution of the comonomer in blocks within the polymer backbone. In particular, the inventive interpolymers may comprise alternating blocks of differing comonomer content (including homopolymer blocks). The inventive interpolymers may also comprise a distribution in number and/or block size of polymer blocks of differing density or comonomer content, which is a Schultz-Flory type of distribution. In addition, the inventive interpolymers also have a unique peak melting point and crystallization temperature profile that is substantially independent of polymer density, modulus, and morphology. In a preferred embodiment, the microcrystalline order of the polymers demonstrates characteristic spherulites and lamellae that are distinguishable from random or block copolymers, even at PDI values that are less than 1.7, or even less than 1.5, down to less than 1.3.
[75] Moreover, the inventive interpolymers may be prepared using techniques to influence the degree or level of blockiness. That is the amount of comonomer and length of each polymer block or segment can be altered by controlling the ratio and type of catalysts and shuttling agent as well as the temperature of the polymerization, and other polymerization variables. A surprising benefit of this phenomenon is the discovery that as the degree of blockiness is increased, the optical properties, tear strength, and high temperature recovery properties of the resulting polymer are improved. In particular, haze decreases while clarity, tear strength, and high temperature recovery properties increase as the average number of blocks in the polymer increases. By selecting shuttling agents and catalyst combinations having the desired chain transferring ability (high rates of shuttling with low levels of chain termination) other forms of polymer termination are effectively suppressed. Accordingly, little if any β-hydride elimination is observed in the polymerization of ethylene/ α-olefin comonomer mixtures according to embodiments of the invention, and the resulting crystalline blocks are highly, or substantially completely, linear, possessing little or no long chain branching.
[76] Polymers with highly crystalline chain ends can be selectively prepared in accordance with embodiments of the invention. In elastomer applications, reducing the relative quantity of polymer that terminates with an amorphous block reduces the intermolecular dilutive effect on crystalline regions. This result can be obtained by choosing chain shuttling agents and catalysts having an appropriate response to hydrogen or other chain terminating agents. Specifically, if the catalyst which produces highly crystalline polymer is more susceptible to chain termination (such as by use of hydrogen) than the catalyst responsible for producing the less crystalline polymer segment (such as through higher comonomer incorporation, regio-error, or atactic polymer formation), then the highly crystalline polymer segments will preferentially populate the terminal portions of the polymer. Not only are the resulting terminated groups crystalline, but upon termination, the highly crystalline polymer forming catalyst site is once again available for reinitiation of polymer formation. The initially formed polymer is therefore another highly crystalline polymer segment. Accordingly, both ends of the resulting multi-block copolymer are preferentially highly crystalline.
[77] The ethylene α-olefin interpolymers used in the embodiments of the invention are preferably interpolymers of ethylene with at least one C3-C20 α-olefin. Copolymers of ethylene and a C3-C2O α-olefin are especially preferred. The interpolymers may further comprise C4-C18 diolefin and/or alkenylbenzene. Suitable unsaturated comonomers useful for polymerizing with ethylene include, for example, ethylenically unsaturated monomers, conjugated or nonconjugated dienes, polyenes, alkenylbenzenes, etc. Examples of such comonomers include C3-C20 α -olefins such as propylene, isobutylene, 1-butene, 1-hexene,
1-pentene, 4-methyl-l-pentene, 1-heptene, 1-octene, 1-nonene, 1-decene, and the like. 1- Butene and 1-octene are especially preferred. Other suitable monomers include styrene, halo- or alkyl-substituted styrenes, vinylbenzocyclobutane, 1 ,4-hexadiene, 1,7-octadiene, and naphthenics (e.g., cyclopentene, cyclohexene and cyclooctene).
[78] While ethylene/α-olefin interpolymers are preferred polymers, other ethylene/olefin polymers may also be used. Olefins as used herein refer to a family of unsaturated hydrocarbon-based compounds with at least one carbon-carbon double bond. Depending on the selection of catalysts, any olefin may be used in embodiments of the invention. Preferably, suitable olefins are C3-C2O aliphatic and aromatic compounds containing vinylic unsaturation, as well as cyclic compounds, such as cyclobutene, cyclopentene, dicyclopentadiene, and norbornene, including but not limited to, norbornene substituted in the 5 and 6 position with C1-C20 hydrocarbyl or cyclohydrocarbyl groups. Also included are mixtures of such olefins as well as mixtures of such olefins with C4-C40 diolefin compounds.
[79] Examples of olefin monomers include, but are not limited to propylene, isobutylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, and 1- dodecene, 1-tetradecene, 1-hexadecene, 1-octadecene, 1-eicosene, 3 -methyl- 1-butene, 3- methyl- 1-pentene, 4-methyl- 1-pentene, 4,6-dimethyl- 1-heptene, 4-vinylcyclohexene, vinylcyclohexane, norbornadiene, ethylidene norbornene, cyclopentene, cyclohexene, dicyclopentadiene, cyclooctene, C4-C40 dienes, including but not limited to 1,3 -butadiene, 1,3-pentadiene, 1,4-hexadiene, 1,5-hexadiene, 1,7-octadiene, 1,9-decadiene, other C4-C40 α- olefins, and the like. In certain embodiments, the α-olefin is propylene, 1-butene, 1- pentene, 1-hexene, 1-octene or a combination thereof. Although any hydrocarbon containing a vinyl group potentially may be used in embodiments of the invention, practical issues such as monomer availability, cost, and the ability to conveniently remove unreacted monomer from the resulting polymer may become more problematic as the molecular weight of the monomer becomes too high.
[80] The polymerization processes described herein are well suited for the production of olefin polymers comprising monovinylidene aromatic monomers including styrene, o-methyl styrene, p-methyl styrene, t-butylstyrene, and the like. In particular, interpolymers comprising ethylene and styrene can be prepared by following the teachings herein. Optionally, copolymers comprising ethylene, styrene and a C3-C20 alpha olefin, optionally comprising a C4-C2O diene, having improved properties can be prepared. [81] Suitable non-conjugated diene monomers can be a straight chain, branched chain or cyclic hydrocarbon diene having from 6 to 15 carbon atoms. Examples of suitable non-conjugated dienes include, but are not limited to, straight chain acyclic dienes, such as 1,4-hexadiene, 1,6-octadiene, 1,7-octadiene, 1,9-decadiene, branched chain acyclic dienes, such as 5 -methyl- 1,4-hexadiene; 3,7-dimethyl-l,6-octadiene; 3,7-dimethyl-l,7-octadiene and mixed isomers of dihydromyricene and dihydroocinene, single ring alicyclic dienes, such as 1,3-cyclopentadiene; 1,4-cyclohexadiene; 1,5-cyclooctadiene and 1,5-cyclododecadiene, and multi-ring alicyclic fused and bridged ring dienes, such as tetrahydroindene, methyl tetrahydroindene, dicyclopentadiene, bicyclo-(2,2,l)-hepta-2,5-diene; alkenyl, alkylidene, cycloalkenyl and cycloalkylidene norbornenes, such as 5-methylene-2-norbornene (MNB); 5- propenyl-2-norbornene, 5-isopropylidene-2-norbornene, 5-(4-cyclopentenyl)-2-norbornene, 5-cyclohexylidene-2-norbornene, 5-vinyl-2-norbornene, and norbornadiene. Of the dienes typically used to prepare EPDMs, the particularly preferred dienes are 1,4-hexadiene (HD), 5-ethylidene-2-norbornene (ENB), 5-vinylidene-2-norbornene (VNB), 5-methylene-2- norbornene (MNB), and dicyclopentadiene (DCPD). The especially preferred dienes are 5- ethylidene-2-norbornene (ENB) and 1,4-hexadiene (HD).
[82] One class of desirable polymers that can be made in accordance with embodiments of the invention are elastomeric interpolymers of ethylene, a C3-C2O α-olefin, especially propylene, and optionally one or more diene monomers. Preferred α-olefins for use in this embodiment of the present invention are designated by the formula CH2=CHR*, where R* is a linear or branched alkyl group of from 1 to 12 carbon atoms. Examples of suitable α-olefins include, but are not limited to, propylene, isobutylene, 1-butene, 1-pentene, 1-hexene, 4-methyl- 1-pentene, and 1-octene. A particularly preferred α-olefin is propylene. The propylene based polymers are generally referred to in the art as EP or EPDM polymers. Suitable dienes for use in preparing such polymers, especially multi-block EPDM type polymers include conjugated or non-conjugated, straight or branched chain-, cyclic- or polycyclic- dienes comprising from 4 to 20 carbons. Preferred dienes include 1 ,4-pentadiene, 1,4-hexadiene, 5-ethylidene-2-norbornene, dicyclopentadiene, cyclohexadiene, and 5- butylidene-2-norbornene. A particularly preferred diene is 5-ethylidene-2-norbornene. [83] Because the diene containing polymers comprise alternating segments or blocks containing greater or lesser quantities of the diene (including none) and α-olefin (including none), the total quantity of diene and α-olefin may be reduced without loss of subsequent polymer properties. That is, because the diene and α-olefin monomers are preferentially incorporated into one type of block of the polymer rather than uniformly or randomly throughout the polymer, they are more efficiently utilized and subsequently the crosslink density of the polymer can be better controlled. Such crosslinkable elastomers and the cured products have advantaged properties, including higher tensile strength and better elastic recovery.
[84] In some embodiments, the inventive interpolymers made with two catalysts incorporating differing quantities of comonomer have a weight ratio of blocks formed thereby from 95:5 to 5:95. The elastomeric polymers desirably have an ethylene content of from 20 to 90 percent, a diene content of from 0.1 to 10 percent, and an α-olefin content of from 10 to 80 percent, based on the total weight of the polymer. Further preferably, the multi-block elastomeric polymers have an ethylene content of from 60 to 90 percent, a diene content of from 0.1 to 10 percent, and an α-olefin content of from 10 to 40 percent, based on the total weight of the polymer. Preferred polymers are high molecular weight polymers, having a weight average molecular weight (Mw) from 10,000 to about 2,500,000, preferably from 20,000 to 500,000, more preferably from 20,000 to 350,000, and a polydispersity less than 3.5, more preferably less than 3.0, and a Mooney viscosity (ML (1+4) 125°C.) from 1 to 250. More preferably, such polymers have an ethylene content from 65 to 75 percent, a diene content from 0 to 6 percent, and an α-olefin content from 20 to 35 percent.
[85] The ethylene/α-olefin interpolymers can be functionalized by incorporating at least one functional group in its polymer structure. Exemplary functional groups may include, for example, ethylenically unsaturated mono- and di-functional carboxylic acids, ethylenically unsaturated mono- and di-functional carboxylic acid anhydrides, salts thereof and esters thereof. Such functional groups may be grafted to an ethylene/α -olefin interpolymer, or it may be copolymerized with ethylene and an optional additional comonomer to form an interpolymer of ethylene, the functional comonomer and optionally other comonomer(s). Means for grafting functional groups onto polyethylene are described for example in U.S. Patents Nos. 4,762,890, 4,927,888, and 4,950,541, the disclosures of these patents are incorporated herein by reference in their entirety. One particularly useful functional group is malic anhydride. [86] The amount of the functional group present in the functional interpolymer can vary. The functional group can typically be present in a copolymer-type functionalized interpolymer in an amount of at least about 1.0 weight percent, preferably at least about 5 weight percent, and more preferably at least about 7 weight percent. The functional group will typically be present in a copolymer-type functionalized interpolymer in an amount less than about 40 weight percent, preferably less than about 30 weight percent, and more preferably less than about 25 weight percent.
Other Components [87] The composition can comprise at least two other components, in addition to the interpolymer, for the purposes of improving and/or controlling the viscosity, adhesive properties, shelf-life, stability and cost. In particular, the composition comprises a tackifier and an oil or a low molecular weight polymer in addition to the interpolymer. Non-limiting examples of additional components include waxes, antioxidants, UV stabilizers, colorants or pigments, fillers, flow aids, coupling agents, crosslinking agents, surfactants, solvents, and combinations thereof. Some components for adhesive compositions have been described in U.S. Patent Nos. 5,750,623 and 5,143,968, both of which are incorporated herein by reference, all of which can be used in embodiments of the invention with or without modifications. [88] The tackifier of the composition may modify the properties of the composition such as viscoelastic properties (e.g., storage modulus, viscous modulus, tan delta), rheological properties (e.g., viscosity), tackiness (i.e., ability to stick), pressure sensitivity, and wetting property. In some embodiments, the tackifier is used to improve the tackiness of the composition. In other embodiments, the tackifier is used to reduce the viscosity of the composition. Preferably, the tackifier is used to render the composition a pressure-sensitive adhesive. In some embodiments, the tackifier is used to wet out adherent surfaces and/or improve the adhesion to the adherent surfaces.
[89] Any tackifier known to a person of ordinary skill in the art may be used in the adhesion composition disclosed herein. Tackifiers suitable for the compositions disclosed herein can be solids, semi-solids, or liquids at room temperature. Non-limiting examples of tackifiers include (1) natural and modified rosins (e.g., gum rosin, wood rosin, tall oil rosin, distilled rosin, hydrogenated rosin, dimerized rosin, and polymerized rosin); (2) glycerol and pentaerythritol esters of natural and modified rosins (e.g., the glycerol ester of pale, wood rosin, the glycerol ester of hydrogenated rosin, the glycerol ester of polymerized rosin, the pentaerythritol ester of hydrogenated rosin, and the phenolic-modified pentaerythritol ester of rosin); (3) copolymers and terpolymers of natured terpenes (e.g., styrene/terpene and alpha methyl styrene/terpene); (4) polyterpene resins and hydrogenated polyterpene resins; (5) phenolic modified terpene resins and hydrogenated derivatives thereof (e.g., the resin product resulting from the condensation, in an acidic medium, of a bicyclic terpene and a phenol); (6) aliphatic or cycloaliphatic hydrocarbon resins and the hydrogenated derivatives thereof (e.g., resins resulting from the polymerization of monomers consisting primarily of olefins and diolefins); (7) aromatic hydrocarbon resins and the hydrogenated derivatives thereof; (8) aromatic modified aliphatic or cycloaliphatic hydrocarbon resins and the hydrogenated derivatives thereof; and combinations thereof. The amount of the tackifier in the composition can be from about 5 to about 70 wt %, from about 10 to about 65 wt %, or from about 15 to about 60 wt % of the total weight of the composition.
[90] In other embodiments, the tackifiers include rosin-based tackifiers (e.g.
