CA2499517C - Polymer compositions for extrusion coating - Google Patents
Polymer compositions for extrusion coating Download PDFInfo
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- CA2499517C CA2499517C CA 2499517 CA2499517A CA2499517C CA 2499517 C CA2499517 C CA 2499517C CA 2499517 CA2499517 CA 2499517 CA 2499517 A CA2499517 A CA 2499517A CA 2499517 C CA2499517 C CA 2499517C
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- branched polyethylene
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- 239000000203 mixture Substances 0.000 title claims abstract description 78
- 229920000642 polymer Polymers 0.000 title claims description 44
- 238000007765 extrusion coating Methods 0.000 title abstract description 7
- 229920000573 polyethylene Polymers 0.000 claims abstract description 54
- -1 polyethylene Polymers 0.000 claims description 49
- 239000004698 Polyethylene Substances 0.000 claims description 47
- 239000000155 melt Substances 0.000 claims description 20
- 239000005977 Ethylene Substances 0.000 claims description 12
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims description 11
- 238000009826 distribution Methods 0.000 claims description 10
- 229920001684 low density polyethylene Polymers 0.000 claims description 7
- 239000004702 low-density polyethylene Substances 0.000 claims description 7
- 238000002844 melting Methods 0.000 claims description 5
- 230000008018 melting Effects 0.000 claims description 5
- 238000001938 differential scanning calorimetry curve Methods 0.000 claims 2
- 239000004711 α-olefin Substances 0.000 claims 2
- 230000000977 initiatory effect Effects 0.000 abstract description 5
- 229920000098 polyolefin Polymers 0.000 abstract 1
- 229920001577 copolymer Polymers 0.000 description 16
- 229920000089 Cyclic olefin copolymer Polymers 0.000 description 7
- 239000011248 coating agent Substances 0.000 description 6
- 238000000576 coating method Methods 0.000 description 6
- 238000000034 method Methods 0.000 description 6
- 229920005989 resin Polymers 0.000 description 6
- 239000011347 resin Substances 0.000 description 6
- 229920003048 styrene butadiene rubber Polymers 0.000 description 6
- 239000004793 Polystyrene Substances 0.000 description 5
- 229920000092 linear low density polyethylene Polymers 0.000 description 5
- 239000004707 linear low-density polyethylene Substances 0.000 description 5
- 229920002223 polystyrene Polymers 0.000 description 5
- 239000000758 substrate Substances 0.000 description 5
- 238000000113 differential scanning calorimetry Methods 0.000 description 4
- 238000001125 extrusion Methods 0.000 description 4
- 238000009472 formulation Methods 0.000 description 4
- 239000000178 monomer Substances 0.000 description 4
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 4
- 229920001862 ultra low molecular weight polyethylene Polymers 0.000 description 4
- 239000004708 Very-low-density polyethylene Substances 0.000 description 3
- 125000004432 carbon atom Chemical group C* 0.000 description 3
- 229920005606 polypropylene copolymer Polymers 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 229920001866 very low density polyethylene Polymers 0.000 description 3
- VXNZUUAINFGPBY-UHFFFAOYSA-N 1-Butene Chemical compound CCC=C VXNZUUAINFGPBY-UHFFFAOYSA-N 0.000 description 2
- KWKAKUADMBZCLK-UHFFFAOYSA-N 1-octene Chemical compound CCCCCCC=C KWKAKUADMBZCLK-UHFFFAOYSA-N 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- 239000003054 catalyst Substances 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 229920001038 ethylene copolymer Polymers 0.000 description 2
- 235000011389 fruit/vegetable juice Nutrition 0.000 description 2
- 229920005684 linear copolymer Polymers 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000004806 packaging method and process Methods 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 229920005630 polypropylene random copolymer Polymers 0.000 description 2
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 2
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 2
- 150000003254 radicals Chemical class 0.000 description 2
- 229920005604 random copolymer Polymers 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- OWYWGLHRNBIFJP-UHFFFAOYSA-N Ipazine Chemical compound CCN(CC)C1=NC(Cl)=NC(NC(C)C)=N1 OWYWGLHRNBIFJP-UHFFFAOYSA-N 0.000 description 1
- 229920010126 Linear Low Density Polyethylene (LLDPE) Polymers 0.000 description 1
- 239000004809 Teflon Substances 0.000 description 1
- 229920006362 Teflon® Polymers 0.000 description 1
- BGYHLZZASRKEJE-UHFFFAOYSA-N [3-[3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoyloxy]-2,2-bis[3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoyloxymethyl]propyl] 3-(3,5-ditert-butyl-4-hydroxyphenyl)propanoate Chemical compound CC(C)(C)C1=C(O)C(C(C)(C)C)=CC(CCC(=O)OCC(COC(=O)CCC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)(COC(=O)CCC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)COC(=O)CCC=2C=C(C(O)=C(C=2)C(C)(C)C)C(C)(C)C)=C1 BGYHLZZASRKEJE-UHFFFAOYSA-N 0.000 description 1
- 230000001133 acceleration Effects 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- MTAZNLWOLGHBHU-UHFFFAOYSA-N butadiene-styrene rubber Chemical compound C=CC=C.C=CC1=CC=CC=C1 MTAZNLWOLGHBHU-UHFFFAOYSA-N 0.000 description 1
- 239000012967 coordination catalyst Substances 0.000 description 1
- 125000004122 cyclic group Chemical group 0.000 description 1
- 229920005565 cyclic polymer Polymers 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 239000000806 elastomer Substances 0.000 description 1
- 239000005038 ethylene vinyl acetate Substances 0.000 description 1
- 239000011888 foil Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 229920001519 homopolymer Polymers 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 239000003999 initiator Substances 0.000 description 1
- 229920000554 ionomer Polymers 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000012968 metallocene catalyst Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- TVMXDCGIABBOFY-UHFFFAOYSA-N n-Octanol Natural products CCCCCCCC TVMXDCGIABBOFY-UHFFFAOYSA-N 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- JFNLZVQOOSMTJK-KNVOCYPGSA-N norbornene Chemical compound C1[C@@H]2CC[C@H]1C=C2 JFNLZVQOOSMTJK-KNVOCYPGSA-N 0.000 description 1
- 239000002530 phenolic antioxidant Substances 0.000 description 1
- 239000011990 phillips catalyst Substances 0.000 description 1
- 239000002952 polymeric resin Substances 0.000 description 1
- 229920005629 polypropylene homopolymer Polymers 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 239000011342 resin composition Substances 0.000 description 1
- 239000011369 resultant mixture Substances 0.000 description 1
- 239000000565 sealant Substances 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 235000011888 snacks Nutrition 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
