阅读说明：本技术 聚烯烃共混物组合物 (Polyolefin blend compositions ) 是由 L·P·勃拉姆 于 2019-05-09 设计创作，主要内容包括：本公开内容涉及具有改进的冲击性能的基于聚丙烯的和基于聚乙烯的聚烯烃组合物。在至少一个实施方案中,聚烯烃组合物包括乙烯聚合物、丙烯聚合物、基于丙烯的弹性体和基于乙烯的塑性体。本公开内容的组合物可以具有以下性质中一个或多个：8kJ/m~2或更大的23℃缺口卡毕冲击强度、6ft-lb/in.或更大的23℃缺口Izod冲击强度、10ft-lb/in.或更大的23℃无缺口Izod冲击强度和所述组合物的一部分具有50％或更大的每mm~2的亚微米结构域含量。(The present disclosure relates to polypropylene-based and polyethylene-based polyolefin compositions having improved impact properties. In at least one embodiment, the polyolefin composition includes an ethylene polymer, a propylene-based elastomer, and an ethylene-based plastomer. The compositions of the present disclosure may have one or more of the following properties: 8kJ/m 2 Or greater 23 ℃ notched Izod impact strength, 6ft-lb/in, or greater 23 ℃ notched Izod impact strength, 10ft-lb/in, or greater 23 ℃ unnotched Izod impact strength and a portion of the composition having 50% or greaterPer mm of 2 Sub-micron domain content.)

1. A polyolefin composition comprising:

an ethylene polymer;

a propylene polymer;

a propylene-based elastomer; and

an ethylene-based plastomer.

2. The polyolefin composition of claim 1, wherein:

the ethylene polymer and propylene polymer comprise 70 wt% to 90 wt% of the composition;

the propylene-based elastomer is present in a range of from 0.2 wt% to 20 wt%, based on the weight of the composition, and

the ethylene-based plastomer is present in the range of 0.2 wt% to 20 wt%, based on the weight of the composition.

3. The polyolefin composition of claim 1 or 2, wherein the ratio (by weight) of the propylene-based elastomer to the ethylene-based plastomer is from 60:40 to 30: 70.

4. The polyolefin composition of any of claims 1-3, wherein the ratio (by weight) of the ethylene polymer to the propylene polymer in the composition is from 90:10 to 10: 90.

5. The polyolefin composition of any of claims 1-4, wherein the composition has 8kJ/m²Or greater 23 ℃ notched Charpy impact strength.

6. The polyolefin composition of any of claims 1-5, wherein the composition has a 23 ℃ notched Izod impact strength of 6ft-lb/in.

7. The polyolefin composition of any of claims 1-6, wherein a portion of the composition has 50% or greater per mm²Sub-micron domain content.

8. The polyolefin composition of any of claims 1-7, wherein a portion of the composition has 90% or greater per mm²Sub-micron domain content.

9. The polyolefin composition of any of claims 1-8, wherein the ethylene polymer has an alpha-olefin comonomer content of greater than 5 wt% and 0.916g/cm³-0.950g/cm³The density of (c).

10. The polyolefin composition of any of claims 1-9, wherein the alpha-olefin comonomer is C₆-C₁₂An olefin.

11. The polyolefin composition of any of claims 1-10, wherein the ethylene polymer is an ethylene/propylene copolymer, an ethylene/butene copolymer, an ethylene/hexene copolymer, an ethylene/octene copolymer, an ethylene/a-olefin/diene terpolymer, or combinations thereof.

12. The polyolefin composition of any of claims 1-11, wherein the propylene polymer is selected from the group consisting of random copolymer polypropylene, impact copolymer polypropylene, isotactic polypropylene, syndiotactic polypropylene, polypropylene homopolymer, and combinations thereof.

13. The polyolefin composition of any of claims 1-12, wherein the propylene polymer has an alpha-olefin selected from the group consisting of ethylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, 1-undecene, 1-dodecene, 4-methyl-1-pentene, 4-methyl-1-hexene, 5-methyl-1-hexene, vinylcyclohexene, and styrene.

14. The polyolefin composition of any of claims 1-13, wherein the propylene polymer has in one embodiment a comonomer content of the copolymer in the range of from 5 wt% to 35 wt%.

15. The polyolefin composition of any of claims 1-14, wherein the propylene polymer has a melt flow rate of 50g/10min or less.

16. The polyolefin composition of any of claims 1-15, wherein the propylene polymer has a heat of fusion from 1J/g to 75J/g.

17. The polyolefin composition of any of claims 1-16, wherein the propylene-based elastomer has a propylene content of about 70 wt% or greater.

18. The polyolefin composition of any of claims 1-17, wherein the propylene-based elastomer has a C of 8 wt% to about 25 wt%₄-C₁₀Comonomer content.

19. The polyolefin composition of any of claims 1-18, wherein the propylene-based elastomer has a triad tacticity of at least 75%.

20. The polyolefin composition of any of claims 1-19, wherein the propylene-based elastomer has a heat of fusion of about 80J/g or less.

21. The polyolefin composition of any of claims 1-20, wherein the propylene-based elastomer has a Tm of about 110 ℃ or less.

22. The polyolefin composition of any of claims 1-21, wherein the propylene-based elastomer has about 0.850g/cm³-about 0.900g/cm³The density of (c).

23. The polyolefin composition of any of claims 1-22, wherein the propylene-based elastomer has a melt flow rate of from 2g/10min to about 50g/10 min.

24. The polyolefin composition of any of claims 1-23, wherein the propylene-based elastomer has an elongation at break of about 800% or less.

25. The polyolefin composition of any of claims 1-24, wherein the propylene-based elastomer has a weight average molecular weight of from 50,000g/mol to 400,000 g/mol.