AQUATAC® 9027, AQUATAC® 4188, SYLVALITE®, SYLVATAC® and SYL VA GUM® rosin esters from Arizona Chemical, Jacksonville, FL). In other embodiments, the tackifiers include polyterpenes or terpene resins (e.g., SYLV ARES® terpene resins from Arizona Chemical, Jacksonville, FL). In other embodiments, the tackifiers include aliphatic hydrocarbon resins such as resins resulting from the polymerization of monomers consisting of olefins and diolefins (e.g., ESCOREZ® 1310LC, ESCOREZ® 2596 from ExxonMobil Chemical Company, Houston, Tex. or PICCOTAC® 1095 from Eastman Chemical Company, Kingsport, Tenn.) and the hydrogenated derivatives thereof; alicyclic petroleum hydrocarbon resins and the hydrogenated derivatives thereof (e.g. ESCOREZ® 5300 and 5400 series from ExxonMobil Chemical Company; EASTOTAC® resins from Eastman Chemical Company). In some embodiments, the tackifiers include hydrogenated cyclic hydrocarbon resins (e. g. REGALREZ® and REGALITE® resins from Eastman Chemical Company). In further embodiments, the tackifiers are modified with tackifier modifiers including aromatic compounds (e.g., ESCOREZ® 2596 from
ExxonMobil Chemical Company or PICCOTAC® 7590 from Eastman Chemical Company) and low softening point resins (e.g., AQUATAC 5527 from Arizona Chemical, Jacksonville, FL). In some embodiments, the tackifier is an aliphatic hydrocarbon resin having at least five carbon atoms. In other embodiments, the tackifier has a Ring and Ball (R&B) softening point equal to or greater than 8O0C. The Ring and Ball (R&B) softening point can be measured by the method described in ASTM E28, which is incorporated herein by reference. [91] In some embodiments, the performance characteristics of the tackifier in the composition disclosed herein can be directly related to its compatibility with the ethylene/α- olefin interpolymer. Preferably, compositions with desirable adhesive properties can be obtained with tackifiers that are compatible with the interpolymer. For example, when a compatible tackifier is added in the correct concentration to the interpolymer, desirable tack properties can be produced. Although incompatible tackifiers may not produce desirable tack properties, they may be used to impact other desirable properties. For example, the properties of the composition can be fine-tuned by the addition of a tackifier having limited compatibility to reduce the tack level and/or increase the cohesive strength characteristics. [92] In addition, the compositions disclosed herein comprise a plasticizer or plasticizing oil or an extender oil that may reduce viscosity and/or improve tack properties. Any plasticizer known to a person of ordinary skill in the art may be used in the adhesion composition disclosed herein. Non-limiting examples of plasticizers include olefin oligomers, low molecular weight polyolefins such as liquid polybutene, low molecular weight non-aromatic polymers (e.g. REGALREZ® 1018 from Eastman Chemical Company), phthalates, mineral oils such as naphthenic, paraffinic, or hydrogenated (white) oils (e.g. Kaydol oil or ParaLux™ oils (Chevron U.S.A. Inc.)), vegetable and animal oil and their derivatives, petroleum derived oils, and combinations thereof. Low molecular weight polyolefins may include those with Mw as low as 100, in particular, those in the range of from about 100 to 3000, in the range of from about 250 to about 2000 and in the range of from about 300 to about 1000. Paraffinic oils are especially preferred. In some embodiments, the plasticizers include polypropylene, polybutene, hydrogenated polyisoprene, hydrogenated polybutadiene, polypiperylene and copolymers of piperylene and isoprene, and the like having average molecular weights between about 350 and about 10,000. In other embodiments, the plasticizers include glyceryl esters of the usual fatty acids and polymerization products thereof.
[93] In some embodiments, a suitable insoluble plasticizer may be selected from the group which includes dipropylene glycol dibenzoate, pentaerythritol tetrabenzoate; polyethylene glycol 400-di-2-ethylhexoate; 2-ethylhexyl diphenyl phsophate; butyl benzyl phthalate, dibutyl phthalate, dioctyl phthalate, various substituted citrates, and glycerates. Suitable dipropylene glycol dibenzoate and pentaerythritol tetrabenzoate may be purchased from Velsicol Chemical Company of Chicago, 111. under the trade designations "Benzoflex 9- 88 and S-552", respectively. Further, a suitable polyethylene glycol 400-di-2-ethylhexoate may be purchased from CP. Hall Company of Chicago, 111. under the trade designation "Tegmer 809". A suitable 2-ethylhexyl diphenyl phosphate, and a butyl benzyl phthalate may be purchased from Monsanto Industrial Chemical Company of St. Louis, Mo. under the trade designation "Santicizer 141 and 160", respectively. When Benzoflex is used as a plasticizer in an adhesive composition, it can delay the crystallization in diaper core stabilization adhesives, which are used to stabilize the thinner cores of diapers and adult incontinence products.
[94] In further embodiments, the compositions disclosed herein optionally can comprise a wax that may reduce the melt viscosity in addition to reducing costs. Any wax known to a person of ordinary skill in the art can be used in the adhesion composition disclosed herein. Non- limiting examples of suitable waxes include petroleum waxes, polyolefin waxes such as low molecular weight polyethylene or polypropylene , synthetic waxes, paraffin and microcrystalline waxes having melting points from about 55 to about 1100C, Fischer- Tropsch waxes and combinations thereof. In some embodiments, the wax is a low molecular weight polyethylene homopolymer or interpolymer having a number average molecular weight of about 400 to about 6,000 g/mole. In particular, the inventive interpolymer having such an average molecular weight can be used as a wax, in addition to the higher molecular weight inventive polymer being used as a polymeric component. Where used, the amount of the wax in the composition can be from greater than 0 to about 50 wt %, from about 10 to about 45 wt %, or from about 25 to about 40 wt % of the total weight of the composition.
[95] In some embodiments, the tackifier to ethylene/α-olefin block copolymer ratio is in the range of from about 3.2:1 to about 10:1, preferably about 3.5:1 to about 8:1, and more preferably about 4.0:1 to about 6.0:1. In addition, the oil or low molecular weight polymer to ethylene/α-olefin block copolymer ratio may be an amount in the range of from about 1.2: 1 to about 3.0:1, preferably about 1.3:1 to about 2.5: 1, and more preferably in the range of from about 1.5:1 to about 2.0:1.
[96] In further embodiments, the compositions disclosed herein optionally can comprise an antioxidant or a stabilizer. Any antioxidant known to a person of ordinary skill in the art may be used in the adhesion composition disclosed herein. Non-limiting examples of suitable antioxidants include amine-based antioxidants such as alkyl diphenylamines, phenyl-α- naphthylamine, alkyl or aralkyl substituted phenyl-α-naphthylamine, alkylated p- phenylene diamines, tetramethyl-diaminodiphenylamine and the like; and hindered phenol compounds such as 2,6-di-t-butyl-4-methylphenol; l,3,5-trimethyl-2,4,6-tris(3',5'-di-t-butyl- 4'-hydroxybenzyl)benzene; tetrakis[(methylene(3,5-di-t-butyl-4- hydroxyhydrocinnamate)]methane (e.g., IRGANOX™ 1010, from Ciba Geigy, New York); octadecyl-3,5-di-t-butyl-4-hydroxycinnamate (e.g., IRGANOX™ 1076, commercially available from Ciba Geigy) and combinations thereof. Where used, the amount of the antioxidant in the composition can be from about greater than 0 to about 1 wt %, from about 0.05 to about 0.75 wt %, or from about 0.1 to about 0.5 wt % of the total weight of the composition.
[97] In further embodiments, the compositions disclosed herein optionally can comprise an UV stabilizer that may prevent or reduce the degradation of the compositions by UV radiation. Any UV stabilizer known to a person of ordinary skill in the art may be used in the adhesion composition disclosed herein. Non- limiting examples of suitable UV stabilizers include benzophenones, benzotriazoles, aryl esters, oxanilides, acrylic esters, Formamidine carbon black, hindered amines, nickel quenchers, hindered amines, phenolic antioxidants, metallic salts, zinc compounds and combinations thereof. Where used, the amount of the UV stabilizer in the composition can be from about greater than 0 to about 1 wt %, from about 0.05 to about 0.75 wt %, or from about 0.1 to about 0.5 wt % of the total weight of the composition.
[98] In further embodiments, the compositions disclosed herein optionally can comprise a colorant or pigment. Any colorant or pigment known to a person of ordinary skill in the art may be used in the adhesion composition disclosed herein. Non-limiting examples of suitable colorants or pigments include inorganic pigments such as titanium dioxide and carbon black, phthalocyanine pigments, and other organic pigments such as IRGAZIN®, CROMOPHT AL®, MONASTRAL®, CINQUASIA®, IRGALITE®, ORASOL®, all of which are available from Ciba Specialty Chemicals, Tarrytown, NY. Where used, the amount of the colorant or pigment in the composition can be from about greater than 0 to about 10 wt %, from about 0.1 to about 5 wt %, or from about 0.5 to about 2 wt % of the total weight of the composition.
[99] The compositions disclosed herein may also optionally comprise a fragrance such as a perfume or other odorant. Such fragrances may be contained in release agents such as microcapsules that may, for example, release fragrance upon removal of a release liner from the composition.
[100] In further embodiments, the compositions disclosed herein optionally can comprise a filler. Any filler known to a person of ordinary skill in the art may be used in the adhesion composition disclosed herein. Non-limiting examples of suitable fillers include sand, talc, dolomite, calcium carbonate, clay, silica, mica, wollastonite, feldspar, aluminum silicate, alumina, hydrated alumina, glass bead, glass microsphere, ceramic microsphere, thermoplastic microsphere, barite, wood flour, and combinations thereof. Where used, the amount of the filler in the composition can be from about greater than 0 to about 60 wt %, from about 1 to about 50 wt %, or from about 5 to about 40 wt % of the total weight of the composition.
[101] In formulating the composition, it is preferable that each of the additives are compatible with the ethylene/α-olefin interpolymer disclosed herein so that the additives do not phase separate from the ethylene/α-olefin interpolymer, particularly in molten state. In general, the compatibility of an additive with the ethylene/α-olefin interpolymer increases with a decrease in the difference between their solubility parameters such as Hildebrand solubility parameters. Some Hildebrand solubility parameters are tabulated for solvents in: Barton, A. F. M., Handbook of Solubility and Other Cohesion Parameters, 2nd Ed. CRC Press, Boca Raton, FL (1991); for monomers and representative polymers in Polymer Handbook, 3rd Ed., J. Brandrup & E. H. Immergut, Eds. John Wiley, NY, pages 519-557 (1989); and for many commercially available polymers in Barton, A. F. M., Handbook of Polymer-Liquid Interaction Parameters and Solubility Parameters, CRC Press, Boca Raton, FL (1990), all of which are incorporated herein by reference. The Hildebrand solubility parameter for a copolymer may be calculated using a volume fraction weighting of the individual Hildebrand solubility parameters for each monomer comprising the copolymer, as described for binary copolymers in Barton A. F. M., Handbook of Solubility Parameters and Other Cohesion Parameters, CRC Press, Boca Raton, page 12 (1990). The magnitude of the Hildebrand solubility parameter for polymeric materials is also known to be weakly dependent upon the molecular weight of the polymer, as noted in Barton, pages 446-448. Therefore, there will be a preferred molecular weight range for a given ethylene/α-olefin interpolymer, and adhesive strength may be additionally controlled by manipulating the molecular weight of the ethylene/α-olefin interpolymer or the additives such as the tackifier. In some embodiments, the absolute difference in Hildebrand solubility parameter between the ethylene/α-olefin interpolymer and an additive such as the tackifier, plasticizer or oil, and the wax falls within the range of greater than 0 to about 10 MPa1/2, about 0.1 to about 5 MPa1/2, about 0.5 to about 4.0 MPa1/2, or about 1 to about 3.0 MPa1/2. [102] The compatibility of the additives with the ethylene/α-olefin interpolymer can also be determined by cloud point measurement and dynamic mechanical analysis. The cloud point temperature is the temperature at which a component begins to solidify or "cloud up" as it cools from a clear liquid phase to the solid phase. For example, for waxes, the cloud point is usually close to the melting point of the wax. Generally, the lower the cloud point temperature, the greater the compatibility. The cloud point measurement is disclosed in "Adhesives and Coatings Manual" by National Distillers and Chemical Corporation (1983), which is incorporated herein by reference.
[103] Dynamic mechanical analysis (DMA) can be another technique to identify compatibility characteristics of the additives with the ethylene/α-olefin interpolymer. When an additive, such as the tackifier having a first glass transition temperature (Tg), is compatible with the ethylene/α-olefin interpolymer having a second Tg, DMA generally reveals one single glass transition zone but with the second Tg shift to a different temperature due to the contribution of the first Tg. This indicates an intimate mix (solubility) between the tackifier and the ethylene/α-olefin interpolymer. In case of incompatibility, DMA can detect a separate phase transition for each of the tackifier and the ethylene/α-olefin interpolymer.
Preparation of Compositions Comprising Ethylene/α-Olefin Interpolymers
[104] In some embodiments, the compositions disclosed herein are adhesive compositions comprising an ethylene/α-olefin interpolymer, a tackifier, a plasticizer and optional other additives. The blending of the ethylene/α-olefin interpolymer with the additives can be done by any known method that can result in a substantially homogeneous distribution of the components of the adhesive. The ingredients of the compositions can be blended using methods known to a person of ordinary skill in the art. Non-limiting examples of suitable blending methods include melt blending, solvent blending, and the like.
[105] In some embodiments, the ingredients of the compositions are melt blended by a method as described by Guerin et al. in U.S. Patent No. 4,152,189. That is, all solvent
(if used) is removed from the ingredients by heating to an appropriate elevated temperature of about 1000C to about 2000C or about 1500C to about 175°C at a pressure of about 5 Torr to about 10 Torr. Then, the ingredients are weighed into a vessel in the desired proportions. The blend is then formed by heating the contents of the vessel to about 1500C to about 175°C while stirring. [106] In other embodiments, the ingredients of the compositions are processed using solvent blending. The ingredients in the blend are substantially soluble in the solvents used.
[107] Physical blending devices that provide dispersive mixing, distributive mixing, or a combination of dispersive and distributive mixing can be useful in preparing homogenous blends. Both batch and continuous methods of physical blending can be used. Non- limiting examples of batch methods include those methods using BRABENDER® mixing equipment (e.g., BRABENDER PREP CENTER®, available from C. W. Brabender Instruments, Inc., South Hackensack, N. J.), Sigma blade mixing, or B ANBURY® internal mixing and roll milling (available from Farrel Company, Ansonia, Conn.) equipment. In some embodiments, the mixing time required for blending the formulation is in the range of from 5 min to 20 min, and preferably in the range of from 10 min to 15 minutes. Non- limiting examples of continuous methods include single screw extruding, twin screw extruding, disk extruding, reciprocating single screw extruding, and pin barrel single screw extruding.