- 229920001897 terpolymer Polymers 0.000 description 1
- 229920006029 tetra-polymer Polymers 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions 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
- C08L23/04—Homopolymers or copolymers of ethene
- C08L23/08—Copolymers of ethene
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions 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
- C08L23/04—Homopolymers or copolymers of ethene
- C08L23/08—Copolymers of ethene
- C08L23/0846—Copolymers of ethene with unsaturated hydrocarbons containing other atoms than carbon or hydrogen atoms
- C08L23/0869—Acids or derivatives thereof
- C08L23/0876—Neutralised polymers, i.e. ionomers
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/18—Manufacture of films or sheets
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions 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
- C08L23/04—Homopolymers or copolymers of ethene
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions 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
- C08L23/04—Homopolymers or copolymers of ethene
- C08L23/08—Copolymers of ethene
- C08L23/0807—Copolymers of ethene with unsaturated hydrocarbons only containing more than three carbon atoms
- C08L23/0815—Copolymers of ethene with aliphatic 1-olefins
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L31/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an acyloxy radical of a saturated carboxylic acid, of carbonic acid or of a haloformic acid; Compositions of derivatives of such polymers
- C08L31/02—Homopolymers or copolymers of esters of monocarboxylic acids
- C08L31/04—Homopolymers or copolymers of vinyl acetate
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2205/00—Polymer mixtures characterised by other features
- C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L2205/00—Polymer mixtures characterised by other features
- C08L2205/03—Polymer mixtures characterised by other features containing three or more polymers in a blend
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions 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
- C08L23/04—Homopolymers or copolymers of ethene
- C08L23/06—Polyethene
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions 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
- C08L23/04—Homopolymers or copolymers of ethene
- C08L23/08—Copolymers of ethene
- C08L23/0846—Copolymers of ethene with unsaturated hydrocarbons containing other atoms than carbon or hydrogen atoms
- C08L23/0853—Vinylacetate
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions 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
- C08L23/10—Homopolymers or copolymers of propene
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions 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
- C08L23/10—Homopolymers or copolymers of propene
- C08L23/14—Copolymers of propene
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31855—Of addition polymer from unsaturated monomers
Abstract
Compositions suitable for use in extrusion coating are claimed. The compositions comprise a mixture of a homogeneous ethylene polymer and a heterogeneous ethylene polymer together with a high melt strength polyolefin.
Film layers made from the compositions have improved "neck-in" and excellent heat seal initiation.
Film layers made from the compositions have improved "neck-in" and excellent heat seal initiation.
Description
,~,,...~..~~ ~.~.. ~ .,,., ~..~....,.,~.~. .m.. ._.. ww.,.w.....,.~. - ~_ .~:
._ . . ,~..~ __ .. . _-,..,_ . , . . . . , _ ~
POLYMER COMPOSITIONS FOR EXTRUSION COATING
Tliis invention relates generally to film conlpositions useful for extrusion coating applications, and nzore specifically to providing sealant layers for packaging applications.
There are many examples of polymer compositions useful for ex~trusion coating applications, including blends of linear low density polyethylene (LLDPE) with high pressure (fiee radical) low density polyetliylene (LDPE).
Extri.ision coating is a means of coating a substrate with a particular polymer such that the substrate is providing functionality such as sealability to yet another substrate or to itself. Examples include juice packs, typically having an interior polymer extrusion coated onto a foil substrate where the polymer coating is then sealed (adhered) to itself. Extrusion coating is a very particular process where "neck-in" is important in forming the coating. "Neclc-in" refers to the ability of the polymer formulation to retain its width, or its original dimensions after exrtrusion. Minimizing the "neclc-in" allows for the polymer formulation to more effectively and uniformly coat the substrate.
For example, United States Patent 5,587,247 discloses resin compositions for extrusion molding comprising a high pressure ethylene polymer having an endothermic peak in the range of 80 -120 C, an ethylene copolymer having an endothermic pealc in the range of 118 -130 C and an ethylene copolymer having, among other properties, no endothermic pealc above 110C.
However, there is still a need for a polymer formulation which reduces "neck-in" while maintaining good sealability.
Vr'e have now discovered polymer compositions uniquely suited for extrusion coating having miniinuni "neck-in" and excellent sealing characteristics (for example, low heat seal initiation temperatures) and toughness properties.
These compositions coinprise (A) from 60 to 80 weight percent of a mixture of at least one homogeneously branched polyethylene and at least one heterogeneously branched polyethylene and (B) from 20 to 40 weight percent of at least one polymer having a melt strength at least twice that of mixture (A). A filni layer 50068-.78 made from these compositions is also within the scope of the invention.
In another embodiment of the invention, a film is made which comprises at least two layers, (A) one layer being made from a polymer composition, the composition comprising a mixture of at least one homogeneously branched polyethylene and at least one heterogeneously branched polyethylene and (B) one other layer comprising at least one other polymer having a melt strength at least twice that of the mixture of (A).
According to one aspect of the present invention, there is provided a polymer composition comprising (A) from 60 to 80 weight percent of a mixture of at least one homogeneously branched polyethylene and at least one heterogeneously branched polyethylene wherein the mixture of (A) comprises from 40 to 75 weight percent of the at least one homogeneously branched polyethylene and from 25 to 60 weight percent of the at least one heterogeneously branched polyethylene and (B) from 20 to 40 weight percent of at least one low density polyethylene polymer having a melt strength at least twice that of mixture (A).