26. The polyolefin composition of any of claims 1-25, wherein the propylene-based elastomer has a molecular weight distribution of from 1.5 to about 5.

27. The polyolefin composition of any of claims 1-26, wherein the propylene-based elastomer has a temperature tensile elasticity determined at 23 ℃ of 1,000 megapascals (MPa) or less.

28. The polyolefin composition of any of claims 1-27, wherein the ethylene-based plastomer has a C of from about 15 wt% to about 35 wt%₄-C₁₀Comonomer content based on the total weight of the ethylene-based plastomer.

29. The polyolefin composition of any of claims 1-28, wherein the ethylene-based plastomer has 0.91g/cm³Or a lower density.

30. The polyolefin composition of any of claims 1-29, wherein the ethylene-based plastomer has a heat of fusion of 90J/g or less.

31. The polyolefin composition of any of claims 1-30, wherein the ethylene-based plastomer has a crystallinity of 40% or less.

32. The polyolefin composition of any of claims 1-31, wherein the ethylene-based plastomer has a melting point (Tm, first melting peak) of 100 ℃ or less.

33. The polyolefin composition of any of claims 1-32, wherein the ethylene-based plastomer has a glass transition temperature (Tg) of-20 ℃ or less.

34. The polyolefin composition of any of claims 1-33, wherein the ethylene-based plastomer has a melt index (MI, 2.16kg at 190 ℃) of from 0.5 to 40g/10 min.

35. The polyolefin composition of any of claims 1-34, wherein the ethylene polymer and the propylene polymer are post-consumer recycled materials.

Technical Field

The present disclosure relates to polypropylene-based and polyethylene-based polyolefin compositions having improved impact properties.

Background

The supply chain for post-consumer recycled (PCR) products is very complex, comprising a number of parties that may collect, separate, de-label, grind, wash, re-separate, compound and ultimately sell to customers who will make plastic parts. It is common to blend more than 10% of polypropylene (PP) material into a High Density Polyethylene (HDPE) post consumer recycle base material. However, the incompatibility tendency of HDPE and PP results in blends with limited properties. In fact, the post-consumer recycled rigid High Density Polyethylene (HDPE) and polypropylene (PP) industries strive to balance and maintain the desired physical properties of the recycled material, such as impact resistance. For example, the lack of an effective method of separating PP and HDPE from each other results in one polyolefin contaminant being present in high concentrations in the other polyolefin. In addition, impact modifiers or compatibilizers are often added to improve the properties as dictated by industry. It is common to add one to ten different modifiers to the final product before sale to the manufacturer. Once the customer is ready to make plastic parts, they may also add additional modifiers as needed. However, modifiers generally improve one property of the material (e.g., impact resistance), and only slightly (e.g., by 1kJ/m at room temperature)²). In addition, most modifiers also reduce one or more desirable material properties (e.g., flow modification).

There remains a need for compositions and methods that can provide compositions with enhanced composition properties, such as flow modification and impact properties.

Disclosure of Invention

The present disclosure relates to polypropylene-based and polyethylene-based polyolefin compositions having improved impact properties. In at least one embodiment, the polyolefin composition comprises an ethylene polymer, a propylene polymer, a polyolefin based polymerPropylene elastomers and ethylene-based plastomers. The compositions of the present disclosure may have one or more of the following properties: 8kJ/m²Or greater 23 ℃ notched Charpy (Charpy) impact strength, 0.6ft-lb/in, or greater 23 ℃ notched Izod impact strength and a portion of the composition having 50% or greater per mm²Sub-micron domain content (a submicron domain content).

Drawings

Fig. 1 is a microscope image of a composition according to an embodiment.

FIG. 2 is a graph illustrating notched Izod performance of a composition according to one embodiment.

Fig. 3 is an atomic force microscope image of a composition according to an embodiment.

FIG. 4 is a graph illustrating overall deflection, tension, and impact data for a composition according to one embodiment.

Detailed Description

Before the present compounds, components, compositions, and/or methods are disclosed and described, it is to be understood that this disclosure is not limited to particular compounds, components, compositions, reactants, reaction conditions, ligands, metallocene structures, catalyst structures, or the like, unless otherwise specified, as such can vary, unless otherwise specified. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.

The present disclosure relates to polypropylene-based and polyethylene-based polyolefin compositions having improved impact properties. The present disclosure provides compositions (blends) comprising one or more polyethylenes, one or more polypropylenes, one or more propylene-based elastomers, and one or more ethylene-based plastomers. In some embodiments, the compositions and methods described herein involve the use of polyolefin elastomers such as VISTAMAXX^TM(available from ExxonMobil Chemical Company) and ENGAGE^TMImprovements in recycled polyolefin resins (available from the Dow Chemical Company), and methods of forming them. In at least one embodiment of the present invention,by combining low levels of one or more polyolefin elastomers such as VISTA MAX^TMThe addition to the polymer blend can improve the final end properties such as flow improvement and impact of polypropylene and polyethylene rich post consumer recycled materials. In HDPE-rich materials, VISTA MAXX^TMPolypropylene domains may be surrounded to help improve physical properties. For example, include, for example, VISTA MAXX^TMAnd ENGAGE^TM(50/50) the unique blend of polymers can improve post-consumer recycled materials rich in HDPE, which can provide the composition with increased impact strength. Among the post-HDPE rich recycled materials, VISTA MAX^TMAnd ENGAGE^TMThe blends of polymers have a synergistic behavior in which the polypropylene domains are significantly smaller and more rounded. In contrast to contaminants, these domains instead more like impact modifiers.

As used herein, a "composition" can include a component (e.g., polyethylene, polypropylene, propylene-based elastomer, and/or ethylene-based plastomer) as well as contact products of the component and/or reaction products of the component.

