WO2021040760A1 - Polyolefin compositions for films - Google Patents

Polyolefin compositions for films Download PDF

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Publication number
WO2021040760A1
WO2021040760A1 PCT/US2019/060688 US2019060688W WO2021040760A1 WO 2021040760 A1 WO2021040760 A1 WO 2021040760A1 US 2019060688 W US2019060688 W US 2019060688W WO 2021040760 A1 WO2021040760 A1 WO 2021040760A1
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polyolefin composition
mpa
film
determined
astm
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PCT/US2019/060688
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French (fr)
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Luis A. SOTOMAYOR
George J. Pehlert
Mosha H. ZHAO
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Exxonmobil Chemical Patents Inc.
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Publication of WO2021040760A1 publication Critical patent/WO2021040760A1/en

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/06Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/32Layered products comprising a layer of synthetic resin comprising polyolefins
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/18Manufacture of films or sheets
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/04Homopolymers or copolymers of ethene
    • C08L23/06Polyethene
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/04Homopolymers or copolymers of ethene
    • C08L23/08Copolymers of ethene
    • C08L23/0807Copolymers of ethene with unsaturated hydrocarbons only containing more than three carbon atoms
    • C08L23/0815Copolymers of ethene with aliphatic 1-olefins
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/10Homopolymers or copolymers of propene
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00Layers arrangement
    • B32B2250/24All layers being polymeric
    • B32B2250/242All polymers belonging to those covered by group B32B27/32
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00Layers arrangement
    • B32B2250/40Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2270/00Resin or rubber layer containing a blend of at least two different polymers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2439/00Containers; Receptacles
    • B32B2439/70Food packaging
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2323/00Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2323/02Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
    • C08J2323/04Homopolymers or copolymers of ethene
    • C08J2323/06Polyethene
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2323/00Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2323/02Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
    • C08J2323/04Homopolymers or copolymers of ethene
    • C08J2323/08Copolymers of ethene
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2323/00Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2323/02Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
    • C08J2323/10Homopolymers or copolymers of propene
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2323/00Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2323/02Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
    • C08J2323/10Homopolymers or copolymers of propene
    • C08J2323/12Polypropene
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2423/00Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2423/02Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
    • C08J2423/10Homopolymers or copolymers of propene
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2423/00Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2423/02Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
    • C08J2423/10Homopolymers or copolymers of propene
    • C08J2423/12Polypropene
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2203/00Applications
    • C08L2203/16Applications used for films

Definitions

  • polymers with good processability are desired to achieve commercial throughput rates, while maintaining sufficient toughness.
  • desirable physical properties for the final film product include stiffness, roughness, and/or tear strength.
  • High density polyethylene (HDPE) and polypropylene (PP) are two possible blending partners for polyethylene (PE) film to increase the stiffness.
  • PE polyethylene
  • there are limited cases for selecting PP as a blending partner because PP and PE have different crystallinity phases and types, and there is little to no co-crystallinity between PP and PE.
  • Lean blending PP with PE can increase PE film stiffness while decreasing the PE film toughness at same time.
  • PP contains many advantages versus HDPE, like much lower density, higher stiffness, and higher heat resistance. If PP can be used in a majority PE formulation to improve the film stiffness part while still maintaining toughness properties, it will show huge value for industrial and food package down-gauging of the PP/PE film structure. [0005] Therefore, there is a need for improved polyolefin compositions having a relatively high stiffness and an enhanced toughness, and methods for forming films from the polyolefin compositions.
  • polyolefin compositions that contain one or more broad orthogonal composition distribution (BOCD) polyethylenes and one or more polypropylenes.
  • the polyolefin composition comprises (or consists of, or consists essentially of) about 40 wt% to about 95 wt% of the BOCD polyethylene and about 5 wt% to about 60 wt% of a polypropylene, by weight of the polyolefin composition.
  • the BOCD polyethylene contains about 70 mol% to about 100 mol% of ethylene and has a density of about 0.91 g/cm 3 to about 0.925 g/cm 3 , in accordance with ASTM D-4703 and ASTM D-1505/ISO 1183 and a branching index (gVis) of 0.98 or greater.
  • the polyolefin composition has a 1% secant flexural modulus in the machine direction (MD) of greater than 200 MPa and a 1 % secant flexural modulus in the transverse direction (TD) of greater than 200 MPa, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm.
  • the polyolefin composition also has a Tensile at Yield strength in the MD of greater than 8.5 MPa and a Tensile at Yield strength in the TD of greater than 9.7 MPa, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm, as determined by ASTM D882.
  • a polyolefin composition comprises (or consists of, or consists essentially of) about 40 wt% to about 95 wt% of a BOCD polyethylene containing about 70 mol% to about 100 mol% of ethylene and about 5 wt% to about 60 wt% of a polypropylene, by weight of the polyolefin composition.
  • the BOCD polyethylene contains about 70 mol% to about 100 mol% of ethylene and having a density of about 0.91 g/cm 3 to about 0.925 g/cm 3 , in accordance with ASTM D-4703 and ASTM D-1505/ISO 1183.
  • the polyolefin composition has a 1% secant flexural modulus in the MD of greater than 200 MPa and a 1% secant flexural modulus in the TD of greater than 200 MPa, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm.
  • the polyolefin composition also has a Tensile at Yield strength in the MD of greater than 8.5 MPa and a Tensile at Yield strength in the TD of greater than 9.7 MPa, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm, as determined by ASTM D882.
  • the polyolefin composition also has an Elmendorf tear in the MD of about 9.5 g/pm to about 20 g/pm and an Elmendorf tear in the TD of about 9 g/pm to about 20 g/pm, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm.
  • a flexible food package includes the polyolefin composition as described and discussed herein.
  • the polyolefin composition includes from about 5 wt% to about 50 wt% of the polypropylene and from about 50 wt% to about 95 wt% of the polyethylene, each by weight of the polyolefin composition, and the polyolefin composition is a film that is optionally laminated to one or more additional polymeric films.
  • a method of forming a film includes extruding the polyolefin composition through one or more die openings to form the film.
  • the method can include extruding the polyolefin composition containing one or more BOCD polyethylenes and one or more polypropylenes through the die opening to form the film and cooling the film at a distance away from the die opening to produce a finished film.
  • the film can be cooled by blowing air, nitrogen, argon, or other gases on at least a portion of the film.
  • FIGS. 1A and IB are TREF contour plots which are used to determine if a polyethylene is a BOCD PE polymer (FIG. 1 A) as opposed to a conventional PE polymer (FIG. IB).
  • FIG. 2 is a plot of Compositional Distribution (molecular weight as a function of branching) plotting (MWI/MW2) values as a function of (Twi-Tw2) for BOCD PE polymers and conventional PE polymer.
  • FIGS. 3A and 3B are plots of Stiffness for films containing polyolefin compositions with varying concentrations of broad orthogonal composition distribution (BOCD) polyethylene and polypropylenes of different compositions, according to one or more embodiments described and discussed herein.
  • BOCD broad orthogonal composition distribution
  • FIGS. 4A and 4B are plots of Tensile at Yield strength for films containing polyolefin compositions with varying concentrations of BOCD polyethylene and polypropylenes of different compositions, according to one or more embodiments described and discussed herein.
  • FIGS. 5A and 5B are plots of Tear strength for films containing polyolefin compositions with varying concentrations of BOCD polyethylene and polypropylenes of different compositions, according to one or more embodiments described and discussed herein.
  • FIGS. 4A and 4B are plots of Tensile at Yield strength for films containing polyolefin compositions with varying concentrations of BOCD polyethylene and polypropylenes of different compositions, according to one or more embodiments described and discussed herein.
  • FIG. 6A and 6B are plots of Elongation at Break strength for films containing polyolefin compositions with varying concentrations of BOCD polyethylene and polypropylenes of different compositions, according to one or more embodiments described and discussed herein.
  • FIG. 7 is a plot of Dart Drop strength for films containing polyolefin compositions with varying concentrations of BOCD polyethylene and polypropylenes of different compositions, according to one or more embodiments described and discussed herein.
  • FIG. 8 is a plot of Haze for films containing polyolefin compositions with varying concentrations of BOCD polyethylene and polypropylenes of different compositions, according to one or more embodiments described and discussed herein.
  • the present disclosure provides polyolefin compositions that contain one or more broad orthogonal composition distribution (BOCD) polyethylenes and one or more polypropylenes.
  • the polypropylene can be or include one or more high melt strength polypropylenes (HMS PPs), one or more trimmed polypropylenes (tPPs), one or more broad molecular weight distribution (BMWD or BWD) PPs, one or more homopolymers of PP (hPP), impact copolymers (ICPs) of PP, random copolymer (RCPs) of PP, or any combination thereof.
  • HMS PPs high melt strength polypropylenes
  • tPPs trimmed polypropylenes
  • BMWD or BWD broad molecular weight distribution
  • ICPs impact copolymers
  • RCPs random copolymer
  • Films made from such compositions can have a stiffness (1% secant flexural modulus) in the machine direction (MD) and the transverse direction (TD) of greater than 200 MPa, or greater than 225 MPa, such as about 250 MPa to about 1,000 MPa and a Tensile at Yield strength in the MD of greater than 8.5 MPa and a Tensile at Yield strength in the TD of greater than 9.7 MPa.
  • MD machine direction
  • TD transverse direction
  • the following types of layers and films contain the polyolefin composition: a monolayer containing the polyolefin composition, a two-layer film having a layer containing the polyolefin composition and a layer containing a BOCD polyethylene, and several configurations of three-layer films where one, two, or three layers contain the polyolefin composition.
  • the three-layer film has a core layer containing the polyolefin composition disposed between two skin layers containing a BOCD polyethylene.
  • the three-layer film has a core layer containing the polyolefin composition disposed between two skin layers containing the polyolefin composition.
  • the three-layer film has a core layer containing a BOCD polyethylene disposed between two skin layers containing the polyolefin composition.
  • the polyolefin composition contains from about 30 wt%, about 35 wt%, about 40 wt%, about 45 wt%, or about 50 wt% to about 55 wt%, about 60 wt%, about 65 wt%, about 70 wt%, about 75 wt%, about 80 wt%, about 85 wt%, about 88 wt%, about 90 wt%, about 92 wt%, or about 95 wt% of the BOCD polyethylene, by weight of the polyolefin composition.
  • the polyolefin composition contains from about 30 wt% to about 95 wt%, about 35 wt% to about 95 wt%, about 40 wt% to about 95 wt%, about 50 wt% to about
  • 80 wt% about 35 wt% to about 80 wt%, about 40 wt% to about 80 wt%, about 50 wt% to about 80 wt%, about 60 wt% to about 80 wt%, about 70 wt% to about 80 wt%, about 75 wt% to about
  • the polyolefin composition contains from about 5 wt%, about
  • the polyolefin composition contains from about 5 wt% to about 70 wt%, about 5 wt% to about 60 wt%, about 5 wt% to about 50 wt%, about 5 wt% to about 45 wt%, about 5 wt% to about 40 wt%, about 5 wt% to about 35 wt%, about 5 wt% to about 30 wt%, about 5 wt% to about 25 wt%, about 5 wt% to about 20 wt%, about 5 wt% to about 15 wt%, about 5 wt% to about 10 wt%, about 10 wt% to about 70 wt%, about 10 wt% to about 60 wt%, about 10 wt% to about 50 wt%, about 10 wt% to about 45 wt%, about 10 wt% to about 40 wt%, about 10 wt% to about 35 wt%, about 10 wt%,
  • the polyolefin composition contains from about 40 wt% to about 95 wt% of the BOCD polyethylene and about 5 wt% to about 60 wt% of a polypropylene, by weight of the polyolefin composition. In some examples, the polyolefin composition contains about 50 wt% to about 90 wt% of the BOCD polyethylene and about 10 wt% to about 50 wt% of a polypropylene, by weight of the polyolefin composition.
  • the polyolefin composition contains about 55 wt% to about 80 wt% of the BOCD polyethylene and about 20 wt% to about 45 wt% of a polypropylene, by weight of the polyolefin composition. In some examples, the polyolefin composition contains about 70 wt% to about 88 wt% of the BOCD polyethylene and about 12 wt% to about 30 wt% of a polypropylene, by weight of the polyolefin composition.
  • the polyolefin composition contains about 60 wt% to about 75 wt% of the BOCD polyethylene and about 25 wt% to about 40 wt% of a polypropylene, by weight of the polyolefin composition.
  • a monolayer containing the polyolefin composition has relatively high values for Stiffness (1% secant flexural modulus), in each of the MD and the TD, independently.
  • the polyolefin composition has a 1% secant flexural modulus MD (in the machine direction) of greater than 200 MPa, greater than 225 MPa, greater than 250 MPa, or greater than 275 MPa, such as about 300 MPa, about 400 MPa, about 500 MPa, or about 600 MPa to about 700 MPa, about 800 MPa, about 900 MPa, about 1,000 MPa, about 1,200 MPa, about 1,500 MPa or greater, as determined if a layer (e.g., monolayer or core layer) of the polyolefin composition has a thickness of about 50 pm.
  • a layer e.g., monolayer or core layer
  • the polyolefin composition has a 1% secant flexural modulus MD of greater than or about 200 MPa to about 1,500 MPa, greater than or about 225 MPa to about 1,500 MPa, greater than or about 250 MPa to about 1,500 MPa, greater than or about 275 MPa to about 1,500 MPa, about 300 MPa to about 1,500 MPa, about 300 MPa to about 1,200 MPa, about 300 MPa to about 1,000 MPa, about 250 MPa to about 1 ,000 MPa, about 300 MPa to about 800 MPa, about 300 MPa to about 600 MPa, about 300 MPa to about 500 MPa, about 400 MPa to about 1,200 MPa, about 400 MPa to about 1,000 MPa, about 400 MPa to about 800 MPa, or about 400 MPa to about 600 MPa, as determined if a film comprising the polyolefin composition has a thickness of about 50 pm.
  • the 1% secant flexural modulus is determined by the ExxonMobil PLFL-242.001 standard, as provided below
  • a monolayer containing the polyolefin composition has a 1% secant flexural modulus TD (in the traverse direction) of greater than 200 MPa, greater than 225 MPa, greater than 250 MPa, greater than 275 MPa, or greater than 300 MPa, such as from about 320 MPa, about 340 MPa, about 350 MPa, about 400 MPa, about 500 MPa, or about 600 MPa to about 700 MPa, about 800 MPa, about 900 MPa, about 1,000 MPa, about 1,200 MPa, about 1,500 MPa or greater, as determined if a layer (e.g., monolayer or core layer) of the polyolefin composition has a thickness of about 50 pm.
  • TD secant flexural modulus
  • the polyolefin composition has a 1% secant flexural modulus TD of about 250 MPa to about 1,500 MPa, about 250 MPa to about 1,200 MPa, about 250 MPa to about 1,000 MPa, about 250 MPa to about 800 MPa, about 250 MPa to about 600 MPa, about 250 MPa to about 500 MPa, about 340 MPa to about 1,500 MPa, about 340 MPa to about 1,200 MPa, about 340 MPa to about 1,000 MPa, about 340 MPa to about 800 MPa, about 340 MPa to about 600 MPa, about 340 MPa to about 500 MPa, about 400 MPa to about 1,200 MPa, about 400 MPa to about 1,000 MPa, about 400 MPa to about 800 MPa, or about 400 MPa to about 600 MPa, as determined if a film comprising the polyolefin composition has a thickness of about 50 pm.
  • a monolayer containing the polyolefin composition has a Dart Drop Impact (Method A) of greater than 5 g/pm, such as from about 10 g/pm, about 15 g/pm, or about 20 g/pm to about 25 g/pm, about 30 g/pm, about 35 g/pm, about 40 g/pm, about 45 g/pm, or about 50 g/pm, as determined if a layer (e.g., monolayer or core layer) containing the polyolefin composition has a thickness of about 50 pm.
  • Method A Dart Drop Impact
  • the polyolefin composition has a Dart Drop Impact (Method A) of greater than 5 g/pm to about 50 g/pm, about 10 g/pm to about 50 g/pm, about 20 g/pm to about 50 g/pm, about 30 g/pm to about 50 g/pm, or about 40 g/pm to about 50 g/pm, as determined if a layer containing the polyolefin composition has a thickness of about 50 pm.
  • Method A Dart Drop Impact
  • a monolayer containing the polyolefin composition has an Elmendorf tear in the MD (machine direction) of greater than 4 g/pm, such as from about 4.5 g/pm, about 5 g/pm, about 5.5 g/pm, or about 6 g/pm to about 6.5 g/pm, about 7 g/pm, about 7.5 g/pm, about 8 g/pm, about 8.5 g/pm, about 9 g/pm, about 9.5 g/pm, or about 10 g/pm, as determined if a layer (e.g., monolayer or core layer) containing the polyolefin composition has a thickness of about 50 pm.
  • a layer e.g., monolayer or core layer
  • the polyolefin composition has an Elmendorf tear in the MD of greater than 4 g/mih to about 10 g/mih, about 4 g/mih to about 10 g/mih, about 5 g/mih to about 10 g/mih, about 6 g/mih to about 10 g/mih, about 7 g/mih to about 10 g/mih, about 8 g/mih to about 10 g/mih, or about 9 g/mih to about 10 g/mih, as determined if a layer containing the polyolefin composition as determined if a layer containing the polyolefin composition has a thickness of about 50 pm.
  • the Elmendorf tear in the MD and TD values provided herein are determined by the ASTM D1922 standard.
  • a monolayer containing the polyolefin composition has an Elmendorf tear in the TD (traverse direction) of greater than 5 g/pm or greater than 6 g/pm, such as from about 6.5 g/pm, about 7 g/pm, about 8 g/pm, or about 9 g/pm to about 10 g/pm, about 11 g/pm, about 12 g/pm, about 13 g/pm, about 14 g/pm, about 15 g/pm, or about 16 g/pm, as determined if a layer (e.g., monolayer or core layer) containing the polyolefin composition and having a thickness of about 50 pm.
  • a layer e.g., monolayer or core layer
  • the polyolefin composition has an Elmendorf tear in the TD of greater than 5 g/pm to about 16 g/ pm, about 6 g/ pm to about 16 g/pm, about 7 g/pm to about 16 g/pm, about 8 g/pm to about 16 g/pm, about 10 g/pm to about 16 g/pm, about 12 g/pm to about 16 g/pm, or about 14 g/pm to about 16 g/pm, as determined if a layer containing the polyolefin composition has a thickness of about 50 pm.
  • Properties of multi-laver film containing the polyolefin composition are properties of multi-laver film containing the polyolefin composition
  • a three-layer film has a core layer containing the polyolefin composition disposed between two skin layers containing a BOCD polyethylene.
  • the polyolefin composition has a Stiffness (1% secant flexural modulus), in each of the MD and the TD, independently, of greater than 200 MPa, greater than 225 MPa, greater than 250 MPa, or greater than 275 MPa, such as about 300 MPa, about 350 MPa, about 400 MPa, about 450 MPa, or about 500 MPa to about 550 MPa, about 600 MPa, about 650 MPa, about 700 MPa, about 800 MPa, about 900 MPa, or about 1,000 MPa, as determined if a film (e.g., 2, 3, 4, or more layer film) containing the polyolefin composition has a thickness of about
  • a film e.g., 2, 3, 4, or more layer film
  • the polyolefin composition has a 1% secant flexural modulus MD of greater than 225 MPa to about 1,500 MPa, greater than 225 MPa to about 1,200 MPa, greater than 225 MPa to about 1,000 MPa, greater than 225 MPa to about 800 MPa, greater than 225 MPa to about 600 MPa, greater than 225 MPa to about 500 MPa, about 250 MPa to about 1,500 MPa, about 250 MPa to about 1,200 MPa, about 250 MPa to about 1,000 MPa, about 250 MPa to about 800 MPa, about 250 MPa to about 600 MPa, about 250 MPa to about 500 MPa, about 300 MPa to about 1,500 MPa, about 300 MPa to about 1,200 MPa, about 300 MPa to about 1,000 MPa, about 300 MPa to about 800 MPa, about 300 MPa to about 600 MPa, about 300 MPa to about 500 MPa, about 400 MPa to about 1,200 MPa, about 400 MPa to about 1,000 MPa, about 400 MPa to about 800 MPa, about 300 MPa
  • the polyolefin composition has a Tensile at Yield strength, in each of the MD and the TD, independently, of greater than 7 MPa, greater than 8 MPa, greater than 8.5 MPa, greater than 8.8 MPa, greater than 9 MPa, greater than 9.5 MPa, or greater than 9.7 MPa, such as about 10 MPa, about 12 MPa, about 15 MPa, about 18 MPa, or about 20 MPa to about 22 MPa, about 25 MPa, about 30 MPa, about 40 MPa, about 45 MPa, about 50 MPa, about 60 MPa, about 70 MPa, about 80 MPa, or about 100 MPa, as determined if a film (e.g., film containing 2, 3, 4, or more layers) containing the polyolefin composition has a thickness of about 90 pm, and as determined by ASTM D882.
  • a film e.g., film containing 2, 3, 4, or more layers
  • the polyolefin composition has a Tensile at Yield strength, in each of the MD and the TD, independently, of greater than 8.5 MPa to about 100 MPa, greater than 8.5 MPa to about 80 MPa, greater than 8.5 MPa to about 60 MPa, greater than 8.5 MPa to about 50 MPa, greater than 8.5 MPa to about 40 MPa, greater than 8.5 MPa to about 35 MPa, greater than 8.5 MPa to about 30 MPa, greater than 8.5 MPa to about 25 MPa, greater than 8.5 MPa to about 20 MPa, greater than 8.5 MPa to about 18 MPa, greater than 8.5 MPa to about 15 MPa, greater than 8.5 MPa to about 12 MPa, about 9 MPa to about 100 MPa, about 9 MPa to about 80 MPa, about 9 MPa to about 60 MPa, about 9 MPa to about 50 MPa, about 9 MPa to about 40 MPa, about 9 MPa to about 35 MPa, about 9 MPa to about 30 MPa, about 9 MPa to about 25
  • the polyolefin composition has a Tensile at Yield strength a Tensile at Yield strength in the MD of greater than 8.5 MPa and in the TD of greater than 9.7 MPa. In some examples, the polyolefin composition has a Tensile at Yield strength a Tensile at Yield strength in the MD of greater than 8.5 MPa to about 100 MPa and in the TD of greater than 9.7 MPa to about 100 MPa. In other examples, the polyolefin composition has a Tensile at Yield strength a Tensile at Yield strength in the MD of about 9 MPa to about 25 MPa and in the TD of about 10 MPa to about 25 MPa.
  • the polyolefin composition has a Elongation at Break strength, in each of the MD and the TD, independently, of greater than 400%, greater than 450%, or greater than 500%, such as about 510%, about 520%, about 530%, about 540%, about 550%, about 555%, about 560%, about 570%, about 580%, about 590%, or about 600% to about 610%, about 620%, about 625%, about 630%, about 640%, about 650%, about 660%, about 670%, about 680%, about 690%, about 700%, about 750%, about 800%, about 850%, or about 900%, as determined if a film (e.g., film containing 2, 3, 4, or more layers) containing the polyolefin composition has a thickness of about 90 pm, and as determined by ASTM D882.
  • a film e.g., film containing 2, 3, 4, or more layers
  • the polyolefin composition has a Elongation at Break strength, in each of the MD and the TD, independently, of greater than 400% to about 900%, greater than 400% to about 800%, greater than 400% to about 750%, greater than 400% to about 700%, greater than 400% to about 650%, greater than 400% to about 600%, greater than 400% to about 550%, greater than 400% to about 500%, greater than 540% to about 900%, greater than 540% to about 800%, greater than 540% to about 750%, greater than 540% to about 700%, greater than 540% to about 650%, greater than 540% to about 600%, greater than 540% to about 550%, about 550% to about 900%, about 550% to about 800%, about 550% to about 750%, about 550% to about 700%, about 550% to about 650%, about 550% to about 600%, about 550% to about 575%, about 600% to about 900%, about 600% to about 800%, about 600% to about 750%, about 600% to about 700
  • the polyolefin composition has a Elongation at Break strength in the MD of greater than 540% and in the TD of greater than 580%. In some examples, the polyolefin composition has a Elongation at Break strength in the MD of about 550% to about 700% and in the TD of about 600% to about 700%. In other examples, the polyolefin composition has a Elongation at Break strength in the MD of about 555% to about 625% and in the TD of about 605% to about 650%.
  • the polyolefin composition has a Dart Drop Impact (Method A) of at or greater than 8 g/pm, at or greater than 8.5 g/pm, at or greater than 9 g/pm, at or greater than 10 g/pm, or at or greater than 12 g/pm, such as from about 13 g/pm, about 16 g/pm, about 16.5 g/pm, or about 17 g/pm to about 17.5 g/pm, about 18 g/pm, about 18.5 g/pm, about 19 g/pm, about 19.5 g/pm, about 20 g/pm, or about 22 g/pm, as determined if a film (e.g., 2, 3, 4, or more layer film) containing the polyolefin composition has a thickness of about 90 pm.
  • the polyolefin composition has a Dart Drop Impact (Method A) of at or greater than
  • the polyolefin composition has an Elmendorf tear in the MD of greater than 5 g/pm, greater than 5.6 g/pm, greater than 6 g/pm, greater than 6.5 g/pm, or greater than 7 g/pm, such as from about 7.2 g/pm, about 7.5 g/pm, about 7.8 g/pm, about 8 g/pm, about 8.2 g/pm, about 8.5 g/pm, about 8.8 g/pm, about 9 g/pm, about 9.2 g/pm, about 9.5 g/pm, about 9.8 g/pm or about 10 g/ pm to about 10.2 g/ pm, about 10.5 g/ pm, about 11 g/pm, about 12 g/pm, about 15 g/pm, about 18 g/pm, about 20 g/pm, as determined if a film (e.g., 2, 3, 4, or more layer film) containing the polyolefin composition has a thickness of about 90 pm.
  • a film e.
  • the polyolefin composition has an Elmendorf tear in the MD of greater than 5 g/pm to about 20 g/pm, greater than 5.6 g/pm to about 20 g/pm, about 6 g/pm to about 20 g/pm, about 8 g/pm to about 20 g/pm, about 9 g/pm to about 20 g/pm, about 9.5 g/pm to about 20 g/pm, about 10 g/pm to about 20 g/pm, about 12 g/pm to about 20 g/pm, about 15 g/pm to about 20 g/pm, greater than 5 g/pm to about 15 g/pm, greater than 5.6 g/pm to about 15 g/pm, about 6 g/pm to about 15 g/pm, about 8 g/pm to about 15 g/pm, about 9 g/pm to about 15 g/pm, about 9.5 g/pm to about 15 g/pm, about 10 g/pm to about 15 g/pm, about 12 g/
  • the polyolefin composition has an Elmendorf tear in the TD of greater than 8 g/pm, greater than 8.9 g/pm, greater than 9.5 g/pm, greater than 10 g/pm, greater than 11 g/pm, greater than 12 g/pm, greater than 12.8 g/pm, or greater than 13 g/pm, such as from about 13.2 g/pm, about 13.5 g/pm, about 13.8 g/pm, about 14 g/pm, about 14.2 g/pm, or about 14.5 g/pm to about 14.8 g/pm, about 15 g/pm, about 15.2 g/pm, about 15.5 g/pm, about 15.8 g/pm, or about 16 g/pm, as determined if a film (e.g., 2, 3, 4, or more layer film) containing the polyolefin composition has a thickness of about 90 pm.
  • a film e.g., 2, 3, 4, or more layer film
  • the polyolefin composition has an Elmendorf tear in the TD of about 8 g/pm to about 20 g/pm, about 9 g/pm to about 20 g/pm, about 10 g/pm to about 20 g/pm, about 12 g/pm to about 20 g/pm, about 15 g/pm to about 20 g/ pm, about 18 g/ pm to about 20 g/ pm, about 8 g/ pm to about 15 g/ pm, about
  • the polyolefin compositions of the present disclosure include one or more broad orthogonal composition distribution (BOCD) polyethylenes. It can be desirable for the polyethylene copolymers to possess a broad orthogonal composition distribution which provides enhanced stiffness, toughness, and processability (S/T/P) balance of the polyethylene and compositions that include these polymers.
  • BOCD broad orthogonal composition distribution
  • polymers having BOCD are branched polymers that have a preponderance, if not all, of any branching that may occur on the high molecular weight molecules of the polymer, making them less crystalline. This microstructure has a tendency to improve certain properties of products made from such BOCD-type polymers including the polyolefin composition described and discussed herein.
  • ZN Ziegler-Natta
  • the BOCD polyethylene may have an orthogonal comonomer distribution or "broad orthogonal composition distribution" ("BOCD").