[108] An aqueous dispersion of the ethylene/α-olefin interpolymer may also be used in the formulation of various compositions. U.S. Patent No. 5,574,091, incorporated by reference herein in its entirety, teaches the preparation of aqueous dispersions of olefin copolymers in the presence of a stabilizing and an emulsifying amount of a suitable surfactant, such as sulfate of an ethoxylated phenol, e.g., poly(oxy-l,2-ethanediyl)α-sulfo-ω (nonylphonoxy) ammonium salt. Such methods can also be used to make aqueous dispersions of the ethylene/α-olefin interpolymer. Additional suitable methods are disclosed in U.S. Patent No. 5,539,021, which is incorporated by reference herein in its entirety.
Applications of Compositions Comprising Ethylene/α-Olefin Interpolymers
[109] The compositions disclosed herein can be used as hot melt adhesives, pressure sensitive adhesives, hot melt pressure sensitive adhesives or as thermoplastic marking compositions. It can be applied to manufacture any article that requires or comprises a hot melt adhesive or a pressure sensitive adhesive. Non-limiting examples of suitable articles include paper products, packaging materials, laminated wood panels, kitchen countertops, vehicles, labels, disposable diapers, hospital pads, feminine sanitary napkins, surgical drapes, tapes, cases, cartons, trays, medical devices, and bandages. In a further embodiment, the adhesive composition can be used in tapes, cases, cartons, trays, medical devices, and bandages.
[110] In some embodiments, the compositions are used as hot melt adhesives. Such hot melt adhesive compositions can be used in industrial applications including packaging, particularly for low temperature use such as for dairy products or for freezer packaging of food products, and in sanitary disposable consumer articles, for example, diapers, feminine care pads, napkins, and the like. Some other suitable applications include book-binding, wood working and labeling.
[Ill] The compositions disclosed herein may be used as PSAs. Such PSA compositions can be applied to sheeting products (e.g., decorative, reflective, and graphical), labelstock, and tape backings. The substrate can be any suitable type of material depending on the desired application. In certain embodiments, the substrate comprises a nonwoven, paper, polymeric film (e.g., polypropylene (e.g., biaxially oriented polypropylene (BOPP)), polyethylene, polyurea, polybutylene or a polyethylene-polypropylene copolymer, but may also be wholly or partly polyamide such as nylon, polyester such as polyethylene terephthalate, polyvinylidene fluoride, polyacrylate such as poly(methyl methacry late) (only in blends) and the like or polyester (e.g., polyethylene terephthalate (PET)), and blends thereof, or release liner (e.g., siliconized liner).
[112] Preferably, the compositions may be used as hot melt PSAs for health and hygiene related applications. In some embodiments, the invention may further comprise articles comprising the inventive composition. In particular, the compositions may be used as adhesives in nonwoven laminates and elastic nonwoven laminates. Such nonwoven laminate materials have found use in the hygiene and medical market particularly in such applications as diaper construction adhesives, assembly adhesives, elastic diaper tabs, side panels of training pants, leg gathers, feminine hygiene articles, swim pants, incontinent wear, veterinary products, protective clothing, bandages, items of health care such as surgeon's gowns, surgical drapes, sterilization wrap, wipes, and the like. These materials may also find use in other nonwoven applications including but are not limited to filters (gas and liquid), automotive and marine protective covers, home furnishing such as bedding, carpet underpaddings, wall coverings, floor coverings, window shades, scrims etc. Use of these adhesives may allow advantages such as downgauging of backing sheets for applications such as diapers and feminine hygiene products.
[113] In still other embodiments, the compositions can be utilized to form tape. For example, the PSA or hot melt adhesive composition is applied to at least one side of the backing of the tape. The adhesive composition may then be crosslinked to further improve its shear strength. Any suitable crosslinking method (e.g., exposure to radiation, such as ultraviolet or electron beam) or crosslinker additive (e.g., phenolic and silane curatives) may be utilized. [114] The adhesive compositions disclosed herein may be applied to the desired substrate or adhered in any manner known in the art, particularly those methods used traditionally for making tapes, cases, cartons, trays, medical devices, health and hygiene applications and bandages. In other embodiments, the adhesive compositions can be applied by a coating head or nozzle, with associated equipment. The adhesive compositions can be applied as fine lines, dots or spray coatings, in addition to other traditional forms as desired.
[115] Preferably, the adhesive compositions may be applied via spiral spray techniques. The compositions of the present invention may be applied at lower temperatures as compared to conventional such adhesive compositions. In particular, the composition may be applied at temperatures in the range of from about 110 0C to about 150 0C, preferably in the range of from about 115 0C to 140 0C, and more preferably in the range of from about
120 0C to about 130 0C. The compositions may be applied via spiral spray processes such as those described by the NORDSON Corporation in "An Update on Hot Melt Adhesive Fiberization", Adhesives Age, Feb. 1994. Typical coating weights and spray patterns can range from 1 to 10 gsm with pattern widths from 1A" to 5". [116] The invention additionally provides a method of applying the adhesive compositions of the present invention comprising applying the adhesive onto a substrate at a temperature in the range of from about 110 0C to about 150 0C, preferably in the range of from about 115 0C to 140 0C, and more preferably in the range of from about 120 0C to about 130 0C. In particular, the method comprises applying the adhesive via spiral spray. In some embodiments, the substrate is a polyethylene backing sheet. In further embodiments, the method further comprises forming a laminate by applying a nonwoven sheet onto the adhesive on the substrate after applying the adhesive. In preferred embodiments, the nonwoven sheet comprises a spunbond polypropylene sheet. The method of the present invention may provide advantages such as reduced risk of burnthrough of the substrate and improved thermal stability of the adhesive, due to the lower application temperature as compared to conventional adhesives.
[117] In some embodiments, the adhesive compositions can be applied using melt extrusion techniques. The adhesive composition can be applied by either continuous or batch processes. An example of a batch process is the placement of a portion of the adhesive composition between a substrate to which the adhesive composition is to be adhered and a surface capable of releasing the adhesive to form a composite structure. An example of a continuous forming method includes drawing the adhesive composition out of a heated film die and subsequently contacting the drawn composition to a moving plastic web or other suitable substrate.
[118] In other embodiments, the adhesive compositions can be coated using a solvent-based method. For example, the solvent-based adhesive composition can be coated by such methods as knife coating, roll coating, gravure coating, rod coating, curtain coating, and air knife coating. The coated solvent-based adhesive composition is then dried to remove the solvent. Preferably, the applied solvent-based adhesive composition is subjected to elevated temperatures, such as those supplied by an oven, to expedite drying. [119] In some embodiments, the compositions disclosed herein are used as thermoplastic marking compositions for marking roads. The thermoplastic marking compositions can be in the form of a hot melt extrusion road marking, hot melt spray road marking, hot melt hand applied road marking, colored hot melt marked bicycle lane, simulation or training road marking, preformed extruded traffic symbol or tape, flexible and soft sports/playground surface marking, safety marking on a ship, or a reflective traffic safety coating. The general formulations and descriptions of thermoplastic marking compositions have been disclosed in U.S. Patent No. 6,552,110, which is incorporated herein by reference. In particular embodiments, the thermoplastic marking compositions comprise the ethylene/α- olefin interpolymer disclosed herein, a tackifier, a filler and optionally a pigment. Preferably, the filler is glass beads or glass microspheres. [120] The filler will be provided to the thermoplastic marking composition in an amount of from 40 to 90 weight percent, preferably from 50 to 90 weight percent. In particularly preferred embodiments, the filler will comprise a combination of the following: 0 to 60 weight percent sand, 0 to 100 percent dolomite or talc, 0 to 50 weight percent glass microspheres, and 1 to 20 weight percent pigment.
[121] When it is desired that the thermoplastic coating composition have reflective attributes, a reflective inorganic filler will be employed. One particularly preferred reflective inorganic filler is glass microspheres. When a reflective inorganic filler is employed, it will typically be provided to the thermoplastic coating composition in an amount of at least 5 weight percent, preferably at least 10 weight percent, and more preferably at least 20 weight percent. The reflective inorganic filler will be provided to the thermoplastic coating composition in an amount of no more than 70, preferably no more than 50 weight percent, and most preferably no more than 40 weight percent.
[122] Certain inorganic fillers will typically be employed in an effort to reduce the cost of the formulation. One suitable extending filler is dolomite clay. When employed, the dolomite filler will be provided in an amount of at least 10 weight percent, more preferably at least 20 weight percent, and most preferably at least 30 weight percent of the thermoplastic coating composition. The dolomite filler will typically be provided in an amount of no more than 80 weight percent, more preferably no more than 75 weight percent, and most preferably no more than 70 weight percent of the thermoplastic coating composition.
[123] The thermoplastic marking compositions are advantageous in that they may be readily designed to be applied by the various techniques used in the industry. For instance, it is now possible to develop a single formulation, which may be usefully applied by extrusion, screed, or spray techniques. [124] The thermoplastic marking compositions will preferably exhibit an adhesion, as measured in accordance with the techniques set forth in Example Two of U.S. Patent No. 6,552,110, of at least 1.0 N/mm2, preferably at least 1.2 N/mm2, more preferably at least 1.3 N/mm , and most preferably at least 1.5 N/mm . U.S. Patent No. 6,552,110 is incorporated herein by reference. [125] The thermoplastic marking compositions will preferably exhibit a luminance factor, as measured in accordance with the techniques set forth in Example Two of U.S. Patent No. 6,552,110, of at least 70, preferably at least 75, more preferably at least 76, and most preferably at least 78.
[126] The thermoplastic marking compositions further exhibit good low temperature abrasion resistance. The subject formulations exhibit improved low temperature flexibility and low temperature adhesion, and exhibit improved smoke and low odor properties at high temperatures. The subject formulations exhibit a broad potential range of application temperatures, particularly at temperatures of from 150 0C to 250 0C, which makes them suitable for application by different means. For instance, the ability of the compositions to be applied at lower application temperatures, that is, temperatures of about 150 to 170 0C, makes them suitable for application by extrusion coating techniques; while the ability of the compositions to be applied at higher application temperatures, that is, temperatures of 200 0C to 250 0C makes them suitable for application by spray coating techniques. The subject formulations are preferably resistant to dirt pick-up, and further preferably exhibit less viscosity variability relative to systems which lack the homogeneous ethylene polymer. [127] The subject formulations are usefully applied via spray, screed, and extrusion techniques. In addition, the subject formulations may be provided as preformed tapes, which are laid upon the surface and bonded to it by heating with, for example, a gas flame, optionally under some applied pressure, as by rolling.
[128] Exemplary applications for the thermoplastic marking compositions are in hot melt extrusion road marking; hot melt spray road marking; hot melt hand applied road markings; colored hot melt marked bicycle lanes applied by spray or extrusion; marking of simulation/training roads for icy surface driving; preformed extruded traffic symbols (such as arrows, letters, etc.) and tapes (such as for traffic safety, information, decoration, etc.) (also called premarks or hot melt tapes); marking of flexible and soft sports/playground surfaces, such as tartan (for instance, in the marking of tennis courts, outdoor and indoor sports floorings, etc.); safety markings on ships, oil rigs, etc.; and reflecting traffic safety coatings for tunnels, concrete, metals with glass beads or other reflecting/self-glowing pigments.
[129] In one preferred application, the subject thermoplastic marking compositions will be employed in embossed road markings. Embossed road markings are formed by extrusion of a marking composition onto a surface; applying reflective particles, such as glass beads, to the extruded marking; and embossing the extruded marking such as to create channels or other ridges. Such embossed markings are desirable, in that they provide enhanced water drainage and improve nighttime reflective properties, particularly in rainy weather. The thermoplastic marking compositions of the invention are advantageous in embossed road marking applications, as they provide the requisite degree of flexibility, adhesion, and abrasion, even under cold temperature conditions.
Specific Embodiments
1. An adhesive composition comprising:
(i) about 10 wt% to about 40 wt%, based on total weight of the adhesive composition, of at least one ethylene/α-olefin block copolymer, wherein the ethylene/α- olefin block copolymer comprises greater than 50 mol% ethylene based on total weight of the copolymer and:
(a) has a Mw/Mn from about 1.7 to about 3.5, at least one melting point, Tm, in degrees Celsius, and a density, d, in grams/cubic centimeter, wherein the numerical values of Tm and d correspond to the relationship: Tm > -2002.9 + 4538.5(d) - 2422.2(d)2, or
(b) has a Mw/Mn from about 1.7 to about 3.5, and is characterized by a heat of fusion, ΔH in J/g, and a delta quantity, ΔT, in degrees Celsius, defined as the temperature difference between the tallest DSC peak and the tallest CRYSTAF peak, wherein the numerical values of ΔT and ΔH have the following relationships: ΔT > -0.1299(ΔH) + 62.81 for ΔH greater than zero and up to 130 J/g,
ΔT > 48°C for ΔH greater than 130 J/g , wherein the CRYSTAF peak is determined using at least 5 percent of the cumulative polymer, and if less than 5 percent of the polymer has an identifiable CRYSTAF peak, then the CRYSTAF temperature is 300C; or (c) is characterized by an elastic recovery, Re, in percent at 300 percent strain and 1 cycle measured with a compression-molded film of the ethylene/α- olefin interpolymer, and has a density, d, in grams/cubic centimeter, wherein the numerical values of Re and d satisfy the following relationship when ethylene/α-olefin interpolymer is substantially free of a cross-linked phase: Re >1481-1629(d); or
(d) has a molecular fraction which elutes between 400C and 1300C when fractionated using TREF, characterized in that the fraction has a molar comonomer content of at least 5 percent higher than that of a comparable random ethylene interpolymer fraction eluting between the same temperatures, wherein said comparable random ethylene interpolymer has the same comonomer(s) and has a melt index, density, and molar comonomer content (based on the whole polymer) within 10 percent of that of the ethylene/α-olefin interpolymer; or
(e) has a storage modulus at 25°C, G'(25°C), and a storage modulus at 1000C, G' (1000C), wherein the ratio of G' (25°C) to G' (1000C) is in the range of about 1:1 to about 9:1; or
(f) has a molecular fraction which elutes between 400C and 1300C when fractionated using TREF, characterized in that the fraction has a block index of at least 0.5 and up to about 1; or (g) has an average block index greater than zero and up to about 1.0 and a molecular weight distribution, Mw/Mn, greater than about 1.3; and,
(ii) about 30 wt% to about 70 wt%, based on total weight of the adhesive composition, of at least one tackifier; and,
(iii) about 10 wt% to about 30 wt%, based on total weight of the adhesive composition, of an oil or a low molecular weight polymer.
2. The composition of embodiment 1, wherein the ethylene/α-olefin interpolymer has a Mw/Mn from about 1.7 to about 3.5, at least one melting point, Tm, in degrees Celsius, and a density, d, in grams/cubic centimeter, wherein the numerical values of Tm and d correspond to the relationship: Tm > 858.91 - 1825.3(d) + 1112.8(d)2.