For purposes of this disclosure, ethylene should be considered an alpha-olefin.

An "olefin," alternatively referred to as an "olefinic hydrocarbon," is a linear, branched, or cyclic compound of carbon and hydrogen having at least one double bond. For purposes of this disclosure, ethylene should be considered an alpha-olefin. An "alkylene" group is a linear, branched, or cyclic group of carbon and hydrogen having at least one double bond.

For purposes of this specification and the claims thereto, when a polymer or copolymer is referred to as comprising an olefin, the olefin present in such polymer or copolymer is the polymerized form of the olefin. For example, when a copolymer is said to have an "ethylene" content of 35 wt% to 55 wt%, it is understood that the "monomer" units in the copolymer are derived from ethylene in the polymerization reaction and the derived units are present at 35 wt% to 55 wt% based on the weight of the copolymer. A "polymer" has two or more identical or different monomer units.

As used herein, "polymer" may refer to homopolymers, copolymers, interpolymers, terpolymers, etc. A "polymer" has two or more identical or different monomer units. A "homopolymer" is a polymer having the same monomer units. A "copolymer" is a polymer having two or more monomer units that are different from each other. A "terpolymer" is a polymer having three monomer units that differ from each other. The term "different" as used in reference to a monomeric unit indicates that the monomeric units differ from each other by at least one atom or are isomerically different. Thus, the definition of copolymer as used herein includes terpolymers and the like. Also, as used herein, the definition of polymer includes copolymers and the like. Thus, the terms "polyethylene", "ethylene polymer" and "ethylene-based polymer" as used herein refer to a polymer or copolymer comprising at least 50 mol% ethylene units (e.g. at least 70 mol% ethylene units, such as at least 80 mol% ethylene units, such as at least 90 mol% ethylene units, such as at least 95 mol% ethylene units or 100 mol% ethylene units (in the case of a homopolymer)).

The term "homopolymer" as used herein is a polymer comprising identical monomer units (mer units). The term "copolymer" refers to a polymer having two or more monomer units that are different from each other. A "terpolymer" is a polymer having three monomer units that differ from each other. "different" as used in reference to a monomeric unit indicates that the monomeric units differ from each other by at least one atom or are isomerically different. Thus, the definition of copolymer as used herein includes terpolymers and the like.

As used herein, when a polymer is said to comprise a monomer, the monomer is present in the polymer in the polymerized form of the monomer or in the form of a derivative of the monomer. When a polymer is said to contain a certain percentage wt% of monomer, the percentage of monomer is based on the total amount of monomer units in the polymer.

For purposes of this disclosure, having a density of 0.910-0.940g/cm³Ethylene polymers of density of (a) are known as "low density polyethylene" (LDPE); has a density of 0.890-0.930g/cm³The linearity of the density of (A) does not contain muchEthylene polymers having a high amount of long chain branching are referred to as "linear low density polyethylene" (LLDPE) and can be prepared with conventional ziegler-natta catalysts, vanadium catalysts or with metallocene catalysts in gas phase reactors, high pressure tubular reactors and/or slurry reactors and/or with any of the disclosed catalysts in solution reactors. By "linear" is meant polyethylene with no long chain branching or only a few long chain branches, typically referred to as g' vis of 0.97 or above. Having a density in excess of 0.940g/cm³The density of ethylene polymer of (a) is referred to as "high density polyethylene" (HDPE).

As used herein, "elastomer" or "elastomer composition" refers to any polymer or combination of polymers (e.g., a blend of polymers) as defined in accordance with ASTM D1566. Elastomers include mixed blends of polymers, such as melt-mixed and/or reactor blends of polymers.

As used herein, "plastomer" means having a viscosity of about 0.85 to 0.915g/cm³(iii) density (ASTM D4703 method B and ASTM D1505). The plastomer in the compositions described herein may exhibit an MFR of from about 0.5g/10min to about 30g/10 min. The plastomer in the composition may comprise a copolymer of ethylene derived units and higher alpha-olefin derived units such as propylene, 1-butene, 1-hexene and 1-octene.

The use of "first" polymer and "second" polymer herein is merely an identifier used for convenience and should not be construed as a limitation on the individual ethylene copolymers, their relative order, or the number of ethylene copolymers used, unless otherwise specified herein.

A first polymer: polyethylene

Polyethylene includes polyethylene homopolymers and ethylene-alpha-olefin copolymers. The ethylene-alpha-olefin copolymer has an alpha-olefin comonomer(s) content of greater than 5 wt%, for example greater than 10 wt%, based on the total weight of polymerizable monomers. The comonomer(s) can be incorporated in an amount greater than 15 weight percent, such as greater than 20 weight percent, such as greater than 25 weight percent, such as greater than 30 weight percent, such as greater than 35 weight percent, such as greater than 40 weight percent, such as greater than 45 weight percent, such as greater than 50 weight percent, based on the total weight of polymerizable monomers.

The comonomer comprises one or more C₃-C₄₀Olefins, e.g. C₄-C₂₀Olefins, e.g. C₆-C₁₂An olefin. Said C is₃-C₄₀The olefin monomers may be linear, branched or cyclic. Said C is₃-C₄₀The cyclic olefin may be strained (strained) or unstrained (unstrained), monocyclic or polycyclic, and may optionally include heteroatoms and/or one or more functional groups. In at least one embodiment, the comonomer is selected from the group consisting of propylene, butene, pentene, hexene, heptene, octene, nonene, decene, undecene, dodecene, and isomers thereof. In at least one embodiment, the comonomer comprises one or more C₄-C₄₀Olefins, e.g. C₄-C₂₀Olefins, e.g. C₆-C₁₂An olefin. C₄-C₄₀The olefin monomers may be linear, branched or cyclic. C₄-C₄₀The cyclic olefins may be strained or unstrained, monocyclic or polycyclic, and may optionally include heteroatoms and/or one or more functional groups.