  • orthogonal comonomer distribution is used herein to mean across the molecular weight range of the ethylene polymer, comonomer contents for the various polymer fractions are not substantially uniform and a higher molecular weight fraction thereof generally has a higher comonomer content than that of a lower molecular weight fraction.
  • substantially uniform comonomer distribution is used herein to mean that comonomer content of the polymer fractions across the molecular weight range of the ethylene-based polymer vary by ⁇ 10.0 wt%.
  • a substantially uniform comonomer distribution may refer to ⁇ 8.0 wt%, ⁇ 5.0 wt%, or ⁇ 2.0 wt%. Both a substantially uniform and an orthogonal comonomer distribution may be determined using fractionation techniques such as gel permeation chromatography - differential viscometry (GPC-DV), temperature rising elution fraction-differential viscometry (TREF-DV) or cross-fractionation techniques.
  • GPC-DV gel permeation chromatography - differential viscometry
  • TREF-DV temperature rising elution fraction-differential viscometry
  • cross-fractionation techniques such as gel permeation chromatography - differential viscometry (GPC-DV), temperature rising elution fraction-differential viscometry (TREF-DV) or cross-fractionation techniques.
  • a visual examination of the TREF contour plot is sufficient to confirm that the distribution is BOCD- like as opposed to the conventional-type, such as is shown in the graphs of FIGS. 1A and IB.
  • Such an evaluation consists of a non-quantitative method of ordering the polyethylene copolymers under consideration by increasing or decreasing BOCD-like character based on the "tilt" of the TREF contours in the 2D plane. For example, the slope of the line in FIG. 1A is less than 0 (negative "tilt") whereas the slope of the line in FIG. IB is greater than 0 (positive "tilt"), and this allows one to conclude that the graph depicted by FIG. 1A has more BOCD- like character than the graph depicted by FIG. IB.
  • FIGS. 1A and IB exemplify the "tilt” and “spread” in temperature elution fractionation (TREF) data of two LLDPEs: BOCD polyethylene (FIG. 1A) and conventional polyethylene (FIG. IB), where the dashed, guide-to- the-eye lines roughly connect the two main peaks and are qualitative indicators of the tilt of the branching distribution; the slope of the line in FIG. 1 A is less than 0 (negative tilt) whereas the slope of the line in FIG. IB is greater than 0 (positive tilt).
  • TEZE temperature elution fractionation
  • the BOCD polyethylene of the present disclosure comprises from about 70 mole percent (mol%) to about 100 mol% of units derived from ethylene.
  • the lower amount on the range of ethylene content may be from 70 mol%, 75 mol%, 80 mol%, 85 mol%, 90 mol%, 92 mol%, 94 mol%, 95 mol%, 96 mol%, 97 mol%, 98 mol%, or 99 mol% based on the mol% of polymer units derived from ethylene.
  • the BOCD polyethylene may have an upper ethylene amount of 80 mol%, 85 mol%, 90 mol%, 92 mol%, 94 mol%, 95 mol%, 96 mol%, 97 mol%, 98 mol%, 99 mol%, 99.5 mol%, or 100 mol%, based on polymer units derived from ethylene.
  • the BOCD polyethylene may have less than 50 mol% of polymer units derived from a C3-C20 olefin, such as an alpha-olefin, e.g., hexene or octene.
  • the lower amount on the range of C3-C20 olefin-content may be 25 mol%, 20 mol%, 15 mol%, 10 mol%, 8 mol%, 6 mol%, 5 mol%, 4 mol%, 3 mol%, 2 mol%, 1 mol%, or 0.5 mol%, based on polymer units derived from the C3-C20 olefin.
  • the upper amount on the range of C3-C20 olefin-content may be 20 mol%, 15 mol%, 10 mol%, 8 mol%, 6 mol%, 5 mol%, 4 mol%, 3 mol%, 2 mol%, or 1 mol%, based on polymer units derived from the C3 to C20 olefin. Any of the lower amounts may be combined with any of the upper amounts to form a range. Comonomer content is based on the total content of all monomers in the polymer.
  • the BOCD polyethylene may have low amounts of long chain branching (e.g., less than 1.0 long-chain branch/1,000 carbon atoms, such as particularly 0.05 to 0.50 long-chain branch/1,000 carbon atoms). Such values are characteristic of a linear structure that is consistent with a branching index (as defined below) of g' vis 0.980 or greater,
  • long chain branches may be present (e.g., less than 1.0 long-chain branch/1,000 carbon atoms, such as less than 0.5 long-chain branch/1,000 carbon atoms, such as 0.05 to 0.50 long-chain branch/1,000 carbon atoms).
  • the BOCD polyethylenes may have a density in accordance with ASTM D-4703 and ASTM D-1505/ISO 1183 of 0.910 g/cm 3 to 0.925 g/cm 3 , from 0.910 g/cm 3 to 0.923 g/cm 3 , from 0.910 g/cm 3 to 0.920 g/cm 3 , from 0.915 g/cm 3 to 0.921 g/cm 3 , from 0.910 g/cm 3 to 0.918 g/cm 3 , from 0.912 g/cm 3 to 0.918 g/cm 3 , or from 0.912 g/cm 3 to 0.917 g/cm 3 .
  • the weight average molecular weight (M w ) of the BOCD polyethylenes may be from 15,000 g/mol to 500,000 g/mol, from 20,000 g/mol to 250,000 g/mol, from 25,000 g/mol to 150,000 g/mol, from 150,000 g/mol to 400,000 g/mol, from 200,000 g/mol to 400,000 g/mol, or from 250,000 g/mol to 350,000 g/mol as determined by GPC.
  • the BOCD polyethylenes may have a molecular weight distribution (MWD) or (M w /Mn) of 1.5 to 5, from 2 to 4, from 3 to 4, or from 2.5 to 4.
  • MFD molecular weight distribution
  • M w /Mn molecular weight distribution
  • the BOCD polyethylenes may have a z-average molecular weight (M z ) to weight average molecular weight (M w ) greater than 1.5, or greater than 1.7, or greater than 2. In any embodiment, this ratio is from 1.7 to 3.5, from 2 to 3, or from 2.2 to 3.
  • the BOCD polyethylenes may have a melt index (MI) or (B.ib) as measured by ASTM D-1238-E (190°C/2.16 kg) of 0.1 to 300 g/10 min, 0.1 to 100 g/10 min, 0.1 to 50 g/10 min, 0.1 g/10 min to 5 g/10 min, 0.1 g/10 min to 3 g/10 min, 0.1 g/10 min to 2 g/10 min, 0.1 g/10 min to 1.2 g/10 min, 0.2 g/lOminto 1.5 g/10 min, 0.2 g/lOmin to 1.1 g/10 min, 0.3 g/lOmin to 1 g/10 min, 0.4 g/lOminto 1 g/10 min, 0.5 g/lOminto 1 g/10 min, 0.6 g/lOminto 1 g/10 min, 0.7 g/lOmin to 1 g/10 min, or 0.75 g/lOmin to 0.95 g/10 min.
  • MI melt index
  • the BOCD polyethylenes may have a melt index ratio (MIR) (I21.6 /I2.16) (as defined below) of 10 to 50, from 15 to 45, from 20 to 40, from 20 to 35, from 22 to 38, from 20 to 32, from 25 to 31, or from 28 to 30.
  • MIR melt index ratio
  • the BOCD polyethylenes may contain less than 5 ppm of hafnium, less than 2 ppm of hafnium, less than 1.5 ppm of hafnium, or less than 1 ppm of hafnium. In other embodiments, the BOCD polyethylenes may contain from 0.01 ppm to 2 ppm of hafnium, from 0.01 ppm to 1.5 ppm of hafnium, or from 0.01 ppm to 1 ppm of hafnium. [0052] Typically, the amount of hafnium is greater than the amount of zirconium in the
  • the ratio of hafnium to zirconium is at least 2, at least 10, at least 15, at least 17, at least 20, at least 25, at least 50, at least 100, at least 200, or at least 500 or more. Since zirconium is generally present as an impurity in hafnium, it will be realized that hafnium-containing catalysts contain some amount of zirconium as an impurity. In any embodiment where particularly pure hafnium-containing catalysts are used, the amount of zirconium may be extremely low, resulting in an undetectable amount or a substantially undetectable amount of zirconium in the BOCD polyethylene. Thus, the upper limit on the ratio of hafnium to zirconium in the polymer may be quite large.
  • the BOCD polyethylenes may have at least a first peak and a second peak in a comonomer distribution analysis, wherein the first peak has a maximum at a log(M w ) value of 4 to 5.4, 4.3 to 5, or 4.5 to 4.7; and a TREF elution temperature of 70°C to 100°C, 80°C to 95°C, or 85°C to 90°C.
  • the second peak in the comonomer distribution analysis has a maximum at a log(M w ) value of 5 to 6, 5.3 to 5.7, or 5.4 to 5.6; and a TREF elution temperature of 40°C to 60°C, 45°C to 60°C, or 48°C to 54°C.
  • the BOCD Polyethylene may have one or more of the following properties: a melt index (MI) (190°C/2.16 kg) of 0.1 g/10 min to 5 g/10 min; a melt index ratio (MIR) of 15 to 30; an M w of 20,000 to 200,000 g/mol; a M w /M n of 2 to 4.5; and a density of 0.910 to 0.925 g/cm 3 .
  • MI melt index
  • MIR melt index ratio
  • the amount of hafnium is greater than the amount of zirconium and a ratio of hafnium to zirconium (ppm/ppm) may be at least 2, at least 10, at least 15, at least 17, at least 20, or at least 25.
  • Exceed XPTM metallocene polyethylene mPE
  • Exceed XPTM mPE offers step-out performance with respect to, for example, dart drop impact strength, flex-crack resistance, and machine direction (MD) tear, as well as maintaining stiffness at lower densities.
  • Exceed XPTM mPE also provides a good balance of melt strength, toughness, stiffness, and sealing capabilities which makes this family of polymers well-suited for, for example, blown film/sheet solutions.
  • FIG. 2 is a plot of Compositional Distribution (molecular weight as a function of branching) plotting (MWI/MW2) values as a function of (Twi-Tw2) for BOCD PE polymers and conventional PE polymer, according to any embodiment.
  • the values for Twi, Tw2, Mwi, and MW2 can be determined from cross-fractionation chromatography (CFC), where the procedures for interpreting the data obtained from CFC and for determining the values for Twi, Tw2, Mwi, and MW2 are discussed in more detail in U.S. Pub. No. 2018/0155474, which is incorporated by reference for discussion on CFC and determining the values for Twi, Tw2, Mwi, and Mw2.
  • this techniques helps to elucidate the level of comonomer on high- to-low molecular weight fractions of polyethylenes. Calculations are used to determine branching within the molecular weight fractions of polyethylenes.
  • a gradient of molecular weight fractions of the polyethylene elutes from at least one temperature-gradient gel permeation chromatographic column at a gradient of temperatures and molecular weights, where 50 wt% or less of the cumulative molecular weight polyethylene fractions elutes at a temperature Twi, and greater than 50 wt% cumulative molecular weight polyethylene fractions elute at a temperature Tw2, the molecular weight fractions eluting at Twi being a molecular weight component Mwi and the fractions eluting at Tw2 being a molecular weight component Mw2.
  • FIG. 2 is a semi-log plot of (MWI/MW2) as a function of (Twi-Tw2) designed to show the important differences in MWD/short chain branching distribution (SCBD) combination among examples compared to commercial benchmarks. Such differences are believed to play a key role in determining the trade-off pattern and/or balance of various performance attributes such as stiffness, toughness and processability.
  • the polyethylenes are above the mid-horizontal line, while conventional polyethylenes having typical short-chain branching distribution (SCBD) are below the mid-line.
  • SCBD short-chain branching distribution
  • NSCBD narrow short chain branching distribution
  • BSCBD broad short chain branching distribution
  • the polyethylenes are in-between the extremes, represented by an MWI/MW2 value of between 0.9 and 10, more preferably 1.5 and 5.
  • MWI/MW2 value of between 0.9 and 10, more preferably 1.5 and 5.
  • SCBD and MWD are described together. That is, the combination of molecular weight characteristic and SCB of a particular population is highlighted, rather than the Mw or SCB separately. Therefore, between the NSCBD extreme (far right vertical line) and BSCBD extreme (far left vertical line, not center line) is described a region of the plot.
  • There are two further divisions to set different polyethylene product concepts apart an upper half above and a lower half below the center line in the plot of FIG. 2. The upper half above the center line in the plot of FIG.
  • BOCD polyethylenes are located, that is, the combination of Low Mw/High Tw (low SCB, high density) population with High Mw/Low Tw (high SCB, low density) population.
  • Low Mw/High Tw low SCB, high density
  • High Mw/Low Tw high SCB, low density
  • the lower half below the center line in the plot of FIG. 2 is what is typically called “conventional” (Ziegler-Natta-like), that is, the combination of High Mw/Low Tw (low SCB, low density) population with Low Mw/High Tw (high SCB, high density) population.
  • ExceedTM 1018 and EnableTM 2010 polyethylenes are obtained from ExxonMobil Chemical Company (Baytown, TX).
  • VPR is a polyethylene made in a metallocene gas phase process as described in PCT/US2015/015119 (Polymer 1-10, Table 1).
  • the BOCD polyethylene has an M WI /M W 2 of greater than 1 , such as from about 1.2, about 1.5, about 1.8, about 2, about 2.5, about 3, about 3.5, or about 4 to about 4.5, about 5, about 5.5, about 6, about 7, about 8, about 9, or about 10.
  • M WI /M W 2 of greater than 1 , such as from about 1.2, about 1.5, about 1.8, about 2, about 2.5, about 3, about 3.5, or about 4 to about 4.5, about 5, about 5.5, about 6, about 7, about 8, about 9, or about 10.
  • BOCD polyethylene has an M WI /M W 2 of greater than 1 to about 10, greater than 1 to about 8, greater than 1 to about 7, greater than 1 to about 6, greater than 1 to about 5, greater than 1 to about 4, greater than 1 to about 3, about 1.5 to about 10, about 1.5 to about 8, about 1.5 to about 7, about 1.5 to about 6, about 1.5 to about 5, about 1.5 to about 4, about 1.5 to about 3, about 2 to about 10, about 2 to about 8, about 2 to about 7, about 2 to about 6, about 2 to about 5, about 2 to about 4, or about 2 to about 3.
  • M WI /M W 2 of greater than 1 to about 10, greater than 1 to about 8, greater than 1 to about 7, greater than 1 to about 6, greater than 1 to about 5, greater than 1 to about 4, greater than 1 to about 3, about 1.5 to about 10, about 1.5 to about 8, about 1.5 to about 7, about 1.5 to about 6, about 1.5 to about 5, about 1.5 to about 4, about 1.5 to about 3, about 2 to about 10, about 2 to about 8, about 2 to about 7, about 2 to about 6, about 2 to about 5, about 2 to about 4, or about 2 to about 3.
  • the BOCD polyethylene has a T wi -Tw2 of less than 0°C, such as from about -1°C, about -5°C, about -10°C, about -15°C, or about -20°C to about -25°C, about -30°C, about -35°C, about -40°C, or about -45°C.
  • the BOCD polyethylene has a T wi -T W2 of less than 0°C to about -45°C, less than 0°C to about -40°C, less than 0°C to about -35°C, less than 0°C to about -25°C, less than 0°C to about -20°C, less than 0°C to about -15°C, less than 0°C to about -10°C, -5°C to about -45°C, -5°C to about -40°C, -5°C to about -35°C, -5°C to about -25°C, -5°C to about -20°C, -5°C to about -15°C, -5°C to about -10°C, -10°C to about -45°C, -10°C to about -40°C, -10°C to about -35°C, -10°C to about -25°C, -10°C to about -20°C, or -10°C to about -15
  • compositions of the present disclosure include one or more polypropylenes.
  • the "polypropylene” is a polymer that contains at least 50 mol% propylene-derived units.
  • the polypropylene can have less than 50 mol% of polymer units derived from ethylene and/or one or more C4 to C20 olefins, such as, an alpha-olefin, for example, hexene or octene.
  • the concentration of the ethylene and/or one or more C4 to C20 olefins be 45 mol%, 40 mol%, 35 mol%, 30 mol%, 25 mol%, 20 mol%, 15 mol%, 10 mol%, 8 mol%, 6 mol%, 5 mol%, 4 mol%, 3 mol%, 2 mol%, 1 mol%, or 0.5 mol%, based on polymer units derived from the ethylene and/or one or more C4 to C20 olefins.
  • Comonomer content is based on the total content of all monomers in the polymer.
  • Desirable polypropylenes include homopolymers, copolymers (random or block) comprising from 0.2, or 0.5 wt% comonomer derived units to 10, or 15, or 20 wt% comonomer derived units, terpolymers comprising at least 50 wt% propylene derived units, impact copolymers (a blend of a homopolymer and copolymer), and blends thereof.
  • the polypropylene can be or include one or more high melt strength polypropylenes (HMS PPs), one or more trimmed polypropylenes (tPPs), one or more broad molecular weight distribution (BMWD or BWD) PPs, one or more homopolymers of PP (hPP), impact copolymers (ICPs) of PP, random copolymer (RCPs) of PP, or any combination thereof.
  • HMS PPs high melt strength polypropylenes
  • tPPs trimmed polypropylenes
  • BMWD or BWD broad molecular weight distribution
  • ICPs impact copolymers
  • RCPs random copolymer
  • the polypropylene can be or include a base or reactor grade polypropylene.
  • the polypropylene can be or include one or more high melt strength polypropylenes (HMS PPs) and/or one or more trimmed polypropylenes (tPPs).
  • HMS PPs high melt strength polypropylenes
  • tPPs trimmed polypropylenes
  • the tPP contains and/or is produced from one or more HMS PPs, as described and discussed herein.
  • trim refers to the reduction, either chemically or by dilution, of the high molecular weight tail of a polymer, which is manifest by a reduction of the z-average molecular weight of the polymer, independently and relative to the number average and weight average molecular weight.
  • a “film” is a solid flexible material that may take on any suitable two-dimensional length and width and have an average thickness within the range of about 10 pm or about 20 pm or about 30 pm or about 40 pm to an upper limit of about 50 pm or about 60 pm or about 80 pm or about 100 pm or about 150 pm or about 200 pm or about 300 pm, or about 400 pm, or about 500 pm, wherein the length and width of the film is much greater than its thickness.
  • an exemplary average thickness of a film is within the range of about 10 pm to about 60 pm, about 50 pm to about 120 pm, or about 80 pm to about 100 pm.
  • a "multi-layered film” as used herein comprises two or more layers, and may comprise 3, 4, 5, 6, or more layers in any embodiment, and may have a combined thickness of up to about 1,000, or about 1,500, or about 2,000, or about 2,500 pm.
  • film also includes the possibility of coatings, such as when the film is extruded onto a surface such as a metal, glass, another polymer, or other stiff or flexible surface.
  • the term "layer” refers to each of the one or more materials, the same or different, that are secured to one another in the form of a thin sheet or film by any appropriate means such as by an inherent tendency of the materials to adhere to one another, or by inducing the materials to adhere as by a heating, radiative, chemical, or some other appropriate process.
  • a layer is not limited to detectable, discrete materials contacting one another such that a distinct boundary exists between the materials.
  • the materials used to make one layer of a film will be different (e.g., the weight percent of components, the properties of each component, and/or the identity of the components may differ) from the materials used to make an adjacent, and adhering, layer.
  • a layer includes a finished product having a continuum of materials throughout its thickness.
  • Trimming of an HMS PP can occur by either chemical treatment with a long half- life organic peroxide, by physical dilution with a narrow molecular weight distribution (MWD) polypropylene, or a combination of the two.
  • MWD molecular weight distribution
  • the HMS PP's described herein are trimmed only by treatment with a long-half-life organic peroxide.
  • a process to prepare a tPP includes combining an HMS PP containing at least 50 mol% of propylene, and having a molecular weight distribution (Mw/Mn) greater than 6, a branching index (gVis) of at least 0.95, and a melt strength of at least 20 cN determined using an extensional rheometer at 190°C, with (i) from about 20 ppm to about 1,000 ppm of a long half-life organic peroxide; and/or (ii) from about 20 wt% to about 70 wt% of a narrow MWD polypropylene containing at least 50 mol% of propylene, and having a molecular weight distribution (Mw/Mn) of less than 6, and isolating a trimmed polypropylene.
  • Mw/Mn molecular weight distribution
  • gVis branching index
  • the tPP contains at least 50 mol% of propylene and has a molecular weight distribution (Mw/Mn) of less than 22, 20, 18, 16, or 15, or from about 5, about 6, about 7, about 7.5, about 8, about 8.5, or about 9 to about 15, about 16, about 18, about 20, or about 22; a z-average molecular weight of less than 2,500,000 g/mol, 2,000,000 g/mol, 1,600,000 g/mol, 1,400,000 g/mol, or 1,200,000 g/mol, or from about 500,000 g/mol, about
  • Mw/Mn molecular weight distribution
  • tPP 600,000 g/mol, or about 800,000 g/mol to about 1,200,000 g/mol, about 1,400,000 g/mol, or about 1,600,000 g/mol; a branching index (gVis) of at least 0.95; and a melt strength less than 20 cN (e.g., from about 1 cN to about 15 cN) as determined using an extensional rheometer at 190°C.
  • cN e.g., from about 1 cN to about 15 cN
  • the film quality of a film containing HMS PP can improve without surface/bulk irregularity at commercial rates of film formation of at least 13 lb/hr/in.
  • concentration of high molecular weight tail can be reduced by addition of low levels of peroxides that have relatively "long" half-lives (e.g., LuperoxTM 101, TriganoxTM 101).
  • the film quality of a film containing HMS PP can improve without surface/bulk irregularity at the commercial rates of film formation of at least 13 lb/hr/in.
  • High Melt Strength Polypropylenes (HMS PP) [0075]
  • HMS PP High Melt Strength Polypropylenes
  • the tPPs, and films (or coatings) therefrom, derive from a polypropylene having a relatively high Melt Strength (greater than 15 cN, or 20 cN), referred to herein simply as a "high melt strength polypropylene" (or HMS PP) having one or more features as described here, made according to the disclosure in WO 2014/070386.
  • the HMS PP contains at least 50 mol%, about 60 mol%, about 70 mol%, about 80 mol%, or 90 mol% propylene-derived monomer units, or from about 50 mol%, about 60 mol%, or about 80 mol% to about 95 mol%, about 97 mol%, or about 99 mol% propylene-derived units, the remainder being a comonomer selected from ethylene and C4 to C20 a-olefms, for example, ethylene or 1 -butene.
  • the HMS PP is a homopolymer of propylene-derived monomer units.
  • the HMS PP can be or include AchieveTM Advanced PP6282NE1 PP, commercially available from ExxonMobil Chemical Company (Houston, Texas).
  • the HMS PP has an isotactic pentad percentage of greater than 90%, 92%, or 95% as determined by 13 C NMR spectroscopy.
  • the HMS PP has a melt flow rate (MFR) from about 0.1, about 1, or about 2 g/10 min to about 12, about 16, about 20, or about 40 g/10 min, as determined according to ASTM D1238 Condition L (230°C/2.16 kg).
  • MFR melt flow rate
  • the HMS PPs can have an MFR of about 2, about 2.5, about 3, about 3.5, or about 4 g/10 min to about 4.5, about 5, about 5.5, or about 6 g/10 min, as determined by ASTM D1238.
  • the HMS PPs can have an MFR of about 2 g/10 min to about 6 g/10 min, about 2.5 g/10 min to about 6 g/10 min, about 3 g/10 min to about 6 g/10 min, about
  • a HMS PP has an MFR of about 4 g/10 min (4MFR).
  • the HMS PP has a weight average molecular weight (Mw) from about 200,000 g/mol, about 300,000 g/mol, or about 350,000 g/mol to about 500,000 g/mol, about 600,000 g/mol, or about 700,000 g/mol; a number average molecular weight (Mn) from about 15,000 g/mol or about 20,000 g/mol to about 30,000 g/mol, about 35,000 g/mol, or about 40,000 g/mol; and/or a z-average molecular weight from about 900,000 g/mol, about 1,000,000 g/mol, or about 1,200,000 g/mol to about 1,800,000 g/mol, about 2,000,000 g/mol, about 2,200,000 g/mol, or about 2,500,000 g/mol, as determined by Size Exclusion Chromatograph
  • the HMS PP has a z-average molecular weight of less than 2,500,000 g/mol.
  • the HMS PP has a molecular weight distribution (Mw/Mn) of greater than 6, 7, or 8; or from about 6, about 7, about 8, about 10, or about 12 to about 14, about 16, about 18, about 20, about 22, or about 24.
  • the HMS PP has a molecular weight distribution (Mw/Mn) of about 7 to about 22.
  • the HMS PP has an Mz/Mw of greater than 3, 3.4, or 3.6, or from about 3, about 3.4, or about 3.6 to about 3.8, about 4, or about 4.4.
  • the HMS PP can have a Mz/Mn of greater than 35, 40, 55, or 60, or from about 35, about 40, or about 55 to about 60, about 65, about 70, about 75, or about 80.
  • Polymer molecular weight (weight-average molecular weight, Mw, number-average molecular weight, Mn, and z-averaged molecular weight, Mz) and molecular weight distribution (Mw/Mn) are determined using SEC.
  • Equipment includes of a High Temperature Size Exclusion Chromatograph (either from Waters Corporation or Polymer Laboratories), with a differential refractive index detector (DRI) or infrared (IR) detector.
  • DRI differential refractive index detector
  • IR infrared
  • the HMS PPs can be linear as evidenced by a high branching index.
  • the HMS PPs have a branching index (g 1 , also referred to in the literature as gVis avg) of 0.95 or greater, such as 0.96, 0.97, or 0.98, as determined in column 37 of U.S. Pat. No. 7,807,769 determined by using aHigh Temperature Size Exclusion Chromatograph (either from Waters Corporation or Polymer Laboratories), equipped with three in-line detectors, a differential refractive index detector (DRI), a light scattering (LS) detector, and a viscometer.
  • a branching index g 1 , also referred to in the literature as gVis avg
  • gVis avg branching index of 0.95 or greater, such as 0.96, 0.97, or 0.98, as determined in column 37 of U.S. Pat. No. 7,807,769 determined by using aHigh Temperature Size Exclusion Chromatograph (
  • the HMS PPs can have a melt strength of at least 15 cN or 20 cN determined using an extensional rheometer at 190°C; or from about 10 cN, about 15 cN, or about 20 cN to about 35 cN, about 40 cN, about 60 cN, about 80 cN, or about 100 cN. In some examples, the HMS PPs has a melt strength of less than 20 cN.
  • the HMS PPs have a viscosity ratio from about 35 to about 80 determined from the complex viscosity ratio at 0.01 to 100 rad/s angular frequency at a fixed strain of 10% at 190°C.
  • the HMS PP has a Peak Extensional Viscosity (annealed) from about 10 kPa*s or about 20 kPa*s to about 40 kPa*s. about 50 kPa*s. about 55 kPa » s, about 60 kPa » s, about 80 kPa » s, or about 100 kPa » s at a strain rate of 0.01 /sec (190°C).
  • the HMS PP has a heat distortion temperature of greater than or equal to 100°C, determined according to ASTM D648 using a load of 0.45 MPa (66 psi). In some embodiments, the HMS PP has a Modulus from about 1,800 MPa or about 2,000 MPa to about 2,400 MPa or about 2,500 MPa, determined according to ASTM D790A on nucleated samples with 0.01 to 0.1 wt% a-nucleating agent.
  • the HMS PPs can have a peak melting point temperature (second melt, Tim) of greater than 160°C or 164°C, or from about 160°C or about 164°C to about 168°C or about 170°C (by DSC); and a crystallization temperature (Tc) of greater than 100°C, 105°C, or 110°C, or from about 100°C, about 105°C, or about 110°C to about 115°C or about 120°C (by DSC).
  • second melt, Tim peak melting point temperature
  • Tc crystallization temperature
  • the HMS PPs used to make the tPPs and films therefrom are a reactor-grade material, meaning that HMS PP is used as it comes out of the reactor used to produce it, optionally having been further made into pellets of material that has not altered any of its properties such as the branching index, MWD, or melt flow rate by more than 1% of its original value.
  • the HMS PP has not been cross-linked or reacted with any radiation or chemical substance to cause cross-linking and/or long-chain branching. Typical forms of radiation known to cause cross-linking and/or long-chain branching include use of so called e-beams or other radiation (beta or gamma rays) that interact with the polymer.
  • Exemplary HMS PP's that are commercially available are AchieveTM Advanced polypropylene grades from ExxonMobil Chemical Company (Houston, Texas).
  • the process to prepare the tPP can include combining the HMS PP with either a long half-life organic peroxide, a narrow MWD polypropylene, or a combination thereof.