According to another aspect of the present invention, there is provided a film layer made from a polymer composition, the composition comprising (A) from 60 to 80 weight percent of a mixture of at least one homogeneously branched polyethylene and at least one heterogeneously branched polyethylene wherein the mixture of (A) comprises from 40 to 75 weight percent of the at least one homogeneously branched polyethylene and from 25 to 60 weight percent of the at least one heterogeneously branched .50068-.78 polyethylene and (B) from 20 to 40 weight percent of at least one low density polyethylene polymer having a melt strength at least twice that of mixture (A).
According to still another aspect of the present invention, there is provided a fabricated article comprising the film layer described herein.
According to yet another aspect of the present invention, there is provided a film comprising at least two layers, wherein one of the at least two layers comprises:
(A) a mixture of at least one homogeneously branched polyethylene and at least one heterogeneously branched polyethylene wherein the mixture of (A) comprises from 40 to 75 weight percent of the homogeneously branched polyethylene and from 25 to 60 weight percent of the heterogeneously branched polyethylene and one other layer comprising; and a second of the at least two layers comprises: (B) at least one low density polyethylene polymer having a melt strength at least twice that of the mixture of (A).
Figure 1 shows a graph of differential scanning calorimetry (DSC) of the mixture (A) of the invention. Note that three distinct melting peaks are evident.
The polymer resins usable in this invention are polyethylenes, and for component (B) additionally polypropylene random copolymer (PPRCP), styrene/butadiene copolymers (SBC), polystyrene, ethylene-vinyl acetate copolymers (EVA) and cyclic/olefin copolymers (COC) can be used.
2a 5006=8-78 Polyethylenes usable to this invention fall into two broad categories, those prepared with a free radical initiator at high teniperature and high pressure, and those prepared with a coordination catalyst at high teinperature and relatively low pressure. The former are generally known as LDPE and are characterized by brailched cllains of polymerized monomer units pendant from the polymer baclcbone. LDPE polymers generally have a density between 0.910 and 0.940 g/cm3. Polymer density is measured according to the procedure of ASTM D-792 herein unless otherwise noted.
Etliylene polymers and copolymers prepared by the use of a coordinatiozi catalyst, such as a Ziegler Natta or Phillips catalyst, are generally lcnown as linear polymers because of the substantial absence of branch chains of polymerized monomer units pendant from the backbone. Linear copolymers of etliylene and at least one -olefin of 3 to 12 carbon atoms, preferably of 4 to 8 carbon atonis, are also well l:nown and commercially available. As is well known in the art, the density of a linear ethylene/ -olefin copolymer is a function of both the length of the -olefin and the amount of such monomer in the copolymer relative to the amount of ethylene, the greater the length of the -olefin and the greater the amount of -olefin present, the lower the density of the copolymer. LLDPE is a heterogeneous polymer, meaning that the comonomer is not everily distributed along the polymer backbone. The branching distributions for heterogeneous ethylene polymers is broad due to the non-uniformity of branching. LLDPE is 2b .,. ... . . . . . .. . .. . .....c-'.:~....._.... . w .. . .-.._......_.....-.~,.,.... ...l...... ..: . ...... ..,~Yi . . . .. .... . .. ... . ..... .....
.. , ... -:w . w='.._ typically a copolymer of ethylene and an -olefin of 3 to 20 carbon atoms, preferably 4 to 8 carbon atoms (for example, 1-butene, 1-octene, etc.), that has sufficient -olefin content to reduce the density of the copolymer to that of LDPE
(for exanlple, 0.910 g/cm3 to 0.940 g/cm3). When the copolymer contains even more -olefin, the density will drop below about 0.91 g/cm3 and these copolymers are lmown interchangeably as ultra low density polyethylene (ULDPE) or VLDPE. The densities of VLDPE or ULDPE polymers generally range from 0.87 to 0.91 g/cm3. Both LLDPE and VLDPE or ULDPE are well lcnown in the art, as are their processes of preparation. For example, heterogeneous LLDPE
can be made using Ziegler-Natta catalysts in a slurry, gas phase, solution or high pressure process, such as described in U.S. Pat. 4,076,698 while homogeneous linear ethylene polyiners can be made as described in U.S. Pat. 3,645,992.
Homogeneous ethylene polymers have a uniform branching distribution, that is, substantially all the polymer molecules have the sanle amount of comonomer incorporated in each. Composition distribution branching indices (CDBI) have been used to characterize branching distributions (or homogeneity or heterogeneity) and can be determined in accordance witli United States Patent 5,246,783 using the device described in United States Patent 5,008,204. CDBI
for heterogeneous polyiners is between 30 and 70, while the CDBI for hoinogeneous polymers is between 80 and can be as high as 100.
The polymer nuxture (A) can be a physical blend of dry materials, with subsequent melt blending, or the mixture (A) can be made in-situ, as described and claimed in United States Patent 5,844,045.
High density polyetliylene (HDPE), generally having a density of 0.941 to 0.965 g/cm3, is typically a homopolymer of ethylene, and it contains few branch chains relative to the various linear copolymers of ethylene and an -olefm.
HDPE
is well lalown, commercially available in various grades, and may be used in this invention.
The polypropylene copolymers of this invention are polymers comprising un.its derived from propylene and ethylene and/or one or more Lursaturated comonomers. The term "copolymer" includes terpolymers, tetrapolymers, etc.
"Random copolymer" means a copolymer in which the monomer is randomly distributed across the polymer chain. Typically, the polypropylene copolymers comprise units derived from propylene in an amount of at least 60, preferably at least 70 and more preferably at least 80, weight percent of the copolymer.