Exemplary C₃-C₄₀Olefin comonomers include propylene, butene, pentene, hexene, heptene, octene, nonene, decene, undecene, dodecene, norbornene, norbornadiene, dicyclopentadiene, cyclopentene, cycloheptene, cyclooctene, cyclooctadiene, cyclododecene, 7-oxanorbornene, 7-oxanorbornadiene, substituted derivatives thereof and isomers thereof, such as hexene, heptene, octene, nonene, decene, dodecene, cyclooctene, 1, 5-cyclooctadiene, 1-hydroxy-4-cyclooctene, 1-acetoxy-4-cyclooctene, 5-methylcyclopentene, cyclopentene, dicyclopentadiene, norbornene, norbornadiene and their corresponding homologs and derivatives, such as norbornene, norbornadiene and dicyclopentadiene.

Exemplary comonomers include, but are not limited to, propylene, isobutylene, 1-butene, 1-pentene, 1-hexene, 3-methyl-1-pentene, 4-methyl-1-pentene, and 1-octene, non-conjugated dienes, polyenesButadiene, isoprene, pentadiene, hexadienes (e.g., 1, 4-hexadiene), octadienes, styrene, halo-substituted styrene, alkyl-substituted styrene, tetrafluoroethylene, vinylbenzocyclobutene, cycloalkanes, cycloalkenes (e.g., cyclopentene, cyclohexene, cyclooctene), and mixtures thereof. Typically, ethylene is mixed with a C₃-C₂₀Alpha-olefin copolymerization.

In at least one embodiment, the polyethylene is a copolymer selected from the group consisting of ethylene/propylene (EP) copolymers, ethylene/butene (EB) copolymers, ethylene/hexene (EH) copolymers, ethylene/octene (EO) copolymers, ethylene/alpha-olefin/diene (EAODM) terpolymers, such as ethylene/propylene/octene terpolymers.

In another embodiment, the polyethylene comprises one or more diene or triene comonomers. The diene or triene comonomer may include 7-methyl-1, 6-octadiene; 3, 7-dimethyl-1, 6-octadiene; 5, 7-dimethyl-1, 6-octadiene; 3,7, 11-trimethyl-1, 6, 10-octatriene; 6-methyl-1, 5-heptadiene; 1, 3-butadiene; 1, 3-pentadiene, norbornadiene, 1, 6-heptadiene; 1, 7-octadiene; 1, 8-nonadiene; 1, 9-decadiene; 1, 10-undecadiene; norbornene; tetracyclododecene; or mixtures thereof; such as butadiene; hexadiene and octadiene; most commonly 1, 4-hexadiene; 1, 9-decadiene; 4-methyl-1, 4-hexadiene; 5-methyl-1, 4-hexadiene; dicyclopentadiene; and 5-ethylidene-2-norbornene (ENB), 1, 3-butadiene, 1, 3-pentadiene, norbornadiene, and dicyclopentadiene; c₈-C₄₀Vinyl aromatic compounds including styrene, o-, m-and p-methylstyrene, divinylbenzene, vinylbiphenyl, vinylnaphthalene; and halogen substituted C₈-C₄₀Vinyl aromatic compounds, such as chlorostyrene and fluorostyrene.

Low density polyethylenes are generally prepared using free radical initiators at high pressure or using ziegler-natta or vanadium catalysts in a gas phase process. The low density polyethylene typically has a density of 0.916g/cm³-0.950g/cm³The density of (c). Typical low density polyethylenes prepared using free radical initiators are known in the industry as "LDPE". LDPE is also known as "branched" or "heterogeneously branched" polyethylene because of the relatively large number of long chain branches extending from the main polymer backbone. In the same density range (e.g., 0.916 g/cm)³-0.950g/cm³) The linear polyethylenes containing no long chain branching are called "linear low density polyethylenes" ("LLDPE") and are typically prepared by conventional ziegler-natta catalysis or with metallocene catalysis. By "linear" is meant that the polyethylene has few, if any, long chain branches, typically considered as a g' vis value of 0.97 or above, e.g., 0.98 or above. The polyethylene having still greater density is a high density polyethylene ("HDPE"), e.g., having greater than 0.950g/cm³And is typically prepared using a ziegler-natta catalyst or a chromium catalyst. Very low density polyethylene ("VLDPE") (also known as ultra low density polyethylene ("ULDPE")) can be prepared by a number of different processes, resulting in a polyethylene having less than 0.916g/cm³Typically 0.890g/cm³-0.915g/cm³Or 0.900g/cm³-0.915g/cm³Polyethylene of density (c).

In at least one embodiment, the polyethylene is one or more of the following: ULDPE, metallocene-based very low density polyethylene (mVLDPE), Low Density Polyethylene (LDPE), Linear Low Density Polyethylene (LLDPE), Medium Density Polyethylene (MDPE), cross-linked polyethylene (PEX or XLPE), High Density Polyethylene (HDPE), high melt strength high density polyethylene (HMS-HDPE), Ultra High Density Polyethylene (UHDPE), Ultra High Molecular Weight Polyethylene (UHMWPE), and combinations thereof. Exemplary polyethylenes are discussed in publications US 7,022,770B2, WO 2012/096698 and WO 2013/043796, which are incorporated herein by reference.