3. The composition of embodiment 1, wherein the ethylene/α-olefin interpolymer has a Mw/Mn from about 1.7 to about 3.5 and is characterized by a heat of fusion, ΔH in J/g, and a delta quantity, ΔT, in degrees Celsius defined as the temperature difference between the tallest DSC peak and the tallest CRYSTAF peak, wherein the numerical values of ΔT and ΔH have the following relationships: ΔT > -0.1299(ΔH) + 62.81 for ΔH greater than zero and up to 130 J/g, ΔT > 48°C for ΔH greater than 130 J/g , wherein the CRYSTAF peak is determined using at least 5 percent of the cumulative polymer, and if less than 5 percent of the polymer has an identifiable CRYSTAF peak, then the CRYSTAF temperature is 300C.
4. The composition of embodiment 1, wherein the ethylene/α-olefin interpolymer is characterized by an elastic recovery, Re, in percent at 300 percent strain and 1 cycle measured with a compression-molded film of the ethylene/α-olefin interpolymer, and has a density, d, in grams/cubic centimeter, wherein the numerical values of Re and d satisfy the following relationship when ethylene/α-olefin interpolymer is substantially free of a cross-linked phase:
Re >1481-1629(d).
5. The composition of embodiment 4, wherein the numerical values of Re and d satisfy the following relationship: Re >1491-1629(d).
6. The composition of embodiment 4, wherein the numerical values of Re and d satisfy the following relationship:
Re >1501-1629(d).
7. The composition of embodiment 4, wherein the numerical values of Re and d satisfy the following relationship:
Re >1511-1629(d).
8. The composition of embodiment 1, wherein the ethylene/α-olefin interpolymer has a molecular fraction which elutes between 400C and 1300C when fractionated using TREF, characterized in that the fraction has a molar comonomer content of at least 5 percent higher than that of a comparable random ethylene interpolymer fraction eluting between the same temperatures, wherein said comparable random ethylene interpolymer has the same comonomer(s) and has a melt index, density, and molar comonomer content (based on the whole polymer) within 10 percent of that of the ethylene/α-olefin interpolymer. 9. The composition of embodiment 1, wherein the ethylene/α-olefin interpolymer has a storage modulus at 25°C, G'(25°C), and a storage modulus at 1000C, G'(100°C), wherein the ratio of G'(25°C) to G'(100°C) is in the range of about 1: 1 to about 9:1. 10. The composition of embodiment 1, wherein the composition is a hot melt adhesive composition, a pressure sensitive adhesive composition or a thermoplastic marking composition.
11. The composition of embodiment 1, wherein the α-olefin is styrene, propylene, 1-butene, 1-hexene, 1-octene, 4-methyl-l-pentene, norbornene, 1-decene, 1,5-hexadiene, or a combination thereof.
12. The composition of embodiment 1, wherein the tackifier is present in the range from about 15 wt% to about 75 wt %, by weight of the total composition.
13. The composition of embodiment 1, wherein the tackifier has a R&B softening point equal to or greater than 8O0C. 14. The composition of embodiment 1, wherein the oil is present in an amount in the range of between 0 wt% to about 30 wt%, by weight of the total composition.
15. The composition of embodiment 1, further comprising at least one additive selected from the group consisting of plasticizers, waxes, antioxidants, UV stabilizers, colorants or pigments, fillers, flow aids, coupling agents, crosslinking agents, surfactants, solvents, fragrances and combinations thereof.
16. The composition of embodiment 1, wherein the ethylene/α-olefin interpolymer has a density of about 0.85 to about 0.88 g/cc.
17. The composition of embodiment 1, wherein the ethylene/α-olefin interpolymer has a density of about 0.86 to about 0.875 g/cc.
18. The composition of embodiment 1, wherein the ethylene/α-olefin interpolymer has a melt index of about 5 to about 50 g/10 minutes.
19. The composition of embodiment 1, wherein the ethylene/α-olefin interpolymer has a melt index of about 10 to about 30 g/10 minutes. 20. The composition of embodiment 1, wherein the ethylene/α-olefin interpolymer is present in a range from about 10% to abut 75% by weight of the total composition.
21. The composition of embodiment 15, wherein the additive is a plasticizer which is a mineral oil, liquid polybutene, or a combination thereof.
22. The composition of embodiment 1, wherein the ethylene/α-olefin interpolymer has a molecular fraction which elutes between 400C and 1300C when fractionated using TREF, characterized in that the fraction has a block index of at least 0.5 and up to about 1. 23. An article comprising a substrate coated with the composition of embodiment 10.
24. The article of embodiment 23, wherein the article is a medical device, a bandage, or a hygiene article.
25. A method of applying the composition of embodiment 1 to a substrate comprising: applying the composition to the substrate at a temperature in the range of from about 100 0C to about 150 0C.
26. The method of embodiment 25 comprising applying the adhesive via spiral spray in non-contact mode or slot die coating in contact mode. 27. The method of embodiment 25 wherein the temperature is in the range of from about 115 0C to about 140 0C.
28. The method of embodiment 25 wherein the temperature is in the range of from about 120 0C to about 130 0C.
29. The method of embodiment 25, wherein the ethylene/α-olefin interpolymer has a Mw/Mn from about 1.7 to about 3.5, at least one melting point, Tm, in degrees
Celsius, and a density, d, in grams/cubic centimeter, wherein the numerical values of Tm and d correspond to the relationship:
Tm > 858.91 - 1825.3(d) + 1112.8(d)2. 30. The method of embodiment 25, wherein the ethylene/α-olefin interpolymer has a Mw/Mn from about 1.7 to about 3.5 and is characterized by a heat of fusion, ΔH in J/g, and a delta quantity, ΔT, in degrees Celsius defined as the temperature difference between the tallest DSC peak and the tallest CRYSTAF peak, wherein the numerical values of ΔT and ΔH have the following relationships:
ΔT > -0.1299(ΔH) + 62.81 for ΔH greater than zero and up to 130 J/g, ΔT > 48°C for ΔH greater than 130 J/g , wherein the CRYSTAF peak is determined using at least 5 percent of the cumulative polymer, and if less than 5 percent of the polymer has an identifiable CRYSTAF peak, then the CRYSTAF temperature is 300C.
31. The method of embodiment 25, wherein the ethylene/α-olefin interpolymer is characterized by an elastic recovery, Re, in percent at 300 percent strain and 1 cycle measured with a compression-molded film of the ethylene/α-olefin interpolymer, and has a density, d, in grams/cubic centimeter, wherein the numerical values of Re and d satisfy the following relationship when ethylene/α-olefin interpolymer is substantially free of a cross-linked phase:
Re >1481-1629(d).
32. The method of embodiment 25, wherein the numerical values of Re and d satisfy the following relationship: Re >1491-1629(d).
33. The method of embodiment 25, wherein the numerical values of Re and d satisfy the following relationship:
Re >1501-1629(d).
34. The method of embodiment 25, wherein the numerical values of Re and d satisfy the following relationship:
Re >1511-1629(d).
35. The method of embodiment 25, wherein the ethylene/α-olefin interpolymer has a molecular fraction which elutes between 400C and 1300C when fractionated using TREF, characterized in that the fraction has a molar comonomer content of at least 5 percent higher than that of a comparable random ethylene interpolymer fraction eluting between the same temperatures, wherein said comparable random ethylene interpolymer has the same comonomer(s) and has a melt index, density, and molar comonomer content (based on the whole polymer) within 10 percent of that of the ethylene/α-olefin interpolymer.
36. The method of embodiment 25, wherein the ethylene/α-olefin interpolymer has a storage modulus at 25°C, G'(25°C), and a storage modulus at 1000C, C(IOO0C), wherein the ratio of G'(25°C) to C(IOO0C) is in the range of about 1:1 to about 9: 1.
37. The method of embodiment 25, wherein the composition is a hot melt adhesive composition, a pressure sensitive adhesive composition or a thermoplastic marking composition.
38. The method of embodiment 25, wherein the α-olefin is styrene, propylene, 1-butene, 1-hexene, 1-octene, 4-methyl-l-pentene, norbornene, 1-decene, 1,5- hexadiene, or a combination thereof. 39. The method of embodiment 25, wherein the tackifier is present in the range from about 15 wt% to about 75 wt %, by weight of the total composition.
40. The method of embodiment 25, wherein the tackifier has a R&B softening point equal to or greater than 8O0C.
41. The method of embodiment 25, wherein the oil is present in an amount in the range of between 0 wt% to about 30 wt%, by weight of the total composition.
42. The method of embodiment 25, further comprising at least one additive selected from the group consisting of plasticizers, waxes, antioxidants, UV stabilizers, colorants or pigments, fillers, flow aids, coupling agents, cros slinking agents, surfactants, solvents, fragrances and combinations thereof. 43. The method of embodiment 25, wherein the ethylene/α-olefin interpolymer has a density of about 0.85 to about 0.88 g/cc.
44. The method of embodiment 25, wherein the ethylene/α-olefin interpolymer has a density of about 0.86 to about 0.875 g/cc.
45. The method of embodiment 25, wherein the ethylene/α-olefin interpolymer has a melt index of about 5 to about 50 g/10 minutes. 46. The method of embodiment 25, wherein the ethylene/α-olefin interpolymer has a melt index of about 10 to about 30 g/10 minutes.
47. The method of embodiment 25, wherein the ethylene/α-olefin interpolymer is present in a range from about 10% to about 75% by weight of the total composition. 48. The method of embodiment 42, wherein the additive is a plasticizer which is a mineral oil, liquid polybutene, or a combination thereof.
49. The method of embodiment 25, wherein the ethylene/α-olefin interpolymer has a molecular fraction which elutes between 400C and 1300C when fractionated using TREF, characterized in that the fraction has a block index of at least 0.5 and up to about 1.
[130] The following examples are presented to exemplify embodiments of the invention but are not intended to limit the invention to the specific embodiments set forth. Unless indicated to the contrary, all parts and percentages are by weight. All numerical values are approximate. When numerical ranges are given, it should be understood that embodiments outside the stated ranges may still fall within the scope of the invention.
Specific details described in each example should not be construed as necessary features of the invention.
Testing Methods
In the examples that follow, the following analytical techniques are employed: GPC Method for Samples 1-4 and A-C
[131] An automated liquid-handling robot equipped with a heated needle set to 16O0C is used to add enough 1,2,4-trichlorobenzene stabilized with 300 ppm Ionol to each dried polymer sample to give a final concentration of 30 mg/mL. A small glass stir rod is placed into each tube and the samples are heated to 16O0C for 2 hours on a heated, orbital- shaker rotating at 250 rpm. The concentrated polymer solution is then diluted to 1 mg/ml using the automated liquid-handling robot and the heated needle set to 16O0C.
[132] A Symyx Rapid GPC system is used to determine the molecular weight data for each sample. A Gilson 350 pump set at 2.0 ml/min flow rate is used to pump helium- purged 1,2-dichlorobenzene stabilized with 300 ppm Ionol as the mobile phase through three Plgel 10 micrometer (μm) Mixed B 300mm x 7.5mm columns placed in series and heated to 16O0C. A Polymer Labs ELS 1000 Detector is used with the Evaporator set to 25O0C, the Nebulizer set to 1650C, and the nitrogen flow rate set to 1.8 SLM at a pressure of 60-80 psi (400-600 kPa) N2. The polymer samples are heated to 16O0C and each sample injected into a 250 μl loop using the liquid-handling robot and a heated needle. Serial analysis of the polymer samples using two switched loops and overlapping injections are used. The sample data is collected and analyzed using Symyx Epoch™ software. Peaks are manually integrated and the molecular weight information reported uncorrected against a polystyrene standard calibration curve.
Standard CRYSTAF Method [133] Branching distributions are determined by crystallization analysis fractionation (CRYSTAF) using a CRYSTAF 200 unit commercially available from
PolymerChar, Valencia, Spain. The samples are dissolved in 1,2,4 trichlorobenzene at 1600C (0.66 mg/mL) for 1 hr and stabilized at 950C for 45 minutes. The sampling temperatures range from 95 to 300C at a cooling rate of 0.2°C/min. An infrared detector is used to measure the polymer solution concentrations. The cumulative soluble concentration is measured as the polymer crystallizes while the temperature is decreased. The analytical derivative of the cumulative profile reflects the short chain branching distribution of the polymer.
[134] The CRYSTAF peak temperature and area are identified by the peak analysis module included in the CRYSTAF Software (Version 200 Lb, PolymerChar, Valencia, Spain). The CRYSTAF peak finding routine identifies a peak temperature as a maximum in the dW/dT curve and the area between the largest positive inflections on either side of the identified peak in the derivative curve. To calculate the CRYSTAF curve, the preferred processing parameters are with a temperature limit of 700C and with smoothing parameters above the temperature limit of 0.1, and below the temperature limit of 0.3. DSC Standard Method (Excluding Samples 1-4 and A-C) [135] Differential Scanning Calorimetry results are determined using a TAI model
QlOOO DSC equipped with an RCS cooling accessory and an autosampler. A nitrogen purge gas flow of 50 ml/min is used. The sample is pressed into a thin film and melted in the press at about 1750C and then air-cooled to room temperature (25°C). 3-10 mg of material is then cut into a 6 mm diameter disk, accurately weighed, placed in a light aluminum pan (ca 50 mg), and then crimped shut. The thermal behavior of the sample is investigated with the following temperature profile. The sample is rapidly heated to 18O0C and held isothermal for 3 minutes in order to remove any previous thermal history. The sample is then cooled to - 4O0C at 10°C/min cooling rate and held at -4O0C for 3 minutes. The sample is then heated to 150 0C at 10°C/min. heating rate. The cooling and second heating curves are recorded.
[136] The DSC melting peak is measured as the maximum in heat flow rate (W/g) with respect to the linear baseline drawn between -300C and end of melting. The heat of fusion is measured as the area under the melting curve between -300C and the end of melting using a linear baseline. GPC Method (Excluding Samples 1-4 and A-C)
[137] The gel permeation chromatographic system consists of either a Polymer Laboratories Model PL-210 or a Polymer Laboratories Model PL-220 instrument. The column and carousel compartments are operated at 140 0C. Three Polymer Laboratories 10- micron Mixed-B columns are used. The solvent is 1,2,4 trichlorobenzene. The samples are prepared at a concentration of 0.1 grams of polymer in 50 milliliters of solvent containing 200 ppm of butylated hydroxy toluene (BHT). Samples are prepared by agitating lightly for 2 hours at 1600C. The injection volume used is 100 microliters and the flow rate is 1.0 ml/minute.