._ . . ,~..~ __ .. . _-,..,_ . , . . . . , _ ~
POLYMER COMPOSITIONS FOR EXTRUSION COATING
Tliis invention relates generally to film conlpositions useful for extrusion coating applications, and nzore specifically to providing sealant layers for packaging applications.
There are many examples of polymer compositions useful for ex~trusion coating applications, including blends of linear low density polyethylene (LLDPE) with high pressure (fiee radical) low density polyetliylene (LDPE).
Extri.ision coating is a means of coating a substrate with a particular polymer such that the substrate is providing functionality such as sealability to yet another substrate or to itself. Examples include juice packs, typically having an interior polymer extrusion coated onto a foil substrate where the polymer coating is then sealed (adhered) to itself. Extrusion coating is a very particular process where "neck-in" is important in forming the coating. "Neclc-in" refers to the ability of the polymer formulation to retain its width, or its original dimensions after exrtrusion. Minimizing the "neclc-in" allows for the polymer formulation to more effectively and uniformly coat the substrate.
For example, United States Patent 5,587,247 discloses resin compositions for extrusion molding comprising a high pressure ethylene polymer having an endothermic peak in the range of 80 -120 C, an ethylene copolymer having an endothermic pealc in the range of 118 -130 C and an ethylene copolymer having, among other properties, no endothermic pealc above 110C.
However, there is still a need for a polymer formulation which reduces "neck-in" while maintaining good sealability.
Vr'e have now discovered polymer compositions uniquely suited for extrusion coating having miniinuni "neck-in" and excellent sealing characteristics (for example, low heat seal initiation temperatures) and toughness properties.
These compositions coinprise (A) from 60 to 80 weight percent of a mixture of at least one homogeneously branched polyethylene and at least one heterogeneously branched polyethylene and (B) from 20 to 40 weight percent of at least one polymer having a melt strength at least twice that of mixture (A). A filni layer 50068-.78 made from these compositions is also within the scope of the invention.
In another embodiment of the invention, a film is made which comprises at least two layers, (A) one layer being made from a polymer composition, the composition comprising a mixture of at least one homogeneously branched polyethylene and at least one heterogeneously branched polyethylene and (B) one other layer comprising at least one other polymer having a melt strength at least twice that of the mixture of (A).
According to one aspect of the present invention, there is provided a polymer composition comprising (A) from 60 to 80 weight percent of a mixture of at least one homogeneously branched polyethylene and at least one heterogeneously branched polyethylene wherein the mixture of (A) comprises from 40 to 75 weight percent of the at least one homogeneously branched polyethylene and from 25 to 60 weight percent of the at least one heterogeneously branched polyethylene and (B) from 20 to 40 weight percent of at least one low density polyethylene polymer having a melt strength at least twice that of mixture (A).
According to another aspect of the present invention, there is provided a film layer made from a polymer composition, the composition comprising (A) from 60 to 80 weight percent of a mixture of at least one homogeneously branched polyethylene and at least one heterogeneously branched polyethylene wherein the mixture of (A) comprises from 40 to 75 weight percent of the at least one homogeneously branched polyethylene and from 25 to 60 weight percent of the at least one heterogeneously branched .50068-.78 polyethylene and (B) from 20 to 40 weight percent of at least one low density polyethylene polymer having a melt strength at least twice that of mixture (A).
According to still another aspect of the present invention, there is provided a fabricated article comprising the film layer described herein.
According to yet another aspect of the present invention, there is provided a film comprising at least two layers, wherein one of the at least two layers comprises:
(A) a mixture of at least one homogeneously branched polyethylene and at least one heterogeneously branched polyethylene wherein the mixture of (A) comprises from 40 to 75 weight percent of the homogeneously branched polyethylene and from 25 to 60 weight percent of the heterogeneously branched polyethylene and one other layer comprising; and a second of the at least two layers comprises: (B) at least one low density polyethylene polymer having a melt strength at least twice that of the mixture of (A).
Figure 1 shows a graph of differential scanning calorimetry (DSC) of the mixture (A) of the invention. Note that three distinct melting peaks are evident.
The polymer resins usable in this invention are polyethylenes, and for component (B) additionally polypropylene random copolymer (PPRCP), styrene/butadiene copolymers (SBC), polystyrene, ethylene-vinyl acetate copolymers (EVA) and cyclic/olefin copolymers (COC) can be used.
2a 5006=8-78 Polyethylenes usable to this invention fall into two broad categories, those prepared with a free radical initiator at high teniperature and high pressure, and those prepared with a coordination catalyst at high teinperature and relatively low pressure. The former are generally known as LDPE and are characterized by brailched cllains of polymerized monomer units pendant from the polymer baclcbone. LDPE polymers generally have a density between 0.910 and 0.940 g/cm3. Polymer density is measured according to the procedure of ASTM D-792 herein unless otherwise noted.
Etliylene polymers and copolymers prepared by the use of a coordinatiozi catalyst, such as a Ziegler Natta or Phillips catalyst, are generally lcnown as linear polymers because of the substantial absence of branch chains of polymerized monomer units pendant from the backbone. Linear copolymers of etliylene and at least one -olefin of 3 to 12 carbon atoms, preferably of 4 to 8 carbon atonis, are also well l:nown and commercially available. As is well known in the art, the density of a linear ethylene/ -olefin copolymer is a function of both the length of the -olefin and the amount of such monomer in the copolymer relative to the amount of ethylene, the greater the length of the -olefin and the greater the amount of -olefin present, the lower the density of the copolymer. LLDPE is a heterogeneous polymer, meaning that the comonomer is not everily distributed along the polymer backbone. The branching distributions for heterogeneous ethylene polymers is broad due to the non-uniformity of branching. LLDPE is 2b .,. ... . . . . . .. . .. . .....c-'.:~....._.... . w .. . .-.._......_.....-.~,.,.... ...l...... ..: . ...... ..,~Yi . . . .. .... . .. ... . ..... .....