An exemplary ULDPE is available from ExxonMobil Chemical Company under the trade name EXCEED^TM1012mVLDPE (resin developed to have better performance than existing conventional VLDPE and ULDPE resins), and EXCEED^TM1015HA mVLDPE and EXCEED^TM3812 mVLDPE. Exemplary ULDPE is also available under The trade name ATTANE from The Dow Chemical Company^TME.g. ATTANE^TM 4201G、ATTANE^TM4203 and ATTANE^TM4404G. ULDPE canHas a melt mass flow rate of 0.5g/10min to 10.0g/10 min. ULDPE may have a melt index of 0.5g/10min to 3g/10min, such as 0.5g/10min to 2g/10min, such as 0.5g/10min to 1.5g/10min, such as 1.0g/10 min.

Exemplary LDPE can be available under the trade name ENABLE from ExxonMobil Chemical Company^TM2005HH、ESCORENE^TM Ultra FL 00328、ESCOR^TM 6000、EXCEED^TM2018MB and EXXONMOBIL^TMLDPE LD 312 series. Exemplary LDPE may also be available from The Dow Chemical Company under The trade name DOW^TMLow Density Polyethylene (LDPE), e.g. DOW^TM LDPE 1321、DOW^TMLDPE 50041 and DOW^TMLDPE PG 7004. The LDPE may have a melt mass flow rate of from 0.2 to 100g/10 min.

An exemplary LLDPE can be obtained from ExxonMobil Chemical Company under the trade name EXXONMOBIL^TMLLDPE LL 6202.19、EXXONMOBIL^TMLLDPE LL 1001AV and EXXONMOBIL^TMLLDPE LL 8460 series. Exemplary LLDPE can also be sold under The trade name DOW from The Dow Chemical Company^TMLinear Low Density Polyethylene (LLDPE), e.g. DOW^TMLLDPE DFDA-7047NT 7. The LLDPE can have a melt mass flow rate of from 0.2g/10min to 50.0g/10 min.

A suitable MDPE is available from ExxonMobil Chemical Company under the trade name EXXONMOBIL^TMESCORENE^TMLD-117MDPE and EXXONMOBIL^TM ESCORENE^TMLD-129 MDPE. MDPE is also available from The Dow Chemical Company under The trade name DOW^TMMedium Density Polyethylene (MDPE), e.g. DOW^TM MDPE 8818、DOW^TMDMDA-8962NT 7 and DOWLEX^TM2432E. The MDPE resin can be characterized as having a density of 0.926g/cm³-0.940g/cm³The density of (c).

Suitable HDPE is available under the trade designation PAXON from ExxonMobil Chemical Company^TM AL55-003、PAXON^TMHYA021L and EXXONMOBIL^TMHDPE HD 7800P. HDPE also available from The Dow Chemical Company under The trade name DOW^TM HDPE 25055E、DOW^TMHDPE KT 10000UE andUNIVAL^TMDMDA-6200NT 7.

The polyethylene homopolymers and copolymers described herein may be prepared using any suitable catalyst and/or method known for preparing polyethylene homopolymers and copolymers. In certain embodiments, polyethylene homopolymers and copolymers may include polyethylene according to U.S. patent nos. 6,342,566; 6,384,142, respectively; 5,741,563, respectively; PCT publications WO 03/040201; and polymers prepared by the procedure in WO 97/19991.

A second polymer: polypropylene

"propylene polymer", alternatively referred to as "polypropylene" or "propylene copolymer", is a polymer or copolymer comprising at least 50 mol% of propylene derived units; and so on. The term "polypropylene" is intended to encompass isotactic polypropylene (iPP), defined as having at least 10% or more isotactic pentads; highly isotactic polypropylene, defined as having 50% or more isotactic pentads; syndiotactic polypropylene (sPP), defined as polypropylene having at least 10% or more syndiotactic pentads, homopolymer polypropylene (hPP, also known as propylene homopolymer or homo-polypropylene) and so-called random copolymer polypropylene (RCP, also known as propylene random copolymer). Here, the RCP may include propylene and 1 to 10 wt% of a material selected from ethylene and C₄-C₈Copolymers of olefins of 1-olefins. For example, an isotactic polymer (iPP) may have at least 20% (e.g., at least 30%, e.g., at least 40%) isotactic pentads. A polyolefin is "atactic", also referred to as "amorphous", if it has less than 10% isotactic and syndiotactic pentads.

The polypropylene of the present disclosure may be in the form of a copolymer or a homopolymer. For example, the polypropylene is selected from random copolymer polypropylene (rcPP), impact copolymer polypropylene (homopolymer polypropylene modified with at least one elastomeric impact modifier) (ICPP) or high impact polypropylene (HIPP), high melt strength polypropylene (HMS-PP), isotactic polypropylene (iPP), syndiotactic polypropylene (sPP), and combinations thereof. Exemplary embodiments include polypropylene homopolymers, for example, the polypropylene component of the composition can consist essentially of polypropylene homopolymer.

Suitable propylene-based polymers include propylene homopolymers and propylene copolymers. The propylene copolymer may be a random or block copolymer, a propylene-based terpolymer or a branched polypropylene.

In at least one embodiment, propylene is reacted with ethylene or a C₄-C₂₀Alpha-olefin copolymerization. Suitable comonomers for copolymerization with propylene include ethylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, 1-undecene, 1-dodecene and also 4-methyl-1-pentene, 4-methyl-1-hexene, 5-methyl-1-hexene, vinylcyclohexene and styrene.

Exemplary propylene copolymers include propylene/ethylene, propylene/1-butene, propylene/1-hexene, propylene/4-methyl-1-pentene, propylene/1-octene, propylene/ethylene/1-butene, propylene/ethylene/ENB, propylene/ethylene/1-hexene, propylene/ethylene/1-octene, propylene/styrene, and propylene/ethylene/styrene.