  • the long half-life organic peroxide is combined with the HMS PP such that it is from about 20 ppm, about 25 ppm, or about 50 ppm to about 400 ppm, about 600 ppm, about 800 ppm, or about 1,000 ppm of a long half-life organic peroxide based on the weight of the peroxide, the HMS PP, and any other additives.
  • long half-life organic peroxide is an organic peroxide (a peroxide-containing hydrocarbon) having a 1 hour half-life temperature (hi/2) of greater than 100°C, or 110°C, or 120°C, or 130°C, as measured in C6 to C16 alkane such as dodecane or decane, or ahalogenated aryl compound such as chlorobenzene.
  • Such peroxides can include those having the general structure R'-OO-R 2 . or R'-OO- R 3 -00-R 2 , or, more generally, (R'-00-R 2 )n.
  • R 1 and R 2 are independently selected from C2 to CIO alkyls, C6 to C12 aryls, and C7 to Cl 6 alkylaryls, such as iso- or tertiary-alkyls, and R 3 is selected from Cl to C6, or CIO alkylenes, C6 to C12 aryls, and C7 to C16 alkylaryls; the "-00-" being the peroxide moiety.
  • Long half-life organic peroxides may be 2,5-dimethyl-2,5-di(tert-butylperoxy)hexane, 2,5- bis(/cT/-butylpero ⁇ y)-2.5-dimethylhe ⁇ ane. di-tertbutyl peroxide, or dicumyl peroxide.
  • the half-life is determined by differential scanning calorimetry-thermal activity monitoring of a dilute solution of the initiator in a suitable solvent. The half-life can then be calculated from the Arrhenius plot as is well known in the art.
  • the high molecular weight component is reduced or "trimmed".
  • the appropriate solvent is determined based on the solubility of the organic peroxide.
  • the HMS PP can be trimmed by combining from about
  • the narrow MWD polypropylene contains at least 50 mol%, 60 mol%, 70 mol%, 75 mol%, or 80 mol% of propylene, and has an MWD of less than 6, or 5, or 4, or from about 2, or about 2.5 to about 4, or about 5, or about 6.
  • the MFR of the narrow MWD polypropylene is from about 4 g/10 min or about 8 g/10 min to about 40 g/10 min, about 60 g/10 min, about 80 g/10 min, or about 100 g/10 min.
  • the narrow MWD polypropylene can be a propylene polymer having at least 50 mol% of propylene-derived units, such as those containing from about 0.1 wt% to about 5 wt% of comonomers such as ethylene-derived units, for example, homopolymers of propylene, such as isotactic poly propylenes.
  • the high molecular weight component of the HMS PP can be diluted or "trimmed” using this technique.
  • the "trimming" includes combining the HMS PP and narrow MWD polypropylene by melt blending as is known in the art, such as through one or two passes through an extruder, such as described in the "two-pass” process of WO 2016053468A1.
  • the "combining" of the HMS PP and the long half-life organic peroxide can be performed by melt blending at least the peroxide and HMS PP at the melting temperature of the HMS PP, such as at a temperature of at least 120°C, about 130°C, about 150°C, or about 160°C, for example at a temperature from about 120°C, about 130°C, about 140°C, about 150°C, or about 160°C to about 220°C, about 240°C, about 260°C, about 280°C, or about 300°C, such temperature being the melt temperature as measured by a thermocouple in the melt upon extrusion from the mixing apparatus used to combine the materials.
  • the melt temperature of any melt including the HMS PP is from about 245°C, or about 250°C to about 260°C.
  • the long half-life organic peroxides are activated towards beta-scissioning of the polypropylene and at the low concentrations used to achieve the trimming, the amount and combining temperature being tailored to the level of trimming for the particular HMS PP.
  • the combining can take place in a single-screw or twin- screw extruder which can have controlled heating capability. This process can take place to form pellets of tPP, or in-line with the film making equipment or other desirable end-use making equipment such as thermoforming or blow molding. Trimmed Polypropylene
  • the process of combining the long half-life organic peroxide with the HMS PP leads to the tPPs.
  • the starting polypropylenes used to make the tPPs typically have a large amount of high molecular weight polymer chains, typically above the critical orientation level. When making certain articles such as films, this can lead to strong films, but with many surface defects and thus unusable for most applications. It has been discovered that if some of the high molecular weight component is reduced or removed, trimmed, the resulting tPP has certain desirable properties, but maintains other desirable properties.
  • the melt strength (measured at 190°C as described herein) of the tPPs is less than 20 cN, 15 cN, or 10 cN, or from about 1 cN or about 2 cN to about 4 cN, about 6 cN, about 10 cN, about 15 cN, or about 20 cN.
  • the crystallization temperature Tc (as measured by DSC) of the tPP is greater than 114°C, 115°C, or 116°C; or from about 114°C, about 115°C, or about 116°C to about 120°C, about 122°C, or about 124°C.
  • the second peak melting temperature Trm (as measured by DSC) of the tPP is greater than 157°C, or 158°C, or 159°C, or from about 157°C, about 158°C, or about 159°C to about 166°C, about 167°C, about
  • the tPPs have a branching index (g 1 , also referred to in the literature as gVis avg) of at least 0.95, 0.97, or 0.98.
  • the tPPs have molecular weight features distinct from the HMS PP from which they are derived.
  • the z-average molecular weight of the tPP is less than 2,500,000 g/mol, 2,000,000 g/mol, 1,600,000 g/mol, 1,400,000 g/mol, or 1,200,000 g/mol, or from about 500,000 g/mol, about 600,000 g/mol, or about 800,000 g/mol to about 1,200,000 g/mol, about 1,400,000 g/mol, about 1,600,000 g/mol, about 2,000,000 g/mol, or about 2,500,000 g/mol.
  • the Mz/Mn value of the tPP is less than 60, 55, or 40, or from about 10, about 15, about 20, or about 25 to about 35 about 40, about 55, or about 60.
  • the Mz/Mw value of the tPP is less than 4, 3.8, or 3.6, or from about 2.5 or about 2.6 to about 3.6, about 3.8, or about 4.
  • the tPPs have a molecular weight distribution (Mw/Mn) of less than 22, 20, 18, 16, or 15, or from about 5, about 6, about 7, about 7.5, about 8, about 8.5, or about 9 to about 15, about 16, about 18, about 20, or about 22.
  • the tPPs have an MFR (2.16 kg/230°C) from about 0.2 g/10 min, about 0.5 g/10 min, about 1 g/10 min, about 2 g/10 min, or about 3 g/10 min to about 4 g/10 min, about 5 g/10 min, about 6 g/10 min, about 8 g/10 min, about 10 g/10 min, or about 20 g/10 min.
  • the MFR of the tPPs is from about 0.2 g/10 min to about 20 g/10 min, about 0.5 g/10 min to about 15 g/10 min, about 0.5 g/10 min to about 10 g/10 min, about 0.5 g/10 min to about 8 g/10 min, about 0.5 g/10 min to about 5 g/10 min, about 0.5 g/10 min to about 4 g/10 min, about 0.5 g/10 min to about 3 g/10 min, or about 0.5 g/10 min to about 2 g/10 min.
  • the tPPs can have elasticity while in the melt phase.
  • the Tan Delta (ratio of the viscous modulus (G") to elastic modulus (G) which is a useful quantifier of the presence and extent of elasticity in the melt) of the trimmed polypropylene is greater than 4, 6, 8, or 10, or from about 4, about 6, about 8, or about 10 to about 20, about 24, about 28, about 32, or about 36.
  • the tPPs also have advantageous bulk-physical properties.
  • the tPP has a Modulus of greater than 13 MPa, 14 MPa, or 15 MPa, or from about 13 MPa, about 14 MPa, or about 15 MPa to about 18 MPa, about 20 MPa, about 22 MPa, or about 24 MPa.
  • the reaction product of multi-functional monomers e.g., polyfunctional acrylates
  • oligomers e.g., polyisobutylene
  • cross-linking agents e.g., silanes, siloxanes
  • the polypropylene, contained in the polyolefin composition includes one or more tPPs which are produced from one or more HMS PPs.
  • the polypropylene has a molecular weight distribution (Mw/Mn) of about 7 to about 22 and a z-average molecular weight of less than 2,500,000 g/mol.
  • the polypropylene also has a branching index (gVis) of 0.95 or greater and a melt strength of less than 20 cN determined using an extensional rheometer at 190°C.
  • Exemplary tPP's that are commercially available are AchieveTM Advanced polypropylene grades from ExxonMobil Chemical Company (Houston, Texas).
  • the polypropylene can be or include one or more BWD PPs.
  • the BWD PP can be or include AchieveTM Advanced PP0502E1 polypropylene, available from ExxonMobil Chemical Co.
  • the BWD PP can have a melt index from about 1, about 1.1, about 1.2, about 1.3, about 1.4, or about 1.5 g/10 min to about 1.6, about 1.7, about 1.8, about 1.9, or about 2 g/10 min, as determined according to ASTM D1238 (190°C/2.16 kg).
  • the BWD PP can have a melt index from about 1 g/10 min to about 2 g/10 min, about 1.2 g/10 min to about 2 g/10 min, about 1.4 g/10 min to about 2 g/10 min, about 1.5 g/10 min to about 2 g/10 min, about 1.6 g/10 min to about 2 g/10 min, about 1.7 g/10 min to about 2 g/10 min, about 1.8 g/10 min to about 2 g/10 min, about 1 g/10 min to about 1.8 g/10 min, about 1.2 g/10 min to about 1.8 g/10 min, about 1.4 g/10 min to about 1.8 g/10 min, about 1.5 g/10 min to about 1.8 g/10 min, about 1.6 g/10 min to about 1.8 g/10 min, about 1.7 g/10 min to about 1.8 g/10 min, about 1 g/10 min to about 1.6 g/10 min, about 1.2 g/10 min to about 1.6 g/10 min, about 1.7 g/10 min to about 1.8 g/10
  • the BWD PP can have a MFR from about 1, about 1.5, about 1.8, about 2, about 2.2, about 2.5, about 2.8, or about 3 g/10 min to about 3.2, about 3.5, about
  • the BWD PP can have an MFR of about 1 g/10 min to about 6 g/10 min, about 1.5 g/10 min to about 6 g/10 min, about 2 g/10 min to about 6 g/10 min, about 2.5 g/10 min to about 6 g/10 min, about 3 g/10 min to about 6 g/10 min, about 3.5 g/10 min to about 6 g/10 min, about 4 g/10 min to about 6 g/10 min, about 4.5 g/10 min to about 6 g/10 min, about 2 g/10 min to about 6 g/10 min, about 2 g/10 min to about 5 g/10 min, about 2 g/10 min to about 4 g/10 min, about 2 g/10 min to about 3.5 g/10 min, about 2 g/10 min to about 3 g/10 min, about 2 g/10 min to about 2.5 g/10 min, about 3
  • the BWD PP can have a density of about 0.8 g/cm 3 , about 0.82 g/cm 3 , about 0.84 g/cm 3 , about 0.85 g/cm 3 , about 0.86 g/cm 3 , about 0.88 g/cm 3 , or about 0.89 g/cm 3 to about 0.90 g/cm 3 , about 0.91 g/cm 3 , about 0.92 g/cm 3 , about 0.95 g/cm 3 , or about 0.98 g/cm 3 .
  • the BWD PP can have a density of about 0.82 g/cm 3 to about 0.98 g/cm 3 , about 0.85 g/cm 3 to about 0.95 g/cm 3 , about 0.87 g/cm 3 to about 0.92 g/cm 3 , about 0.88 g/cm 3 to about 0.92 g/cm 3 , about 0.89 g/cm 3 to about 0.92 g/cm 3 , or about 0.89 g/cm 3 to about 0.91 g/cm 3 .
  • the BWD PP can have a Tensile Strength at Yield independently in the MD and the TD of about 10 MPa, about 15 MPa, about 18 MPa, about 20 MPa, about 25 MPa, about 30 MPa, or about 35 MPa to about 40 MPa, about 45 MPa, about 50 MPa, about 60 MPa, about 80 MPa, or about 100 MPa, as determined by ASTM D638.
  • the BWD PP can have a Tensile Strength at Yield independently in the MD and the TD of about 18 MPa to about 100 MPa, about 18 MPa to about 80 MPa, about 18 MPa to about 60 MPa, about 18 MPa to about 50 MPa, about 18 MPa to about 40 MPa, about 18 MPa to about 35 MPa, about 18 MPa to about 30 MPa, about 30 MPa to about 100 MPa, about 30 MPa to about 80 MPa, about 30 MPa to about 60 MPa, about 30 MPa to about 50 MPa, about 30 MPa to about 40 MPa, about 30 MPa to about 35 MPa, about 35 MPa to about 100 MPa, about 35 MPa to about 80 MPa, about 35 MPa to about 60 MPa, or about 35 MPa to about 50 MPa, as determined by ASTM D638.
  • the polypropylene can be or include one or more homopolymers of PP (hPP).
  • the homopolymer of PP can be or include EM PP4052E1 PP, available from ExxonMobil Chemical Company (Houston, Texas).
  • the hPP can have a MFR from about 1, about 1.2, about 1.4, about 1.6, or about 1.8 g/10 min to about 2, about 2.2, about 2.5, about 2.8, about 3, about 3.5, about 4, about 4.5, about 5, about 5.5, or about 6 g/10 min, as determined according to ASTM D1238 Condition L (230°C/2.16 kg).
  • the hPP can have an MFR of about 1 g/10 min to about 6 g/10 min, about 1.5 g/10 min to about 6 g/10 min, about 2 g/10 min to about 6 g/10 min, about 2.5 g/10 min to about 6 g/10 min, about 3 g/10 min to about 6 g/10 min, about 3.5 g/10 min to about 6 g/10 min, about 4 g/10 min to about 6 g/10 min, about 4.5 g/10 min to about 6 g/10 min, about 1.3 g/10 min to about 6 g/10 min, about 1.3 g/10 min to about 5 g/10 min, about 1.3 g/10 min to about 4 g/10 min, about 1.3 g/10 min to about 3 g/10 min, about 1.3 g/10 min to about 2.5 g/10 min, about 1.3 g/10 min to about 2.2 g/10 min, about 1.3 g/10 min to about 2 g/10 min, about 1.6 g/10 min to about 6 g/10 min, about 1.6 g/10 min to about
  • thehPP can have a density of about 0.8 g/cm 3 , about 0.82 g/cm 3 , about 0.84 g/cm 3 , about 0.85 g/cm 3 , about 0.86 g/cm 3 , or about 0.88 g/cm 3 to about 0.9 g/cm 3 , about 0.92 g/cm 3 , about 0.95 g/cm 3 , or about 0.98 g/cm 3 .
  • the hPP can have a density of about 0.82 g/cm 3 to about 0.98 g/cm 3 , about 0.85 g/cm 3 to about 0.95 g/cm 3 , or about 0.87 g/cm 3 to about 0.92 g/cm 3 .
  • the hPP can have a Tensile Strength at Yield of about 20 MPa, about 25 MPa, about 30 MPa, or about 35 MPa to about 40 MPa, about 45 MPa, about 50 MPa, about 60 MPa, about 80 MPa, or about 100 MPa, as determined by ASTM D638.
  • the hPP can have a Tensile Strength at Yield of about 20 MPa to about 100 MPa, about 20 MPa to about 80 MPa, about 20 MPa to about 60 MPa, about 20 MPa to about 50 MPa, about 20
  • MPa to about 40 MPa about 20 MPa to about 35 MPa, about 20 MPa to about 30 MPa, about
  • the polypropylene can be or include one or more impact copolymers (ICP).
  • ICP impact copolymers
  • the ICP can be or include EM PP7032E2 PP, available from ExxonMobil Chemical Company (Houston, Texas).
  • the ICP can have a MFR from about 1 , about 2, about 2.2, about 2.5, about 2.8, about 3, about 3.2, or about 3.5 g/10 min to about 3.8, about 4, about 4.5, about 5, about 5.5, or about 6 g/10 min, as determined according to ASTM D1238 Condition L (230°C/2.16 kg).
  • the ICP can have an MFR of about 1 g/10 min to about 6 g/10 min, about 2 g/10 min to about 5 g/10 min, about 2 g/10 min to about 4.5 g/10 min, about 2 g/10 min to about 4 g/10 min, about 2 g/10 min to about 3.5 g/10 min, about 2 g/10 min to about 3 g/10 min, about 3 g/10 min to about 5 g/10 min, about 3 g/10 min to about 4.5 g/10 min, about 3 g/10 min to about 4 g/10 min, about 3 g/10 min to about 3.5 g/10 min, about 3 g/10 min to about 3.2 g/10 min, about 3.5 g/10 min to about 5 g/10 min, about 3.5 g/10 min to about 4.5 g/10 min, about 3.5 g/10 min to about 4 g/10 min, or about 3.5 g/10 min to about 3.8 g/10 min, as determined by ASTM D1238.
  • the ICP can have a density of about 0.8 g/cm 3 , about 0.82 g/cm 3 , about 0.84 g/cm 3 , about 0.85 g/cm 3 , about 0.86 g/cm 3 , or about 0.88 g/cm 3 to about 0.9 g/cm 3 , about 0.92 g/cm 3 , about 0.95 g/cm 3 , or about 0.98 g/cm 3 .
  • the ICP can have a density of about 0.82 g/cm 3 to about 0.98 g/cm 3 , about 0.85 g/cm 3 to about 0.95 g/cm 3 , or about 0.87 g/cm 3 to about 0.92 g/cm 3 .
  • the ICP can have a Tensile Strength at Yield of about 10 MPa, about 15 MPa, about 18 MPa, about 20 MPa, about 25 MPa, about 30 MPa, or about 35 MPa to about 40 MPa, about 45 MPa, about 50 MPa, about 60 MPa, about 80 MPa, or about 100
  • the ICP can have a Tensile Strength at Yield of about 18 MPa to about 100 MPa, about 18 MPa to about 80 MPa, about 18 MPa to about 60 MPa, about 18 MPa to about 50 MPa, about 18 MPa to about 40 MPa, about 18 MPa to about 35 MPa, about 18 MPa to about 30 MPa, about 30 MPa to about 100 MPa, about 30 MPa to about 80 MPa, about 30 MPa to about 60 MPa, about 30 MPa to about 50 MPa, about 30 MPa to about 40 MPa, about 30 MPa to about 35 MPa, about 35 MPa to about 100 MPa, about 35 MPa to about 80 MPa, about 35 MPa to about 60 MPa, or about 35 MPa to about 50 MPa, as determined by ASTM D638.
  • Random Copolymer 1RCP of Polypropylene
  • the polypropylene can be or include one or more random copolymers (RCP).
  • RCP random copolymers
  • the RCP can be or include EM PP9054 PP, available from ExxonMobil Chemical Company (Houston, Texas).
  • the RCP can have a MFR from about 5, about 6, about 7, about
  • the RCP can have an MFR of about 5 g/10 min to about 20 g/10 min, about 5 g/10 min to about 18 g/10 min, about 5 g/10 min to about 16 g/10 min, about 5 g/10 min to about 14 g/10 min, about 5 g/10 min to about 12 g/10 min, about 5 g/10 min to about 10 g/10 min, about 5 g/10 min to about 8 g/10 min, about 8 g/10 min to about 20 g/10 min, about 8 g/10 min to about 18 g/10 min, about 8 g/10 min to about 16 g/10 min, about 8 g/10 min to about 14 g/10 min, about 8 g/10 min to about 12 g/10 min, about 8 g/10 min to about 10 g/10 min, about 10 g/10 min to about 14 g/10 min, about 8 g/10 min to about 12 g/10 min, about 8 g/10 min to about 10 g/10 min, about 10 g/10 min to about 14 g/10 min, about 8 g/10 min to
  • the RCP can have melt temperature of about 100°C, about 120°C, about 125°C, about 130°C, about 135°C, about 140°C, about 145°C, or about 150°C to about 155°C, about 160°C, about 165°C, about 170°C, about 175°C, about 180°C, about 190°C, or about 200°C.
  • the RCP can have melt temperature of about 100°C to about 200°C, about 100°C to about 180°C, about 100°C to about 170°C, about 100°C to about 160°C, about 100°C to about 150°C, about 100°C to about 140°C, about 100°C to about 130°C, about 100°C to about 120°C, about 125°C to about 200°C, about 125°C to about 180°C, about 125°C to about 170°C, about 125°C to about 160°C, about 125°C to about 150°C, about 125°C to about 140°C, about 125°C to about 130°C, about 145°C to about 200°C, about 145°C to about
  • additives may also be present in the polyolefin composition, layers, and/or films thereof. These additives may be added before, during, and/or after the formation of the coextruded sheets or films.
  • additives include antioxidants (e.g., hindered phenol- and phosphite-type compounds), stabilizers such as lactone and vitamin E, nucleators (both a-nucleators and b-nucleators), clarifying agents, colorants (dyes or pigments), fillers (silica or talc), UV stabilizers, release agents, slip agents, tackifiers, anti-static agents, acid scavengers (e.g., calcium stearate), anti-blocking agents, anti-blooming agents, polymer processing aid masterbatch (PPA MB) additives/agents, hydrocarbon resins such as OpperaTM type resins, or combinations thereof.
  • antioxidants e.g., hindered phenol- and phosphite-type compounds
  • the polyolefin composition, the core layer, and/or one or more skin layers contains one or more additives in an amount from about 0.5 wt%, about 1 wt%, about 2 wt%, about 3 wt%, about 4 wt%, or about 5 wt% to about 6 wt%, about 8 wt%, or about 10 wt%, based on the weight of the composition/layer.
  • the polyolefin composition contains from about 0.5 wt% to about 10 wt%, about 0.5 wt% to about 8 wt%, about 0.5 wt% to about 5 wt%, about 0.5 wt% to about 3 wt%, about 0.5 wt% to about 2 wt%, about 0.5 wt% to about 1 wt%, about 1 wt% to about 10 wt%, about 1 wt% to about 8 wt%, about 1 wt% to about 5 wt%, about 1 wt% to about 3 wt%, or about 1 wt% to about 2 wt% of the additive.
  • the polyolefin composition, the core layer, and/or one or more skin layers contains one or more additives in an amount from about 50 ppm, about 100 ppm, about 150 ppm, about 200 ppm, about 300 ppm, about 350 ppm, about 400 ppm, about 420 ppm, about 450 ppm, about 500 ppm, about 750 ppm, or about 1,000 ppm to about 1,500 ppm, about 2,000 ppm, about 2,500 ppm, about 3,000 ppm, about 4,000 ppm, about 4,500 ppm, or about 5,000 ppm.
  • the polyolefin composition, the core layer, and/or one or more skin layers contains about 50 ppm to about 5,000 ppm, about 100 ppm to about 5,000 ppm, about 150 ppm to about 5,000 ppm, about 200 ppm to about 5,000 ppm, about 300 ppm to about 5,000 ppm, about 420 ppm to about 5,000 ppm, about 500 ppm to about 5,000 ppm, about 1,000 ppm to about 5,000 ppm, about 1,500 ppm to about 5,000 ppm, about 2,000 ppm to about 5,000 ppm, about 2,500 ppm to about 5,000 ppm, about 3,000 ppm to about 5,000 ppm, about 50 ppm to about 3,000 ppm, about 100 ppm to about 3,000 ppm, about 150 ppm to about 3,000 ppm, about
  • nucleating agents are absent, for example, a-nucleating agents are absent, meaning nucleating agents are not added to the composition or any components of the composition at any stage of the process of formation.
  • a-nucleating agents include salts of monocarboxylic acids and polycarboxylic acids, sorbitols such as dibenzylidenesorbitol, salts of diesters of phosphoric acid, vinylcycloalkane polymers, or combinations thereof.
  • the polyolefin compositions of the present disclosure are particularly useful in films and articles that include films or film coatings. Films of less than 250 pm average thickness can be made using the polyolefin compositions and can contain any number of layers, such as additional layers of linear low-density polyethylene (LLDPE), HDPE, LDPE, iPP, EP copolymers, and combinations thereof. Also, the polyolefin compositions can contain a composition including any of these polymers or combinations of polymers and be present in any desirable amount.
  • LLDPE linear low-density polyethylene
  • sheets having an average thickness of about 250 pm or more can be made using the polyolefin compositions described herein, or may contain one or more layers containing polyolefin compositions and another material such as LLDPE, HDPE, LDPE, iPP, EP copolymers, and combinations thereof.
  • Such sheets, or other desirable structures made using the polyolefin compositions described herein may be thermoformed, blow molded, or injection molded into useful articles, and further, polyolefin compositions may be rotomolded to form useful articles.
  • the polyolefin composition, the core layer, the tie layer, and/or the skin layer can include one or more LLDPEs.
  • the LLDPE is in a concentration of about 5 wt%, about 10 wt%, about 15 wt%, about 20 wt% to about 25 wt%, about 30 wt%, about 40 wt%, or about 50 wt% by weight of the overall polymer composition (e.g., the polyolefin composition, the core layer, or the skin layer).
  • the LLDPE contains ethylene derived units and comonomers selected from C3 to CIO alpha-olefin derived units.
  • polyolefin compositions described herein such as thermoformed articles, blow molded articles, injection molded articles, sheets, fibers, fabrics, and other useful items.
  • the polyolefin compositions can be used to produce industrial and food package articles that have a PP/PE film structure.
  • the polyolefin compositions can be formed into films using any suitable method, especially cast films, extrusion coated films, and blown films, and/or included as at least part of one or more layers of a multi-layered film.
  • Such types of films may have two, three, four or more layers represented such as S/C, S/C/S, S/C/C, S/T/C/S, S/T/C/T/S, wherein "C” is a core layer, "T” is a tie-layer, and "S” is a skin layer, each of which may be made from the same or different materials.
  • Any one or more layers e.g., core, tie, and/or skin layers
  • structures include those that contain a layer having a range from about 50 wt%, about 55 wt%, or about 60 wt% to about 80 wt%, about 85 wt%, or about 90 wt%, based on weight of the components of that layer, of one or more polyolefin compositions.
  • that layer is a core layer with at least one skin layer containing a polyethylene and/or polypropylene.
  • the polyolefin compositions can replace the HDPE in many known film structures and allow down- gauging by about 10% to about 30% relative to when HDPE is used.
  • the polyolefin compositions can be used in making blown films.
  • the ingredients used to form the film are added in any desirable form, such as granules, pellets, or particulates, into a hopper which feeds the material to an extruder, where the materials are melt blended at a desirable temperature through shear forces and/or heating.
  • the molten material is then fed, with or without filtering, to a die which may have just one, or have multiple cavities corresponding to each of multiple layers that will form the film.
  • the die is also heated to a desired temperature and then forced from the die in a direction away from the die.
  • the cooling of the forming film takes place via a device that blows air or one or more other gases (e.g., nitrogen, argon, mixtures thereof) that is at least 5°C or 10°C cooler than the surrounding air, where the "surrounding air” is air that is at least 1 meter from the cooling device, but less than 5 meters.
  • the air can blow against the outside of the film, such as around the entire circumference formed by the film.
  • polypropylenes can be difficult to use for blown film processes because they typically have low melt strength, which will promote breakage of the bubble, balloon, or film.
  • HMS PP of the present disclosure can provide improved melt strength for improved polypropylene-based blown film processes.
  • the polyolefin compositions of the present disclosure have an enhanced toughness and a greater stiffness compared to conventional BOCD polyethylenes.
  • the performance of the compositions containing the polypropylenes being formed into a film can be characterized by its Maximum Die Rate.
  • the "Maximum Die Rate" is a normalized extrusion rate by die size which is commonly used in the blown film industry.
  • the Maximum Die Rate at which the film is formed is greater than 13 lb/in- hr (0.73 kg/mm-hr) or 16 lb/in-hr (0.90 kg/mm-hr) or 24 lb/in-hr (1.34 kg/mm-hr), or from 13 lb/in-hr (0.73 kg/mm-hr) or 16 lb/in-hr (0.90 kg/mm-hr), or 24 lb/in-hr (1.34 kg/mm-hr) to 30 (1.69 kg/mm-hr), or 40 lb/in-hr (2.25 kg/mm-hr).
  • the die dimension is the die circumference
  • the die dimension is the die diameter
  • the full expression is lb/die circumference (in unit of inch)/hr
  • the full expression is kg/die diameter (in unit of mm)/hr.
  • the polyolefin compositions can be processed at advantageously low temperatures.
  • the polyolefin composition can be processed, such as melt extruded, at barrel temperatures of less than 210°C, 200°C, or 190°C, or from about 160°C, about 170°C, about 175°C, about 180°C, or about 185°C to about 190°C, about 195°C, about 200°C, about 205°C, or about 210°C; and die temperatures of less than 210°C, or from about 190°C, about 200°C, or about 205°C to about 210°C.