[138] Calibration of the GPC column set is performed with 21 narrow molecular weight distribution polystyrene standards with molecular weights ranging from 580 to 8,400,000, arranged in 6 "cocktail" mixtures with at least a decade of separation between individual molecular weights. The standards are purchased from Polymer Laboratories (Shropshire, UK). The polystyrene standards are prepared at 0.025 grams in 50 milliliters of solvent for molecular weights equal to or greater than 1,000,000, and 0.05 grams in 50 milliliters of solvent for molecular weights less than 1,000,000. The polystyrene standards are dissolved at 800C 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 molecular weights using the following equation (as described in Williams and Ward, L Polvm. ScL, Polvm. Let., 6, 621 (1968)):
Mpolyethylene = 0.431 (Mpolystyrene) •
[139] Polyethylene equivalent molecular weight calculations are performed using Viscotek TriSEC software Version 3.0. Compression Set
[140] Compression set is measured according to ASTM D 395. The sample is prepared by stacking 25.4 mm diameter round discs of 3.2 mm, 2.0 mm, and 0.25 mm thickness until a total thickness of 12.7 mm is reached. The discs are cut from 12.7 cm x 12.7 cm compression molded plaques molded with a hot press under the following conditions: zero pressure for 3 min at 19O0C, followed by 86 MPa for 2 min at 19O0C, followed by cooling inside the press with cold running water at 86 MPa. Density
[141] Samples for density measurement are prepared according to ASTM D 1928. Measurements are made within one hour of sample pressing using ASTM D792, Method B. Flexural/Secant Modulus/ Storage Modulus
[142] Samples are compression molded using ASTM D 1928. Flexural and 2 percent secant moduli are measured according to ASTM D-790. Storage modulus is measured according to ASTM D 5026-01 or equivalent technique. Optical properties
[143] Films of 0.4 mm thickness are compression molded using a hot press (Carver Model #4095 -4PR 100 IR). The pellets are placed between polytetrafluoroethylene sheets, heated at 190 0C at 55 psi (380 kPa) for 3 min, followed by 1.3 MPa for 3 min, and then 2.6 MPa for 3 min. The film is then cooled in the press with running cold water at 1.3 MPa for 1 min. The compression molded films are used for optical measurements, tensile behavior, recovery, and stress relaxation.
[144] Clarity is measured using BYK Gardner Haze-gard as specified in ASTM D 1746.
[145] 45° gloss is measured using BYK Gardner Glossmeter Microgloss 45° as specified in ASTM D-2457
[146] Internal haze is measured using BYK Gardner Haze-gard based on ASTM D 1003 Procedure A. Mineral oil is applied to the film surface to remove surface scratches. Mechanical Properties - Tensile, Hysteresis, and Tear
[147] Stress-strain behavior in uniaxial tension is measured using ASTM D 1708 microtensile specimens. Samples are stretched with an Instron at 500 % min"1 at 210C. Tensile strength and elongation at break are reported from an average of 5 specimens.
[148] 100% and 300% Hysteresis is determined from cyclic loading to 100% and 300% strains using ASTM D 1708 microtensile specimens with an Instron™ instrument. The sample is loaded and unloaded at 267 % min"1 for 3 cycles at 210C. Cyclic experiments at 300% and 8O0C are conducted using an environmental chamber. In the 80 0C experiment, the sample is allowed to equilibrate for 45 minutes at the test temperature before testing. In the 21 0C, 300% strain cyclic experiment, the retractive stress at 150% strain from the first unloading cycle is recorded. Percent recovery for all experiments are calculated from the first unloading cycle using the strain at which the load returned to the base line. The percent recovery is defined as:
£ £ % Recovery = — -xlOO εf
[149] where Ef is the strain taken for cyclic loading and εs is the strain where the load returns to the baseline during the 1st unloading cycle.
[150] Stress relaxation is measured at 50 percent strain and 37 0C for 12 hours using an Instron™ instrument equipped with an environmental chamber. The gauge geometry was 76 mm x 25 mm x 0.4 mm. After equilibrating at 370C for 45 min in the environmental chamber, the sample was stretched to 50% strain at 333% min"1. Stress was recorded as a function of time for 12 hours. The percent stress relaxation after 12 hours was calculated using the formula:
% Stress Relaxation = ° ~ 12 XlOO
where L0 is the load at 50% strain at 0 time and L12 is the load at 50 percent strain after 12 hours.
[151] Tensile notched tear experiments are carried out on samples having a density of 0.88 g/cc or less using an Instron™ instrument. The geometry consists of a gauge section of 76 mm x 13 mm x 0.4 mm with a 2 mm notch cut into the sample at half the specimen length. The sample is stretched at 508 mm min"1 at 21 0C until it breaks. The tear energy is calculated as the area under the stress-elongation curve up to strain at maximum load. An average of at least 3 specimens are reported. TMA
[152] Thermal Mechanical Analysis (Penetration Temperature) is conducted on 30mm diameter x 3.3 mm thick, compression molded discs, formed at 18O0C and 10 MPa molding pressure for 5 minutes and then air quenched. The instrument used is a TMA 7 brand available from Perkin- Elmer. In the test, a probe with 1.5 mm radius tip (P/N N519- 0416) is applied to the surface of the sample disc with IN force. The temperature is raised at 5°C/min from 250C. The probe penetration distance is measured as a function of temperature. The experiment ends when the probe has penetrated 1 mm into the sample. DMA
[153] Dynamic Mechanical Analysis (DMA) is measured on compression molded disks formed in a hot press at 18O0C at 10 MPa pressure for 5 minutes and then water cooled in the press at 9O0C / min. Testing is conducted using an ARES controlled strain rheometer (TA instruments) equipped with dual cantilever fixtures for torsion testing.
[154] A 1.5mm plaque is pressed and cut in a bar of dimensions 32xl2mm. The sample is clamped at both ends between fixtures separated by 10mm (grip separation ΔL) and subjected to successive temperature steps from -1000C to 2000C (50C per step). At each temperature the torsion modulus G' is measured at an angular frequency of 10 rad/s, the strain amplitude being maintained between 0.1 percent and 4 percent to ensure that the torque is sufficient and that the measurement remains in the linear regime.
[155] An initial static force of 10 g is maintained (auto-tension mode) to prevent slack in the sample when thermal expansion occurs. As a consequence, the grip separation ΔL increases with the temperature, particularly above the melting or softening point of the polymer sample. The test stops at the maximum temperature or when the gap between the fixtures reaches 65 mm. Melt Index
[156] Melt index, or I2, is measured in accordance with ASTM D 1238, Condition 190°C/2.16 kg. Melt index, or I10 is also measured in accordance with ASTM D 1238, Condition 190°C/10 kg. ATREF
[157] Analytical temperature rising elution fractionation (ATREF) analysis is conducted according to the method described in USP 4,798,081 and Wilde, L.; RyIe, T.R.; Knobeloch, D.C.; Peat, LR. ; Determination of Branching Distributions in Polyethylene and Ethylene Copolymers, J. Polym. ScL, 20, 441-455 (1982), which are incorporated by reference herein in their entirety.. 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 200C at a cooling rate of 0.1°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 1200C at a rate of 1.5°C/min. 13C NMR Analysis
[158] The samples are prepared by adding approximately 3g of a 50/50 mixture of tetrachloroethane-d2/orthodichlorobenzene to 0.4 g sample in a 10 mm NMR tube. The samples are dissolved and homogenized by heating the tube and its contents to 15O0C. The data are collected using a JEOL Eclipse™ 400MHz spectrometer or a Varian Unity Plus™ 400MHz spectrometer, corresponding to a 13C resonance frequency of 100.5 MHz. The data are acquired using 4000 transients per data file with a 6 second pulse repetition delay. To achieve minimum signal-to-noise for quantitative analysis, multiple data files are added together. The spectral width is 25,000 Hz with a minimum file size of 32K data points. The samples are analyzed at 130 0C in a 10 mm broad band probe. The comonomer incorporation is determined using Randall's triad method (Randall, J.C.; JMS-Rev. Macromol. Chem. Phys., C29, 201-317 (1989), which is incorporated by reference herein in its entirety. Polymer Fractionation by TREF
[159] Large-scale TREF fractionation is carried by dissolving 15-20 g of polymer in 2 liters of 1 ,2,4-trichlorobenzene (TCB) by stirring for 4 hours at 16O0C. The polymer solution is forced by 15 psig (100 kPa) nitrogen onto a 3 inch by 4 foot (7.6 cm x 12 cm) steel column packed with a 60:40 (v:v) mix of 30-40 mesh (600-425 μm) spherical, technical quality glass beads (available from Potters Industries, HC 30 Box 20, Brownwood, TX, 76801) and stainless steel, 0.028" (0.7mm) diameter cut wire shot (available from Pellets, Inc., 63 Industrial Drive, North Tonawanda, NY, 14120). The column is immersed in a thermally controlled oil jacket, set initially to 160 0C. The column is first cooled ballistically to 125 0C, then slow cooled to 20 0C at 0.04 0C per minute and held for one hour. Fresh TCB is introduced at about 65 ml/min while the temperature is increased at 0.167 0C per minute. [160] Approximately 2000 ml portions of eluant from the preparative TREF column are collected in a 16 station, heated fraction collector. The polymer is concentrated in each fraction using a rotary evaporator until about 50 to 100 ml of the polymer solution remains. The concentrated solutions are allowed to stand overnight before adding excess methanol, filtering, and rinsing (approx. 300-500 ml of methanol including the final rinse). The filtration step is performed on a 3 position vacuum assisted filtering station using 5.0 μm polytetrafluoroethylene coated filter paper (available from Osmonics Inc., Cat#
Z50WP04750). The filtrated fractions are dried overnight in a vacuum oven at 60 0C and weighed on an analytical balance before further testing. Melt Strength
[161] Melt Strength (MS) is measured by using a capillary rheometer fitted with a 2.1 mm diameter, 20:1 die with an entrance angle of approximately 45 degrees. After equilibrating the samples at 1900C for 10 minutes, the piston is run at a speed of 1 inch/minute (2.54 cm/minute). The standard test temperature is 1900C. The sample is drawn uniaxially to a set of accelerating nips located 100 mm below the die with an acceleration of 2.4 mm/sec2. The required tensile force is recorded as a function of the take-up speed of the nip rolls. The maximum tensile force attained during the test is defined as the melt strength. In the case of polymer melt exhibiting draw resonance, the tensile force before the onset of draw resonance was taken as melt strength. The melt strength is recorded in centiNewtons ("cN").
Catalysts
[162] The term "overnight", if used, refers to a time of approximately 16-18 hours, the term "room temperature", refers to a temperature of 20-25 0C, and the term "mixed alkanes" refers to a commercially obtained mixture of C6-9 aliphatic hydrocarbons available under the trade designation Isopar E®, from ExxonMobil Chemical Company. In the event the name of a compound herein does not conform to the structural representation thereof, the structural representation shall control. The synthesis of all metal complexes and the preparation of all screening experiments were carried out in a dry nitrogen atmosphere using dry box techniques. All solvents used were HPLC grade and were dried before their use.
[163] MMAO refers to modified methylalumoxane, a triisobutylaluminum modified methylalumoxane available commercially from Akzo-Noble Corporation.
The preparation of catalyst (Bl) is conducted as follows. a) Preparation of (l-methylethyl)(2-hvdroxy-3,5-di(t-butyl)phenyl)methylimine
[164] 3,5-Di-t-butylsalicylaldehyde (3.00 g) is added to 10 mL of isopropylamine. The solution rapidly turns bright yellow. After stirring at ambient temperature for 3 hours, volatiles are removed under vacuum to yield a bright yellow, crystalline solid (97 percent yield). b) Preparation of l,2-bis-(3,5-di-t-butylphenylene)(l-(N-(l- methylethyl)immino)methyl)(2-oxoyl) zirconium dibenzyl [165] A solution of (l-methylethyl)(2-hydroxy-3,5-di(t-butyl)phenyl)imine (605 mg, 2.2 mmol) in 5 mL toluene is slowly added to a solution of Zr(CH2Ph)4 (500 mg, 1.1 mmol) in 50 mL toluene. The resulting dark yellow solution is stirred for 30 min. Solvent is removed under reduced pressure to yield the desired product as a reddish-brown solid. The preparation of catalyst (B 2) is conducted as follows. a) Preparation of (l-(2-methylcvclohexyl)ethyl)(2-oxoyl-3,5-di(t-butyl)phenyl)imine [166] 2-Methylcyclohexylamine (8.44 mL, 64.0 mmol) is dissolved in methanol (90 mL), and di-t-butylsalicaldehyde (10.00 g, 42.67 mmol) is added. The reaction mixture is stirred for three hours and then cooled to -25°C for 12 hrs. The resulting yellow solid precipitate is collected by filtration and washed with cold methanol (2 x 15 mL), and then dried under reduced pressure. The yield is 11.17 g of a yellow solid. 1H NMR is consistent with the desired product as a mixture of isomers.
b) Preparation of bis-(l-(2-methylcvclohexyl)ethyl)(2-oxoyl-3,5-di(t-butyl)phenyl) immino)zirconium dibenzyl
[167] A solution of (l-(2-methylcyclohexyl)ethyl)(2-oxoyl-3,5-di(t- butyl)phenyl)imine (7.63 g, 23.2 mmol) in 200 mL toluene is slowly added to a solution of Zr(CH2Ph)4 (5.28 g, 11.6 mmol) in 600 mL toluene. The resulting dark yellow solution is stirred for 1 hour at 25°C. The solution is diluted further with 680 mL toluene to give a solution having a concentration of 0.00783 M.
[168] Cocatalyst 1 A mixture of methyldi(Ci4_i8 alky 1) ammonium salts of tetrakis(pentafluorophenyl)borate (here-in- after armeenium borate), prepared by reaction of a long chain trialkylamine (Armeen™ M2HT, available from Akzo-Nobel, Inc.), HCl and Li[B(C6F5)4], substantially as disclosed in USP 5,919,9883, Ex. 2. [169] Cocatalyst 2 Mixed Ci4-I8 alkyldimethylammonium salt of bis(tris(pentafluorophenyl)-alumane)-2-undecylimidazolide, prepared according to USP 6,395,671, Ex. 16.