In at least one embodiment, the polypropylene polymer is a propylene- α -olefin copolymer. As used herein, a "propylene-alpha-olefin copolymer" is a copolymer of propylene derived units and one or more units derived from ethylene or C₄-C₂₀Copolymers of units of an alpha-olefin and optionally one or more diene derived units, and are relatively elastic and/or form elastic nonwoven fibers and fabrics (ultimate elongation greater than 500%). The overall comonomer content of the copolymer is in one embodiment in the range of 5 wt% to 35 wt%.

In at least one embodiment, when more than one comonomer is present, the amount of a particular comonomer can be less than 5 weight percent, but the total comonomer content is greater than 5 weight percent. The propylene-a-olefin copolymer can be described by a number of different parameters, and those parameters can include a range of values consisting of any desirable upper limit and any desirable lower limit described herein for the propylene-a-olefin copolymer.

The propylene- α -olefin copolymer may be a random copolymer (comonomer-derived units are randomly distributed along the polymer backbone) or a block copolymer (comonomer-derived units are present along long sequences) or any variation thereof (with certain properties of each). The presence of randomness or blocks in the copolymer can be determined by C-NMR, which is well known in the art.

In at least one embodiment, the propylene- α -olefin copolymer comprises from 5 wt% to 50 wt%, such as from 6 wt% to 40 wt%, such as from 7 wt% to 35 wt%, such as from 8 wt% to 20 wt%, such as from 10 wt% to 15 wt%, ethylene or C₄-C₂₀Alpha-olefin derived units (or "comonomer derived units") based on the weight of the copolymer. The propylene- α -olefin copolymer may also comprise units derived from two different comonomers. In addition, these copolymers and terpolymers may contain diene-derived units as described below.

In at least one embodiment, the propylene- α -olefin copolymer comprises propylene-derived units and comonomer units selected from ethylene, 1-hexene, and 1-octene. And in a more particular embodiment, the comonomer is ethylene, and thus the propylene-alpha-olefin copolymer is a propylene-ethylene copolymer.

The polypropylene homopolymer or propylene- α -olefin copolymer of the present disclosure can have a melt flow rate ("MFR") of 100g/10min or less, such as 50g/10min or less, such as 30g/10min or less, measured at 230 ℃/2.16kg according to ASTM D1238.

In at least one embodiment, the propylene- α -olefin copolymer is a terpolymer containing 10 wt% or less of diene-derived units (or "dienes"), such as 8 wt% or less, such as 5 wt% or less, such as 3 wt% or less, and in the range of 0.1 wt% to 10 wt%, such as 0.5 wt% to 8 wt%, such as 1 wt% to 5 wt%, based on the total weight of the terpolymer.

Suitable dienes include, for example: 1, 4-hexadiene; 1, 6-octadiene; 5-methyl-1, 4-hexadiene; 3, 7-dimethyl-1, 6-octadiene; dicyclopentadiene (DCPD); ethylidene Norbornene (ENB), norbornadiene, 5-vinyl-2-norbornene (VNB), or combinations thereof.

In at least one embodiment, the propylene-based polymer comprises units derived from propylene (based on the total weight of polymerizable monomers) in an amount of at least 60 wt%, such as at least 80 wt%, for example at least 85 wt% of the polymer. The amount of ethylene-derived units in the propylene/ethylene copolymers can be at least about 0.1 wt%, such as at least about 1 wt%, such as at least about 5 wt%, and the amount of ethylene-derived units present in these copolymers typically does not exceed about 35 wt%, such as not more than about 30 wt%, such as not more than about 20 wt% of the copolymer (based on the total weight of the polymer). The amount of units derived from other unsaturated comonomer(s) (if present) is typically at least about 0.01 wt%, such as at least about 1 wt%, for example at least about 5 wt%, and the amount of units derived from unsaturated comonomer(s) is typically no more than about 35 wt%, such as no more than about 30 wt%, for example no more than about 20 wt% of the copolymer (based on the total weight of the polymer).

The propylene-based polymer used in the present disclosure may have any Molecular Weight Distribution (MWD). In at least one embodiment, the propylene-based polymer is a propylene- α -olefin copolymer having a MWD of 5 or less, such as 4 or less, such as 3 or less. The propylene-alpha-olefin copolymer may have a MWD of 1 to 5, such as 1.5 to 4.5, such as 2 to 4. In another embodiment, the MWD is 3.5 or less, such as 3 or less, e.g. 2.8 or less, such as 2.5 or less, e.g. 2.3 or less. All individual values and subranges from about 1 to 5 are included herein and disclosed herein.

In at least one embodiment, the propylene-based polymer has a percent crystallinity of from 0.5% to 40%, such as from 1% to 30%, such as from 5% to 25%, where "percent crystallinity" is determined according to the DSC procedure described herein.

In at least one embodiment, the propylene-based polymer has a percent crystallinity of less than 40%, less than 35%, less than 30%, less than 25%, less than 20%, or less than 15%.

The propylene polymer may have a melt flow rate ("MFR") of about 500g/10min or less, such as 200g/10min or less, such as 100g/10min or less, such as 75g/10min or less, such as 50g/10min or less, measured according to ASTM D-1238(2.16kg, 230 ℃). The propylene polymer may have an MFR of from about 1 to about 25, for example from about 1 to about 20. The crystallinity of the first polymer should be derived from isotactic polypropylene sequences. The isotacticity of a propylene polymer can be demonstrated by the substantial presence of propylene residues in the polymer, expressed in mm triads. As noted elsewhere herein, the propylene polymer can have a tacticity greater than the blend or ethylene polymer, for example, when the propylene polymer is isotactic and the ethylene polymer is atactic.