.. , ... -:w . w='.._ typically a copolymer of ethylene and an -olefin of 3 to 20 carbon atoms, preferably 4 to 8 carbon atoms (for example, 1-butene, 1-octene, etc.), that has sufficient -olefin content to reduce the density of the copolymer to that of LDPE
(for exanlple, 0.910 g/cm3 to 0.940 g/cm3). When the copolymer contains even more -olefin, the density will drop below about 0.91 g/cm3 and these copolymers are lmown interchangeably as ultra low density polyethylene (ULDPE) or VLDPE. The densities of VLDPE or ULDPE polymers generally range from 0.87 to 0.91 g/cm3. Both LLDPE and VLDPE or ULDPE are well lcnown in the art, as are their processes of preparation. For example, heterogeneous LLDPE
can be made using Ziegler-Natta catalysts in a slurry, gas phase, solution or high pressure process, such as described in U.S. Pat. 4,076,698 while homogeneous linear ethylene polyiners can be made as described in U.S. Pat. 3,645,992.
Homogeneous ethylene polymers have a uniform branching distribution, that is, substantially all the polymer molecules have the sanle amount of comonomer incorporated in each. Composition distribution branching indices (CDBI) have been used to characterize branching distributions (or homogeneity or heterogeneity) and can be determined in accordance witli United States Patent 5,246,783 using the device described in United States Patent 5,008,204. CDBI
for heterogeneous polyiners is between 30 and 70, while the CDBI for hoinogeneous polymers is between 80 and can be as high as 100.
The polymer nuxture (A) can be a physical blend of dry materials, with subsequent melt blending, or the mixture (A) can be made in-situ, as described and claimed in United States Patent 5,844,045.
High density polyetliylene (HDPE), generally having a density of 0.941 to 0.965 g/cm3, is typically a homopolymer of ethylene, and it contains few branch chains relative to the various linear copolymers of ethylene and an -olefm.
HDPE
is well lalown, commercially available in various grades, and may be used in this invention.
The polypropylene copolymers of this invention are polymers comprising un.its derived from propylene and ethylene and/or one or more Lursaturated comonomers. The term "copolymer" includes terpolymers, tetrapolymers, etc.
"Random copolymer" means a copolymer in which the monomer is randomly distributed across the polymer chain. Typically, the polypropylene copolymers comprise units derived from propylene in an amount of at least 60, preferably at least 70 and more preferably at least 80, weight percent of the copolymer.
5'0068-78 Ethylene and/or the one or more unsaturated comonomers of the copolymer comprise at least 0.1, preferably at least 1 and more preferably at least 3, weiglit percent, and the typical maximum amount of unsaturated comonomer does not exceed 40, and preferably it does not exceed 30, weight percent of the copolymer.
Such random copolymers of polypropylene are commercially available, for example, DOW PolyPropylene RESiNSTM available from The Dow Chemical Company.
Styrene/butadiene copolyniers (SBC) are clear resins known in the art.
SBC resins provide both high clarity and good film stiffness. Examples of suitable SBC resins are the K-ResinCR) family of SBC available from Chevron Phillips Chemical Company LP.
Cyclic-Olefm copolymers (COC) are amorphous, glass-clear copolymers of etliylene and norbornene made via metallocene catalysts. COC resins provide good stiffness and high clarity. COC is con~rnercially available, for example, the Topas@ COC copolymers available from Ticona.
Polystyrene is a transparent resin well known in the art and commercially available. Polystyrene provides both high-clarity and good film stiffness. An example of a suitable, commercially available polystyrene is StyronT"r 663 polystyrene available from The Dow Chemical Company.
Ethylene-vinyl acetate copolymers are well-lmown, commercially available elastomers.
Preferably, the mixture of (A) comprises from about 40 to about 75 weight percent of the homogeneously branched polyethylene and from about 25 to about 60 weight percent of the heterogeneously branched polyethylene. The heterogeneously branched polyetliylene has a molecular weight distribution, Mw/Mn, from about 3 to about 6 and the homogeneously branched polyethylene has a molecular iueight distribution, Mw/Mn, from about 1.5 to about 3. The mixtLire of (A) can have a melt index, I2, from 10 grams/l0 ininutes to 30 grams/10 ininutes, preferably about 6 grams/10 minutes to about 20 grams/10 minutes. Melt index (I2) is measured in accordance with ASTM D 1238, Condition 190C/2.16 kg. The mixture of (A) also can have a density of from about 0.88 grains/cubic centimeter to about 0.92 grams/cubic centimeter.
The mixture of (A) has at least 3 melting peaks on a differential scanning calorimetry cunre. Preferably, the mixture of (A) comprises from about 50 to about 60 weight percent of the homogeneously branched polyethylene and from about 40 to about 50 weight percent of the heterogeneously branched polyethylene.
Such random copolymers of polypropylene are commercially available, for example, DOW PolyPropylene RESiNSTM available from The Dow Chemical Company.
Styrene/butadiene copolyniers (SBC) are clear resins known in the art.
SBC resins provide both high clarity and good film stiffness. Examples of suitable SBC resins are the K-ResinCR) family of SBC available from Chevron Phillips Chemical Company LP.
Cyclic-Olefm copolymers (COC) are amorphous, glass-clear copolymers of etliylene and norbornene made via metallocene catalysts. COC resins provide good stiffness and high clarity. COC is con~rnercially available, for example, the Topas@ COC copolymers available from Ticona.
Polystyrene is a transparent resin well known in the art and commercially available. Polystyrene provides both high-clarity and good film stiffness. An example of a suitable, commercially available polystyrene is StyronT"r 663 polystyrene available from The Dow Chemical Company.
Ethylene-vinyl acetate copolymers are well-lmown, commercially available elastomers.