[170] Shuttling Agents The shuttling agents employed include diethylzinc (DEZ, SAl), di(i-butyl)zinc (SA2), di(n-hexyl)zinc (SA3), triethylaluminum (TEA, SA4), trioctylaluminum (SA5), triethylgallium (SA6), i-butylaluminum bis(dimethyl(t- butyl)siloxane) (SA7), i-butylaluminum bis(di(trimethylsilyl)amide) (SA8), n-octylaluminum di(pyridine-2-methoxide) (SA9), bis(n-octadecyl)i-butylaluminum (SAlO), i-butylaluminum bis (di(n-pentyl) amide) (SAI l), n-octylaluminum bis(2,6-di-t-butylphenoxide) (SA12), n- octylaluminum di(ethyl(l-naphthyl) amide) (SA13), ethylaluminum bis(t- butyldimethylsiloxide) (SA14), ethylaluminum di(bis(trimethylsilyl)amide) (SA15), ethylaluminum bis(2,3,6,7-dibenzo-l-azacycloheptaneamide) (SA16), n-octylaluminum bis(2,3,6,7-dibenzo-l-azacycloheptaneamide) (SA17), n-octylaluminum bis(dimethyl(t- butyl)siloxide(SA18), ethylzinc (2,6-diphenylphenoxide) (SA19), and ethylzinc (t-butoxide) (SA20).
Examples 1-4, Comparative Examples A*-C* General High Throughput Parallel Polymerization Conditions [171] Polymerizations are conducted using a high throughput, parallel polymerization reactor (PPR) available from Symyx technologies, Inc. and operated substantially according to U.S. Patent Nos. 6,248,540, 6,030,917, 6,362,309, 6,306,658, and 6,316,663. Ethylene copolymerizations are conducted at 1300C and 200 psi (1.4 MPa) with ethylene on demand using 1.2 equivalents of cocatalyst 1 based on total catalyst used (1.1 equivalents when MMAO is present). A series of polymerizations are conducted in a parallel pressure reactor (PPR) contained of 48 individual reactor cells in a 6 x 8 array that are fitted with a pre-weighed glass tube. The working volume in each reactor cell is 6000 μL. Each cell is temperature and pressure controlled with stirring provided by individual stirring paddles. The monomer gas and quench gas are plumbed directly into the PPR unit and controlled by automatic valves. Liquid reagents are robotically added to each reactor cell by syringes and the reservoir solvent is mixed alkanes. The order of addition is mixed alkanes solvent (4 ml), ethylene, 1-octene comonomer (1 ml), cocatalyst 1 or cocatalyst 1/MMAO mixture, shuttling agent, and catalyst or catalyst mixture. When a mixture of cocatalyst 1 and MMAO or a mixture of two catalysts is used, the reagents are premixed in a small vial immediately prior to addition to the reactor. When a reagent is omitted in an experiment, the above order of addition is otherwise maintained. Polymerizations are conducted for approximately 1-2 minutes, until predetermined ethylene consumptions are reached. After quenching with CO, the reactors are cooled and the glass tubes are unloaded. The tubes are transferred to a centrifuge/vacuum drying unit, and dried for 12 hours at 60 0C. The tubes containing dried polymer are weighed and the difference between this weight and the tare weight gives the net yield of polymer. Results are contained in Table 1. In Table 1 and elsewhere in the application, comparative compounds are indicated by an asterisk (*). [172] Examples 1-4 demonstrate the synthesis of linear block copolymers by the present invention as evidenced by the formation of a very narrow MWD, essentially monomodal copolymer when DEZ is present and a bimodal, broad molecular weight distribution product (a mixture of separately produced polymers) in the absence of DEZ. Due to the fact that Catalyst (Al) is known to incorporate more octene than Catalyst (Bl), the different blocks or segments of the resulting copolymers of the invention are distinguishable based on branching or density. Table 1
Cat. (Al) Cat (Bl) Cocat MMAO shuttling
Ex. (μmol) (μmol) (μmol) (μmol agent (μmol) Yield (g) Mn Mw/Mn hexyls1
A* 0.06 - 0.066 0.3 0.1363 300502 3.32 -
B* - 0.1 0.110 0.5 0.1581 36957 1.22 2.5
C* 0.06 0.1 0.176 0.8 0.2038 45526 5.302 5.5
1 0.06 0.1 0.192 - DEZ (8.0) 0.1974 28715 1.19 4.8
2 0.06 0.1 0.192 - DEZ (80.0) 0.1468 2161 1.12 14.4
3 0.06 0.1 0.192 - TEA (8.0) 0.208 22675 1.71 4.6
4 0.06 0.1 0.192 _ TEA (80.0) 0.1879 3338 1.54 9.4 1 Ce or higher chain content per 1000 carbons 2 Bimodal molecular weight distribution
[173] Further characterizing data for the polymers of Table 1 are determined by reference to the figures. More specifically DSC and ATREF results show the following:
[174] The DSC curve for the polymer of example 1 shows a 115.7°C melting point (Tm) with a heat of fusion of 158.1 J/g. The corresponding CRYSTAF curve shows the tallest peak at 34.5°C with a peak area of 52.9 percent. The difference between the DSC Tm and the Tcrystaf is 81.2°C.
[175] The DSC curve for the polymer of example 2 shows a peak with a 109.70C melting point (Tm) with a heat of fusion of 214.0 J/g. The corresponding CRYSTAF curve shows the tallest peak at 46.2°C with a peak area of 57.0 percent. The difference between the DSC Tm and the Tcrystaf is 63.50C.
[176] The DSC curve for the polymer of example 3 shows a peak with a 120.70C melting point (Tm) with a heat of fusion of 160.1 J/g. The corresponding CRYSTAF curve shows the tallest peak at 66.1°C with a peak area of 71.8 percent. The difference between the DSC Tm and the Tcrystaf is 54.6°C.
[177] The DSC curve for the polymer of example 4 shows a peak with a 104.50C melting point (Tm) with a heat of fusion of 170.7 J/g. The corresponding CRYSTAF < curve shows the tallest peak at 30 0C with a peak area of 18.2 percent. The difference between the DSC Tm and the Tcrystaf is 74.50C.
[178] The DSC curve for Comparative Example A* shows a 90.00C melting point (Tm) with a heat of fusion of 86.7 J/g. The corresponding CRYSTAF curve shows the tallest peak at 48.5°C with a peak area of 29.4 percent. Both of these values are consistent with a resin that is low in density. The difference between the DSC Tm and the Tcrystaf is 41.8°C. [179] The DSC curve for Comparative Example B* shows a 129.8°C melting point (Tm) with a heat of fusion of 237.0 J/g. The corresponding CRYSTAF curve shows the tallest peak at 82.4°C with a peak area of 83.7 percent. Both of these values are consistent with a resin that is high in density. The difference between the DSC Tm and the Tcrystaf is 47.4°C.
[180] The DSC curve for Comparative Example C* shows a 125.3°C melting point (Tm) with a heat of fusion of 143.0 J/g. The corresponding CRYSTAF curve shows the tallest peak at 81.8 0C with a peak area of 34.7 percent as well as a lower crystalline peak at 52.4 0C. The separation between the two peaks is consistent with the presence of a high crystalline and a low crystalline polymer. The difference between the DSC Tm and the Tcrystaf is 43.50C.
Examples 5-19, Comparatives D-F, Continuous Solution Polymerization, Catalyst A1/B2 + DEZ [181] Continuous solution polymerizations are carried out in a computer controlled autoclave reactor equipped with an internal stirrer. Purified mixed alkanes solvent (Isopar™ E available from ExxonMobil Chemical Company), ethylene at 2.70 lbs/hour (1.22 kg/hour), 1-octene, and hydrogen (where used) are supplied to a 3.8 L reactor equipped with a jacket for temperature control and an internal thermocouple. The solvent feed to the reactor is measured by a mass-flow controller. A variable speed diaphragm pump controls the solvent flow rate and pressure to the reactor. At the discharge of the pump, a side stream is taken to provide flush flows for the catalyst and cocatalyst 1 injection lines and the reactor agitator. These flows are measured by Micro-Motion mass flow meters and controlled by control valves or by the manual adjustment of needle valves. The remaining solvent is combined with 1-octene, ethylene, and hydrogen (where used) and fed to the reactor. A mass flow controller is used to deliver hydrogen to the reactor as needed. The temperature of the solvent/monomer solution is controlled by use of a heat exchanger before entering the reactor. This stream enters the bottom of the reactor. The catalyst component solutions are metered using pumps and mass flow meters and are combined with the catalyst flush solvent and introduced into the bottom of the reactor. The reactor is run liquid- full at 500 psig (3.45 MPa) with vigorous stirring. Product is removed through exit lines at the top of the reactor. All exit lines from the reactor are steam traced and insulated. Polymerization is stopped by the addition of a small amount of water into the exit line along with any stabilizers or other additives and passing the mixture through a static mixer. The product stream is then heated by passing through a heat exchanger before devolatilization. The polymer product is recovered by extrusion using a devolatilizing extruder and water cooled pelletizer. Process details and results are contained in Table 2. Selected polymer properties are provided in Table 3.
66202B
Table 2 Process details for preparation of exemplary polymers
Cat Cat Al Cat B2 DEZ DEZ Cocat Cocat Poly
SoIv. H2 T Al2 Flow B23 Flow Cone Flow Cone. Flow [C2H4]/ Rate5 Conv Solids
Ex. kg/hr kg/hr seem1 °c ppm kg/hr ppm kg/hr % kg/hr ppm kg/hr [DEZ]4 kg/hr %6 % Eff.7
D* 1.63 12.7 29.90 120 142.2 0.14 - -- 0.19 0.32 820 0.17 536 1.81 88.8 11.2 95.2
E* " 9.5 5.00 " — -- 109 0.10 0.19 " 1743 0.40 485 1.47 89.9 11.3 126.8
F* " 11.3 251.6 " 71.7 0.06 30.8 0.06 — — " 0.11 - 1.55 88.5 10.3 257.7
5 " " " " 0.14 30.8 0.13 0.17 0.43 " 0.26 419 1.64 89.6 11.1 118.3
6 " 4.92 " " 0.10 30.4 0.08 0.17 0.32 " 0.18 570 1.65 89.3 11.1 172.7
7 " 21.70 " " 0.07 30.8 0.06 0.17 0.25 " 0.13 718 1.60 89.2 10.6 244..1
8 " 36.90 " " 0.06 " " " 0.10 " 0.12 1778 1.62 90.0 10.8 261.1
9 " 78.43 " " " " " " 0.04 " " 4596 1.63 90.2 10.8 267.9
10 " 0.00 123 71.1 0.12 30.3 0.14 0.34 0.19 1743 0.08 415 1.67 90.31 11.1 131.1
11 " " " 120 71.1 0.16 " 0.17 0.80 0.15 1743 0.10 249 1.68 89.56 11.1 100.6
12 " " " 121 71.1 0.15 " 0.07 " 0.09 1743 0.07 396 1.70 90.02 11.3 137.0
13 " " " 122 71.1 0.12 " 0.06 " 0.05 1743 0.05 653 1.69 89.64 11.2 161.9
14 " " " 120 71.1 0.05 " 0.29 " 0.10 1743 0.10 395 1.41 89.42 9.3 114.1
15 2.45 " " " 71.1 0.14 " 0.17 " 0.14 1743 0.09 282 1.80 89.33 11.3 121.3
16 " " " 122 71.1 0.10 " 0.13 " 0.07 1743 0.07 485 1.78 90.11 11.2 159.7
17 " " " 121 71.1 0.10 " 0.14 " 0.08 1743 " 506 1.75 89.08 11.0 155.6
18 0.69 " " 121 71.1 " " 0.22 " 0.11 1743 0.10 331 1.25 89.93 8.8 90.2
19 0.32 " " 122 71.1 0.06 " " " 0.09 1743 0.08 367 1.16 90.74 8.4 106.0
Comparative, not an example of the invention standard cm /min
[N-(2,6-di(l-methylethyl)phenyl)amido)(2-isopropylphenyl)(α-naphthalen-2-diyl(6-pyridin-2-diyl)methane)]hafnium dimethyl bis-(l-(2-methylcyclohexyl)ethyl)(2-oxoyl-3,5-di(t-butyl)phenyl)immino) zirconium dibenzyl molar ratio in reactor polymer production rate percent ethylene conversion in reactor efficiency, kg polymer/g M where g M = g Hf + g Zr
66202B
Figure imgf000066_0001
[182] The resulting polymers are tested by DSC and ATREF as with previous examples. Results are as follows:
[183] The DSC curve for the polymer of example 5 shows a peak with a 119.6 0C melting point (Tm) with a heat of fusion of 60.0 J/g. The corresponding CRYSTAF curve shows the tallest peak at 47.6°C with a peak area of 59.5 percent. The delta between the DSC Tm and the Tcrystaf is 72.00C.
[184] The DSC curve for the polymer of example 6 shows a peak with a 115.2 0C melting point (Tm) with a heat of fusion of 60.4 J/g. The corresponding CRYSTAF curve shows the tallest peak at 44.2°C with a peak area of 62.7 percent. The delta between the DSC Tm and the Tcrystaf is 71.00C.
[185] The DSC curve for the polymer of example 7 shows a peak with a 121.3 0C melting point with a heat of fusion of 69.1 J/g. The corresponding CRYSTAF curve shows the tallest peak at 49.2°C with a peak area of 29.4 percent. The delta between the DSC Tm and the Tcrystaf is 72.10C. [186] The DSC curve for the polymer of example 8 shows a peak with a 123.5 0C melting point (Tm) with a heat of fusion of 67.9 J/g. The corresponding CRYSTAF curve shows the tallest peak at 80.10C with a peak area of 12.7 percent. The delta between the DSC Tm and the Tcrystaf is 43.4°C.
[187] The DSC curve for the polymer of example 9 shows a peak with a 124.6 0C melting point (Tm) with a heat of fusion of 73.5 J/g. The corresponding CRYSTAF curve shows the tallest peak at 80.80C with a peak area of 16.0 percent. The delta between the DSC Tm and the Tcrystaf is 43.8°C.
[188] The DSC curve for the polymer of example 10 shows a peak with a 115.6 0C melting point (Tm) with a heat of fusion of 60.7 J/g. The corresponding CRYSTAF curve shows the tallest peak at 40.90C with a peak area of 52.4 percent. The delta between the DSC Tm and the Tcrystaf is 74.7°C.
[189] The DSC curve for the polymer of example 11 shows a peak with a 113.6 0C melting point (Tm) with a heat of fusion of 70.4 J/g. The corresponding CRYSTAF curve shows the tallest peak at 39.6°C with a peak area of 25.2 percent. The delta between the DSC Tm and the Tcrystaf is 74.10C. [190] The DSC curve for the polymer of example 12 shows a peak with a 113.2 0C melting point (Tm) with a heat of fusion of 48.9 J/g. The corresponding CRYSTAF curve shows no peak equal to or above 30 0C. (Tcrystaf for purposes of further calculation is therefore set at 300C). The delta between the DSC Tm and the Tcrystaf is 83.2°C. [191] The DSC curve for the polymer of example 13 shows a peak with a 114.4 0C melting point (Tm) with a heat of fusion of 49.4 J/g. The corresponding CRYSTAF curve shows the tallest peak at 33.8 0C with a peak area of 7.7 percent. The delta between the DSC Tm and the Tcrystaf is 84.4°C.