The crystallinity of propylene polymers can be expressed in terms of heat of fusion. The propylene polymers of the present disclosure may have a heat of fusion, as determined by DSC, of 1J/g, or 1.5J/g, or 3J/g, or 4J/g, or 6J/g, or 7J/g, or 10 to 20 or 30J/g, or 40J/g, or 50J/g, or 60J/g, or 75J/g. In one embodiment, the propylene polymer has a heat of fusion of less than 45J/g. Without wishing to be bound by theory, it is believed that the propylene polymer has generally isotactic crystallizable propylene sequences, and the above-mentioned heat of fusion is believed to be due to the melting of these crystalline segments.

The level of crystallinity of a propylene polymer may also be reflected in its melting point. For example, the propylene polymer may have a single melting point. However, a sample of the propylene copolymer will typically show a secondary melting peak adjacent to the main peak. The highest peak is considered the melting point. The propylene polymers described herein may have a melting point as measured by DSC within a range having an upper limit of 115 ℃, or 110 ℃, or 105 ℃, or 90 ℃, or 80 ℃, or 70 ℃ and a lower limit of 0 ℃, or 20 ℃, or 25 ℃, or 30 ℃, or 35 ℃, or 40 ℃, or 45 ℃. For example, the propylene polymer may have a melting point of 105 ℃ or less, such as 100 ℃ or less, such as 90 ℃ or less. In at least one embodiment, the propylene polymer has a melting point of 25 ℃ or greater, or 40 ℃ or greater.

The propylene homopolymers and copolymers described herein can be prepared using any suitable catalyst and/or method known for the preparation of polypropylene homopolymers and copolymers. Polypropylene homopolymers and copolymers can be conventional in composition and are prepared by gas phase, slurry or solution type processes and are commercially available from almost all large petrochemical companies, such as ExxonMobil Chemical co.

Propylene-based elastomers

The compositions of the present disclosure comprise a propylene elastomer ("propylene-based elastomer"). For the purposes of this disclosure, the term "elastomer" refers to a natural or synthetic polymer (e.g., rubber) that has elasticity, and is defined as a rubbery material composed of long chain-like molecules or polymers that are capable of recovering their original shape after being stretched to a large extent, hence the name "elastomer" from an "elastic polymer".

The propylene-based elastomer may be propylene-derived units and derived from ethylene or C_4-10Copolymers of units of at least one of the alpha-olefins. The propylene-based elastomer may contain at least about 50 wt% propylene-derived units. The propylene-based elastomer may have limited crystallinity due to adjacent isotactic propylene units and a melting point as described herein. The crystallinity and melting point of propylene-based elastomers are reduced compared to highly isotactic polypropylene due to the introduction of errors in the insertion of propylene. Propylene-based elastomers are generally free of any substantial intermolecular heterogeneity in tacticity and comonomer composition, and are also generally free of any substantial heterogeneity in intramolecular composition distribution.

The amount of propylene-derived units present in the propylene-based elastomer can range from an upper limit of about 95 wt%, about 94 wt%, about 92 wt%, about 90 wt%, or about 85 wt% to a lower limit of about 60 wt%, about 65 wt%, about 70 wt%, about 75 wt%, about 80 wt%, about 84 wt%, or about 85 wt% of the propylene-based elastomer.

Derived from ethylene or C₄-C₁₀The units, or comonomers, of at least one of the alpha-olefins may be present in an amount of from about 1 to about 35 wt%, or from about 5 to about 35 wt%, or about 7-macro, based on the propylene-based elastomerAbout 32 wt%, or about 8 to about 25 wt%, or about 8 to about 20 wt%, or about 8 to about 18 wt% is present. The comonomer content can be adjusted such that the propylene-based elastomer has a heat of fusion of less than about 80J/g, a melting point of about 105 ℃ or less and a crystallinity that is about 2% to about 65% of the crystallinity of isotactic polypropylene, and a Melt Flow Rate (MFR) of about 2 to about 20 g/min.

In some embodiments, the comonomer is ethylene, 1-hexene, or 1-octene, for example ethylene. In embodiments where the propylene-based elastomer comprises ethylene-derived units, the propylene-based elastomer may comprise from about 5 wt% to about 25 wt%, or from about 8 wt% to about 20 wt%, or from about 9 wt% to about 16 wt% ethylene-derived units. In some embodiments, the propylene-based elastomer includes units derived from propylene and ethylene, and the propylene-based elastomer does not contain any other comonomer in the following amounts: excluding amounts that are typically present as impurities in the ethylene and/or propylene feed streams used during polymerization, or amounts that may substantially affect the heat of fusion, melting point, crystallinity, or melt flow rate of the propylene-based elastomer, or such that any other comonomer is deliberately added to the polymerization process.

In some embodiments, the propylene-based elastomer may comprise more than one comonomer. Some embodiments of propylene-based elastomers having more than one comonomer include propylene-ethylene-octene, propylene-ethylene-hexene, and propylene-ethylene-butene polymers. In which more than one group derived from ethylene or C is present₄-C₁₀In embodiments where the comonomer of at least one of the alpha-olefins is less than about 5 wt% of the propylene-based elastomer, but the total amount of comonomer of the propylene-based elastomer is about 5 wt% or greater.

The propylene-based elastomer may have a pass through of at least about 75%, at least about 80%, at least about 82%, at least about 85%, or at least about 90%¹³C NMR measured triad tacticity of three propylene units. In at least one embodiment, based onThe elastomer of propylene has a triad tacticity of from about 50% to about 99%, or from about 60% to about 99% or from about 75% to about 99%, or from about 80 to about 99%. In some embodiments, the propylene-based elastomer may have a triad tacticity of about 60 to 97%.