  • a method of forming a finished film includes extruding a molten polyolefin composition through a die opening to form a film and causing the film to progress in a direction away from the die opening, such as in the molten state, partially molten, or softened due to some partial cooling.
  • the method also includes cooling the molten polyolefin composition in the form of a film at a distance from the die opening, the distance adjusted to effect the properties of the film (e.g., to allow relaxation of the molten polyolefin composition prior to solidification and/or crystallization upon cooling), and isolating a finished film therefrom.
  • a method of forming a film includes extruding the polyolefin composition through one or more die openings to form the film.
  • the method can include extruding a molten polyolefin composition containing one or more BOCD polyethylenes and one or more polypropylenes through the die opening to form the film, and then cooling the film at a distance away from the die opening to produce a finished film.
  • the film can be cooled by blowing air, nitrogen, argon, or other gases on at least a portion of the film.
  • the molten polyolefin composition can include about 40 wt% to about 95 wt% of the BOCD polyethylene and about 5 wt% to about 60 wt% of the polypropylene, by weight of the polyolefin composition.
  • the BOCD polyethylene contains about 70 mol% to about 100 mol% of ethylene and has a density of about 0.91 g/cm 3 to about 0.925 g/cm 3 , in accordance with ASTM D-4703 and ASTM D-1505/ISO 1183 and a branching index (gVis) of 0.98 or greater.
  • a film containing the polyolefin composition has a thickness of about 10 pm, about 30 pm, or about 50 pm to about 100 pm, about 200 pm, about 300 pm, or about 500 pm.
  • the film containing the polyolefin composition has a thickness of about 10 pm to about 300 pm, about 10 pm to about 200 pm, about 10 pm to about 150 pm, about 10 pm to about 100 pm, about 10 pm to about 80 pm, about 10 pm to about 50 pm, about 10 pm to about 40 pm, about 25 pm to about 300 pm, about 25 pm to about 200 pm, about 25 pm to about 150 pm, about 25 pm to about 100 pm, about 25 pm to about 80 pm, about 25 pm to about 50 pm, about 25 pm to about 40 pm, about 50 pm to about 300 pm, about 50 pm to about 200 pm, about 50 pm to about 150 pm, about 50 pm to about 100 pm, or about 50 pm to about 80 pm.
  • the film is a monolayer that has a thickness of about 10 pm to about 100 pm, about 20 pm to about 80 pm, or about 30 pm to about 60 pm. In other examples, the film has a thickness of about 50 pm to about 300 pm, about 60 pm to about 200 pm, or about 80 pm to about 150 pm.
  • the film, the core, or other monolayer contains from about 75 wt% to about 95 wt% of the BOCD polyethylene and from about 5 wt% to about 25 wt% of the polypropylene, by weight of the polyolefin composition.
  • the film has an Elmendorf Tear MD of about 7.2 g/pm to about 10 g/pm, about 7.5 g/pm to about 9.5 g/pm, or about 8 g/pm to about 9.2 g/pm and an Elmendorf Tear TD of about 12.8 g/pm to about 16 g/pm, about 13 g/pm to about 14.5 g/pm, or about 13.5 g/pm to about 14 g/pm.
  • the film includes a core layer disposed between two skin layers. Both skins can have the same composition, or alternatively, each of the skins can have a different composition than the each other.
  • the core layer includes the polyolefin composition which contains one or more HMS PPs or one or more tPPs.
  • each of the skin layers can independently contain the polyolefin composition, the BOCD, an LLDPE, the polypropylene, or any combination thereof.
  • melt By “extruding” what is meant is that the polymer and/or polymer blend if formed into a melt such as by heating and/or sheer forces and is forced to blend with other polymers and/or components (e.g., the polyethylene and the modifier) and is then forced out of a die in a desirable form or shape to affect the form or shape of the emanating polymer melt, such as in a film, such as a tubular film.
  • Any suitable apparatus will be appropriate to provide "extrusion” such as a single or twin-screw extruder, or other melt-blending device as is known in the art and that can be fitted with a suitable die.
  • the “cooling device” such as a cooling ring that blows air on the forming film, is located at least 1 cm, 2 cm, 4 cm, or 8 cm from the die (or other distance as described herein) such as measured from the top or outer edge of the die to the base of the cooling device.
  • causing the film to progress is that the film forming from the die opening from hardening polyethylene is pulled or pushed mechanically or by some other means such as by air pressure (negative or positive) away from the die to create a continuous finished film.
  • a polyethylene melt is extruded through a die such as an annular slit die, usually vertically, to form a thin walled tube. Cooling can be conducted in the air or other gas which is introduced via a ring in the center of the die to blow up the tube like a balloon. Cooling could also be provided by other means, and the air may be nitrogen/oxygen or other gases or mixtures of gases or liquids.
  • a high-speed air ring blows onto the hot film to cool the film.
  • the cooling occurs at some distance from the die, which is at least 1 cm as described above.
  • the tube of film can then continue upwards, continually cooling, until it may pass through nip rolls where the tube is flattened to create what is known as a "lay-flat" tube of film.
  • This lay-flat or collapsed tube can then be taken back down the extrusion "tower” via more rollers.
  • the air inside the bubble is also exchanged. This is known as IBC (Internal Bubble Cooling).
  • lay -flat film is then either kept as such or the edges of the lay-flat are slit off to produce two flat film sheets and wound up onto reels.
  • Articles such as bags can be made from such lay -flat films.
  • the tube of film is made into bags by sealing across the width of film and cutting or perforating to make each bag. This is done either in line with the blown film process or at a later stage.
  • the expansion ratio between die and blown tube of film would be 1.5 times to 4 times the die diameter.
  • the films were blown at a temperature of about 400°F (about 204°C) to about 500°F (about 260°C), such as about 410°F (about 210°C) to about 465°F (about 241°C).
  • the drawdown between the melt wall thickness and the cooled film thickness occurs in both radial and longitudinal directions and is easily controlled by changing the volume of air inside the bubble and by altering the haul off speed. This gives blown film a better balance of properties than traditional cast or extruded film which is drawn down along the extrusion direction only.
  • the polyolefin compositions described herein are suitable for stand up, flexible, packs, or pouches.
  • Such packs would be stiff enough to be formed into a shape to allow it to stand upright, for instance, with labeling on the front, but flexible and soft enough to allow a user to bend and/or squeeze the pack to force and/or pour liquid, gel, or flowable solids from an opening or open top of the pack.
  • the polyethylene content can be adjusted to provide the toughness and low temperature packaging integrity for the pouch while the polypropylene content can be adjusted to provide stiffness and heat resistance during defrosting and/or microwave reheating of the pouch or pack.
  • the packs and pouches can be used for collecting, storing and serving food items such as juice, vegetables, dairy products, desserts, flowable solids, and/or purees.
  • a flexible food pack comprising the polyolefin composition of any one of the preceding claims, where the polyolefin composition contains within the range from about 5, or 10 to 40, or 50 wt% of the polypropylene, and from within the range from about 50, or 60 to 90, or 95 wt% of the polyethylene, each by weight of the composition; and wherein the polyolefin composition is a film that is optionally laminated to one or more additional polymeric films.
  • additional films could be the same or different polyolefin materials and could include a metallized layer of material if microwave heating is not desired.
  • Three-layer films, Samples 1-30, having a core layer disposed between two skin layers were produced with a thickness of 90 pm, as listed in Table 1.
  • Each of the three-layer films contained 25 wt% / 50 wt% / 25 wt% of skin/core/skin, respectively.
  • the skin layers of the three-layer films were prepared with about 90 wt% of BOCD PE (ExceedTM XP 8656ML polyethylene, available from ExxonMobil Chemical Co.) and about 10 wt% of PP (AchieveTM Advanced PP0502E1).
  • the core of the three-layer films were prepared with various concentrations of BOCD PE (ExceedTM XP 8656ML polyethylene, available from ExxonMobil Chemical Co.) and one of the polypropylenes (PP1-PP6), as listed in Table 1.
  • the polypropylenes include:
  • Polypropylene 1 (PP1) - a Broad Weight Distribution (BWD) PP (AchieveTM Advanced PP0502E1 polypropylene, available from ExxonMobil Chemical Co.); Polypropylene 2 (PP2) - a HMS PP with a 4MFR (about 4 g/10 min);
  • Polypropylene 3 (PP3) - a HMS PP (AchieveTM Advanced PP6282NE1 polypropylene, available from ExxonMobil Chemical Co.);
  • Polypropylene 4 (PP4) - ahomopolymer of PP (EM PP4052E1 polypropylene, available from ExxonMobil Chemical Co.);
  • Polypropylene 5 (PP5) - an impact copolymer (ICP) (EM PP7032E2 polypropylene, available from ExxonMobil Chemical Co.); and Polypropylene 6 (PP6) - a random copolymer (RCP) (EM PP9054 polypropylene, available from ExxonMobil Chemical Co.).
  • ICP impact copolymer
  • PP6 Polypropylene 6
  • RCP random copolymer
  • EM PP9054 polypropylene, available from ExxonMobil Chemical Co.
  • Comparative or control samples were used and included three-layer films having a core layer disposed between two skin layers were produced with a thickness of 90 pm.
  • Each film of the control samples contains 25 wt% / 50 wt% / 25 wt% of skin/core/skin, respectively.
  • the core of the control sample films were 100 wt% of BOCD PE (ExceedTM XP 8656ML polyethylene, available from ExxonMobil Chemical Co.).
  • the skin layers of the control sample films were prepared with about 90 wt% of BOCD PE (ExceedTM XP 8656ML polyethylene, available from ExxonMobil Chemical Co.) and about 10 wt% of PP (AchieveTM Advanced PP0502E1).
  • Measured properties for Samples 1-30 and the control sample are listed in Table 2, as well as provided throughout the graphs in Figures 3A-8.
  • the measured properties included Stiffness in the MD and TD (1% secant flexural modulus), Tensile Strength in the MD and TD (determined by ASTM D882), Tear strength in the MD and TD (Elmendorf tear), Elongation at Break in the MD and TD (determined by ASTM D882), Dart Drop Impact, and Haze.
  • FIGS. 3A and 3B are plots of Stiffness for Samples 1-30 and the control sample having a core of BOCD PE.
  • the BOCD PE By blending the BOCD PE with any of PP1-PP6, the 1% Secant is increased both orientations (MD and TD) for Samples 1-30 over the control example.
  • the HMS PPs (PP1 and PP2) in Samples 1-10 and the homopolymer PPs (PP3 and PP4) in Samples 11-20 provide the greatest increase of stiffness over the ICP PP (PP5) in Samples 21-25 and the RCP PP (PP6) in Samples 26-30.
  • FIGS. 4A and 4B are plots of Tensile at Yield strength for Samples 1-30 and the control sample having a core of BOCD PE.
  • the Tensile at Yield strength is increased both orientations (MD and TD) for Samples 1-30 over the control example.
  • the HMS PPs (PP1 and PP2) in Samples 1-10 and the homopolymer PPs (PP3 and PP4) in Samples 11-20 provide the greatest increase of tensile strength over the ICP PP (PP5) in Samples 21-25 and the RCP PP (PP6) in Samples 26-30.
  • FIGS. 5A and 5B are plots of Tear strength for Samples 1-30 and the control sample having a core of BOCD PE.
  • the Tear strength is increased in concentrations from about 10 wt% to about 30 wt% in the MD and about 30 wt% to about 40 wt% in the TD for Samples 1-30 over the control example.
  • the Tear strength was either increased or decreased depending on the specific PP.
  • the ICP PP (PP5) in Samples 21-25 and the RCP PP (PP6) in Samples 26-30 provided the greatest increase in Tear strength and at a broader concentration range compared to the other PPs.
  • FIG. 6A and 6B are plots of Elongation at Break strength for Samples 1-30 and the control sample having a core of BOCD PE.
  • the Elongation at Break strength values for Samples 1-30 were very random in the MD, such that the values increased, decreased, or stayed the same relative to the control example. Most of the values in the Elongation at Break strength values for Samples 1-30 in the TD were increased relative to the control example.
  • FIG. 7 is a plot of Dart Drop Impact strength for Samples 5, 10, 15, and 20-30 and the control sample having a core of BOCD PE.
  • the ICP PP (PP5) in Samples 21-25 and the RCP PP (PP6) in Samples 26-30 maintained high values for the Dart Drop Impact strength relative to the control sample. However, the other PPs in Samples 5, 10, 15, and 20 provided reduced values for the Dart Drop Impact strength relative to the control sample.
  • FIG. 8 is a plot of Haze for Samples 1-30 and the control sample having a core of
  • Extruder B (HX90-G) for a core layer had a Feed Throat Temperature of about 27°C, Barrels #l-#4 Temperature of about 185°C to about 196°C, Barrel #5 Temperature of about 193°C to about 204°C, and Zones #6-#7 Temperature of about 193°C to about 216°C.
  • Extruder B (HX90-G) for a core layer had a Feed Throat Temperature of about 27°C, Barrels #l-#4 Temperature of about 185°C to about 196°C, Barrel #5 Temperature of about 185°C to about 204°C, and Zones #6-#7 Temperature of about 193°C to about 227°C.
  • Extruder C (HX65-S) for a second skin layer had a Feed Throat Temperature of about 27°C, Barrel #1 Temperature of about 177°C to about 188°C, Barrel #2 Temperature of about 204°C to about 216°C, Barrels #3-#5 Temperature of about 199°C to about 210°C, Zones #6-#7 Temperature of about 199°C to about 210°C, Die Zones #l-#4 Temperature of about 227°C to about 241°C, IBC Ring Temperature of about 18°C, Air Ring Temperature of about 18°C, and Nip Roll Temperature of about 27°C. 1% Secant Flexural Modulus
  • the 1 % secant flexural modulus was determined by the following: Equipment used: The United Six (6) station, 60 Degree machine contains the following: A load frame testing console containing an electrically driven crosshead mounted to give horizontal movement. Opposite the crosshead are mounted six (6) separate load cells. These load cells are tension load cells.
  • Units #1 and #3 have load cells with a range of 0-35 pounds.
  • Unit #2 has load cells with a range of 0-110 pounds.
  • Each load cell was equipped with a set of air-actuated jaws. Each jaw had faces designed to form a line grip. The jaw combines one standard flat rubber face and an opposing face from which protrudes a metal half-round.
  • Units #1 and #3 have 1 1/4" wide jaws and Unit #2 has 2 1/4" wide jaws. Secant Modulus was tested on Units #1 and
  • Sample preparation The specimens were conditioned and tested under ASTM laboratory conditions. They were maintained at 23 ⁇ 2° C and 50% + 10% relative humidity. Conditioning time was a minimum of 40 hours under lab conditions and 48 hours after manufacturing. Prepared 12 specimens of each material; six in the machine direction (MD), the direction of flow as polymer exits the die, and six in the transverse direction (TD), the direction perpendicular to the flow as polymer exits the die.
  • MD machine direction
  • TD transverse direction
  • Each specimen should be 1" wide and 7" long.
  • the width (1") of the samples should be cut with the JDC precision, fixed-blade cutters. These cutters were used since nicks or cuts in specimens initiate premature breaks. After cutting each specimen, examined visually to ensure the edges were undamaged (free of nicks). On a periodic basis the owner of the cutters will monitor specimen edge quality by microscopic examination.

Abstract

The present disclosure provides polyolefin compositions and films and methods for producing such films. The polyolefin composition contains about 40 wt% to about 95 wt% of broad orthogonal composition distribution (BOCD) polyethylene and about 5 wt% to about 60 wt% of a polypropylene, by weight of the polyolefin composition. The polyolefin composition has a 1% secant flexural modulus in the machine direction (MD) of greater than 200 MPa and a 1% secant flexural modulus in the transverse direction (TD) of greater than 200 MPa, and a Tensile at Yield strength in the MD of greater than 8.5 MPa and a Tensile at Yield strength in the TD of greater than 9.7 MPa.

Description

POLYOLEFIN COMPOSITIONS FOR FILMS
PRIORITY [0001] This application claims priority to and the benefit of U.S. Provisional Application
No. 62/892,629, filed August 28, 2019, the disclosure of which is incorporated herein by reference.
FIELD
[0002] The present disclosure provides compositions containing polyethylene-based materials and polypropylene-based materials and methods of forming films from the same
BACKGROUND
[0003] In producing polymeric films, especially blown films, polymers with good processability are desired to achieve commercial throughput rates, while maintaining sufficient toughness. Further, desirable physical properties for the final film product include stiffness, roughness, and/or tear strength. High density polyethylene (HDPE) and polypropylene (PP) are two possible blending partners for polyethylene (PE) film to increase the stiffness. However, there are limited cases for selecting PP as a blending partner, because PP and PE have different crystallinity phases and types, and there is little to no co-crystallinity between PP and PE. Lean blending PP with PE can increase PE film stiffness while decreasing the PE film toughness at same time.
[0004] On the other hand, PP contains many advantages versus HDPE, like much lower density, higher stiffness, and higher heat resistance. If PP can be used in a majority PE formulation to improve the film stiffness part while still maintaining toughness properties, it will show huge value for industrial and food package down-gauging of the PP/PE film structure. [0005] Therefore, there is a need for improved polyolefin compositions having a relatively high stiffness and an enhanced toughness, and methods for forming films from the polyolefin compositions.
[0006] Related publications include WO 2017/68106.
SUMMARY [0007] The present disclosure provides polyolefin compositions that contain one or more broad orthogonal composition distribution (BOCD) polyethylenes and one or more polypropylenes. In any embodiment, the polyolefin composition comprises (or consists of, or consists essentially of) about 40 wt% to about 95 wt% of the BOCD polyethylene and about 5 wt% to about 60 wt% of a polypropylene, by weight of the polyolefin composition. The BOCD polyethylene contains about 70 mol% to about 100 mol% of ethylene and has a density of about 0.91 g/cm3 to about 0.925 g/cm3, in accordance with ASTM D-4703 and ASTM D-1505/ISO 1183 and a branching index (gVis) of 0.98 or greater. The polyolefin composition has a 1% secant flexural modulus in the machine direction (MD) of greater than 200 MPa and a 1 % secant flexural modulus in the transverse direction (TD) of greater than 200 MPa, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm. The polyolefin composition also has a Tensile at Yield strength in the MD of greater than 8.5 MPa and a Tensile at Yield strength in the TD of greater than 9.7 MPa, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm, as determined by ASTM D882.
[0008] In any embodiment, a polyolefin composition comprises (or consists of, or consists essentially of) about 40 wt% to about 95 wt% of a BOCD polyethylene containing about 70 mol% to about 100 mol% of ethylene and about 5 wt% to about 60 wt% of a polypropylene, by weight of the polyolefin composition. The BOCD polyethylene contains about 70 mol% to about 100 mol% of ethylene and having a density of about 0.91 g/cm3 to about 0.925 g/cm3, in accordance with ASTM D-4703 and ASTM D-1505/ISO 1183. The polyolefin composition has a 1% secant flexural modulus in the MD of greater than 200 MPa and a 1% secant flexural modulus in the TD of greater than 200 MPa, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm. The polyolefin composition also has a Tensile at Yield strength in the MD of greater than 8.5 MPa and a Tensile at Yield strength in the TD of greater than 9.7 MPa, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm, as determined by ASTM D882. The polyolefin composition also has an Elmendorf tear in the MD of about 9.5 g/pm to about 20 g/pm and an Elmendorf tear in the TD of about 9 g/pm to about 20 g/pm, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm.
[0009] In any embodiment, a flexible food package includes the polyolefin composition as described and discussed herein. In one or more examples, the polyolefin composition includes from about 5 wt% to about 50 wt% of the polypropylene and from about 50 wt% to about 95 wt% of the polyethylene, each by weight of the polyolefin composition, and the polyolefin composition is a film that is optionally laminated to one or more additional polymeric films. [0010] In any embodiment, a method of forming a film includes extruding the polyolefin composition through one or more die openings to form the film. For example, the method can include extruding the polyolefin composition containing one or more BOCD polyethylenes and one or more polypropylenes through the die opening to form the film and cooling the film at a distance away from the die opening to produce a finished film. The film can be cooled by blowing air, nitrogen, argon, or other gases on at least a portion of the film.
BRIEF DESCRIPTION OF THE DRAWINGS [0011] So that the manner in which the above recited features of the disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to implementations, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical implementations of this disclosure and are therefore not to be considered limiting of scope, for the disclosure may admit to other equally effective implementations.
[0012] FIGS. 1A and IB are TREF contour plots which are used to determine if a polyethylene is a BOCD PE polymer (FIG. 1 A) as opposed to a conventional PE polymer (FIG. IB).
[0013] FIG. 2 is a plot of Compositional Distribution (molecular weight as a function of branching) plotting (MWI/MW2) values as a function of (Twi-Tw2) for BOCD PE polymers and conventional PE polymer.
[0014] FIGS. 3A and 3B are plots of Stiffness for films containing polyolefin compositions with varying concentrations of broad orthogonal composition distribution (BOCD) polyethylene and polypropylenes of different compositions, according to one or more embodiments described and discussed herein.
[0015] FIGS. 4A and 4B are plots of Tensile at Yield strength for films containing polyolefin compositions with varying concentrations of BOCD polyethylene and polypropylenes of different compositions, according to one or more embodiments described and discussed herein. [0016] FIGS. 5A and 5B are plots of Tear strength for films containing polyolefin compositions with varying concentrations of BOCD polyethylene and polypropylenes of different compositions, according to one or more embodiments described and discussed herein. [0017] FIGS. 6A and 6B are plots of Elongation at Break strength for films containing polyolefin compositions with varying concentrations of BOCD polyethylene and polypropylenes of different compositions, according to one or more embodiments described and discussed herein. [0018] FIG. 7 is a plot of Dart Drop strength for films containing polyolefin compositions with varying concentrations of BOCD polyethylene and polypropylenes of different compositions, according to one or more embodiments described and discussed herein.
[0019] FIG. 8 is a plot of Haze for films containing polyolefin compositions with varying concentrations of BOCD polyethylene and polypropylenes of different compositions, according to one or more embodiments described and discussed herein.
[0020] To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the Figures. It is contemplated that elements and features of one implementation may be beneficially incorporated in other implementations without further recitation.
DFTA11 FD DESCRIPTION
[0021] The present disclosure provides polyolefin compositions that contain one or more broad orthogonal composition distribution (BOCD) polyethylenes and one or more polypropylenes. In one or more examples, the polypropylene can be or include one or more high melt strength polypropylenes (HMS PPs), one or more trimmed polypropylenes (tPPs), one or more broad molecular weight distribution (BMWD or BWD) PPs, one or more homopolymers of PP (hPP), impact copolymers (ICPs) of PP, random copolymer (RCPs) of PP, or any combination thereof. The polyolefin compositions have an enhanced toughness and a greater stiffness compared to conventional BOCD polyethylenes. Films made from such compositions can have a stiffness (1% secant flexural modulus) in the machine direction (MD) and the transverse direction (TD) of greater than 200 MPa, or greater than 225 MPa, such as about 250 MPa to about 1,000 MPa and a Tensile at Yield strength in the MD of greater than 8.5 MPa and a Tensile at Yield strength in the TD of greater than 9.7 MPa.
[0022] Multiple types of films can be produced using the polyolefin composition. For example, the following types of layers and films contain the polyolefin composition: a monolayer containing the polyolefin composition, a two-layer film having a layer containing the polyolefin composition and a layer containing a BOCD polyethylene, and several configurations of three-layer films where one, two, or three layers contain the polyolefin composition. In one or more examples, the three-layer film has a core layer containing the polyolefin composition disposed between two skin layers containing a BOCD polyethylene. In some examples, the three-layer film has a core layer containing the polyolefin composition disposed between two skin layers containing the polyolefin composition. In other examples, the three-layer film has a core layer containing a BOCD polyethylene disposed between two skin layers containing the polyolefin composition.
[0023] In any embodiment, the polyolefin composition contains from about 30 wt%, about 35 wt%, about 40 wt%, about 45 wt%, or about 50 wt% to about 55 wt%, about 60 wt%, about 65 wt%, about 70 wt%, about 75 wt%, about 80 wt%, about 85 wt%, about 88 wt%, about 90 wt%, about 92 wt%, or about 95 wt% of the BOCD polyethylene, by weight of the polyolefin composition. For example, the polyolefin composition contains from about 30 wt% to about 95 wt%, about 35 wt% to about 95 wt%, about 40 wt% to about 95 wt%, about 50 wt% to about
95 wt%, about 60 wt% to about 95 wt%, about 70 wt% to about 95 wt%, about 80 wt% to about 95 wt%, about 85 wt% to about 95 wt%, about 88 wt% to about 95 wt%, about 90 wt% to about
95 wt%, about 30 wt% to about 90 wt%, about 35 wt% to about 90 wt%, about 40 wt% to about
90 wt%, about 50 wt% to about 90 wt%, about 60 wt% to about 90 wt%, about 70 wt% to about
90 wt%, about 80 wt% to about 90 wt%, about 85 wt% to about 90 wt%, about 30 wt% to about
80 wt%, about 35 wt% to about 80 wt%, about 40 wt% to about 80 wt%, about 50 wt% to about 80 wt%, about 60 wt% to about 80 wt%, about 70 wt% to about 80 wt%, about 75 wt% to about
80 wt%, about 70 wt% to about 95 wt%, about 70 wt% to about 92 wt%, about 70 wt% to about
90 wt%, about 70 wt% to about 88 wt%, about 70 wt% to about 85 wt%, about 70 wt% to about
82 wt%, or about 70 wt% to about 80 wt% of the BOCD polyethylene, by weight of the polyolefin composition. [0024] In any embodiment, the polyolefin composition contains from about 5 wt%, about
10 wt%, about 15 wt%, about 20 wt%, about 25 wt%, or about 30 wt% to about 35 wt%, about 40 wt%, about 45 wt%, about 50 wt%, about 55 wt%, about 60 wt%, about 65 wt%, or about 70 wt% of the polypropylene, by weight of the polyolefin composition. For example, the polyolefin composition contains from about 5 wt% to about 70 wt%, about 5 wt% to about 60 wt%, about 5 wt% to about 50 wt%, about 5 wt% to about 45 wt%, about 5 wt% to about 40 wt%, about 5 wt% to about 35 wt%, about 5 wt% to about 30 wt%, about 5 wt% to about 25 wt%, about 5 wt% to about 20 wt%, about 5 wt% to about 15 wt%, about 5 wt% to about 10 wt%, about 10 wt% to about 70 wt%, about 10 wt% to about 60 wt%, about 10 wt% to about 50 wt%, about 10 wt% to about 45 wt%, about 10 wt% to about 40 wt%, about 10 wt% to about 35 wt%, about 10 wt% to about 30 wt%, about 10 wt% to about 25 wt%, about 10 wt% to about
20 wt%, about 10 wt% to about 15 wt%, about 12 wt% to about 70 wt%, about 12 wt% to about
60 wt%, about 12 wt% to about 50 wt%, about 12 wt% to about 45 wt%, about 12 wt% to about
40 wt%, about 12 wt% to about 35 wt%, about 12 wt% to about 30 wt%, about 12 wt% to about 25 wt%, about 12 wt% to about 20 wt%, about 12 wt% to about 15 wt%, about 20 wt% to about
70 wt%, about 20 wt% to about 60 wt%, about 20 wt% to about 50 wt%, about 20 wt% to about
45 wt%, about 20 wt% to about 40 wt%, about 20 wt% to about 35 wt%, about 20 wt% to about
30 wt%, or about 20 wt% to about 25 wt% of the polypropylene, by weight of the polyolefin composition.
[0025] In one or more examples, the polyolefin composition contains from about 40 wt% to about 95 wt% of the BOCD polyethylene and about 5 wt% to about 60 wt% of a polypropylene, by weight of the polyolefin composition. In some examples, the polyolefin composition contains about 50 wt% to about 90 wt% of the BOCD polyethylene and about 10 wt% to about 50 wt% of a polypropylene, by weight of the polyolefin composition. In other examples, the polyolefin composition contains about 55 wt% to about 80 wt% of the BOCD polyethylene and about 20 wt% to about 45 wt% of a polypropylene, by weight of the polyolefin composition. In some examples, the polyolefin composition contains about 70 wt% to about 88 wt% of the BOCD polyethylene and about 12 wt% to about 30 wt% of a polypropylene, by weight of the polyolefin composition. In other examples, the polyolefin composition contains about 60 wt% to about 75 wt% of the BOCD polyethylene and about 25 wt% to about 40 wt% of a polypropylene, by weight of the polyolefin composition.