[192] The DSC for the polymer of example 14 shows a peak with a 120.8 0C melting point (Tm) with a heat of fusion of 127.9 J/g. The corresponding CRYSTAF curve shows the tallest peak at 72.9 0C with a peak area of 92.2 percent. The delta between the DSC Tm and the Tcrystaf is 47.9°C.
[193] The DSC curve for the polymer of example 15 shows a peak with a 114.3 0C melting point (Tm) with a heat of fusion of 36.2 J/g. The corresponding CRYSTAF curve shows the tallest peak at 32.3 0C with a peak area of 9.8 percent. The delta between the DSC Tm and the Tcrystaf is 82.00C.
[194] The DSC curve for the polymer of example 16 shows a peak with a 116.6 0C melting point (Tm) with a heat of fusion of 44.9 J/g. The corresponding CRYSTAF curve shows the tallest peak at 48.0 0C with a peak area of 65.0 percent. The delta between the DSC Tm and the Tcrystaf is 68.6°C.
[195] The DSC curve for the polymer of example 17 shows a peak with a 116.0 0C melting point (Tm) with a heat of fusion of 47.0 J/g. The corresponding CRYSTAF curve shows the tallest peak at 43.1 0C with a peak area of 56.8 percent. The delta between the DSC Tm and the Tcrystaf is 72.9°C. [196] The DSC curve for the polymer of example 18 shows a peak with a 120.5 0C melting point (Tm) with a heat of fusion of 141.8 J/g. The corresponding CRYSTAF curve shows the tallest peak at 70.0 0C with a peak area of 94.0 percent. The delta between the DSC Tm and the Tcrystaf is 50.5 0C.
[197] The DSC curve for the polymer of example 19 shows a peak with a 124.8 0C melting point (Tm) with a heat of fusion of 174.8 J/g. The corresponding CRYSTAF curve shows the tallest peak at 79.9 0C with a peak area of 87.9 percent. The delta between the DSC Tm and the Tcrystaf is 45.0 0C.
[198] The DSC curve for the polymer of Comparative Example D* shows a peak with a 37.3°C melting point (Tm) with a heat of fusion of 31.6 J/g. The corresponding CRYSTAF curve shows no peak equal to and above 300C. Both of these values are consistent with a resin that is low in density. The delta between the DSC Tm and the Tcrystaf is 7.3°C.
[199] The DSC curve for the polymer of Comparative Example E* shows a peak with a 124.0 0C melting point (Tm) with a heat of fusion of 179.3 J/g. The corresponding CRYSTAF curve shows the tallest peak at 79.3°C with a peak area of 94.6 percent. Both of these values are consistent with a resin that is high in density. The delta between the DSC Tm and the Tcrystaf is 44.6°C.
[200] The DSC curve for the polymer of Comparative Example F* shows a peak with a 124.8 0C melting point (Tm) with a heat of fusion of 90.4 J/g. The corresponding CRYSTAF curve shows the tallest peak at 77.6°C with a peak area of 19.5 percent. The separation between the two peaks is consistent with the presence of both a high crystalline and a low crystalline polymer. The delta between the DSC Tm and the Tcrystaf is 47.2°C. [201] Physical Property Testing [202] Polymer samples are evaluated for physical properties such as high temperature resistance properties, as evidenced by TMA temperature testing, pellet blocking strength, high temperature recovery, high temperature compression set and storage modulus ratio, G'(25°C)/G'(100°C). Several commercially available polymers are included in the tests: Comparative Example G* is a substantially linear ethylene/1-octene copolymer (AFFINITY®, available from The Dow Chemical Company), Comparative Example H* is an elastomeric, substantially linear ethylene/ 1-octene copolymer (AFFINITYOEG8100, available from The Dow Chemical Company), Comparative Example I* is a substantially linear ethylene/1-octene copolymer (AFFINIT Yd)PL 1840, available from The Dow Chemical Company), Comparative Example J* is a hydrogenated styrene/butadiene/styrene triblock copolymer (KRATON™ G1652, available from KRATON Polymers LLC), Comparative Example K* is a thermoplastic vulcanizate (TPV, a polyolefin blend containing dispersed therein a crosslinked elastomer). Results are presented in Table 4. Table 4 High Temperature Mechanical Properties
Figure imgf000070_0001
[203] In Table 4, Comparative Example F* (which is a physical blend of the two polymers resulting from simultaneous polymerizations using catalyst Al and Bl) has a 1 mm penetration temperature of about 700C, while Examples 5-9 have a 1 mm penetration temperature of 1000C or greater. Further, examples 10-19 all have a 1 mm penetration temperature of greater than 85°C, with most having 1 mm TMA temperature of greater than 900C or even greater than 1000C. This shows that the novel polymers have better dimensional stability at higher temperatures compared to a physical blend. Comparative Example J* (a commercial SEBS) has a good 1 mm TMA temperature of about 1070C, but it has very poor (high temperature 700C) compression set of about 100 percent and it also failed to recover (sample broke) during a high temperature (800C) 300 percent strain recovery. Thus the exemplified polymers have a unique combination of properties unavailable even in some commercially available, high performance thermoplastic elastomers. [204] Similarly, Table 4 shows a low (good) storage modulus ratio,
G'(25°C)/G'(100°C), for the inventive polymers of 6 or less, whereas a physical blend (Comparative Example F*) has a storage modulus ratio of 9 and a random ethylene/octene copolymer (Comparative Example G*) of similar density has a storage modulus ratio an order of magnitude greater (89). It is desirable that the storage modulus ratio of a polymer be as close to 1 as possible. Such polymers will be relatively unaffected by temperature, and fabricated articles made from such polymers can be usefully employed over a broad temperature range. This feature of low storage modulus ratio and temperature independence is particularly useful in elastomer applications such as in pressure sensitive adhesive formulations.
[205] The data in Table 4 also demonstrate that the polymers of the invention possess improved pellet blocking strength. In particular, Example 5 has a pellet blocking strength of 0 MPa, meaning it is free flowing under the conditions tested, compared to Comparatives F and G which show considerable blocking. Blocking strength is important since bulk shipment of polymers having large blocking strengths can result in product clumping or sticking together upon storage or shipping, resulting in poor handling properties. [206] High temperature (700C) compression set for the inventive polymers is generally good, meaning generally less than about 80 percent, preferably less than about 70 percent and especially less than about 60 percent. In contrast, Comparatives F, G, H and J all have a 700C compression set of 100 percent (the maximum possible value, indicating no recovery). Good high temperature compression set (low numerical values) is especially needed for applications such as gaskets, window profiles, o-rings, and the like.
66202B
Figure imgf000072_0001
1 Tested at 51 cm/minute
2 measured at 38°C for 12 hours
66202
[207] Table 5 shows results for mechanical properties for the new polymers as well as for various comparison polymers at ambient temperatures. It may be seen that the inventive polymers have very good abrasion resistance when tested according to ISO 4649, generally showing a volume loss of less than about 90 mm3, preferably less than about 80 mm3, and especially less than about 50 mm3. In this test, higher numbers indicate higher volume loss and consequently lower abrasion resistance.
[208] Tear strength as measured by tensile notched tear strength of the inventive polymers is generally 1000 mJ or higher, as shown in Table 5. Tear strength for the inventive polymers can be as high as 3000 mJ, or even as high as 5000 mJ. Comparative polymers generally have tear strengths no higher than 750 mJ.
[209] Table 5 also shows that the polymers of the invention have better retractive stress at 150 percent strain (demonstrated by higher retractive stress values) than some of the comparative samples. Comparative Examples F*, G* and H* have retractive stress value at 150 percent strain of 400 kPa or less, while the inventive polymers have retractive stress values at 150 percent strain of 500 kPa (Ex. 11) to as high as about 1100 kPa (Ex. 17). Polymers having higher than 150 percent retractive stress values would be quite useful for elastic applications, such as elastic fibers and fabrics, especially nonwoven fabrics. Other applications include diaper, hygiene, and medical garment waistband applications, such as tabs and elastic bands.
[210] Table 5 also shows that stress relaxation (at 50 percent strain) is also improved (less) for the inventive polymers as compared to, for example, Comparative Example G*. Lower stress relaxation means that the polymer retains its force better in applications such as diapers and other garments where retention of elastic properties over long time periods at body temperatures is desired.
66202
Optical Testing
Figure imgf000074_0001
[211] The optical properties reported in Table 6 are based on compression molded films substantially lacking in orientation. Optical properties of the polymers may be varied over wide ranges, due to variation in crystallite size, resulting from variation in the quantity of chain shuttling agent employed in the polymerization. Extractions of Multi-Block Copolymers
[212] Extraction studies of the polymers of examples 5, 7 and Comparative Example E* are conducted. In the experiments, the polymer sample is weighed into a glass fritted extraction thimble and fitted into a Kumagawa type extractor. The extractor with sample is purged with nitrogen, and a 500 mL round bottom flask is charged with 350 mL of diethyl ether. The flask is then fitted to the extractor. The ether is heated while being stirred. Time is noted when the ether begins to condense into the thimble, and the extraction is allowed to proceed under nitrogen for 24 hours. At this time, heating is stopped and the solution is allowed to cool. Any ether remaining in the extractor is returned to the flask. The ether in the flask is evaporated under vacuum at ambient temperature, and the resulting solids are purged dry with nitrogen. Any residue is transferred to a weighed bottle using successive washes of hexane. The combined hexane washes are then evaporated with another nitrogen 66202
purge, and the residue dried under vacuum overnight at 400C. Any remaining ether in the extractor is purged dry with nitrogen.
[213] A second clean round bottom flask charged with 350 mL of hexane is then connected to the extractor. The hexane is heated to reflux with stirring and maintained at reflux for 24 hours after hexane is first noticed condensing into the thimble. Heating is then stopped and the flask is allowed to cool. Any hexane remaining in the extractor is transferred back to the flask. The hexane is removed by evaporation under vacuum at ambient temperature, and any residue remaining in the flask is transferred to a weighed bottle using successive hexane washes. The hexane in the flask is evaporated by a nitrogen purge, and the residue is vacuum dried overnight at 400C.
[214] The polymer sample remaining in the thimble after the extractions is transferred from the thimble to a weighed bottle and vacuum dried overnight at 400C. Results are contained in Table 7. Table 7
Figure imgf000075_0001
Additional Polymer Examples 19 A-F, Continuous Solution Polymerization, Catalyst A1/B2 + DEZ
[215] Continuous solution polymerizations are carried out in a computer controlled well-mixed reactor. Purified mixed alkanes solvent (Isopar™ E available from ExxonMobil Chemical Company), ethylene, 1-octene, and hydrogen (where used) are combined and fed to a 27 gallon reactor. The feeds to the reactor are measured by mass-flow controllers. The temperature of the feed stream is controlled by use of a glycol cooled heat exchanger before entering the reactor. The catalyst component solutions are metered using pumps and mass flow meters. The reactor is run liquid-full at approximately 550 psig pressure. Upon exiting the reactor, water and additive are injected in the polymer solution. The water hydrolyzes the catalysts, and terminates the polymerization reactions. The post reactor solution is then heated in preparation for a two- stage devolatization. The solvent and unreacted monomers 66202
are removed during the devolatization process. The polymer melt is pumped to a die for underwater pellet cutting.
[216] Process details and results are contained in Table 7a. Selected polymer properties are provided in Tables 7b-7c.
66202
Table 7a Polymerization Conditions
Figure imgf000077_0001
1 standard cm3/min
2 [N-(2,6-di(l-methylethyl)phenyl)amido)(2-isopropylphenyl)(α-naphthalen-2-diyl(6-pyridin-2-diyl)methane)]hafnium
3 bis-(l-(2-methylcyclohexyl)ethyl)(2-oxoyl-3,5-di(t-butyl)phenyl)immino) zirconium dimethyl
4 ppm in final product calculated by mass balance
5 polymer production rate
6 weight percent ethylene conversion in reactor
7 efficiency, kg polymer/g M where g M = g Hf + g Z
66202
Table 7b Polymer Physical properties
Figure imgf000078_0001
Table 7c Average Block Index For exemplary polymers
Example Zn/C9- Average BI
Polymer F 0 0
Polymer 8 0.56 0.59
Polymer 19a 1.3 0.62
Polymer 5 2.4 0.52
Polymer 19b 0.56 0.54
Polymer 19h 3.15 0.59
1. Additional information regarding the calculation of the block indices for various polymers is disclosed in U.S. Patent Application Serial No.11/376,835, entitled "Ethylene/α-Olefin Block Interpolymers", filed on March 15, 2006, in the name of Colin L. P. Shan, Lonnie Hazlitt, et. al. and assigned to Dow Global Technologies Inc., the disclosure of which is incorporated by reference herein in its entirety.
2. Zn/C2 *1000 = (Zn feed flow*Zn concentration/1000000/Mw of Zn)/(Total Ethylene feed flow*(l-fractional ethylene conversion rate)/Mw of Ethylene)* 1000. Please note that "Zn" in "Zn/C2*1000" refers to the amount of zinc in diethyl zinc ("DEZ") used in the polymerization process, and "C2" refers to the amount of ethylene used in the polymerization process.
66202
Example 20- Ethylene/α-olefin Interpolymer
[217] Continuous solution polymerization is carried out in a computer controlled well-mixed reactor. Purified mixed alkanes solvent (ISOPAR™ E available from ExxonMobil Chemical Company), ethylene, 1-octene, and hydrogen (if applicable) is combined and fed to a 102 L reactor. The feeds to the reactor are measured by mass-flow controllers. The temperature of the feed stream is controlled by use of a glycol cooled heat exchanger before entering the reactor. The catalyst component solutions are metered using pumps and mass flow meters. The reactor is run liquid-full at approximately 550 psig pressure. Upon exiting the reactor, water and additive are injected in the polymer solution. The water hydrolyzes the catalysts, and terminates the polymerization reactions. The post reactor solution is then heated in preparation for a two-stage devolatilization. The solvent and unreacted monomers are removed during the devolatilization process. The polymer melt is pumped to a die for underwater pellet cutting. Process details and results are contained in Tables 8 and 9. Testing of Example 20
[218] Standard CRYSTAF Method. Branching distributions were determined by crystallization analysis fractionation (CRYSTAF) using a CRYSTAF 200 unit commercially available from PolymerChar, Valencia, Spain. The samples were dissolved in 1,2,4- trichlorobenzene at 1600C (0.66 mg/mL) for 1 hour and stabilized at 950C for 45 minutes. The sampling temperatures ranged from 95 to 300C at a cooling rate of 0.2°C/min. An infrared detector was used to measure the polymer solution concentrations. The cumulative soluble concentration was measured as the polymer crystallized while the temperature was decreased. The analytical derivative of the cumulative profile reflected the short chain branching distribution of the polymer.