Preferably, the mixture of (A) comprises from about 40 to about 75 weight percent of the homogeneously branched polyethylene and from about 25 to about 60 weight percent of the heterogeneously branched polyethylene. The heterogeneously branched polyetliylene has a molecular weight distribution, Mw/Mn, from about 3 to about 6 and the homogeneously branched polyethylene has a molecular iueight distribution, Mw/Mn, from about 1.5 to about 3. The mixtLire of (A) can have a melt index, I2, from 10 grams/l0 ininutes to 30 grams/10 ininutes, preferably about 6 grams/10 minutes to about 20 grams/10 minutes. Melt index (I2) is measured in accordance with ASTM D 1238, Condition 190C/2.16 kg. The mixture of (A) also can have a density of from about 0.88 grains/cubic centimeter to about 0.92 grams/cubic centimeter.
The mixture of (A) has at least 3 melting peaks on a differential scanning calorimetry cunre. Preferably, the mixture of (A) comprises from about 50 to about 60 weight percent of the homogeneously branched polyethylene and from about 40 to about 50 weight percent of the heterogeneously branched polyethylene.
Component (B) can be selected from the group consisting of low density polyethylene, ethylene/carboxylic acid copolymers, ionomers of ethylene/carboxylic acid copolymers, ethylene vinyl acetate copolymers, high melt strength polypropylene homopolymer, and high melt strength polypropylene copolymer. Component (B) should have a melt strength at least twice that of mixture (A), with even greater melt strengths, such as about 2.5 times the melt strength of mixture (A), about 3 times the melt strength of mixture (A) or even greater, also contemplated.
While not being bound by any particular theory, it is believed that the benefit of the triple phase polymer (three melting peaks) is that it enables sealing with low heat seal initiation temperature due to the high percentage of the first peak (that is, the major peak which occurs at the lowest temperature), while the second and third peaks contribute to an overall heat resistance as expressed by Vicat Softening temperature.
Preferably component (A) comprises about 60 to about 80 weight percent of the composition and component (B) comprises about 20 to about 40 weight percent of the composition. Additives commonly used in the art, such as antioxidants may also be used advantageously in the compositions of the present invention.
In another embodiment, a film layer is made from a polymer composition, the composition comprising (A) from about 60 to about 80 weight percent of a mixture of at least one homogeneously branched polyethylene and at least one heterogeneously branched polyethylene and (B) from about 20 to about 40 weight percent of at least one polymer having a melt strength at least twice that of mixture (A).
The inventive film layers are suitable for use in juice packs, snack packaging and vertical/form/fill/seal applications, among others.
EXAMPLES
The following resins were used in the production of the films of the Examples.
LDPE having a melt index, I21 of 2.3 g/10 min (measured by ASTM
D-1238, Condition 190C/2.16 kg)), a density of 0.918 g/cm3 (measured by ASTM D-792), a melt tension of 8 grams measured according to the method previously described in the Detailed Description of the Invention, and having .50068-78 TM
300 ppm of a hindered phenolic antioxidant (in this example, Irganox 1010 available from Ciba Geigy) Milture (A) A mixttiire of 56 weight percent of a homogeneous ethylene polymer having a melt index, I,, of 20 g/10 min (measured by ASTM D-1238, Condition 190C/2.16 kg) and a density of 0.903 g/cm3 (measured by ASTM D-792) ) and 44 weight percent of a heterogeneous ethylene polymer such that the resultant mixture has a final melt index of 20 gralns/10 minutes and a density of 0.907 grams/cubic centimeter.
The formulations were run on an extrusion coating line equipped with a 3.5" extruder (9 cm) (32 L/D) run with the following zone temperatures:
Barrel1 200 Barrel 2 250 Barrel 3 280 Barrel 4 290 Barrel 5 290 Barrel 6 290 Flange 290 Pipe zones 1 to 3 290 Feedblock zones 1-3 290 Die zones 1 to 10 290 Neck-in (mm):
Drawdown (m/min) :
The Differential Scanning Calorimetry (DSC) measurements were performed in a nitrogen atniosphere using a TA Q-1000 differential scanning calorimeter. Each sample was melted by rapidly heating at about 100 C/min. to 180 C, allowed to remain at 180 C for 3 minutes, cooled at 10 C/min. to -40 C, and the conventional DSC endotherm recorded by scanning from -40 C
to 150 C at 100 C/min. The temperature cycle settings appropriate for polymers other than LLDPE may be found in ASTM D-3417 and ASTM D-3418.
Vicat Softening may be n-ieasured according to ASTM D1525 or ISO
306.
Melt Strength is measured using a Goettfert Rheotens capillary rheometer to supply molten polymer at a temperature of 190 C and at a rate of 30.26 mm3/sec to a die with an inside dianieter of 2.1 mm, a die length of 41.9 cm, alid an entrance angle of 90 degrees. The piston diameter is 9.54 nun, the piston velocity is 0.423 mmJsec, the shear rate is 33 sec'1, the draw down is 100 mm.
While not being bound by any particular theory, it is believed that the benefit of the triple phase polymer (three melting peaks) is that it enables sealing with low heat seal initiation temperature due to the high percentage of the first peak (that is, the major peak which occurs at the lowest temperature), while the second and third peaks contribute to an overall heat resistance as expressed by Vicat Softening temperature.
Preferably component (A) comprises about 60 to about 80 weight percent of the composition and component (B) comprises about 20 to about 40 weight percent of the composition. Additives commonly used in the art, such as antioxidants may also be used advantageously in the compositions of the present invention.
In another embodiment, a film layer is made from a polymer composition, the composition comprising (A) from about 60 to about 80 weight percent of a mixture of at least one homogeneously branched polyethylene and at least one heterogeneously branched polyethylene and (B) from about 20 to about 40 weight percent of at least one polymer having a melt strength at least twice that of mixture (A).
The inventive film layers are suitable for use in juice packs, snack packaging and vertical/form/fill/seal applications, among others.
EXAMPLES
The following resins were used in the production of the films of the Examples.