Properties of Monolayer Containing the Polyolefin Composition
[0026] In any embodiment, a monolayer containing the polyolefin composition has relatively high values for Stiffness (1% secant flexural modulus), in each of the MD and the TD, independently. The polyolefin composition has a 1% secant flexural modulus MD (in the machine direction) of greater than 200 MPa, greater than 225 MPa, greater than 250 MPa, or greater than 275 MPa, such as about 300 MPa, about 400 MPa, about 500 MPa, or about 600 MPa to about 700 MPa, about 800 MPa, about 900 MPa, about 1,000 MPa, about 1,200 MPa, about 1,500 MPa or greater, as determined if a layer (e.g., monolayer or core layer) of the polyolefin composition has a thickness of about 50 pm. For example, the polyolefin composition has a 1% secant flexural modulus MD of greater than or about 200 MPa to about 1,500 MPa, greater than or about 225 MPa to about 1,500 MPa, greater than or about 250 MPa to about 1,500 MPa, greater than or about 275 MPa to about 1,500 MPa, about 300 MPa to about 1,500 MPa, about 300 MPa to about 1,200 MPa, about 300 MPa to about 1,000 MPa, about 250 MPa to about 1 ,000 MPa, about 300 MPa to about 800 MPa, about 300 MPa to about 600 MPa, about 300 MPa to about 500 MPa, about 400 MPa to about 1,200 MPa, about 400 MPa to about 1,000 MPa, about 400 MPa to about 800 MPa, or about 400 MPa to about 600 MPa, as determined if a film comprising the polyolefin composition has a thickness of about 50 pm. The 1% secant flexural modulus is determined by the ExxonMobil PLFL-242.001 standard, as provided below in the Experimental Section.
[0027] In any embodiment, a monolayer containing the polyolefin composition has a 1% secant flexural modulus TD (in the traverse direction) of greater than 200 MPa, greater than 225 MPa, greater than 250 MPa, greater than 275 MPa, or greater than 300 MPa, such as from about 320 MPa, about 340 MPa, about 350 MPa, about 400 MPa, about 500 MPa, or about 600 MPa to about 700 MPa, about 800 MPa, about 900 MPa, about 1,000 MPa, about 1,200 MPa, about 1,500 MPa or greater, as determined if a layer (e.g., monolayer or core layer) of the polyolefin composition has a thickness of about 50 pm. For example, the polyolefin composition has a 1% secant flexural modulus TD of about 250 MPa to about 1,500 MPa, about 250 MPa to about 1,200 MPa, about 250 MPa to about 1,000 MPa, about 250 MPa to about 800 MPa, about 250 MPa to about 600 MPa, about 250 MPa to about 500 MPa, about 340 MPa to about 1,500 MPa, about 340 MPa to about 1,200 MPa, about 340 MPa to about 1,000 MPa, about 340 MPa to about 800 MPa, about 340 MPa to about 600 MPa, about 340 MPa to about 500 MPa, about 400 MPa to about 1,200 MPa, about 400 MPa to about 1,000 MPa, about 400 MPa to about 800 MPa, or about 400 MPa to about 600 MPa, as determined if a film comprising the polyolefin composition has a thickness of about 50 pm.
[0028] In any embodiment, a monolayer containing the polyolefin composition has a Dart Drop Impact (Method A) of greater than 5 g/pm, such as from about 10 g/pm, about 15 g/pm, or about 20 g/pm to about 25 g/pm, about 30 g/pm, about 35 g/pm, about 40 g/pm, about 45 g/pm, or about 50 g/pm, as determined if a layer (e.g., monolayer or core layer) containing the polyolefin composition has a thickness of about 50 pm. For example, the polyolefin composition has a Dart Drop Impact (Method A) of greater than 5 g/pm to about 50 g/pm, about 10 g/pm to about 50 g/pm, about 20 g/pm to about 50 g/pm, about 30 g/pm to about 50 g/pm, or about 40 g/pm to about 50 g/pm, as determined if a layer containing the polyolefin composition has a thickness of about 50 pm.
[0029] In any embodiment, a monolayer containing the polyolefin composition has an Elmendorf tear in the MD (machine direction) of greater than 4 g/pm, such as from about 4.5 g/pm, about 5 g/pm, about 5.5 g/pm, or about 6 g/pm to about 6.5 g/pm, about 7 g/pm, about 7.5 g/pm, about 8 g/pm, about 8.5 g/pm, about 9 g/pm, about 9.5 g/pm, or about 10 g/pm, as determined if a layer (e.g., monolayer or core layer) containing the polyolefin composition has a thickness of about 50 pm. For example, the polyolefin composition has an Elmendorf tear in the MD of greater than 4 g/mih to about 10 g/mih, about 4 g/mih to about 10 g/mih, about 5 g/mih to about 10 g/mih, about 6 g/mih to about 10 g/mih, about 7 g/mih to about 10 g/mih, about 8 g/mih to about 10 g/mih, or about 9 g/mih to about 10 g/mih, as determined if a layer containing the polyolefin composition as determined if a layer containing the polyolefin composition has a thickness of about 50 pm. The Elmendorf tear in the MD and TD values provided herein are determined by the ASTM D1922 standard.
[0030] In any embodiment, a monolayer containing the polyolefin composition has an Elmendorf tear in the TD (traverse direction) of greater than 5 g/pm or greater than 6 g/pm, such as from about 6.5 g/pm, about 7 g/pm, about 8 g/pm, or about 9 g/pm to about 10 g/pm, about 11 g/pm, about 12 g/pm, about 13 g/pm, about 14 g/pm, about 15 g/pm, or about 16 g/pm, as determined if a layer (e.g., monolayer or core layer) containing the polyolefin composition and having a thickness of about 50 pm. For example, the polyolefin composition has an Elmendorf tear in the TD of greater than 5 g/pm to about 16 g/ pm, about 6 g/ pm to about 16 g/pm, about 7 g/pm to about 16 g/pm, about 8 g/pm to about 16 g/pm, about 10 g/pm to about 16 g/pm, about 12 g/pm to about 16 g/pm, or about 14 g/pm to about 16 g/pm, as determined if a layer containing the polyolefin composition has a thickness of about 50 pm. Properties of multi-laver film containing the polyolefin composition
[0031] In any embodiment, a three-layer film has a core layer containing the polyolefin composition disposed between two skin layers containing a BOCD polyethylene. In any embodiment, the polyolefin composition has a Stiffness (1% secant flexural modulus), in each of the MD and the TD, independently, of greater than 200 MPa, greater than 225 MPa, greater than 250 MPa, or greater than 275 MPa, such as about 300 MPa, about 350 MPa, about 400 MPa, about 450 MPa, or about 500 MPa to about 550 MPa, about 600 MPa, about 650 MPa, about 700 MPa, about 800 MPa, about 900 MPa, or about 1,000 MPa, as determined if a film (e.g., 2, 3, 4, or more layer film) containing the polyolefin composition has a thickness of about
90 pm. For example, the polyolefin composition has a 1% secant flexural modulus MD of greater than 225 MPa to about 1,500 MPa, greater than 225 MPa to about 1,200 MPa, greater than 225 MPa to about 1,000 MPa, greater than 225 MPa to about 800 MPa, greater than 225 MPa to about 600 MPa, greater than 225 MPa to about 500 MPa, about 250 MPa to about 1,500 MPa, about 250 MPa to about 1,200 MPa, about 250 MPa to about 1,000 MPa, about 250 MPa to about 800 MPa, about 250 MPa to about 600 MPa, about 250 MPa to about 500 MPa, about 300 MPa to about 1,500 MPa, about 300 MPa to about 1,200 MPa, about 300 MPa to about 1,000 MPa, about 300 MPa to about 800 MPa, about 300 MPa to about 600 MPa, about 300 MPa to about 500 MPa, about 400 MPa to about 1,200 MPa, about 400 MPa to about 1,000 MPa, about 400 MPa to about 800 MPa, or about 400 MPa to about 600 MPa, as determined if a film of the polyolefin composition has a thickness of about 90 pm. The 1% secant flexural modulus is determined by the ExxonMobil PLFL-242.001 standard, as provided below in the Experimental Section.
[0032] In any embodiment, the polyolefin composition has a Tensile at Yield strength, in each of the MD and the TD, independently, of greater than 7 MPa, greater than 8 MPa, greater than 8.5 MPa, greater than 8.8 MPa, greater than 9 MPa, greater than 9.5 MPa, or greater than 9.7 MPa, such as about 10 MPa, about 12 MPa, about 15 MPa, about 18 MPa, or about 20 MPa to about 22 MPa, about 25 MPa, about 30 MPa, about 40 MPa, about 45 MPa, about 50 MPa, about 60 MPa, about 70 MPa, about 80 MPa, or about 100 MPa, as determined if a film (e.g., film containing 2, 3, 4, or more layers) containing the polyolefin composition has a thickness of about 90 pm, and as determined by ASTM D882. For example, the polyolefin composition has a Tensile at Yield strength, in each of the MD and the TD, independently, of greater than 8.5 MPa to about 100 MPa, greater than 8.5 MPa to about 80 MPa, greater than 8.5 MPa to about 60 MPa, greater than 8.5 MPa to about 50 MPa, greater than 8.5 MPa to about 40 MPa, greater than 8.5 MPa to about 35 MPa, greater than 8.5 MPa to about 30 MPa, greater than 8.5 MPa to about 25 MPa, greater than 8.5 MPa to about 20 MPa, greater than 8.5 MPa to about 18 MPa, greater than 8.5 MPa to about 15 MPa, greater than 8.5 MPa to about 12 MPa, about 9 MPa to about 100 MPa, about 9 MPa to about 80 MPa, about 9 MPa to about 60 MPa, about 9 MPa to about 50 MPa, about 9 MPa to about 40 MPa, about 9 MPa to about 35 MPa, about 9 MPa to about 30 MPa, about 9 MPa to about 25 MPa, about 9 MPa to about 20 MPa, about 9 MPa to about 18 MPa, about 9 MPa to about 15 MPa, about 9 MPa to about 12 MPa, greater than 9.7 MPa to about 100 MPa, greater than 9.7 MPa to about 80 MPa, greater than 9.7 MPa to about 60 MPa, greater than 9.7 MPa to about 50 MPa, greater than 9.7 MPa to about 40 MPa, greater than 9.7 MPa to about 35 MPa, greater than 9.7 MPa to about 30 MPa, greater than 9.7 MPa to about 25 MPa, greater than 9.7 MPa to about 20 MPa, greater than 9.7 MPa to about 18 MPa, greater than 9.7 MPa to about 15 MPa, greater than 9.7 MPa to about 12 MPa, about 10 MPa to about 100 MPa, about 10 MPa to about 80 MPa, about 10 MPa to about 60 MPa, about 10 MPa to about 50 MPa, about 10 MPa to about 40 MPa, about 10 MPa to about 35 MPa, about 10 MPa to about 30 MPa, about 10 MPa to about 25 MPa, about 10 MPa to about 20 MPa, about 10 MPa to about 18 MPa, about 10 MPa to about 15 MPa, about 10 MPa to about 12 MPa, about 25 MPa to about 100 MPa, about 30 MPa to about 100 MPa, about 30 MPa to about 80 MPa, about 30 MPa to about 60 MPa, about 30 MPa to about 50 MPa, or about 30 MPa to about 40 MPa, as determined if a film of the polyolefin composition has a thickness of about 90 pm, and as determined by ASTM D882.
[0033] In one or more examples, the polyolefin composition has a Tensile at Yield strength a Tensile at Yield strength in the MD of greater than 8.5 MPa and in the TD of greater than 9.7 MPa. In some examples, the polyolefin composition has a Tensile at Yield strength a Tensile at Yield strength in the MD of greater than 8.5 MPa to about 100 MPa and in the TD of greater than 9.7 MPa to about 100 MPa. In other examples, the polyolefin composition has a Tensile at Yield strength a Tensile at Yield strength in the MD of about 9 MPa to about 25 MPa and in the TD of about 10 MPa to about 25 MPa.
[0034] The polyolefin composition has a Elongation at Break strength, in each of the MD and the TD, independently, of greater than 400%, greater than 450%, or greater than 500%, such as about 510%, about 520%, about 530%, about 540%, about 550%, about 555%, about 560%, about 570%, about 580%, about 590%, or about 600% to about 610%, about 620%, about 625%, about 630%, about 640%, about 650%, about 660%, about 670%, about 680%, about 690%, about 700%, about 750%, about 800%, about 850%, or about 900%, as determined if a film (e.g., film containing 2, 3, 4, or more layers) containing the polyolefin composition has a thickness of about 90 pm, and as determined by ASTM D882. For example, the polyolefin composition has a Elongation at Break strength, in each of the MD and the TD, independently, of greater than 400% to about 900%, greater than 400% to about 800%, greater than 400% to about 750%, greater than 400% to about 700%, greater than 400% to about 650%, greater than 400% to about 600%, greater than 400% to about 550%, greater than 400% to about 500%, greater than 540% to about 900%, greater than 540% to about 800%, greater than 540% to about 750%, greater than 540% to about 700%, greater than 540% to about 650%, greater than 540% to about 600%, greater than 540% to about 550%, about 550% to about 900%, about 550% to about 800%, about 550% to about 750%, about 550% to about 700%, about 550% to about 650%, about 550% to about 600%, about 550% to about 575%, about 600% to about 900%, about 600% to about 800%, about 600% to about 750%, about 600% to about 700%, or about 600% to about 650%, as determined if a film (e.g., film containing 2, 3, 4, or more layers) containing the polyolefin composition has a thickness of about 90 pm, and as determined by ASTM D882.
[0035] In one or more examples, the polyolefin composition has a Elongation at Break strength in the MD of greater than 540% and in the TD of greater than 580%. In some examples, the polyolefin composition has a Elongation at Break strength in the MD of about 550% to about 700% and in the TD of about 600% to about 700%. In other examples, the polyolefin composition has a Elongation at Break strength in the MD of about 555% to about 625% and in the TD of about 605% to about 650%.
[0036] In any embodiment, the polyolefin composition has a Dart Drop Impact (Method A) of at or greater than 8 g/pm, at or greater than 8.5 g/pm, at or greater than 9 g/pm, at or greater than 10 g/pm, or at or greater than 12 g/pm, such as from about 13 g/pm, about 16 g/pm, about 16.5 g/pm, or about 17 g/pm to about 17.5 g/pm, about 18 g/pm, about 18.5 g/pm, about 19 g/pm, about 19.5 g/pm, about 20 g/pm, or about 22 g/pm, as determined if a film (e.g., 2, 3, 4, or more layer film) containing the polyolefin composition has a thickness of about 90 pm. For example, the polyolefin composition has a Dart Drop Impact (Method A) of at or greater than
8 g/pm to about 22 g/pm, at or greater than 8 g/pm to about 20 g/pm, at or greater than 8 g/pm to about 18 g/ pm, at or greater than 8 g/pm to about 17 g/ pm, at or greater than 8 g/ pm to about 16 g/pm, at or greater than 8 g/pm to about 15 g/pm, at or greater than 8 g/pm to about 14 g/pm, at or greater than 8 g/pm to about 12 g/pm, at or greater than 8 g/pm to about 10 g/pm, about 9 g/pm to about 22 g/pm, about 9 g/pm to about 20 g/pm, about 9 g/pm to about 18 g/pm, about
9 g/pm to about 17 g/pm, about 9 g/pm to about 16 g/pm, about 9 g/pm to about 15 g/pm, about 9 g/pm to about 14 g/pm, about 9 g/pm to about 12 g/pm, or about 9 g/pm to about 10 g/pm, as determined if a film containing the polyolefin composition has a thickness of about 90 pm. [0037] In any embodiment, the polyolefin composition has an Elmendorf tear in the MD of greater than 5 g/pm, greater than 5.6 g/pm, greater than 6 g/pm, greater than 6.5 g/pm, or greater than 7 g/pm, such as from about 7.2 g/pm, about 7.5 g/pm, about 7.8 g/pm, about 8 g/pm, about 8.2 g/pm, about 8.5 g/pm, about 8.8 g/pm, about 9 g/pm, about 9.2 g/pm, about 9.5 g/pm, about 9.8 g/pm or about 10 g/ pm to about 10.2 g/ pm, about 10.5 g/ pm, about 11 g/pm, about 12 g/pm, about 15 g/pm, about 18 g/pm, about 20 g/pm, as determined if a film (e.g., 2, 3, 4, or more layer film) containing the polyolefin composition has a thickness of about 90 pm. For example, the polyolefin composition has an Elmendorf tear in the MD of greater than 5 g/pm to about 20 g/pm, greater than 5.6 g/pm to about 20 g/pm, about 6 g/pm to about 20 g/pm, about 8 g/pm to about 20 g/pm, about 9 g/pm to about 20 g/pm, about 9.5 g/pm to about 20 g/pm, about 10 g/pm to about 20 g/pm, about 12 g/pm to about 20 g/pm, about 15 g/pm to about 20 g/pm, greater than 5 g/pm to about 15 g/pm, greater than 5.6 g/pm to about 15 g/pm, about 6 g/pm to about 15 g/pm, about 8 g/pm to about 15 g/pm, about 9 g/pm to about 15 g/pm, about 9.5 g/pm to about 15 g/pm, about 10 g/pm to about 15 g/pm, about 12 g/pm to about 15 g/pm, greater than 5 g/mih to about 12 g/mih, greater than 5.6 g/mih to about 12 g/mih, about 6 g/mih to about 12 g/mih, about 8 g/mih to about 12 g/mih, about 9 g/mih to about 12 g/mih, about 9.5 g/mih to about 12 g/mih, about 10 g/pm to about 12 g/mih, greater than 7 g/miti to about 10 g/mih, greater than 7 g/mih to about 9.5 g/mih, greater than 7 g/mih to about 9.2 g/mih, greater than 7 g/mih to about 9 g/mih, greater than 7 g/mih to about 8.5 g/mih, greater than 7 g/mih to about 8 g/mih, greater than 7 g/mih to about 7.8 g/mih, greater than 7 g/mih to about 7.5 g/mih, about 7.2 g/mih to about 10 g/mih, about 7.5 g/mih to about 9.5 g/mih, or about 8 g/mih to about 9.2 g/mih, about
8 g/mih to about 10 g/mih, about 8 g/mih to about 9.5 g/mih, about 8 g/mih to about 9.2 g/mih, about 8 g/mih to about 9 g/mih, or about 8 g/mih to about 8.5 g/mih, as determined if a film containing the polyolefin composition has a thickness of about 90 pm. The Elmendorf tear in the MD and TD values provided herein are determined by the ASTM D1922 standard.
[0038] In any embodiment, the polyolefin composition has an Elmendorf tear in the TD of greater than 8 g/pm, greater than 8.9 g/pm, greater than 9.5 g/pm, greater than 10 g/pm, greater than 11 g/pm, greater than 12 g/pm, greater than 12.8 g/pm, or greater than 13 g/pm, such as from about 13.2 g/pm, about 13.5 g/pm, about 13.8 g/pm, about 14 g/pm, about 14.2 g/pm, or about 14.5 g/pm to about 14.8 g/pm, about 15 g/pm, about 15.2 g/pm, about 15.5 g/pm, about 15.8 g/pm, or about 16 g/pm, as determined if a film (e.g., 2, 3, 4, or more layer film) containing the polyolefin composition has a thickness of about 90 pm. For example, the polyolefin composition has an Elmendorf tear in the TD of about 8 g/pm to about 20 g/pm, about 9 g/pm to about 20 g/pm, about 10 g/pm to about 20 g/pm, about 12 g/pm to about 20 g/pm, about 15 g/pm to about 20 g/ pm, about 18 g/ pm to about 20 g/ pm, about 8 g/ pm to about 15 g/ pm, about
9 g/pm to about 15 g/pm, about 10 g/pm to about 15 g/pm, about 12 g/pm to about 15 g/pm, about 15 g/pm to about 15 g/pm, about 18 g/pm to about 15 g/pm, about 8 g/pm to about 12 g/pm, about 9 g/pm to about 12 g/pm, about 10 g/pm to about 12 g/pm, about 12 g/pm to about
12 g/pm, about 15 g/pm to about 12 g/pm, about 18 g/pm to about 12 g/pm, greater than 12.8 g/pm to about 16 g/pm, about 12.8 g/pm to about 16 g/pm, about 13 g/pm to about 14.5 g/pm, greater than 13 g/pm to about 16 g/pm, greater than 13 g/pm to about 15.5 g/pm, greater than
13 g/pm to about 15 g/pm, greater than 13 g/pm to about 14.5 g/pm, greater than 13 g/pm to about 14 g/pm, greater than 13 g/pm to about 13.5 g/pm, about 13.5 g/pm to about 16 g/pm, about 13.5 g/pm to about 15.5 g/pm, about 13.5 g/pm to about 15 g/pm, about 13.5 g/pm to about 14.5 g/pm, or about 13.5 g/pm to about 14 g/pm, as determined if a film containing the polyolefin composition has a thickness of about 90 pm. BOCD Polvethylenes
[0039] The polyolefin compositions of the present disclosure include one or more broad orthogonal composition distribution (BOCD) polyethylenes. It can be desirable for the polyethylene copolymers to possess a broad orthogonal composition distribution which provides enhanced stiffness, toughness, and processability (S/T/P) balance of the polyethylene and compositions that include these polymers. Given that polymers are a blend of molecules having a distribution of different chain-lengths, polymers having BOCD are branched polymers that have a preponderance, if not all, of any branching that may occur on the high molecular weight molecules of the polymer, making them less crystalline. This microstructure has a tendency to improve certain properties of products made from such BOCD-type polymers including the polyolefin composition described and discussed herein.
[0040] Ziegler-Natta ("ZN") produced polyethylenes tend not to have a BOCD-type structure, most of the short-chain branching being on the low molecular weight portion of the molecules thus produced. Some Metallocene polyethylenes, on the other hand, often can have BOCD-type structure. The value of BOCD polymers relative to conventional polymers is significant.
[0041] In any embodiment, the BOCD polyethylene may have an orthogonal comonomer distribution or "broad orthogonal composition distribution" ("BOCD"). The term "orthogonal comonomer distribution" is used herein to mean across the molecular weight range of the ethylene polymer, comonomer contents for the various polymer fractions are not substantially uniform and a higher molecular weight fraction thereof generally has a higher comonomer content than that of a lower molecular weight fraction. The term "substantially uniform comonomer distribution" is used herein to mean that comonomer content of the polymer fractions across the molecular weight range of the ethylene-based polymer vary by < 10.0 wt%. In any embodiment, a substantially uniform comonomer distribution may refer to < 8.0 wt%, < 5.0 wt%, or < 2.0 wt%. Both a substantially uniform and an orthogonal comonomer distribution may be determined using fractionation techniques such as gel permeation chromatography - differential viscometry (GPC-DV), temperature rising elution fraction-differential viscometry (TREF-DV) or cross-fractionation techniques. [0042] The TREF technique discussed in WO 2015/123164 A1 provides a measure of the bivariate mass distribution of the crystallized portion of such BOCD polyethylenes. A visual examination of the TREF contour plot is sufficient to confirm that the distribution is BOCD- like as opposed to the conventional-type, such as is shown in the graphs of FIGS. 1A and IB. Such an evaluation consists of a non-quantitative method of ordering the polyethylene copolymers under consideration by increasing or decreasing BOCD-like character based on the "tilt" of the TREF contours in the 2D plane. For example, the slope of the line in FIG. 1A is less than 0 (negative "tilt") whereas the slope of the line in FIG. IB is greater than 0 (positive "tilt"), and this allows one to conclude that the graph depicted by FIG. 1A has more BOCD- like character than the graph depicted by FIG. IB. In particular, FIGS. 1A and IB exemplify the "tilt" and "spread" in temperature elution fractionation (TREF) data of two LLDPEs: BOCD polyethylene (FIG. 1A) and conventional polyethylene (FIG. IB), where the dashed, guide-to- the-eye lines roughly connect the two main peaks and are qualitative indicators of the tilt of the branching distribution; the slope of the line in FIG. 1 A is less than 0 (negative tilt) whereas the slope of the line in FIG. IB is greater than 0 (positive tilt). This aspect is described further in U.S. 2017/0363605.
[0043] The BOCD polyethylene of the present disclosure comprises from about 70 mole percent (mol%) to about 100 mol% of units derived from ethylene. The lower amount on the range of ethylene content may be from 70 mol%, 75 mol%, 80 mol%, 85 mol%, 90 mol%, 92 mol%, 94 mol%, 95 mol%, 96 mol%, 97 mol%, 98 mol%, or 99 mol% based on the mol% of polymer units derived from ethylene. The BOCD polyethylene may have an upper ethylene amount of 80 mol%, 85 mol%, 90 mol%, 92 mol%, 94 mol%, 95 mol%, 96 mol%, 97 mol%, 98 mol%, 99 mol%, 99.5 mol%, or 100 mol%, based on polymer units derived from ethylene. For polyethylene copolymers, the BOCD polyethylene may have less than 50 mol% of polymer units derived from a C3-C20 olefin, such as an alpha-olefin, e.g., hexene or octene. The lower amount on the range of C3-C20 olefin-content may be 25 mol%, 20 mol%, 15 mol%, 10 mol%, 8 mol%, 6 mol%, 5 mol%, 4 mol%, 3 mol%, 2 mol%, 1 mol%, or 0.5 mol%, based on polymer units derived from the C3-C20 olefin. The upper amount on the range of C3-C20 olefin-content may be 20 mol%, 15 mol%, 10 mol%, 8 mol%, 6 mol%, 5 mol%, 4 mol%, 3 mol%, 2 mol%, or 1 mol%, based on polymer units derived from the C3 to C20 olefin. Any of the lower amounts may be combined with any of the upper amounts to form a range. Comonomer content is based on the total content of all monomers in the polymer.
[0044] In a class of embodiments, the BOCD polyethylene may have low amounts of long chain branching (e.g., less than 1.0 long-chain branch/1,000 carbon atoms, such as particularly 0.05 to 0.50 long-chain branch/1,000 carbon atoms). Such values are characteristic of a linear structure that is consistent with a branching index (as defined below) of g'vis 0.980 or greater,
0.985 or greater, 0.99 or greater, 0.995 or greater, or 1.0. While such values are indicative of little to no long chain branching, some long chain branches may be present (e.g., less than 1.0 long-chain branch/1,000 carbon atoms, such as less than 0.5 long-chain branch/1,000 carbon atoms, such as 0.05 to 0.50 long-chain branch/1,000 carbon atoms).
[0045] In any embodiment, the BOCD polyethylenes may have a density in accordance with ASTM D-4703 and ASTM D-1505/ISO 1183 of 0.910 g/cm3 to 0.925 g/cm3, from 0.910 g/cm3 to 0.923 g/cm3, from 0.910 g/cm3 to 0.920 g/cm3, from 0.915 g/cm3 to 0.921 g/cm3, from 0.910 g/cm3 to 0.918 g/cm3, from 0.912 g/cm3 to 0.918 g/cm3, or from 0.912 g/cm3 to 0.917 g/cm3. [0046] The weight average molecular weight (Mw) of the BOCD polyethylenes may be from 15,000 g/mol to 500,000 g/mol, from 20,000 g/mol to 250,000 g/mol, from 25,000 g/mol to 150,000 g/mol, from 150,000 g/mol to 400,000 g/mol, from 200,000 g/mol to 400,000 g/mol, or from 250,000 g/mol to 350,000 g/mol as determined by GPC.
[0047] The BOCD polyethylenes may have a molecular weight distribution (MWD) or (Mw/Mn) of 1.5 to 5, from 2 to 4, from 3 to 4, or from 2.5 to 4.
[0048] The BOCD polyethylenes may have a z-average molecular weight (Mz) to weight average molecular weight (Mw) greater than 1.5, or greater than 1.7, or greater than 2. In any embodiment, this ratio is from 1.7 to 3.5, from 2 to 3, or from 2.2 to 3.
[0049] The BOCD polyethylenes may have a melt index (MI) or (B.ib) as measured by ASTM D-1238-E (190°C/2.16 kg) of 0.1 to 300 g/10 min, 0.1 to 100 g/10 min, 0.1 to 50 g/10 min, 0.1 g/10 min to 5 g/10 min, 0.1 g/10 min to 3 g/10 min, 0.1 g/10 min to 2 g/10 min, 0.1 g/10 min to 1.2 g/10 min, 0.2 g/lOminto 1.5 g/10 min, 0.2 g/lOmin to 1.1 g/10 min, 0.3 g/lOmin to 1 g/10 min, 0.4 g/lOminto 1 g/10 min, 0.5 g/lOminto 1 g/10 min, 0.6 g/lOminto 1 g/10 min, 0.7 g/lOmin to 1 g/10 min, or 0.75 g/lOmin to 0.95 g/10 min.
[0050] The BOCD polyethylenes may have a melt index ratio (MIR) (I21.6 /I2.16) (as defined below) of 10 to 50, from 15 to 45, from 20 to 40, from 20 to 35, from 22 to 38, from 20 to 32, from 25 to 31, or from 28 to 30.