[219] The CRYSTAF peak temperature and area were identified by the peak analysis module included in the CRYSTAF Software (Version 2001. b, PolymerChar, Valencia, Spain). The CRYSTAF peak finding routine identified a peak temperature as a maximum in the dW/dT curve and the area between the largest positive inflections on either side of the identified peak in the derivative curve. To calculate the CRYSTAF curve, the preferred processing parameters were with a temperature limit of 700C and with smoothing parameters above the temperature limit of 0.1 , and below the temperature limit of 0.3. The CRYSTAF peak temperature and the peak area of each example are listed in Table 9 below. 66202
[220] DSC Standard Method Differential Scanning Calorimetry results were determined using a TAI model QlOOO DSC equipped with an RCS cooling accessory and an autosampler. A nitrogen purge gas flow of 50 ml/min was used. The sample was pressed into a thin film and melted in the press at about 1750C and then air-cooled to room temperature (25°C). The sample (-3-10 mg) was then cut into a 6 mm diameter disk, accurately weighed, placed in a light aluminum pan (-50 mg), and then crimped shut. The thermal behavior of the sample was investigated with the following temperature profile. The sample was rapidly heated to 18O0C and held isothermal for 3 minutes in order to remove any previous thermal history. The sample was then cooled to -4O0C at 10°C/min cooling rate and held at -4O0C for 3 minutes. The sample was then heated to 150 0C at 10°C/minute heating rate. The cooling and second heating curves were recorded. The melting peak (Tm) and cooling peak (Tc) were determined.
[221] Where a minor melting or cooling peak was observed, the peak was noted as Tm2 or Tc2. The heat of fusion, Tm and Tc of each example are listed in Table 9 below.
[222] GPC Method. The gel permeation chromatographic system consisted of either a Polymer Laboratories Model PL-210 or a Polymer Laboratories Model PL- 220 instrument. The column and carousel compartments were operated at 1400C. Three Polymer Laboratories 10-micron Mixed-B columns were used. The solvent was 1 ,2,4-trichlorobenzene. The samples were prepared at a concentration of 0.1 grams of polymer in 50 milliliters of solvent containing 200 ppm of butylated hydroxytoluene (BHT). Samples were prepared by agitating lightly for 2 hours at 1600C. The injection volume used was 100 microliters and the flow rate was 1.0 ml/minute.
[223] Calibration of the GPC column set was performed with 21 narrow molecular weight distribution polystyrene standards with molecular weights ranging from 580 to 8,400,000, daltons arranged in 6 "cocktail" mixtures with at least a decade of separation between individual molecular weights. The standards were purchased from Polymer Laboratories (Shropshire, UK). The polystyrene standards were prepared at 0.025 grams in 50 milliliters of solvent for molecular weights equal to or greater than 1,000,000, and 0.05 grams in 50 milliliters of solvent for molecular weights less than 1,000,000. The polystyrene standards were dissolved at 800C with gentle agitation for 30 minutes. The narrow standards mixtures were run first and in order of decreasing highest molecular weight component to minimize degradation. The polystyrene standard peak molecular weights were converted to 66202
polyethylene molecular weights using the following equation (as described in Williams and Ward, /. Polym. ScL, Polym. Let., 6, 621 (1968)): Mpoiyethyiene = 0.431(Mpoiystyrene). Polyetheylene equivalent molecular weight calculations are performed using Viscotek TriSEC software Version 3.0. In Table 9, the weight average molecular weight Mw, the number average molecular weight Mn, and their ratio Mw/Mn are reported.
[224] Density. Samples for density measurement were prepared according to ASTM D 1928. Density measurements were made within one hour of sample pressing using ASTM D792, Method B, which is incorporated herein by reference. The density of each example is listed in Table 9 below.
[225] Melt Index. Melt index, I2, was measured in accordance with ASTM D 1238,
Condition 190°C/2.16 kg. Melt index, I10, is also measured in accordance with ASTM D 1238, Condition 190°C/10 kg. The I2, 110 and I10/I2 ratio of each example are listed in Table 9 below.
Table 8. Process Conditions and Results for Example 20.
Figure imgf000082_0001
1 standard cm3/min
2 [N-(2,6-di(l-methylethyl)phenyl)amido)(2-isopropylphenyl)(α-naphthalen-2-diyl(6-pyridin-2-diyl)methane)]hafnium dimethyl
3 bis-(l-(2-methylcyclohexyl)ethyl)(2-oxoyl-3,5-di(t-butyl)phenyl)immino) zirconium dibenzyl
4. molar ratio in reactor
5. polymer production rate
6. percent ethylene conversion in reactor
7 efficiency, kg polymer/g M where g M = g Hf + g Zr
10
15 Table 9. Various Physical Properties of Example 20
Figure imgf000082_0002
66202
General Procedure for the Preparation of Adhesive Formulations
[226] The adhesive formulations are prepared using a Sigma blade mixer. A 1 kg capacity Readco Sigma blade mixer attached to a Sterlco Hot Oil Temperature Control Unit is pre-heated for 45 minutes using oil at 35O0F. Polymer Example 20 is charged under nitrogen and mixed for 15 minutes. Tackifier is added in quarters, and the batch is mixed an additional 45 minutes before addition of oil. Oil is added slowly, and the batch is mixed for an additional 30 minutes after all components are added. A 0.7 kg batch is prepared.
[227] Preferred ranges of viscosity for the formulated adhesive are from about 100 to about 300,000 cP at 3500F (177°C) as measured by Brookfield viscosity, more preferably from about 100 to about 150,000 cP, and most preferably from about 100 to about 50,000 cP, all of which are measured at 3500F (177°C).
Adhesive test procedures
Brookfield Viscosity
[228] Melt viscosity is determined by ASTM D3236, which is incorporated herein by reference, using a Brookfield Laboratories D VII+ Viscometer equipped with disposable aluminum sample chambers. In general, a SC-31 spindle is used, suitable for measuring viscosities in the range of from 30 to 100,000 centipoise (cP). If the viscosity is outside this range, an alternate spindle should be used which is suitable for the viscosity of the polymer. A cutting blade is employed to cut samples into pieces small enough to fit into the 1 inch wide, 5 inches long samples chamber. The disposable tube is charged with 8-9 grams of polymer. The sample is placed in the chamber, which is in turn inserted into a Brookfield Thermosel and locked into place with bent needle-nose pliers. The sample chamber has a notch on the bottom that fits in the bottom of the Brookfield Thermosel to ensure that the chamber is not allowed to turn when the spindle is inserted and spinning. The sample is heated to the desired temperature (170°C/338°F). The viscometer apparatus is lowered and the spindle submerged into the sample chamber. Lowering is continued until brackets on the viscometer align on the Thermosel. The viscometer is turned on, and set to a shear rate which leads to a torque reading in the range of 40 to 70 percent. Readings are taken every minute for about 15 minutes, or until the values stabilize, and then the final reading is recorded.
Peel Test Methods 66202
Polyethylene/nonwoven laminates are peeled apart using an Instron Materials Tester set at a peel rate of 300 mm/minute and the average force recorded for 33 seconds or 165 mm of material in pounds per linear inch (pli). Twenty samples of each laminate are peeled and the average of the 20 measurements are recorded along with the standard deviation. Initial peel means that the laminate is peeled at room temperature after equilibrating at room temperature for 24 hours. Room Temperature Aged peel means that the laminate is aged at room temperature for 24 hrs, then aged for an additional two weeks before peeling. 400C Aged Peel means that the laminate is aged at room temperature for 24 hours, then at 400C for two weeks and then equilibrated at room temperature for 24 hours and then peeled. The 370C peel means conditioning the bonds for 24 hours at RT and then placing the constructs in a chamber set at 370C for one hour and peeling them at 370C.
Table 10 - Adhesive Formulations and Viscosities
Figure imgf000084_0001
1 - Eastotac HlOOL
2 - Kaydol oil
* - pph based on total parts of adhesive formulation
Spiral Spray Bond Testing
Table 11 - Spiral Spray Conditions and Peel Results
Figure imgf000084_0002
66202
[229] Adhesive formulations and viscosities are given in Table 10. Each adhesive formulation is applied to a polyethylene backsheet, DH215 1 mil (Clopay), such as may be used in a diaper construction, using a 0.020" spiral spray nozzle of an Acumeter Laboratories Spray Coater Model CL310.5, equipped with Dittberner applicators and a nozzle to PE gap of 1.25 inches, at temperatures indicated in Table 11, and a line speed of 350 ft/min. Other processing parameters are also shown in Table 11. Air pressure at the nozzle is measured in pounds per square inch (psi). Then, a spunbond polypropylene nonwoven sheet, BBA SB 603 16.9 gsm (BBA Nonwovens Simpsonville Inc.) is pressed against the adhesive formulation side of the backsheet to form a laminate. As may be seen in Table 11 above, Formulation 1 may be applied at a significantly lower temperature with equal or better results than that of Formulation A, which could not be applied at 250 0F. In particular, it may be seen that the initial peel strength of Formulation 1 is 5.5 pounds per linear inch and increases with aging to 15.2 pli and 14.2 pli. All of which would be useful in a diaper construction or similar such personal hygiene article. [230] While the invention has been described with respect to a limited number of embodiments, the specific features of one embodiment should not be attributed to other embodiments of the invention. No single embodiment is representative of all aspects of the invention. In some embodiments, the compositions or methods may include numerous compounds or steps not mentioned herein. In other embodiments, the compositions or methods do not include, or are substantially free of, any compounds or steps not enumerated herein. Variations and modifications from the described embodiments exist. Finally, any number disclosed herein should be construed to mean approximate, regardless of whether the word "about" or "approximately" is used in describing the number. The appended claims intend to cover all those modifications and variations as falling within the scope of the invention.

Claims

66202What is claimed is:
1. An adhesive composition comprising:
(i) about 10 wt% to about 40 wt%, based on total weight of the adhesive composition, of at least one ethylene/α-olefin block copolymer, wherein the ethylene/α- olefin block copolymer comprises greater than 50 mol% ethylene based on total weight of the copolymer and:
(a) has a Mw/Mn from about 1.7 to about 3.5, at least one melting point, Tm, in degrees Celsius, and a density, d, in grams/cubic centimeter, wherein the numerical values of Tm and d correspond to the relationship: Tm > -2002.9 + 4538.5(d) - 2422.2(d)2, or
(b) has a Mw/Mn from about 1.7 to about 3.5, and is characterized by a heat of fusion, ΔH in J/g, and a delta quantity, ΔT, in degrees Celsius, defined as the temperature difference between the tallest DSC peak and the tallest CRYSTAF peak, wherein the numerical values of ΔT and ΔH have the following relationships: ΔT > -0.1299(ΔH) + 62.81 for ΔH greater than zero and up to 130 J/g,
ΔT > 48°C for ΔH greater than 130 J/g , wherein the CRYSTAF peak is determined using at least 5 percent of the cumulative polymer, and if less than 5 percent of the polymer has an identifiable CRYSTAF peak, then the CRYSTAF temperature is 300C; or (c) is characterized by an elastic recovery, Re, in percent at 300 percent strain and 1 cycle measured with a compression-molded film of the ethylene/α- olefin interpolymer, and has a density, d, in grams/cubic centimeter, wherein the numerical values of Re and d satisfy the following relationship when ethylene/α-olefin interpolymer is substantially free of a cross-linked phase: Re >1481-1629(d); or
(d) has a molecular fraction which elutes between 400C and 1300C when fractionated using TREF, characterized in that the fraction has a molar comonomer content of at least 5 percent higher than that of a comparable random ethylene interpolymer fraction eluting between the same temperatures, wherein said comparable random ethylene interpolymer has the same comonomer(s) and has a melt 66202
index, density, and molar comonomer content (based on the whole polymer) within 10 percent of that of the ethylene/α-olefin interpolymer; or
(e) has a storage modulus at 25°C, G'(25°C), and a storage modulus at 1000C, C(IOO0C), wherein the ratio of G'(25°C) to C(IOO0C) is in the range of about 1 : 1 to about 9: 1 ; or
(f) has a molecular fraction which elutes between 400C and 1300C when fractionated using TREF, characterized in that the fraction has a block index of at least 0.5 and up to about 1 ; or
(g) has an average block index greater than zero and up to about 1.0 and a molecular weight distribution, Mw/Mn, greater than about 1.3; and,
(ii) about 30 wt% to about 70 wt%, based on total weight of the adhesive composition, of at least one tackifier; and,
(iii) about 10 wt% to about 30 wt%, based on total weight of the adhesive composition, of an oil or a low molecular weight polymer.
2. The composition of Claim 1, wherein the composition is a hot melt adhesive composition, a pressure sensitive adhesive composition or a thermoplastic marking composition.
3. The composition of Claim 1 or Claim 2, wherein the tackifier is present in the range from about 15 wt% to about 75 wt %, by weight of the total composition.
4. The composition of any of the preceding claims, wherein the tackifier has a R&B softening point equal to or greater than 8O0C.
5. The composition of any of the preceding claims, wherein the oil is present in an amount in the range of between 0 wt% to about 30 wt%, by weight of the total composition.
6. The composition of any of the preceding claims, further comprising at least one additive selected from the group consisting of plasticizers, waxes, antioxidants, UV stabilizers, colorants or pigments, fillers, flow aids, coupling agents, crosslinking agents, surfactants, solvents, fragrances and combinations thereof. 66202
7. The composition of any of the preceding claims, wherein the ethylene/α- olefin interpolymer has a density of about 0.85 to about 0.88 g/cc and preferably of about 0.86 to about 0.875 g/cc.
8. The composition of any of the preceding claims, wherein the ethylene/α- olefin interpolymer has a melt index of about 5 to about 50 g/10 minutes and preferably of about 10 to about 30 g/10 minutes.
9. The composition of any of the preceding claims, wherein the ethylene/α- olefin interpolymer is present in a range from about 10% to abut 75% by weight of the total composition.
10. An article comprising a substrate coated with the composition of any of the preceding claims.
11. The article of claim 10, wherein the article is a medical device, a bandage, or a hygiene article.
12. A method of applying the composition of any of Claims 1 to 9 to a substrate comprising: applying the composition to the substrate at a temperature in the range of from about 100 0C to about 150 0C, preferably from about 115 0C to about 140 0C and more preferably from about 120 0C to about 130 0C.
13. The method of Claim 12 comprising applying the adhesive via spiral spray in non-contact mode or slot die coating in contact mode.
PCT/US2008/073831 2007-08-24 2008-08-21 ADHESIVES MADE FROM INTERPOLYMERS OF ETHYLENE/α-OLEFINS WO2009029476A1 (en)

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US12/674,198 US8222339B2 (en) 2007-08-24 2008-08-21 Adhesives made from interpolymers of ethylene/alpha-olefins
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