LDPE having a melt index, I21 of 2.3 g/10 min (measured by ASTM
D-1238, Condition 190C/2.16 kg)), a density of 0.918 g/cm3 (measured by ASTM D-792), a melt tension of 8 grams measured according to the method previously described in the Detailed Description of the Invention, and having .50068-78 TM
300 ppm of a hindered phenolic antioxidant (in this example, Irganox 1010 available from Ciba Geigy) Milture (A) A mixttiire of 56 weight percent of a homogeneous ethylene polymer having a melt index, I,, of 20 g/10 min (measured by ASTM D-1238, Condition 190C/2.16 kg) and a density of 0.903 g/cm3 (measured by ASTM D-792) ) and 44 weight percent of a heterogeneous ethylene polymer such that the resultant mixture has a final melt index of 20 gralns/10 minutes and a density of 0.907 grams/cubic centimeter.
The formulations were run on an extrusion coating line equipped with a 3.5" extruder (9 cm) (32 L/D) run with the following zone temperatures:
Barrel1 200 Barrel 2 250 Barrel 3 280 Barrel 4 290 Barrel 5 290 Barrel 6 290 Flange 290 Pipe zones 1 to 3 290 Feedblock zones 1-3 290 Die zones 1 to 10 290 Neck-in (mm):
Drawdown (m/min) :
The Differential Scanning Calorimetry (DSC) measurements were performed in a nitrogen atniosphere using a TA Q-1000 differential scanning calorimeter. Each sample was melted by rapidly heating at about 100 C/min. to 180 C, allowed to remain at 180 C for 3 minutes, cooled at 10 C/min. to -40 C, and the conventional DSC endotherm recorded by scanning from -40 C
to 150 C at 100 C/min. The temperature cycle settings appropriate for polymers other than LLDPE may be found in ASTM D-3417 and ASTM D-3418.
Vicat Softening may be n-ieasured according to ASTM D1525 or ISO
306.
Melt Strength is measured using a Goettfert Rheotens capillary rheometer to supply molten polymer at a temperature of 190 C and at a rate of 30.26 mm3/sec to a die with an inside dianieter of 2.1 mm, a die length of 41.9 cm, alid an entrance angle of 90 degrees. The piston diameter is 9.54 nun, the piston velocity is 0.423 mmJsec, the shear rate is 33 sec'1, the draw down is 100 mm.
50,068-78 The melt is then pulled with the 1vheels of a Goettfert Rheotens Model 71.97 extensional rheometer with an air gap of 10 cm and an acceleration rate of 2.4mm2/sec. The Melt Strength is the plateau value of the force in the spinline measured in centinewtons (cN), or the peak value in the case of a lack of a plateau, as is often experienced witli high strength materials.
The tensile properties of the polymers were measured using ISO 527-3 or an equivalent standard test metllod. Tensile properties include 2percentSecant Modulus, Maximum Tensile Strength, and Percent Elongation at Maximum Tensile Strength. A J&B Topwave was used to determine the Hot Tack Initiation Teinperature according to ASTM D-3706 and was also used to make the heat seals. The heat sealer was equiped with 5 mm wide Teflon coated heat seal bars and the seals were made using 0.5 Newtons/ mm^2 seal bar pressure and 0.5 second dvvell time. After a 2 second delay following the mak.ing of the heat seals, an Instron universal tester was used to measure the Heat Seal Strength according to ASTM D-88. A Sentinel or a Lloyd K instrument with may be used to measure Heat Seal Initiation Temperature.
Drawn down is a measure of the drawability of a polymer and thus serves as an indicator of how thin a polymer can be drawn in a stable web configuration.
Draw down is determined by first establishing the stable coating weigllt and the line speed equivalent to a constant extrusion output under set process conditions. The draw down speed is measured by maintaining constant extrusion output while increasing the line speed until a classified web defect occurs. Web defects classified as melt drawing limiting included edge tear, web tear, and edge waving beyond +/-3 mm ion either side of the web.
The tensile properties of the polymers were measured using ISO 527-3 or an equivalent standard test metllod. Tensile properties include 2percentSecant Modulus, Maximum Tensile Strength, and Percent Elongation at Maximum Tensile Strength. A J&B Topwave was used to determine the Hot Tack Initiation Teinperature according to ASTM D-3706 and was also used to make the heat seals. The heat sealer was equiped with 5 mm wide Teflon coated heat seal bars and the seals were made using 0.5 Newtons/ mm^2 seal bar pressure and 0.5 second dvvell time. After a 2 second delay following the mak.ing of the heat seals, an Instron universal tester was used to measure the Heat Seal Strength according to ASTM D-88. A Sentinel or a Lloyd K instrument with may be used to measure Heat Seal Initiation Temperature.
Drawn down is a measure of the drawability of a polymer and thus serves as an indicator of how thin a polymer can be drawn in a stable web configuration.
Draw down is determined by first establishing the stable coating weigllt and the line speed equivalent to a constant extrusion output under set process conditions. The draw down speed is measured by maintaining constant extrusion output while increasing the line speed until a classified web defect occurs. Web defects classified as melt drawing limiting included edge tear, web tear, and edge waving beyond +/-3 mm ion either side of the web.
Claims (19)
1. A polymer composition comprising (A) from 60 to 80 weight percent of a mixture of at least one homogeneously branched polyethylene and at least one heterogeneously branched polyethylene wherein the mixture of (A) comprises from 40 to 75 weight percent of the at least one homogeneously branched polyethylene and from 25 to 60 weight percent of the at least one heterogeneously branched polyethylene and (B) from 20 to 40 weight percent of at least one low density polyethylene polymer having a melt strength at least twice that of mixture (A).
2. The composition of claim 1, wherein the at least one homogeneously branched polyethylene is an interpolymer of ethylene and at least one C3-C20 alpha-olefin.
3. The composition of claim 1 or 2, wherein the at least one heterogeneously branched polyethylene has a molecular weight distribution, Mw/Mn, from 3 to 6.
4. The composition of any one of claims 1 to 3, wherein the mixture of (A) has a melt index, 12, measured in accordance with ASTM D-1238 condition 190°C/2.16 Kg, from 10 grams/10 minutes to 30 grams/10 minutes.