[0051] In some embodiments, the BOCD polyethylenes may contain less than 5 ppm of hafnium, less than 2 ppm of hafnium, less than 1.5 ppm of hafnium, or less than 1 ppm of hafnium. In other embodiments, the BOCD polyethylenes may contain from 0.01 ppm to 2 ppm of hafnium, from 0.01 ppm to 1.5 ppm of hafnium, or from 0.01 ppm to 1 ppm of hafnium. [0052] Typically, the amount of hafnium is greater than the amount of zirconium in the
BOCD polyethylene. In a particular class of embodiments, the ratio of hafnium to zirconium (ppm/ppm) is at least 2, at least 10, at least 15, at least 17, at least 20, at least 25, at least 50, at least 100, at least 200, or at least 500 or more. Since zirconium is generally present as an impurity in hafnium, it will be realized that hafnium-containing catalysts contain some amount of zirconium as an impurity. In any embodiment where particularly pure hafnium-containing catalysts are used, the amount of zirconium may be extremely low, resulting in an undetectable amount or a substantially undetectable amount of zirconium in the BOCD polyethylene. Thus, the upper limit on the ratio of hafnium to zirconium in the polymer may be quite large.
[0053] In several classes of embodiments, the BOCD polyethylenes may have at least a first peak and a second peak in a comonomer distribution analysis, wherein the first peak has a maximum at a log(Mw) value of 4 to 5.4, 4.3 to 5, or 4.5 to 4.7; and a TREF elution temperature of 70°C to 100°C, 80°C to 95°C, or 85°C to 90°C. The second peak in the comonomer distribution analysis has a maximum at a log(Mw) value of 5 to 6, 5.3 to 5.7, or 5.4 to 5.6; and a TREF elution temperature of 40°C to 60°C, 45°C to 60°C, or 48°C to 54°C.
[0054] In any of the embodiments described above, the BOCD Polyethylene may have one or more of the following properties: a melt index (MI) (190°C/2.16 kg) of 0.1 g/10 min to 5 g/10 min; a melt index ratio (MIR) of 15 to 30; an Mw of 20,000 to 200,000 g/mol; a Mw/Mn of 2 to 4.5; and a density of 0.910 to 0.925 g/cm3. In any of these embodiments, the amount of hafnium is greater than the amount of zirconium and a ratio of hafnium to zirconium (ppm/ppm) may be at least 2, at least 10, at least 15, at least 17, at least 20, or at least 25.
[0055] Materials and processes for making the BOCD polyethylene have been described in, for example, U.S. Pat. No. 6,956,088, particularly Example 1; U.S. Patent Application Publication No. 2009/0297810, particularly Example 1; U.S. Patent Application Publication No. 2015/0291748, particularly PE1-PE5 in the Examples; and WO 2014/099356, particularly PE3 referenced on page 12 and in the Examples, including the use of a silica supported hafnium transition metal metallocene/methylalumoxane catalyst system described in, for example, U.S. Pat. Nos. 6,242,545 and 6,248,845, particularly Example 1. [0056] One or more BOCD polyethylenes can be obtained commercially available from
ExxonMobil Chemical Company, Houston, TX, and sold under Exceed XP™ metallocene polyethylene (mPE). Exceed XP™ mPE offers step-out performance with respect to, for example, dart drop impact strength, flex-crack resistance, and machine direction (MD) tear, as well as maintaining stiffness at lower densities. Exceed XP™ mPE also provides a good balance of melt strength, toughness, stiffness, and sealing capabilities which makes this family of polymers well-suited for, for example, blown film/sheet solutions.
[0057] FIG. 2 is a plot of Compositional Distribution (molecular weight as a function of branching) plotting (MWI/MW2) values as a function of (Twi-Tw2) for BOCD PE polymers and conventional PE polymer, according to any embodiment. The values for Twi, Tw2, Mwi, and MW2 can be determined from cross-fractionation chromatography (CFC), where the procedures for interpreting the data obtained from CFC and for determining the values for Twi, Tw2, Mwi, and MW2 are discussed in more detail in U.S. Pub. No. 2018/0155474, which is incorporated by reference for discussion on CFC and determining the values for Twi, Tw2, Mwi, and Mw2. Among other information, this techniques helps to elucidate the level of comonomer on high- to-low molecular weight fractions of polyethylenes. Calculations are used to determine branching within the molecular weight fractions of polyethylenes.
[0058] Qualitatively, a gradient of molecular weight fractions of the polyethylene (a gradient based on both molecular weight of individual polymer chains and the level of branching on each chain) elutes from at least one temperature-gradient gel permeation chromatographic column at a gradient of temperatures and molecular weights, where 50 wt% or less of the cumulative molecular weight polyethylene fractions elutes at a temperature Twi, and greater than 50 wt% cumulative molecular weight polyethylene fractions elute at a temperature Tw2, the molecular weight fractions eluting at Twi being a molecular weight component Mwi and the fractions eluting at Tw2 being a molecular weight component Mw2. [0059] Quantitatively, to calculate values of Twi, Tw2, Mwi, and Mw2, the data obtained from fractional CFC is divided into two roughly equal halves, hence, this analysis is sometimes referred to as the Equal Halves Analysis. For each half, the Twi and Mwi for each fraction "i" is calculated according to the conventional definition of weight average. Fractions which do not have sufficient quantity (<0.5 wt%) to be processed for molecular weight averages in the original data file are excluded from the calculation of Twi, Tw2, Mwi, and Mw2.
[0060] FIG. 2 is a semi-log plot of (MWI/MW2) as a function of (Twi-Tw2) designed to show the important differences in MWD/short chain branching distribution (SCBD) combination among examples compared to commercial benchmarks. Such differences are believed to play a key role in determining the trade-off pattern and/or balance of various performance attributes such as stiffness, toughness and processability. The polyethylenes are above the mid-horizontal line, while conventional polyethylenes having typical short-chain branching distribution (SCBD) are below the mid-line. Also in FIG. 2, the narrow short chain branching distribution (NSCBD) region of the plot is highlighted along with the broad short chain branching distribution (BSCBD) region. The polyethylenes are in-between the extremes, represented by an MWI/MW2 value of between 0.9 and 10, more preferably 1.5 and 5. [0061] In the plot of FIG. 2, SCBD and MWD are described together. That is, the combination of molecular weight characteristic and SCB of a particular population is highlighted, rather than the Mw or SCB separately. Therefore, between the NSCBD extreme (far right vertical line) and BSCBD extreme (far left vertical line, not center line) is described a region of the plot. There are two further divisions to set different polyethylene product concepts apart - an upper half above and a lower half below the center line in the plot of FIG. 2. The upper half above the center line in the plot of FIG. 2 is where the BOCD polyethylenes are located, that is, the combination of Low Mw/High Tw (low SCB, high density) population with High Mw/Low Tw (high SCB, low density) population. The lower half below the center line in the plot of FIG. 2 is what is typically called "conventional" (Ziegler-Natta-like), that is, the combination of High Mw/Low Tw (low SCB, low density) population with Low Mw/High Tw (high SCB, high density) population.
[0062] The lower half below the center line in FIG. 2 is what is typically called "conventional" (Ziegler-Natta-like), that is, the combination of High Mw/Low Tw (low SCB, low density) population with Low Mw/High Tw (high SCB, high density) population. The measurements are summarized in Table 3 of U.S. Pub. No. 2018/0155474, where the following are comparative examples:
• Dowlex™ 2045 polyethylene obtained from the Dow Chemical Company (Midland, MI).
• Borstar™ FB2230 polyethylene obtained from Borealis AG (Austria).
• Evolve™ 3010 polyethylene from Mitsui Chemical Company (Japan).
• Elite™ 5400 polyethylene obtained from The Dow Chemical Company (Midland, MI).
• Exceed™ 1018 and Enable™ 2010 polyethylenes are obtained from ExxonMobil Chemical Company (Baytown, TX).
• LL3001 polyethylene is obtained from ExxonMobil Chemical Company (Baytown, TX).
• VPR is a polyethylene made in a metallocene gas phase process as described in PCT/US2015/015119 (Polymer 1-10, Table 1).
[0063] In any embodiment, the BOCD polyethylene has an MWI/MW2 of greater than 1 , such as from about 1.2, about 1.5, about 1.8, about 2, about 2.5, about 3, about 3.5, or about 4 to about 4.5, about 5, about 5.5, about 6, about 7, about 8, about 9, or about 10. For example, the
BOCD polyethylene has an MWI/MW2 of greater than 1 to about 10, greater than 1 to about 8, greater than 1 to about 7, greater than 1 to about 6, greater than 1 to about 5, greater than 1 to about 4, greater than 1 to about 3, about 1.5 to about 10, about 1.5 to about 8, about 1.5 to about 7, about 1.5 to about 6, about 1.5 to about 5, about 1.5 to about 4, about 1.5 to about 3, about 2 to about 10, about 2 to about 8, about 2 to about 7, about 2 to about 6, about 2 to about 5, about 2 to about 4, or about 2 to about 3.
[0064] The BOCD polyethylene has a Twi-Tw2 of less than 0°C, such as from about -1°C, about -5°C, about -10°C, about -15°C, or about -20°C to about -25°C, about -30°C, about -35°C, about -40°C, or about -45°C. The BOCD polyethylene has a Twi-TW2 of less than 0°C to about -45°C, less than 0°C to about -40°C, less than 0°C to about -35°C, less than 0°C to about -25°C, less than 0°C to about -20°C, less than 0°C to about -15°C, less than 0°C to about -10°C, -5°C to about -45°C, -5°C to about -40°C, -5°C to about -35°C, -5°C to about -25°C, -5°C to about -20°C, -5°C to about -15°C, -5°C to about -10°C, -10°C to about -45°C, -10°C to about -40°C, -10°C to about -35°C, -10°C to about -25°C, -10°C to about -20°C, or -10°C to about -15°C. Polypropylenes
[0065] Compositions of the present disclosure include one or more polypropylenes. The "polypropylene" is a polymer that contains at least 50 mol% propylene-derived units. The polypropylene can have less than 50 mol% of polymer units derived from ethylene and/or one or more C4 to C20 olefins, such as, an alpha-olefin, for example, hexene or octene. The concentration of the ethylene and/or one or more C4 to C20 olefins be 45 mol%, 40 mol%, 35 mol%, 30 mol%, 25 mol%, 20 mol%, 15 mol%, 10 mol%, 8 mol%, 6 mol%, 5 mol%, 4 mol%, 3 mol%, 2 mol%, 1 mol%, or 0.5 mol%, based on polymer units derived from the ethylene and/or one or more C4 to C20 olefins. Comonomer content is based on the total content of all monomers in the polymer. Desirable polypropylenes include homopolymers, copolymers (random or block) comprising from 0.2, or 0.5 wt% comonomer derived units to 10, or 15, or 20 wt% comonomer derived units, terpolymers comprising at least 50 wt% propylene derived units, impact copolymers (a blend of a homopolymer and copolymer), and blends thereof. [0066] In any embodiment, the polypropylene can be or include one or more high melt strength polypropylenes (HMS PPs), one or more trimmed polypropylenes (tPPs), one or more broad molecular weight distribution (BMWD or BWD) PPs, one or more homopolymers of PP (hPP), impact copolymers (ICPs) of PP, random copolymer (RCPs) of PP, or any combination thereof. [0067] In one or more examples, the polypropylene can be or include a base or reactor grade polypropylene. In some examples, the polypropylene can be or include one or more high melt strength polypropylenes (HMS PPs) and/or one or more trimmed polypropylenes (tPPs). The tPP contains and/or is produced from one or more HMS PPs, as described and discussed herein. [0068] As used herein, the terms "trim," "trimmed," and "trimming" refer to the reduction, either chemically or by dilution, of the high molecular weight tail of a polymer, which is manifest by a reduction of the z-average molecular weight of the polymer, independently and relative to the number average and weight average molecular weight. In one or more examples, the terms "trim," "trimmed," and "trimming" can refer to chemical reduction. [0069] As used herein, a "film" is a solid flexible material that may take on any suitable two-dimensional length and width and have an average thickness within the range of about 10 pm or about 20 pm or about 30 pm or about 40 pm to an upper limit of about 50 pm or about 60 pm or about 80 pm or about 100 pm or about 150 pm or about 200 pm or about 300 pm, or about 400 pm, or about 500 pm, wherein the length and width of the film is much greater than its thickness. Thus, an exemplary average thickness of a film is within the range of about 10 pm to about 60 pm, about 50 pm to about 120 pm, or about 80 pm to about 100 pm.
[0070] A "multi-layered film" as used herein comprises two or more layers, and may comprise 3, 4, 5, 6, or more layers in any embodiment, and may have a combined thickness of up to about 1,000, or about 1,500, or about 2,000, or about 2,500 pm. The term "film" also includes the possibility of coatings, such as when the film is extruded onto a surface such as a metal, glass, another polymer, or other stiff or flexible surface.
[0071] As used herein, the term "layer" refers to each of the one or more materials, the same or different, that are secured to one another in the form of a thin sheet or film by any appropriate means such as by an inherent tendency of the materials to adhere to one another, or by inducing the materials to adhere as by a heating, radiative, chemical, or some other appropriate process. A layer is not limited to detectable, discrete materials contacting one another such that a distinct boundary exists between the materials. In some examples, the materials used to make one layer of a film will be different (e.g., the weight percent of components, the properties of each component, and/or the identity of the components may differ) from the materials used to make an adjacent, and adhering, layer. A layer includes a finished product having a continuum of materials throughout its thickness.
[0072] Trimming of an HMS PP can occur by either chemical treatment with a long half- life organic peroxide, by physical dilution with a narrow molecular weight distribution (MWD) polypropylene, or a combination of the two. In any embodiment, the HMS PP's described herein are trimmed only by treatment with a long-half-life organic peroxide. In any embodiment, a process to prepare a tPP includes combining an HMS PP containing at least 50 mol% of propylene, and having a molecular weight distribution (Mw/Mn) greater than 6, a branching index (gVis) of at least 0.95, and a melt strength of at least 20 cN determined using an extensional rheometer at 190°C, with (i) from about 20 ppm to about 1,000 ppm of a long half-life organic peroxide; and/or (ii) from about 20 wt% to about 70 wt% of a narrow MWD polypropylene containing at least 50 mol% of propylene, and having a molecular weight distribution (Mw/Mn) of less than 6, and isolating a trimmed polypropylene. Other properties of the starting materials HMS PP and tPP will be described below.
[0073] In any embodiment, the tPP contains at least 50 mol% of propylene and has a molecular weight distribution (Mw/Mn) of less than 22, 20, 18, 16, or 15, or from about 5, about 6, about 7, about 7.5, about 8, about 8.5, or about 9 to about 15, about 16, about 18, about 20, or about 22; a z-average molecular weight of less than 2,500,000 g/mol, 2,000,000 g/mol, 1,600,000 g/mol, 1,400,000 g/mol, or 1,200,000 g/mol, or from about 500,000 g/mol, about
600,000 g/mol, or about 800,000 g/mol to about 1,200,000 g/mol, about 1,400,000 g/mol, or about 1,600,000 g/mol; a branching index (gVis) of at least 0.95; and a melt strength less than 20 cN (e.g., from about 1 cN to about 15 cN) as determined using an extensional rheometer at 190°C. Other properties of the tPP will be described below. [0074] By diluting the concentration of the high molecular weight chains in polymers such as an HMS PP having a high molecular weight component or "tail," such as by blending the HMS PP with a narrow MWD homopolymer PP, it has been discovered that the film quality can improve without surface/bulk irregularity at commercial rates of film formation of at least 13 lb/hr/in. It has been discovered that the concentration of high molecular weight tail can be reduced by addition of low levels of peroxides that have relatively "long" half-lives (e.g., Luperox™ 101, Triganox™ 101). Using this approach, the film quality of a film containing HMS PP can improve without surface/bulk irregularity at the commercial rates of film formation of at least 13 lb/hr/in.
High Melt Strength Polypropylenes (HMS PP) [0075] The tPPs, and films (or coatings) therefrom, derive from a polypropylene having a relatively high Melt Strength (greater than 15 cN, or 20 cN), referred to herein simply as a "high melt strength polypropylene" (or HMS PP) having one or more features as described here, made according to the disclosure in WO 2014/070386. In any embodiment, the HMS PP contains at least 50 mol%, about 60 mol%, about 70 mol%, about 80 mol%, or 90 mol% propylene-derived monomer units, or from about 50 mol%, about 60 mol%, or about 80 mol% to about 95 mol%, about 97 mol%, or about 99 mol% propylene-derived units, the remainder being a comonomer selected from ethylene and C4 to C20 a-olefms, for example, ethylene or 1 -butene. In any embodiment, the HMS PP is a homopolymer of propylene-derived monomer units. In one or more examples, the HMS PP can be or include Achieve™ Advanced PP6282NE1 PP, commercially available from ExxonMobil Chemical Company (Houston, Texas).
[0076] In any embodiment, the HMS PP has an isotactic pentad percentage of greater than 90%, 92%, or 95% as determined by 13C NMR spectroscopy. Also, the HMS PP has a melt flow rate (MFR) from about 0.1, about 1, or about 2 g/10 min to about 12, about 16, about 20, or about 40 g/10 min, as determined according to ASTM D1238 Condition L (230°C/2.16 kg). In some embodiments, the HMS PPs can have an MFR of about 2, about 2.5, about 3, about 3.5, or about 4 g/10 min to about 4.5, about 5, about 5.5, or about 6 g/10 min, as determined by ASTM D1238. For example, the HMS PPs can have an MFR of about 2 g/10 min to about 6 g/10 min, about 2.5 g/10 min to about 6 g/10 min, about 3 g/10 min to about 6 g/10 min, about
3.5 g/10 min to about 6 g/10 min, about 4 g/10 min to about 6 g/10 min, about 4.5 g/10 min to about 6 g/10 min, about 2 g/10 min to about 5 g/10 min, about 2.5 g/10 min to about 5 g/10 min, about 3 g/10 min to about 5 g/10 min, about 3.5 g/10 min to about 5 g/10 min, about 4 g/10 min to about 5 g/10 min, about 4.5 g/10 min to about 5 g/10 min, about 2 g/10 min to about 4.5 g/10 min, about 2.5 g/10 min to about 4.5 g/10 min, about 3 g/10 min to about 4.5 g/10 min, about
3.5 g/10 min to about 4.5 g/10 min, about 4 g/10 min to about 4.5 g/10 min, or about 4 g/10 min to about 4.5 g/10 min, as determined by ASTM D1238. In one or more examples, a HMS PP has an MFR of about 4 g/10 min (4MFR).
[0077] In any embodiment, the HMS PP has a weight average molecular weight (Mw) from about 200,000 g/mol, about 300,000 g/mol, or about 350,000 g/mol to about 500,000 g/mol, about 600,000 g/mol, or about 700,000 g/mol; a number average molecular weight (Mn) from about 15,000 g/mol or about 20,000 g/mol to about 30,000 g/mol, about 35,000 g/mol, or about 40,000 g/mol; and/or a z-average molecular weight from about 900,000 g/mol, about 1,000,000 g/mol, or about 1,200,000 g/mol to about 1,800,000 g/mol, about 2,000,000 g/mol, about 2,200,000 g/mol, or about 2,500,000 g/mol, as determined by Size Exclusion Chromatograph
("SEC"). For example, the HMS PP has a z-average molecular weight of less than 2,500,000 g/mol. In any embodiment, the HMS PP has a molecular weight distribution (Mw/Mn) of greater than 6, 7, or 8; or from about 6, about 7, about 8, about 10, or about 12 to about 14, about 16, about 18, about 20, about 22, or about 24. For example, the HMS PP has a molecular weight distribution (Mw/Mn) of about 7 to about 22. In any embodiment, the HMS PP has an Mz/Mw of greater than 3, 3.4, or 3.6, or from about 3, about 3.4, or about 3.6 to about 3.8, about 4, or about 4.4. The HMS PP can have a Mz/Mn of greater than 35, 40, 55, or 60, or from about 35, about 40, or about 55 to about 60, about 65, about 70, about 75, or about 80. Polymer molecular weight (weight-average molecular weight, Mw, number-average molecular weight, Mn, and z-averaged molecular weight, Mz) and molecular weight distribution (Mw/Mn) are determined using SEC. Equipment includes of a High Temperature Size Exclusion Chromatograph (either from Waters Corporation or Polymer Laboratories), with a differential refractive index detector (DRI) or infrared (IR) detector.
[0078] The HMS PPs can be linear as evidenced by a high branching index. In any embodiment, the HMS PPs have a branching index (g1, also referred to in the literature as gVis avg) of 0.95 or greater, such as 0.96, 0.97, or 0.98, as determined in column 37 of U.S. Pat. No. 7,807,769 determined by using aHigh Temperature Size Exclusion Chromatograph (either from Waters Corporation or Polymer Laboratories), equipped with three in-line detectors, a differential refractive index detector (DRI), a light scattering (LS) detector, and a viscometer. [0079] In any embodiment, the HMS PPs can have a melt strength of at least 15 cN or 20 cN determined using an extensional rheometer at 190°C; or from about 10 cN, about 15 cN, or about 20 cN to about 35 cN, about 40 cN, about 60 cN, about 80 cN, or about 100 cN. In some examples, the HMS PPs has a melt strength of less than 20 cN.
[0080] In any embodiment, the HMS PPs have a viscosity ratio from about 35 to about 80 determined from the complex viscosity ratio at 0.01 to 100 rad/s angular frequency at a fixed strain of 10% at 190°C. Also in any embodiment, the HMS PP has a Peak Extensional Viscosity (annealed) from about 10 kPa*s or about 20 kPa*s to about 40 kPa*s. about 50 kPa*s. about 55 kPa»s, about 60 kPa»s, about 80 kPa»s, or about 100 kPa»s at a strain rate of 0.01 /sec (190°C). [0081] In any embodiment, the HMS PP has a heat distortion temperature of greater than or equal to 100°C, determined according to ASTM D648 using a load of 0.45 MPa (66 psi). In some embodiments, the HMS PP has a Modulus from about 1,800 MPa or about 2,000 MPa to about 2,400 MPa or about 2,500 MPa, determined according to ASTM D790A on nucleated samples with 0.01 to 0.1 wt% a-nucleating agent.
[0082] The HMS PPs can have a peak melting point temperature (second melt, Tim) of greater than 160°C or 164°C, or from about 160°C or about 164°C to about 168°C or about 170°C (by DSC); and a crystallization temperature (Tc) of greater than 100°C, 105°C, or 110°C, or from about 100°C, about 105°C, or about 110°C to about 115°C or about 120°C (by DSC).
[0083] In any embodiment, the HMS PPs used to make the tPPs and films therefrom are a reactor-grade material, meaning that HMS PP is used as it comes out of the reactor used to produce it, optionally having been further made into pellets of material that has not altered any of its properties such as the branching index, MWD, or melt flow rate by more than 1% of its original value. In any embodiment, the HMS PP has not been cross-linked or reacted with any radiation or chemical substance to cause cross-linking and/or long-chain branching. Typical forms of radiation known to cause cross-linking and/or long-chain branching include use of so called e-beams or other radiation (beta or gamma rays) that interact with the polymer. Exemplary HMS PP's that are commercially available are Achieve™ Advanced polypropylene grades from ExxonMobil Chemical Company (Houston, Texas).
Process to produce the Trimmed Polypropylene
[0084] As stated above, the process to prepare the tPP can include combining the HMS PP with either a long half-life organic peroxide, a narrow MWD polypropylene, or a combination thereof. The long half-life organic peroxide is combined with the HMS PP such that it is from about 20 ppm, about 25 ppm, or about 50 ppm to about 400 ppm, about 600 ppm, about 800 ppm, or about 1,000 ppm of a long half-life organic peroxide based on the weight of the peroxide, the HMS PP, and any other additives. By "long half-life organic peroxide," what is meant is an organic peroxide (a peroxide-containing hydrocarbon) having a 1 hour half-life temperature (hi/2) of greater than 100°C, or 110°C, or 120°C, or 130°C, as measured in C6 to C16 alkane such as dodecane or decane, or ahalogenated aryl compound such as chlorobenzene. [0085] Such peroxides can include those having the general structure R'-OO-R2. or R'-OO- R3-00-R2, or, more generally, (R'-00-R2)n. where "n" is an integer from 1 to 5; and wherein each of R1 and R2 are independently selected from C2 to CIO alkyls, C6 to C12 aryls, and C7 to Cl 6 alkylaryls, such as iso- or tertiary-alkyls, and R3 is selected from Cl to C6, or CIO alkylenes, C6 to C12 aryls, and C7 to C16 alkylaryls; the "-00-" being the peroxide moiety. Long half-life organic peroxides may be 2,5-dimethyl-2,5-di(tert-butylperoxy)hexane, 2,5- bis(/cT/-butylpero\y)-2.5-dimethylhe\ane. di-tertbutyl peroxide, or dicumyl peroxide. [0086] The half-life is determined by differential scanning calorimetry-thermal activity monitoring of a dilute solution of the initiator in a suitable solvent. The half-life can then be calculated from the Arrhenius plot as is well known in the art. Thus, by treating the HMS PP, having a large amount of a high molecular weight component or "tail", with the long half-life peroxide the high molecular weight component is reduced or "trimmed". The appropriate solvent is determined based on the solubility of the organic peroxide.
[0087] Alternatively, or additionally, the HMS PP can be trimmed by combining from about
20 wt% or about 30 wt% to about 50 wt%, about 60 wt%, or about 70 wt%, by weight of the combined components, of a "narrow MWD polypropylene". The narrow MWD polypropylene contains at least 50 mol%, 60 mol%, 70 mol%, 75 mol%, or 80 mol% of propylene, and has an MWD of less than 6, or 5, or 4, or from about 2, or about 2.5 to about 4, or about 5, or about 6. In any embodiment, the MFR of the narrow MWD polypropylene is from about 4 g/10 min or about 8 g/10 min to about 40 g/10 min, about 60 g/10 min, about 80 g/10 min, or about 100 g/10 min. The narrow MWD polypropylene can be a propylene polymer having at least 50 mol% of propylene-derived units, such as those containing from about 0.1 wt% to about 5 wt% of comonomers such as ethylene-derived units, for example, homopolymers of propylene, such as isotactic poly propylenes. Thus, the high molecular weight component of the HMS PP can be diluted or "trimmed" using this technique. The "trimming" includes combining the HMS PP and narrow MWD polypropylene by melt blending as is known in the art, such as through one or two passes through an extruder, such as described in the "two-pass" process of WO 2016053468A1.
[0088] In any embodiment, the "combining" of the HMS PP and the long half-life organic peroxide can be performed by melt blending at least the peroxide and HMS PP at the melting temperature of the HMS PP, such as at a temperature of at least 120°C, about 130°C, about 150°C, or about 160°C, for example at a temperature from about 120°C, about 130°C, about 140°C, about 150°C, or about 160°C to about 220°C, about 240°C, about 260°C, about 280°C, or about 300°C, such temperature being the melt temperature as measured by a thermocouple in the melt upon extrusion from the mixing apparatus used to combine the materials. In some examples, the melt temperature of any melt including the HMS PP is from about 245°C, or about 250°C to about 260°C. At such temperatures the long half-life organic peroxides are activated towards beta-scissioning of the polypropylene and at the low concentrations used to achieve the trimming, the amount and combining temperature being tailored to the level of trimming for the particular HMS PP. The combining can take place in a single-screw or twin- screw extruder which can have controlled heating capability. This process can take place to form pellets of tPP, or in-line with the film making equipment or other desirable end-use making equipment such as thermoforming or blow molding. Trimmed Polypropylene
Figure imgf000028_0001
[0089] The process of combining the long half-life organic peroxide with the HMS PP leads to the tPPs. The starting polypropylenes used to make the tPPs typically have a large amount of high molecular weight polymer chains, typically above the critical orientation level. When making certain articles such as films, this can lead to strong films, but with many surface defects and thus unusable for most applications. It has been discovered that if some of the high molecular weight component is reduced or removed, trimmed, the resulting tPP has certain desirable properties, but maintains other desirable properties.
[0090] In any embodiment, the melt strength (measured at 190°C as described herein) of the tPPs is less than 20 cN, 15 cN, or 10 cN, or from about 1 cN or about 2 cN to about 4 cN, about 6 cN, about 10 cN, about 15 cN, or about 20 cN. The crystallization temperature Tc (as measured by DSC) of the tPP is greater than 114°C, 115°C, or 116°C; or from about 114°C, about 115°C, or about 116°C to about 120°C, about 122°C, or about 124°C. The second peak melting temperature Trm (as measured by DSC) of the tPP is greater than 157°C, or 158°C, or 159°C, or from about 157°C, about 158°C, or about 159°C to about 166°C, about 167°C, about
168°C, or about 169°C.