5. The composition of any one of claims 1 to 4, wherein the mixture of (A) has a density, measured in accordance with ASTM D-792, of from 0.88 grams/cubic centimeter to 0.92 grams/cubic centimeter.
6. The composition of any one of claims 1 to 5, wherein the mixture of (A) has at least 3 melting peaks on a differential scanning calorimetry curve.
7. The composition of any one of claims 1 to 6, wherein the at least one homogeneously branched polyethylene has a molecular weight distribution, Mw/Mn, from 1.5 to 3.
8. The composition of any one of claims 1 to 7, wherein the mixture of (A) comprises from 50 to 60 weight percent of the at least one homogeneously branched polyethylene and from 40 to 50 weight percent of the at least one heterogeneously branched polyethylene.
9. A film layer made from a polymer composition, the composition comprising (A) from 60 to 80 weight percent of a mixture of at least one homogeneously branched polyethylene and at least one heterogeneously branched polyethylene wherein the mixture of (A) comprises from 40 to 75 weight percent of the at least one homogeneously branched polyethylene and from 25 to 60 weight percent of the at least one heterogeneously branched polyethylene and (B) from 20 to 40 weight percent of at least one low density polyethylene polymer having a melt strength at least twice that of mixture (A).
10. The film layer of claim 9, wherein the at least one homogeneously branched polyethylene is an interpolymer of ethylene and at least C3-C20 alpha-olefin.
11. The film layer of claim 9 or 10, wherein the at least one heterogeneously branched polyethylene has a molecular weight distribution, Mw/Mn, from 3 to 6.
12. The film layer of any one of claims 9 to 11, wherein the mixture of (A) has a melt index, 12, measured in accordance with ASTM D-1238 condition 190°C/2.16 Kg, from 10 grams/10 minutes to 30 grams/10 minutes.
13. The film layer of any one of claims 9 to 12, wherein the mixture of (A) has a density, measured in accordance with ASTM D-792, of from 0.88 grams/cubic centimeter to 0.92 grams/cubic centimeter.
14. The film layer of any one of claims 9 to 13, wherein the mixture of (A) has at least 3 melting peaks on a differential scanning calorimetry curve.
15. The film layer of any one of claims 9 to 14, wherein the at least one homogeneously branched polyethylene has a molecular weight distribution, Mw/Mn, from 1.5 to 3.
16. The film layer of any one of claims 9 to 15, wherein the mixture of (A) comprises from 50 to 60 weight percent of the at least one homogeneously branched polyethylene and from 40 to 50 weight percent of the at least one heterogeneously branched polyethylene.
17. A fabricated article comprising the film layer defined in any one of claims 9 to 16.
18. The film layer of any one of claims 9 to 16 further comprising at least one other layer.
19. A film comprising at least two layers, wherein one of the at least two layers comprises:
(A) a mixture of at least one homogeneously branched polyethylene and at least one heterogeneously branched polyethylene wherein the mixture of (A) comprises from 40 to 75 weight percent of the homogeneously branched polyethylene and from 25 to 60 weight percent of the heterogeneously branched polyethylene and one other layer comprising;
and a second of the at least two layers comprises:
(B) at least one low density polyethylene polymer having a melt strength at least twice that of the mixture of (A).
(A) a mixture of at least one homogeneously branched polyethylene and at least one heterogeneously branched polyethylene wherein the mixture of (A) comprises from 40 to 75 weight percent of the homogeneously branched polyethylene and from 25 to 60 weight percent of the heterogeneously branched polyethylene and one other layer comprising;
and a second of the at least two layers comprises:
(B) at least one low density polyethylene polymer having a melt strength at least twice that of the mixture of (A).
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2003
- 2003-09-22 MX MXPA05003160A patent/MXPA05003160A/en active IP Right Grant
- 2003-09-22 BR BRPI0314479A patent/BRPI0314479B1/en active IP Right Grant
- 2003-09-22 CA CA 2499517 patent/CA2499517C/en not_active Expired - Lifetime
- 2003-09-22 AU AU2003275062A patent/AU2003275062A1/en not_active Abandoned
- 2003-09-22 WO PCT/US2003/029620 patent/WO2004026955A2/en active IP Right Grant
- 2003-09-22 US US10/528,610 patent/US7846552B2/en active Active
- 2003-09-22 EP EP20030759328 patent/EP1546254B1/en not_active Expired - Lifetime
- 2003-09-22 DE DE2003617692 patent/DE60317692T2/en not_active Expired - Lifetime
- 2003-09-22 JP JP2004538296A patent/JP2006500443A/en active Pending
- 2003-09-22 CN CNB038226928A patent/CN100537649C/en not_active Expired - Lifetime
- 2003-09-22 ES ES03759328T patent/ES2293022T3/en not_active Expired - Lifetime
- 2003-09-22 DK DK03759328T patent/DK1546254T3/en active
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DK1546254T3 (en) | 2008-04-14 |
KR20050047543A (en) | 2005-05-20 |
BRPI0314479B1 (en) | 2015-10-13 |
AU2003275062A1 (en) | 2004-04-08 |
EP1546254A2 (en) | 2005-06-29 |
MXPA05003160A (en) | 2005-07-05 |
WO2004026955A2 (en) | 2004-04-01 |
CN100537649C (en) | 2009-09-09 |
WO2004026955A3 (en) | 2004-06-24 |
US20050256270A1 (en) | 2005-11-17 |
JP2006500443A (en) | 2006-01-05 |
EP1546254B1 (en) | 2007-11-21 |
ES2293022T3 (en) | 2008-03-16 |
DE60317692T2 (en) | 2008-10-30 |
CA2499517A1 (en) | 2004-04-01 |
DE60317692D1 (en) | 2008-01-03 |
BR0314479A (en) | 2005-07-26 |
CN1685006A (en) | 2005-10-19 |
US7846552B2 (en) | 2010-12-07 |
KR101043187B1 (en) | 2011-06-20 |
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