[0091] In any embodiment, the tPPs have a branching index (g1, also referred to in the literature as gVis avg) of at least 0.95, 0.97, or 0.98. The tPPs have molecular weight features distinct from the HMS PP from which they are derived. In any embodiment, the z-average molecular weight of the tPP is less than 2,500,000 g/mol, 2,000,000 g/mol, 1,600,000 g/mol, 1,400,000 g/mol, or 1,200,000 g/mol, or from about 500,000 g/mol, about 600,000 g/mol, or about 800,000 g/mol to about 1,200,000 g/mol, about 1,400,000 g/mol, about 1,600,000 g/mol, about 2,000,000 g/mol, or about 2,500,000 g/mol. The Mz/Mn value of the tPP is less than 60, 55, or 40, or from about 10, about 15, about 20, or about 25 to about 35 about 40, about 55, or about 60. The Mz/Mw value of the tPP is less than 4, 3.8, or 3.6, or from about 2.5 or about 2.6 to about 3.6, about 3.8, or about 4. The tPPs have a molecular weight distribution (Mw/Mn) of less than 22, 20, 18, 16, or 15, or from about 5, about 6, about 7, about 7.5, about 8, about 8.5, or about 9 to about 15, about 16, about 18, about 20, or about 22.
[0092] In any embodiment, the tPPs have an MFR (2.16 kg/230°C) from about 0.2 g/10 min, about 0.5 g/10 min, about 1 g/10 min, about 2 g/10 min, or about 3 g/10 min to about 4 g/10 min, about 5 g/10 min, about 6 g/10 min, about 8 g/10 min, about 10 g/10 min, or about 20 g/10 min. For example, the MFR of the tPPs is from about 0.2 g/10 min to about 20 g/10 min, about 0.5 g/10 min to about 15 g/10 min, about 0.5 g/10 min to about 10 g/10 min, about 0.5 g/10 min to about 8 g/10 min, about 0.5 g/10 min to about 5 g/10 min, about 0.5 g/10 min to about 4 g/10 min, about 0.5 g/10 min to about 3 g/10 min, or about 0.5 g/10 min to about 2 g/10 min. The tPPs can have elasticity while in the melt phase. In any embodiment, the Tan Delta (ratio of the viscous modulus (G") to elastic modulus (G) which is a useful quantifier of the presence and extent of elasticity in the melt) of the trimmed polypropylene is greater than 4, 6, 8, or 10, or from about 4, about 6, about 8, or about 10 to about 20, about 24, about 28, about 32, or about 36.
[0093] The tPPs also have advantageous bulk-physical properties. In any embodiment, the tPP has a Modulus of greater than 13 MPa, 14 MPa, or 15 MPa, or from about 13 MPa, about 14 MPa, or about 15 MPa to about 18 MPa, about 20 MPa, about 22 MPa, or about 24 MPa. In any embodiment, as with the base HMS PP, the reaction product of multi-functional monomers (e.g., polyfunctional acrylates) or oligomers (e.g., polyisobutylene), or cross-linking agents (e.g., silanes, siloxanes) are absent from the tPPs.
[0094] In any embodiment, the polypropylene, contained in the polyolefin composition, includes one or more tPPs which are produced from one or more HMS PPs. The polypropylene has a molecular weight distribution (Mw/Mn) of about 7 to about 22 and a z-average molecular weight of less than 2,500,000 g/mol. The polypropylene also has a branching index (gVis) of 0.95 or greater and a melt strength of less than 20 cN determined using an extensional rheometer at 190°C. Exemplary tPP's that are commercially available are Achieve™ Advanced polypropylene grades from ExxonMobil Chemical Company (Houston, Texas).
Broad Molecular Weight Distribution (BMWD or BWD) Polypropylenes [0095] In any embodiment, the polypropylene can be or include one or more BWD PPs. In one or more examples, the BWD PP can be or include Achieve™ Advanced PP0502E1 polypropylene, available from ExxonMobil Chemical Co. [0096] In any embodiment, the BWD PP can have a melt index from about 1, about 1.1, about 1.2, about 1.3, about 1.4, or about 1.5 g/10 min to about 1.6, about 1.7, about 1.8, about 1.9, or about 2 g/10 min, as determined according to ASTM D1238 (190°C/2.16 kg). For example, the BWD PP can have a melt index from about 1 g/10 min to about 2 g/10 min, about 1.2 g/10 min to about 2 g/10 min, about 1.4 g/10 min to about 2 g/10 min, about 1.5 g/10 min to about 2 g/10 min, about 1.6 g/10 min to about 2 g/10 min, about 1.7 g/10 min to about 2 g/10 min, about 1.8 g/10 min to about 2 g/10 min, about 1 g/10 min to about 1.8 g/10 min, about 1.2 g/10 min to about 1.8 g/10 min, about 1.4 g/10 min to about 1.8 g/10 min, about 1.5 g/10 min to about 1.8 g/10 min, about 1.6 g/10 min to about 1.8 g/10 min, about 1.7 g/10 min to about 1.8 g/10 min, about 1 g/10 min to about 1.6 g/10 min, about 1.2 g/10 min to about 1.6 g/10 min, about 1.4 g/10 min to about 1.6 g/10 min, or about 1.5 g/10 min to about 1.6 g/10 min, as determined according to ASTM D1238 (190°C/2.16 kg).
[0097] In any embodiment, the BWD PP can have a MFR from about 1, about 1.5, about 1.8, about 2, about 2.2, about 2.5, about 2.8, or about 3 g/10 min to about 3.2, about 3.5, about
4, about 4.5, about 5, about 5.5, or about 6 g/10 min, as determined according to ASTM D1238 Condition L (230°C/2.16 kg). For example, the BWD PP can have an MFR of about 1 g/10 min to about 6 g/10 min, about 1.5 g/10 min to about 6 g/10 min, about 2 g/10 min to about 6 g/10 min, about 2.5 g/10 min to about 6 g/10 min, about 3 g/10 min to about 6 g/10 min, about 3.5 g/10 min to about 6 g/10 min, about 4 g/10 min to about 6 g/10 min, about 4.5 g/10 min to about 6 g/10 min, about 2 g/10 min to about 6 g/10 min, about 2 g/10 min to about 5 g/10 min, about 2 g/10 min to about 4 g/10 min, about 2 g/10 min to about 3.5 g/10 min, about 2 g/10 min to about 3 g/10 min, about 2 g/10 min to about 2.5 g/10 min, about 3 g/10 min to about 6 g/10 min, about 3 g/10 min to about 5 g/10 min, about 3 g/10 min to about 4 g/10 min, about 3 g/10 min to about 3.8 g/10 min, or about 3 g/10 min to about 3.5 g/10 min, as determined by ASTM D1238.
[0098] In any embodiment, the BWD PP can have a density of about 0.8 g/cm3, about 0.82 g/cm3, about 0.84 g/cm3, about 0.85 g/cm3, about 0.86 g/cm3, about 0.88 g/cm3, or about 0.89 g/cm3 to about 0.90 g/cm3, about 0.91 g/cm3, about 0.92 g/cm3, about 0.95 g/cm3, or about 0.98 g/cm3. For example, the BWD PP can have a density of about 0.82 g/cm3 to about 0.98 g/cm3, about 0.85 g/cm3 to about 0.95 g/cm3, about 0.87 g/cm3 to about 0.92 g/cm3, about 0.88 g/cm3 to about 0.92 g/cm3, about 0.89 g/cm3 to about 0.92 g/cm3, or about 0.89 g/cm3 to about 0.91 g/cm3.
[0099] In any embodiment, the BWD PP can have a Tensile Strength at Yield independently in the MD and the TD of about 10 MPa, about 15 MPa, about 18 MPa, about 20 MPa, about 25 MPa, about 30 MPa, or about 35 MPa to about 40 MPa, about 45 MPa, about 50 MPa, about 60 MPa, about 80 MPa, or about 100 MPa, as determined by ASTM D638. For example, the BWD PP can have a Tensile Strength at Yield independently in the MD and the TD of about 18 MPa to about 100 MPa, about 18 MPa to about 80 MPa, about 18 MPa to about 60 MPa, about 18 MPa to about 50 MPa, about 18 MPa to about 40 MPa, about 18 MPa to about 35 MPa, about 18 MPa to about 30 MPa, about 30 MPa to about 100 MPa, about 30 MPa to about 80 MPa, about 30 MPa to about 60 MPa, about 30 MPa to about 50 MPa, about 30 MPa to about 40 MPa, about 30 MPa to about 35 MPa, about 35 MPa to about 100 MPa, about 35 MPa to about 80 MPa, about 35 MPa to about 60 MPa, or about 35 MPa to about 50 MPa, as determined by ASTM D638.
Homonolvmers of Polypropylene thPP)
[00100] In any embodiment, the polypropylene can be or include one or more homopolymers of PP (hPP). In one or more examples, the homopolymer of PP can be or include EM PP4052E1 PP, available from ExxonMobil Chemical Company (Houston, Texas).
[00101] In any embodiment, the hPP can have a MFR from about 1, about 1.2, about 1.4, about 1.6, or about 1.8 g/10 min to about 2, about 2.2, about 2.5, about 2.8, about 3, about 3.5, about 4, about 4.5, about 5, about 5.5, or about 6 g/10 min, as determined according to ASTM D1238 Condition L (230°C/2.16 kg). For example, the hPP can have an MFR of about 1 g/10 min to about 6 g/10 min, about 1.5 g/10 min to about 6 g/10 min, about 2 g/10 min to about 6 g/10 min, about 2.5 g/10 min to about 6 g/10 min, about 3 g/10 min to about 6 g/10 min, about 3.5 g/10 min to about 6 g/10 min, about 4 g/10 min to about 6 g/10 min, about 4.5 g/10 min to about 6 g/10 min, about 1.3 g/10 min to about 6 g/10 min, about 1.3 g/10 min to about 5 g/10 min, about 1.3 g/10 min to about 4 g/10 min, about 1.3 g/10 min to about 3 g/10 min, about 1.3 g/10 min to about 2.5 g/10 min, about 1.3 g/10 min to about 2.2 g/10 min, about 1.3 g/10 min to about 2 g/10 min, about 1.6 g/10 min to about 6 g/10 min, about 1.6 g/10 min to about 5 g/10 min, about 1.6 g/10 min to about 4 g/10 min, about 1.6 g/10 min to about 3 g/10 min, about 1.6 g/10 min to about 2.5 g/10 min, about 1.6 g/10 min to about 2.2 g/10 min, or about 1.6 g/10 min to about 2 g/10 min, as determined by ASTM D1238.
[00102] In any embodiment, thehPP can have a density of about 0.8 g/cm3, about 0.82 g/cm3, about 0.84 g/cm3, about 0.85 g/cm3, about 0.86 g/cm3, or about 0.88 g/cm3 to about 0.9 g/cm3, about 0.92 g/cm3, about 0.95 g/cm3, or about 0.98 g/cm3. For example, the hPP can have a density of about 0.82 g/cm3 to about 0.98 g/cm3, about 0.85 g/cm3 to about 0.95 g/cm3, or about 0.87 g/cm3 to about 0.92 g/cm3.
[00103] In any embodiment, the hPP can have a Tensile Strength at Yield of about 20 MPa, about 25 MPa, about 30 MPa, or about 35 MPa to about 40 MPa, about 45 MPa, about 50 MPa, about 60 MPa, about 80 MPa, or about 100 MPa, as determined by ASTM D638. For example, the hPP can have a Tensile Strength at Yield of about 20 MPa to about 100 MPa, about 20 MPa to about 80 MPa, about 20 MPa to about 60 MPa, about 20 MPa to about 50 MPa, about 20
MPa to about 40 MPa, about 20 MPa to about 35 MPa, about 20 MPa to about 30 MPa, about
30 MPa to about 100 MPa, about 30 MPa to about 80 MPa, about 30 MPa to about 60 MPa, about 30 MPa to about 50 MPa, about 30 MPa to about 40 MPa, about 30 MPa to about 35 MPa, about 35 MPa to about 100 MPa, about 35 MPa to about 80 MPa, about 35 MPa to about 60 MPa, or about 35 MPa to about 50 MPa, as determined by ASTM D638.
Impact Copolymer tlCP) of Polypropylene
[00104] In any embodiment, the polypropylene can be or include one or more impact copolymers (ICP). In one or more examples, the ICP can be or include EM PP7032E2 PP, available from ExxonMobil Chemical Company (Houston, Texas).
[00105] In any embodiment, the ICP can have a MFR from about 1 , about 2, about 2.2, about 2.5, about 2.8, about 3, about 3.2, or about 3.5 g/10 min to about 3.8, about 4, about 4.5, about 5, about 5.5, or about 6 g/10 min, as determined according to ASTM D1238 Condition L (230°C/2.16 kg). For example, the ICP can have an MFR of about 1 g/10 min to about 6 g/10 min, about 2 g/10 min to about 5 g/10 min, about 2 g/10 min to about 4.5 g/10 min, about 2 g/10 min to about 4 g/10 min, about 2 g/10 min to about 3.5 g/10 min, about 2 g/10 min to about 3 g/10 min, about 3 g/10 min to about 5 g/10 min, about 3 g/10 min to about 4.5 g/10 min, about 3 g/10 min to about 4 g/10 min, about 3 g/10 min to about 3.5 g/10 min, about 3 g/10 min to about 3.2 g/10 min, about 3.5 g/10 min to about 5 g/10 min, about 3.5 g/10 min to about 4.5 g/10 min, about 3.5 g/10 min to about 4 g/10 min, or about 3.5 g/10 min to about 3.8 g/10 min, as determined by ASTM D1238.
[00106] In any embodiment, the ICP can have a density of about 0.8 g/cm3, about 0.82 g/cm3, about 0.84 g/cm3, about 0.85 g/cm3, about 0.86 g/cm3, or about 0.88 g/cm3 to about 0.9 g/cm3, about 0.92 g/cm3, about 0.95 g/cm3, or about 0.98 g/cm3. For example, the ICP can have a density of about 0.82 g/cm3 to about 0.98 g/cm3, about 0.85 g/cm3 to about 0.95 g/cm3, or about 0.87 g/cm3 to about 0.92 g/cm3.
[00107] In any embodiment, the ICP can have a Tensile Strength at Yield of about 10 MPa, about 15 MPa, about 18 MPa, about 20 MPa, about 25 MPa, about 30 MPa, or about 35 MPa to about 40 MPa, about 45 MPa, about 50 MPa, about 60 MPa, about 80 MPa, or about 100
MPa, as determined by ASTM D638. For example, the ICP can have a Tensile Strength at Yield of about 18 MPa to about 100 MPa, about 18 MPa to about 80 MPa, about 18 MPa to about 60 MPa, about 18 MPa to about 50 MPa, about 18 MPa to about 40 MPa, about 18 MPa to about 35 MPa, about 18 MPa to about 30 MPa, about 30 MPa to about 100 MPa, about 30 MPa to about 80 MPa, about 30 MPa to about 60 MPa, about 30 MPa to about 50 MPa, about 30 MPa to about 40 MPa, about 30 MPa to about 35 MPa, about 35 MPa to about 100 MPa, about 35 MPa to about 80 MPa, about 35 MPa to about 60 MPa, or about 35 MPa to about 50 MPa, as determined by ASTM D638. Random Copolymer 1RCP) of Polypropylene
[00108] In any embodiment, the polypropylene can be or include one or more random copolymers (RCP). In one or more examples, the RCP can be or include EM PP9054 PP, available from ExxonMobil Chemical Company (Houston, Texas). [00109] In any embodiment, the RCP can have a MFR from about 5, about 6, about 7, about
8, about 9, about 10, about 11, or about 12 g/10 min to about 13, about 14, about 15, about 16, about 18, or about 20 g/10 min, as determined according to ASTM D1238 Condition L (230°C/2.16 kg). For example, the RCP can have an MFR of about 5 g/10 min to about 20 g/10 min, about 5 g/10 min to about 18 g/10 min, about 5 g/10 min to about 16 g/10 min, about 5 g/10 min to about 14 g/10 min, about 5 g/10 min to about 12 g/10 min, about 5 g/10 min to about 10 g/10 min, about 5 g/10 min to about 8 g/10 min, about 8 g/10 min to about 20 g/10 min, about 8 g/10 min to about 18 g/10 min, about 8 g/10 min to about 16 g/10 min, about 8 g/10 min to about 14 g/10 min, about 8 g/10 min to about 12 g/10 min, about 8 g/10 min to about 10 g/10 min, about 10 g/10 min to about 20 g/10 min, about 10 g/10 min to about 18 g/10 min, about 10 g/10 min to about 16 g/10 min, about 10 g/10 min to about 14 g/10 min, or about
10 g/10 min to about 12 g/10 min, as determined according to ASTM D1238.
[00110] In any embodiment, the RCP can have melt temperature of about 100°C, about 120°C, about 125°C, about 130°C, about 135°C, about 140°C, about 145°C, or about 150°C to about 155°C, about 160°C, about 165°C, about 170°C, about 175°C, about 180°C, about 190°C, or about 200°C. For example, the RCP can have melt temperature of about 100°C to about 200°C, about 100°C to about 180°C, about 100°C to about 170°C, about 100°C to about 160°C, about 100°C to about 150°C, about 100°C to about 140°C, about 100°C to about 130°C, about 100°C to about 120°C, about 125°C to about 200°C, about 125°C to about 180°C, about 125°C to about 170°C, about 125°C to about 160°C, about 125°C to about 150°C, about 125°C to about 140°C, about 125°C to about 130°C, about 145°C to about 200°C, about 145°C to about
180°C, about 145°C to about 170°C, about 145°C to about 160°C, about 145°C to about 150°C, about 150°C to about 200°C, about 150°C to about 180°C, about 150°C to about 170°C, about 150°C to about 160°C, about 155°C to about 200°C, about 155°C to about 180°C, about 155°C to about 170°C, or about 155°C to about 160°C. Additives and other Polymers
[00111] In some embodiments, other "additives" may also be present in the polyolefin composition, layers, and/or films thereof. These additives may be added before, during, and/or after the formation of the coextruded sheets or films. Such additives include antioxidants (e.g., hindered phenol- and phosphite-type compounds), stabilizers such as lactone and vitamin E, nucleators (both a-nucleators and b-nucleators), clarifying agents, colorants (dyes or pigments), fillers (silica or talc), UV stabilizers, release agents, slip agents, tackifiers, anti-static agents, acid scavengers (e.g., calcium stearate), anti-blocking agents, anti-blooming agents, polymer processing aid masterbatch (PPA MB) additives/agents, hydrocarbon resins such as Oppera™ type resins, or combinations thereof.
[00112] In any embodiment, the polyolefin composition, the core layer, and/or one or more skin layers contains one or more additives in an amount from about 0.5 wt%, about 1 wt%, about 2 wt%, about 3 wt%, about 4 wt%, or about 5 wt% to about 6 wt%, about 8 wt%, or about 10 wt%, based on the weight of the composition/layer. For example, the polyolefin composition contains from about 0.5 wt% to about 10 wt%, about 0.5 wt% to about 8 wt%, about 0.5 wt% to about 5 wt%, about 0.5 wt% to about 3 wt%, about 0.5 wt% to about 2 wt%, about 0.5 wt% to about 1 wt%, about 1 wt% to about 10 wt%, about 1 wt% to about 8 wt%, about 1 wt% to about 5 wt%, about 1 wt% to about 3 wt%, or about 1 wt% to about 2 wt% of the additive. In other embodiments, the polyolefin composition, the core layer, and/or one or more skin layers contains one or more additives in an amount from about 50 ppm, about 100 ppm, about 150 ppm, about 200 ppm, about 300 ppm, about 350 ppm, about 400 ppm, about 420 ppm, about 450 ppm, about 500 ppm, about 750 ppm, or about 1,000 ppm to about 1,500 ppm, about 2,000 ppm, about 2,500 ppm, about 3,000 ppm, about 4,000 ppm, about 4,500 ppm, or about 5,000 ppm. For example, the polyolefin composition, the core layer, and/or one or more skin layers contains about 50 ppm to about 5,000 ppm, about 100 ppm to about 5,000 ppm, about 150 ppm to about 5,000 ppm, about 200 ppm to about 5,000 ppm, about 300 ppm to about 5,000 ppm, about 420 ppm to about 5,000 ppm, about 500 ppm to about 5,000 ppm, about 1,000 ppm to about 5,000 ppm, about 1,500 ppm to about 5,000 ppm, about 2,000 ppm to about 5,000 ppm, about 2,500 ppm to about 5,000 ppm, about 3,000 ppm to about 5,000 ppm, about 50 ppm to about 3,000 ppm, about 100 ppm to about 3,000 ppm, about 150 ppm to about 3,000 ppm, about
200 ppm to about 3,000 ppm, about 300 ppm to about 3,000 ppm, about 420 ppm to about 3,000 ppm, about 500 ppm to about 3,000 ppm, about 1,000 ppm to about 3,000 ppm, about 1,500 ppm to about 3,000 ppm, about 2,000 ppm to about 3,000 ppm, or about 2,500 ppm to about 3,000 ppm of the additive.
[00113] In any embodiment, nucleating agents are absent, for example, a-nucleating agents are absent, meaning nucleating agents are not added to the composition or any components of the composition at any stage of the process of formation. Examples of a-nucleating agents include salts of monocarboxylic acids and polycarboxylic acids, sorbitols such as dibenzylidenesorbitol, salts of diesters of phosphoric acid, vinylcycloalkane polymers, or combinations thereof.
[00114] The polyolefin compositions of the present disclosure are particularly useful in films and articles that include films or film coatings. Films of less than 250 pm average thickness can be made using the polyolefin compositions and can contain any number of layers, such as additional layers of linear low-density polyethylene (LLDPE), HDPE, LDPE, iPP, EP copolymers, and combinations thereof. Also, the polyolefin compositions can contain a composition including any of these polymers or combinations of polymers and be present in any desirable amount. Furthermore, sheets having an average thickness of about 250 pm or more can be made using the polyolefin compositions described herein, or may contain one or more layers containing polyolefin compositions and another material such as LLDPE, HDPE, LDPE, iPP, EP copolymers, and combinations thereof. Such sheets, or other desirable structures made using the polyolefin compositions described herein, may be thermoformed, blow molded, or injection molded into useful articles, and further, polyolefin compositions may be rotomolded to form useful articles.
[00115] In any embodiment, the polyolefin composition, the core layer, the tie layer, and/or the skin layer can include one or more LLDPEs. The LLDPE is in a concentration of about 5 wt%, about 10 wt%, about 15 wt%, about 20 wt% to about 25 wt%, about 30 wt%, about 40 wt%, or about 50 wt% by weight of the overall polymer composition (e.g., the polyolefin composition, the core layer, or the skin layer). In some examples, the LLDPE contains ethylene derived units and comonomers selected from C3 to CIO alpha-olefin derived units.
[00116] The various descriptive elements and numerical ranges disclosed herein for the polyolefin compositions and methods of forming the polyolefin compositions and films therefrom can be combined with other descriptive elements and numerical ranges to describe the embodiments; further, for a given element, any upper numerical limit can be combined with any lower numerical limit described herein, including the examples. Films formed from the Polyolefin Compositions
[00117] Many articles can be formed from the polyolefin compositions described herein such as thermoformed articles, blow molded articles, injection molded articles, sheets, fibers, fabrics, and other useful items. For example, the polyolefin compositions can be used to produce industrial and food package articles that have a PP/PE film structure. The polyolefin compositions can be formed into films using any suitable method, especially cast films, extrusion coated films, and blown films, and/or included as at least part of one or more layers of a multi-layered film. Such types of films may have two, three, four or more layers represented such as S/C, S/C/S, S/C/C, S/T/C/S, S/T/C/T/S, wherein "C" is a core layer, "T" is a tie-layer, and "S" is a skin layer, each of which may be made from the same or different materials. Any one or more layers (e.g., core, tie, and/or skin layers) can contain or comprise, consist essentially of, or consist of one or more polyolefin compositions. In some examples, structures include those that contain a layer having a range from about 50 wt%, about 55 wt%, or about 60 wt% to about 80 wt%, about 85 wt%, or about 90 wt%, based on weight of the components of that layer, of one or more polyolefin compositions. In other examples, that layer is a core layer with at least one skin layer containing a polyethylene and/or polypropylene. The polyolefin compositions can replace the HDPE in many known film structures and allow down- gauging by about 10% to about 30% relative to when HDPE is used.
[00118] The polyolefin compositions can be used in making blown films. In a typical blown film process the ingredients used to form the film are added in any desirable form, such as granules, pellets, or particulates, into a hopper which feeds the material to an extruder, where the materials are melt blended at a desirable temperature through shear forces and/or heating. The molten material is then fed, with or without filtering, to a die which may have just one, or have multiple cavities corresponding to each of multiple layers that will form the film. The die is also heated to a desired temperature and then forced from the die in a direction away from the die. The cooling of the forming film takes place via a device that blows air or one or more other gases (e.g., nitrogen, argon, mixtures thereof) that is at least 5°C or 10°C cooler than the surrounding air, where the "surrounding air" is air that is at least 1 meter from the cooling device, but less than 5 meters. For example, the air can blow against the outside of the film, such as around the entire circumference formed by the film. There is also air blown internally that both cools and blows the film up like a bubble/balloon. The film starts to expand where the film eventually cools and crystallizes to form a blown film. Conventional polypropylenes can be difficult to use for blown film processes because they typically have low melt strength, which will promote breakage of the bubble, balloon, or film. However, HMS PP of the present disclosure can provide improved melt strength for improved polypropylene-based blown film processes. In addition, the polyolefin compositions of the present disclosure have an enhanced toughness and a greater stiffness compared to conventional BOCD polyethylenes. [00119] The performance of the compositions containing the polypropylenes being formed into a film can be characterized by its Maximum Die Rate. The "Maximum Die Rate" is a normalized extrusion rate by die size which is commonly used in the blown film industry. The Maximum Die Rate as used herein is expressed as follows: Maximum Die Rate [lb/in-hr] = Extrusion Rate [lb/hr] / Die Circumference [inch]. Another definition of the Maximum Die Rate is expressed as follows: Maximum Die Rate [kg/mm-hr] = Extrusion Rate [kg/hr] / Die Diameter [mm]. The Maximum Die Rate at which the film is formed is greater than 13 lb/in- hr (0.73 kg/mm-hr) or 16 lb/in-hr (0.90 kg/mm-hr) or 24 lb/in-hr (1.34 kg/mm-hr), or from 13 lb/in-hr (0.73 kg/mm-hr) or 16 lb/in-hr (0.90 kg/mm-hr), or 24 lb/in-hr (1.34 kg/mm-hr) to 30 (1.69 kg/mm-hr), or 40 lb/in-hr (2.25 kg/mm-hr). Note that for the "Maximum Die Rate" in the English unit, the die dimension is the die circumference, while in metric units, the die dimension is the die diameter. Thus, for die factor in lb/in-hr, the full expression is lb/die circumference (in unit of inch)/hr; and for die factor in kg/mm-hr, the full expression is kg/die diameter (in unit of mm)/hr.
[00120] The polyolefin compositions can be processed at advantageously low temperatures. In any embodiment, the polyolefin composition can be processed, such as melt extruded, at barrel temperatures of less than 210°C, 200°C, or 190°C, or from about 160°C, about 170°C, about 175°C, about 180°C, or about 185°C to about 190°C, about 195°C, about 200°C, about 205°C, or about 210°C; and die temperatures of less than 210°C, or from about 190°C, about 200°C, or about 205°C to about 210°C. [00121] In any embodiment, a method of forming a finished film includes extruding a molten polyolefin composition through a die opening to form a film and causing the film to progress in a direction away from the die opening, such as in the molten state, partially molten, or softened due to some partial cooling. The method also includes cooling the molten polyolefin composition in the form of a film at a distance from the die opening, the distance adjusted to effect the properties of the film (e.g., to allow relaxation of the molten polyolefin composition prior to solidification and/or crystallization upon cooling), and isolating a finished film therefrom. [00122] In some examples, a method of forming a film includes extruding the polyolefin composition through one or more die openings to form the film. For example, the method can include extruding a molten polyolefin composition containing one or more BOCD polyethylenes and one or more polypropylenes through the die opening to form the film, and then cooling the film at a distance away from the die opening to produce a finished film. The film can be cooled by blowing air, nitrogen, argon, or other gases on at least a portion of the film. In one or more examples, the molten polyolefin composition can include about 40 wt% to about 95 wt% of the BOCD polyethylene and about 5 wt% to about 60 wt% of the polypropylene, by weight of the polyolefin composition. In some examples, the BOCD polyethylene contains about 70 mol% to about 100 mol% of ethylene and has a density of about 0.91 g/cm3 to about 0.925 g/cm3, in accordance with ASTM D-4703 and ASTM D-1505/ISO 1183 and a branching index (gVis) of 0.98 or greater.
[00123] In any embodiment, a film containing the polyolefin composition has a thickness of about 10 pm, about 30 pm, or about 50 pm to about 100 pm, about 200 pm, about 300 pm, or about 500 pm. For example, the film containing the polyolefin composition has a thickness of about 10 pm to about 300 pm, about 10 pm to about 200 pm, about 10 pm to about 150 pm, about 10 pm to about 100 pm, about 10 pm to about 80 pm, about 10 pm to about 50 pm, about 10 pm to about 40 pm, about 25 pm to about 300 pm, about 25 pm to about 200 pm, about 25 pm to about 150 pm, about 25 pm to about 100 pm, about 25 pm to about 80 pm, about 25 pm to about 50 pm, about 25 pm to about 40 pm, about 50 pm to about 300 pm, about 50 pm to about 200 pm, about 50 pm to about 150 pm, about 50 pm to about 100 pm, or about 50 pm to about 80 pm. In some examples, the film is a monolayer that has a thickness of about 10 pm to about 100 pm, about 20 pm to about 80 pm, or about 30 pm to about 60 pm. In other examples, the film has a thickness of about 50 pm to about 300 pm, about 60 pm to about 200 pm, or about 80 pm to about 150 pm.
[00124] In one or more examples, the film, the core, or other monolayer contains from about 75 wt% to about 95 wt% of the BOCD polyethylene and from about 5 wt% to about 25 wt% of the polypropylene, by weight of the polyolefin composition. The film has an Elmendorf Tear MD of about 7.2 g/pm to about 10 g/pm, about 7.5 g/pm to about 9.5 g/pm, or about 8 g/pm to about 9.2 g/pm and an Elmendorf Tear TD of about 12.8 g/pm to about 16 g/pm, about 13 g/pm to about 14.5 g/pm, or about 13.5 g/pm to about 14 g/pm.
[00125] In other embodiments, the film includes a core layer disposed between two skin layers. Both skins can have the same composition, or alternatively, each of the skins can have a different composition than the each other. The core layer includes the polyolefin composition which contains one or more HMS PPs or one or more tPPs. In some examples, each of the skin layers can independently contain the polyolefin composition, the BOCD, an LLDPE, the polypropylene, or any combination thereof. [00126] By "extruding" what is meant is that the polymer and/or polymer blend if formed into a melt such as by heating and/or sheer forces and is forced to blend with other polymers and/or components (e.g., the polyethylene and the modifier) and is then forced out of a die in a desirable form or shape to affect the form or shape of the emanating polymer melt, such as in a film, such as a tubular film. Any suitable apparatus will be appropriate to provide "extrusion" such as a single or twin-screw extruder, or other melt-blending device as is known in the art and that can be fitted with a suitable die.
[00127] By "at a distance from the die", what is meant is that the "cooling device", such as a cooling ring that blows air on the forming film, is located at least 1 cm, 2 cm, 4 cm, or 8 cm from the die (or other distance as described herein) such as measured from the top or outer edge of the die to the base of the cooling device.
[00128] By "causing the film to progress", what is meant is that the film forming from the die opening from hardening polyethylene is pulled or pushed mechanically or by some other means such as by air pressure (negative or positive) away from the die to create a continuous finished film. [00129] In a typical process, a polyethylene melt is extruded through a die such as an annular slit die, usually vertically, to form a thin walled tube. Cooling can be conducted in the air or other gas which is introduced via a ring in the center of the die to blow up the tube like a balloon. Cooling could also be provided by other means, and the air may be nitrogen/oxygen or other gases or mixtures of gases or liquids. Mounted on top of the die, a high-speed air ring blows onto the hot film to cool the film. The cooling occurs at some distance from the die, which is at least 1 cm as described above. The tube of film can then continue upwards, continually cooling, until it may pass through nip rolls where the tube is flattened to create what is known as a "lay-flat" tube of film. This lay-flat or collapsed tube can then be taken back down the extrusion "tower" via more rollers. On higher output lines, the air inside the bubble is also exchanged. This is known as IBC (Internal Bubble Cooling). [00130] The lay -flat film is then either kept as such or the edges of the lay-flat are slit off to produce two flat film sheets and wound up onto reels. Articles such as bags can be made from such lay -flat films. In this regard, if kept as lay -flat, the tube of film is made into bags by sealing across the width of film and cutting or perforating to make each bag. This is done either in line with the blown film process or at a later stage.
[00131] In some examples, the expansion ratio between die and blown tube of film would be 1.5 times to 4 times the die diameter. The films were blown at a temperature of about 400°F (about 204°C) to about 500°F (about 260°C), such as about 410°F (about 210°C) to about 465°F (about 241°C). The drawdown between the melt wall thickness and the cooled film thickness occurs in both radial and longitudinal directions and is easily controlled by changing the volume of air inside the bubble and by altering the haul off speed. This gives blown film a better balance of properties than traditional cast or extruded film which is drawn down along the extrusion direction only.
[00132] In any embodiment, the polyolefin compositions described herein are suitable for stand up, flexible, packs, or pouches. Such packs would be stiff enough to be formed into a shape to allow it to stand upright, for instance, with labeling on the front, but flexible and soft enough to allow a user to bend and/or squeeze the pack to force and/or pour liquid, gel, or flowable solids from an opening or open top of the pack. The polyethylene content can be adjusted to provide the toughness and low temperature packaging integrity for the pouch while the polypropylene content can be adjusted to provide stiffness and heat resistance during defrosting and/or microwave reheating of the pouch or pack. The packs and pouches can be used for collecting, storing and serving food items such as juice, vegetables, dairy products, desserts, flowable solids, and/or purees. Thus in any embodiment is a flexible food pack comprising the polyolefin composition of any one of the preceding claims, where the polyolefin composition contains within the range from about 5, or 10 to 40, or 50 wt% of the polypropylene, and from within the range from about 50, or 60 to 90, or 95 wt% of the polyethylene, each by weight of the composition; and wherein the polyolefin composition is a film that is optionally laminated to one or more additional polymeric films. Such additional films could be the same or different polyolefin materials and could include a metallized layer of material if microwave heating is not desired. EXPERIMENTAL SECTION
[00133] Three-layer films, Samples 1-30, having a core layer disposed between two skin layers were produced with a thickness of 90 pm, as listed in Table 1. Each of the three-layer films contained 25 wt% / 50 wt% / 25 wt% of skin/core/skin, respectively. The skin layers of the three-layer films were prepared with about 90 wt% of BOCD PE (Exceed™ XP 8656ML polyethylene, available from ExxonMobil Chemical Co.) and about 10 wt% of PP (Achieve™ Advanced PP0502E1). The core of the three-layer films were prepared with various concentrations of BOCD PE (Exceed™ XP 8656ML polyethylene, available from ExxonMobil Chemical Co.) and one of the polypropylenes (PP1-PP6), as listed in Table 1. The polypropylenes include:
Polypropylene 1 (PP1) - a Broad Weight Distribution (BWD) PP (Achieve™ Advanced PP0502E1 polypropylene, available from ExxonMobil Chemical Co.); Polypropylene 2 (PP2) - a HMS PP with a 4MFR (about 4 g/10 min);
Polypropylene 3 (PP3) - a HMS PP (Achieve™ Advanced PP6282NE1 polypropylene, available from ExxonMobil Chemical Co.);
Polypropylene 4 (PP4) - ahomopolymer of PP (EM PP4052E1 polypropylene, available from ExxonMobil Chemical Co.);
Polypropylene 5 (PP5) - an impact copolymer (ICP) (EM PP7032E2 polypropylene, available from ExxonMobil Chemical Co.); and Polypropylene 6 (PP6) - a random copolymer (RCP) (EM PP9054 polypropylene, available from ExxonMobil Chemical Co.).
Figure imgf000041_0001
Figure imgf000042_0001
[00134] Comparative or control samples were used and included three-layer films having a core layer disposed between two skin layers were produced with a thickness of 90 pm. Each film of the control samples contains 25 wt% / 50 wt% / 25 wt% of skin/core/skin, respectively. The core of the control sample films were 100 wt% of BOCD PE (Exceed™ XP 8656ML polyethylene, available from ExxonMobil Chemical Co.). The skin layers of the control sample films were prepared with about 90 wt% of BOCD PE (Exceed™ XP 8656ML polyethylene, available from ExxonMobil Chemical Co.) and about 10 wt% of PP (Achieve™ Advanced PP0502E1). [00135] Measured properties for Samples 1-30 and the control sample are listed in Table 2, as well as provided throughout the graphs in Figures 3A-8. The measured properties included Stiffness in the MD and TD (1% secant flexural modulus), Tensile Strength in the MD and TD (determined by ASTM D882), Tear strength in the MD and TD (Elmendorf tear), Elongation at Break in the MD and TD (determined by ASTM D882), Dart Drop Impact, and Haze.
Figure imgf000042_0002
Figure imgf000043_0001
[00136] FIGS. 3A and 3B are plots of Stiffness for Samples 1-30 and the control sample having a core of BOCD PE. By blending the BOCD PE with any of PP1-PP6, the 1% Secant is increased both orientations (MD and TD) for Samples 1-30 over the control example. The HMS PPs (PP1 and PP2) in Samples 1-10 and the homopolymer PPs (PP3 and PP4) in Samples 11-20 provide the greatest increase of stiffness over the ICP PP (PP5) in Samples 21-25 and the RCP PP (PP6) in Samples 26-30. [00137] FIGS. 4A and 4B are plots of Tensile at Yield strength for Samples 1-30 and the control sample having a core of BOCD PE. By blending the BOCD PE with any of PP1-PP6, the Tensile at Yield strength is increased both orientations (MD and TD) for Samples 1-30 over the control example. The HMS PPs (PP1 and PP2) in Samples 1-10 and the homopolymer PPs (PP3 and PP4) in Samples 11-20 provide the greatest increase of tensile strength over the ICP PP (PP5) in Samples 21-25 and the RCP PP (PP6) in Samples 26-30.
[00138] FIGS. 5A and 5B are plots of Tear strength for Samples 1-30 and the control sample having a core of BOCD PE. By blending the BOCD PE with any of PP1-PP6, the Tear strength is increased in concentrations from about 10 wt% to about 30 wt% in the MD and about 30 wt% to about 40 wt% in the TD for Samples 1-30 over the control example. In other concentrations of the PP, the Tear strength was either increased or decreased depending on the specific PP. The ICP PP (PP5) in Samples 21-25 and the RCP PP (PP6) in Samples 26-30 provided the greatest increase in Tear strength and at a broader concentration range compared to the other PPs. [00139] FIGS. 6A and 6B are plots of Elongation at Break strength for Samples 1-30 and the control sample having a core of BOCD PE. The Elongation at Break strength values for Samples 1-30 were very random in the MD, such that the values increased, decreased, or stayed the same relative to the control example. Most of the values in the Elongation at Break strength values for Samples 1-30 in the TD were increased relative to the control example. [00140] FIG. 7 is a plot of Dart Drop Impact strength for Samples 5, 10, 15, and 20-30 and the control sample having a core of BOCD PE. The ICP PP (PP5) in Samples 21-25 and the RCP PP (PP6) in Samples 26-30 maintained high values for the Dart Drop Impact strength relative to the control sample. However, the other PPs in Samples 5, 10, 15, and 20 provided reduced values for the Dart Drop Impact strength relative to the control sample. [00141] FIG. 8 is a plot of Haze for Samples 1-30 and the control sample having a core of
BOCD PE. The values of Haze were overall relatively high for Samples 1-30. Blending PPs into the BOCD PE provided very little or no improvement in optics.
[00142] All film samples were made on three layer Alpine II extruder under the following conditions. [00143] Extruder A (HX65-G) for a first skin layer had a Feed Throat Temperature of about
27°C, Barrels #l-#4 Temperature of about 185°C to about 196°C, Barrel #5 Temperature of about 193°C to about 204°C, and Zones #6-#7 Temperature of about 193°C to about 216°C. [00144] Extruder B (HX90-G) for a core layer had a Feed Throat Temperature of about 27°C, Barrels #l-#4 Temperature of about 185°C to about 196°C, Barrel #5 Temperature of about 185°C to about 204°C, and Zones #6-#7 Temperature of about 193°C to about 227°C. [00145] Extruder C (HX65-S) for a second skin layer had a Feed Throat Temperature of about 27°C, Barrel #1 Temperature of about 177°C to about 188°C, Barrel #2 Temperature of about 204°C to about 216°C, Barrels #3-#5 Temperature of about 199°C to about 210°C, Zones #6-#7 Temperature of about 199°C to about 210°C, Die Zones #l-#4 Temperature of about 227°C to about 241°C, IBC Ring Temperature of about 18°C, Air Ring Temperature of about 18°C, and Nip Roll Temperature of about 27°C. 1% Secant Flexural Modulus
[00146] The 1 % secant flexural modulus was determined by the following: Equipment used: The United Six (6) station, 60 Degree machine contains the following: A load frame testing console containing an electrically driven crosshead mounted to give horizontal movement. Opposite the crosshead are mounted six (6) separate load cells. These load cells are tension load cells.
[00147] Units #1 and #3 have load cells with a range of 0-35 pounds. Unit #2 has load cells with a range of 0-110 pounds. Each load cell was equipped with a set of air-actuated jaws. Each jaw had faces designed to form a line grip. The jaw combines one standard flat rubber face and an opposing face from which protrudes a metal half-round. Units #1 and #3 have 1 1/4" wide jaws and Unit #2 has 2 1/4" wide jaws. Secant Modulus was tested on Units #1 and
#3 only.
[00148] Sample preparation: The specimens were conditioned and tested under ASTM laboratory conditions. They were maintained at 23 ± 2° C and 50% + 10% relative humidity. Conditioning time was a minimum of 40 hours under lab conditions and 48 hours after manufacturing. Prepared 12 specimens of each material; six in the machine direction (MD), the direction of flow as polymer exits the die, and six in the transverse direction (TD), the direction perpendicular to the flow as polymer exits the die.
[00149] Note: It is recommended that materials only 0-3 mils should be tested on Units #1 and #3 and all material thickness can be tested on Unit #2. But note that oriented PP which measures -0.7 mils can have loads up to 35 lbs. When testing unfamiliar materials, use caution and watch loads.
[00150] Each specimen should be 1" wide and 7" long. The width (1") of the samples should be cut with the JDC precision, fixed-blade cutters. These cutters were used since nicks or cuts in specimens initiate premature breaks. After cutting each specimen, examined visually to ensure the edges were undamaged (free of nicks). On a periodic basis the owner of the cutters will monitor specimen edge quality by microscopic examination.
[00151] Testing information: Secant Modulus: (Based on ASTM-D882-10) Template (#) Test Method:
• (5) 1% Secant Modulus Properties of Film - ORG (Units #1 and #3 Only);
• (9) 1% and 2% Secant Modulus Properties of Film - ORG (Units #1 and #3 Only); and
• (14) 1% and 5% Secant Modulus Properties of Film - ORG (Units #1 and #3 Only). [00152] Methods of film fabrication, density, resin grade, resin type, and thickness all affect testing data. The stiffness properties were determined based on ASTM D882-10. These methods used a jaw separation of 5 inches and a sample 1-inch wide. The index of stiffness of thin films was determined by pulling the specimen at a rate of jaw separation (crosshead speed) of 0.5 inches per minute to a designated strain of 1%, or 1% and 2%, or 1% and 5% of its original length and recording the load at these points. [00153] Overall, polyolefin compositions of the present disclosure and films made therefrom provide enhanced toughness and high stiffness.
[00154] All documents described herein are incorporated by reference herein, including any priority documents and/or testing procedures to the extent they are not inconsistent with this text. As is apparent from the foregoing general description and the specific embodiments, while forms of the present disclosure have been illustrated and described, various modifications can be made without departing from the spirit and scope of the present disclosure. Accordingly, it is not intended that the present disclosure be limited thereby.
[00155] Certain embodiments and features have been described using a set of numerical upper limits and a set of numerical lower limits. It should be appreciated that ranges including the combination of any two values, e.g., the combination of any lower value with any upper value, the combination of any two lower values, and/or the combination of any two upper values are contemplated unless otherwise indicated. Certain lower limits, upper limits and ranges appear in one or more claims below.

Claims

CLAIMS:
1 A polyolefin composition, comprising: about 40 wt% to about 95 wt%, by weight of the polyolefin composition, of a broad orthogonal composition distribution (BOCD) polyethylene comprising about 70 mol% to about 100 mol% of ethylene and having: i. a density of about 0.91 g/cm3 to about 0.925 g/cm3, in accordance with ASTM D-4703 and ASTM D-1505/ISO 1183; and ii. a branching index (gVis) of 0.98 or greater; about 5 wt% to about 60 wt%, by weight of the polyolefin composition, of a polypropylene; wherein the polyolefin composition has: a 1% secant flexural modulus in the machine direction (MD) of greater than 200 MPa and a 1% secant flexural modulus in the transverse direction (TD) of greater than 200 MPa, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm; and a Tensile at Yield strength in the MD of greater than 8.5 MPa and a Tensile at Yield strength in the TD of greater than 9.7 MPa, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm, as determined by ASTM D882.
2 The polyolefin composition of claim 1, wherein the composition comprises from about 50 wt% to about 90 wt% of the BOCD polyethylene and about 10 wt% to about 50 wt% of a polypropylene, by weight of the polyolefin composition.
3. The polyolefin composition of claim 1 or 2, wherein the composition comprises from about 70 wt% to about 88 wt% of the BOCD polyethylene and about 12 wt% to about 30 wt% of a polypropylene, by weight of the polyolefin composition.
4. The polyolefin composition according to any one of claims 1-3, comprising a 1% secant flexural modulus in the MD of greater than 225 MPa, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm.
5. The polyolefin composition according to any one of claims 1 -4, comprising a 1 % secant flexural modulus in the MD of from about 250 MPa to about 1,000 MPa, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm.
6. The polyolefin composition according to any one of claims 1 -5, comprising a 1 % secant flexural modulus in the TD of greater than 225 MPa, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm.
7. The polyolefin composition according to any one of claims 1 -6, comprising a 1 % secant flexural modulus in the TD of from about 250 MPa to about 1,000 MPa, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm.
8. The polyolefin composition according to any one of claims 1-7, comprising a Tensile at Yield strength in the MD of greater than 8.5 MPa to about 100 MPa, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm, as determined by ASTM D882.
9. The polyolefin composition according to any one of claims 1-8, comprising a Tensile at Yield strength in the MD of from about 9 MPa to about 25 MPa, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm, as determined by ASTM D882.
10. The polyolefin composition according to any one of claims 1-9, comprising a Tensile at Yield strength in the TD of greater than 9.7 MPa to about 100 MPa, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm, as determined by ASTM D882.
11. The polyolefin composition according to any one of claims 1-10, comprising a Tensile at Yield strength in the TD of from about 10 MPa to about 25 MPa, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm, as determined by ASTM D882.
12. The polyolefin composition according to any one of claims 1-11, comprising a Elongation at Break strength in the MD of greater than 540%, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm, as determined by ASTM D882.
13. The polyolefin composition according to any one of claims 1-12, comprising a Elongation at Break strength in the MD of from about 550% to about 700%, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm, as determined by ASTM D882.
14. The polyolefin composition according to any one of claims 1-13, comprising a Elongation at Break strength in the MD of from about 555% to about 625%, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm.
15. The polyolefin composition according to any one of claims 1-14, comprising a Elongation at Break strength in the TD of greater than 580%, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm, as determined by ASTM D882.
16. The polyolefin composition according to any one of claims 1-15, comprising a Elongation at Break strength in the TD of from about 600% to about 700%, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm, as determined by ASTM D882.
17. The polyolefin composition according to any one of claims 1-16, comprising a Elongation at Break strength in the TD of from about 605% to about 650%, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm, as determined by ASTM D882.
18. The polyolefin composition according to any one of claims 1-17, comprising an Elmendorf tear in the MD of greater than 5.6 g/pm, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm.
19. The polyolefin composition according to any one of claims 1-18, comprising an
Elmendorf tear in the MD of from about 9.5 g/pm to about 20 g/pm, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm.
20. The polyolefin composition according to any one of claims 1-19, comprising an
Elmendorf tear in the TD of greater than 8.9 g/pm, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm.
21. The polyolefin composition according to any one of claims 1-20, comprising an Elmendorf tear in the TD of from about 9 g/pm to about 20 g/pm, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm.
22. The polyolefin composition according to any one of claims 1-21, comprising a Dart Drop Impact (Method A) of greater than 8.5 g/pm, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm.
23. The polyolefin composition according to any one of claims 1-22, comprising a Dart Drop Impact (Method A) of from about 9 g/pm to about 20 g/pm, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm.
24. The polyolefin composition according to any one of claims 1-23, wherein the BOCD polyethylene has an MWI/MW2 of greater than 1 and a Twi-TW2 of less than 0°C.
25. The polyolefin composition according to any one of claims 1-24, wherein the BOCD polyethylene has an MWI/MW2 of about 1.5 to about 8.
26. The polyolefin composition according to any one of claims 1-25, wherein the BOCD polyethylene has a Twi-TW2 of about -5°C to about -40°C.
27. The polyolefin composition according to any one of claims 1-26, wherein the polypropylene comprises a trimmed polypropylene (tPP).
28. The polyolefin composition of claim 27, wherein the tPP is produced from a high melt strength polypropylene (HMS PP).
29. The polyolefin composition of claim 28, wherein the HMS PP has a melt flow rate of from about 2 g/10 min to about 6 g/10 min, as determined by ASTM D1238.
30. The polyolefin composition of claim 29, wherein the HMS PP has a melt flow rate of from about 3.5 g/10 min to about 4.5 g/10 min, as determined by ASTM D1238.
31. The polyolefin composition according to any one of claims 1-30, wherein the polypropylene has a molecular weight distribution (Mw/Mn) of from about 7 to about 22
32. The polyolefin composition according to any one of claims 1-31, wherein the polypropylene has a z-average molecular weight of less than 2,500,000 g/mol.
33. The polyolefin composition according to any one of claims 1-32, wherein the polypropylene has a branching index (gVis) of 0.95 or greater.
34. The polyolefin composition according to any one of claims 1-33, wherein the polypropylene has a melt strength of less than 20 cN determined using an extensional rheometer at 190°C.
35. The polyolefin composition according to any one of claims 1-34, wherein the polypropylene comprises a homopolymer.
36. The polyolefin composition of claim 35, wherein the homopolymer has a melt flow rate of from about 1.6 g/10 min to about 2.2 g/10 min, as determined by ASTM D1238.
37. The polyolefin composition of claim 35, wherein the homopolymer has a density of from about 0.85 g/cm3 to about 0.95 g/cm3.
38. The polyolefin composition of claim 35, wherein the homopolymer has a Tensile
Strength at Yield of from about 30 MPa to about 50 MPa, as determined by ASTM D638.
39. The polyolefin composition according to any one of claims 1-38, wherein the polypropylene comprises an impact copolymer (ICP).
40. The polyolefin composition of claim 39, wherein the ICP has a melt flow rate of from about 3.5 g/10 min to about 4.5 g/10 min, as determined by ASTM D1238.
41. The polyolefin composition of claim 39, wherein the ICP has a density of from about 0.85 g/cm3 to about 0.95 g/cm3.
42. The polyolefin composition of claim 39, wherein the ICP has a Tensile Strength at Yield of from about 18 MPa to about 50 MPa, as determined by ASTM D638.
43. The polyolefin composition according to any one of claims 1-42, wherein the polypropylene comprises a random copolymer (RCP).
44. The polyolefin composition of claim 43, wherein the RCP has a melt flow rate of from about 10 g/10 min to about 14 g/10 min, as determined by ASTM D1238.
45. The polyolefin composition of claim 43, wherein the RCP has a melt temperature of from about 145°C to about 160°C.
46. The polyolefin composition according to any one of claims 1-45, wherein the BOCD polyethylene has a density of from about 0.912 g/cm3 to about 0.918 g/cm3, in accordance with ASTM D-4703 and ASTM D-1505/ISO 1183.
47. The polyolefin composition according to any one of claims 1-46, wherein the BOCD polyethylene has a density of from about 0.915 g/cm3 to about 0.921 g/cm3, in accordance with ASTM D-4703 and ASTM D-1505/ISO 1183.
48. The polyolefin composition according to any one of claims 1-47, wherein the BOCD polyethylene has a branching index (gVis) of from about 0.985 to 1.0.
49. The polyolefin composition according to any one of claims 1 -48, wherein the polyolefin composition is in the form of granules, pellets, or particulates.
50. A film comprising the polyolefin composition according to any one of claims 1-49, having a thickness of from about 10 pm to about 300 pm.
51. The film of claim 50, wherein the film is a monolayer having a thickness of from about 10 pm to about 100 pm.
52. The film of claim 50 or 51, wherein the film comprises from about 75 wt% to about 95 wt% of the BOCD polyethylene and from about 5 wt% to about 25 wt% of the polypropylene, by weight of the polyolefin composition.
53. The film according to any one of claims 50-52, wherein the film has an Elmendorf Tear MD of from about 8 g/pm to about 10 g/pm and an Elmendorf Tear TD of from about 13.5 g/pm to about 16 g/pm.
54. The film according to any one of claims 50-53, wherein the film comprises a core layer disposed between two skin layers, and wherein the core layer comprises the polyolefin composition.
55. The film of claim 54, wherein the core layer further comprises a high melt strength polypropylene (HMS PP), a trimmed polypropylene (tPP), a broad molecular weight distribution (BMWD) polypropylene, a homopolymer of polypropylene (hPP), an impact copolymer (ICP), a random copolymer (RCP).
56. The film of claim 54, wherein one or two of the skin layers comprise the polyolefin composition.
57. The film according to any one of claims 50-56, wherein the film has a thickness of from about 50 pm to about 300 pm.
58. A polyolefin composition, comprising: a) about 40 wt% to about 95 wt%, by weight of the polyolefin composition, of a broad orthogonal composition distribution (BOCD) polyethylene comprising about 70 mol% to about 100 mol% of ethylene and having a density of about 0.91 g/cm3 to about 0.925 g/cm3, in accordance with ASTM D-4703 and ASTM D-1505/ISO 1183; b) about 5 wt% to about 60 wt%, by weight of the polyolefin composition, of a polypropylene; wherein the polyolefin composition has: c) a 1% secant flexural modulus in the machine direction (MD) of greater than 200 MPa and a 1% secant flexural modulus in the transverse direction (TD) of greater than 200 MPa, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm; d) a Tensile at Yield strength in the MD of greater than 8.5 MPa and a Tensile at Yield strength in the TD of greater than 9.7 MPa, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm, as determined by ASTM D882; and e) an Elmendorf tear in the MD of about 9.5 g/pm to about 20 g/pm and an Elmendorf tear in the TD of about 9 g/pm to about 20 g/pm, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm.
59. A flexible food package comprising the polyolefin composition of any one of the preceding claims, wherein the polyolefin composition comprises from about 5 wt% to about 50 wt% of the polypropylene and from about 50 wt% to about 95 wt% of the polyethylene, each by weight of the polyolefin composition, and wherein the polyolefin composition is a film that is optionally laminated to one or more additional polymeric films.
60. A method of forming a film comprising extruding the polyolefin composition according to any one of claims 1-58 through a die opening to form the film.
61. A method of forming a finished film comprising: a) extruding a polyolefin composition comprising about 40 wt% to about 95 wt%, by weight of the polyolefin composition, of a broad orthogonal composition distribution (BOCD) polyethylene and about 5 wt% to about 60 wt%, by weight of the polyolefin composition, of a polypropylene, wherein the BOCD polyethylene comprises about 70 mol% to about 100 mol% of ethylene and has: i. a density of about 0.91 g/cm3 to about 0.925 g/cm3, in accordance with ASTM D-4703 and ASTM D-1505/ISO 1183, and ii. a branching index (gVis) of 0.98 or greater, wherein the polyolefin composition has a 1% secant flexural modulus in the machine direction (MD) of greater than 200 MPa and a 1% secant flexural modulus in the transverse direction (TD) of greater than 200 MPa, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm, and wherein the polyolefin composition has a Tensile at Yield strength in the MD of greater than 8.5 MPa and a Tensile at Yield strength in the TD of greater than 9.7 MPa, as determined if a film comprising the polyolefin composition has a thickness of about 90 pm, as determined by ASTM D882; and b) cooling the film at a distance away from the die opening to produce the finished film.
62. The method of claim 61, wherein cooling the film comprises blowing air on at least a portion of the film.
PCT/US2019/060688 2019-08-28 2019-11-11 Polyolefin compositions for films WO2021040760A1 (en)

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