The propylene-based elastomer has a heat of fusion ("H") as determined by DSC of about 80J/g or less, or about 70J/g or less, or about 50J/g or less, or about 40J/g or less_f"). The propylene-based elastomer may have a lower limit Hf of about 0.5J/g, or about 1J/g or about 5J/g. E.g. H_fValues can range from about 1J/g, 1.5J/g, 3J/g, 4J/g, 6J/g, or 7J/g to about 30J/g, 35J/g, 40J/g, 50J/g, 60J/g, 70J/g, 75J/g, or 80J/g.

The propylene-based elastomer may have a percent crystallinity of from about 2% to about 65%, or from about 0.5% to about 40%, or from about 1% to about 30%, or from about 5% to about 35%, of the crystallinity of isotactic polypropylene, as determined according to the DSC procedure described herein. The maximum order heat energy (i.e., 100% crystallinity) of propylene was estimated to be 189J/g. In some embodiments, the copolymer has a crystallinity that is less than 40%, or from about 0.25% to about 25%, or from about 0.5% to about 22% of the crystallinity of isotactic polypropylene.

Embodiments of the propylene-based elastomer may have a tacticity index (m/r) (by)¹³C NMR measurement). In some embodiments, the propylene-based elastomer has an isotacticity index (by passage) greater than 0%, or in a range having an upper limit of about 50%, or about 25%, and a lower limit of about 3%, or about 10%¹³C NMR measurement).

In some embodiments, the propylene-based elastomer may further comprise diene-derived units ("dienes" as used herein). The optional diene can be any hydrocarbon structure having at least two unsaturated bonds, wherein at least one unsaturated bond is readily incorporated into the polymer. For example, the optional diene may be selected from linear acyclic olefins such as 1, 4-hexadiene and 1, 6-octadiene; branched acyclic olefins such as 5-methyl-1, 4-hexadiene, 3, 7-dimethyl-1, 6-octadiene and 3, 7-dimethyl-1, 7-octadiene; monocyclic alicyclic olefins such as 1, 4-cyclohexadiene, 1, 5-cyclooctadiene and 1, 7-cyclododecadiene; polycyclic cycloaliphatic fused and bridged cycloalkenes, such as tetrahydroindene, norbornadiene, methyl-tetrahydroindene, dicyclopentadiene, bicyclo (2.2.1) -hepta-2, 5-diene, norbornadiene, alkenylnorbornene, alkylidenenorbornene, such as ethylidene norbornene ("ENB"), cycloalkenyl norbornene and cycloalkylidene norbornene (e.g., 5-methylene-2-norbornene, 5-ethylidene-2-norbornene, 5-propenyl-2-norbornene, 5-isopropylidene-2-norbornene, 5- (4-cyclopentenyl) -2-norbornene, 5-cyclohexylidene-2-norbornene, 5-vinyl-2-norbornene); and cycloalkenyl-substituted alkenes such as vinylcyclohexene, allylcyclohexene, vinylcyclooctene, 4-vinylcyclohexene, allylcyclodecene, vinylcyclododecene and tetracyclo (A-11,12) -5, 8-dodecene. The diene-derived units may be present in the propylene-based elastomer in an amount from an upper limit amount of about 15%, about 10%, about 7%, about 5%, about 4.5%, about 3%, about 2.5%, or about 1.5% to a lower limit amount of about 0%, about 0.1%, about 0.2%, about 0.3%, about 0.5%, about 1%, about 3%, or about 5%, based on the total weight of the propylene-based elastomer.

The propylene-based elastomer may have a single peak melting transition as determined by DSC. In some embodiments, the copolymer has a major peak transition of about 90 ℃ or less with a broad melt transition termination of about 110 ℃ or more. The peak "melting point" ("Tm") is defined as the temperature of the maximum endotherm within the melting range of the sample. However, the copolymer may exhibit secondary melting peaks adjacent to the primary peak and/or at the end of the melt transition. For purposes of this disclosure, these secondary melting peaks are collectively considered a single melting point, with the highest of these peaks being considered the Tm of the propylene-based elastomer. The propylene-based elastomer can have a Tm of about 110 ℃ or less, about 105 ℃ or less, about 100 ℃ or less, about 90 ℃ or less, about 80 ℃ or less, or about 70 ℃ or less. In some embodiments, the propylene-based elastomer has a Tm of from about 25 ℃ to about 105 ℃, or from about 60 ℃ to about 105 ℃, or from about 70 ℃ to about 105 ℃, or from about 90 ℃ to about 105 ℃.

The propylene-based elastomer may have about 0.850 to about 0.900g/cm³Or about 0.860g/cm³-about 0.880g/cm³Density at room temperature measured according to ASTM D1505.

The propylene-based elastomer may have a melt flow rate ("MFR") according to ASTM D1238 at 2.16kg, 230 ℃ of at least about 2g/10 min. In some embodiments, the propylene-based elastomer may have an MFR of from about 2g/10min to about 20g/10min, or from about 2g/10min to about 10g/10min, or from about 2g/10min to about 5g/10 min.

The propylene-based elastomer may have an elongation at break measured according to ASTM D412 of about 2000% or less, about 1800% or less, about 1500% or less, about 1000% or less, or about 800% or less.

The propylene-based elastomer may have a weight average molecular weight (Mw) of from about 5,000g/mol to about 5,000,000g/mol, or from about 10,000g/mol to about 1,000,000g/mol or from about 50,000g/mol to about 400,000 g/mol. The propylene-based elastomer may have a number average molecular weight (Mn) of from about 2,500g/mol to about 250,000g/mol, or from about 10,000g/mol to about 250,000g/mol, or from about 25,000g/mol to about 250,000 g/mol. The propylene-based elastomer may have a z-average molecular weight (Mz) of from about 10,000g/mol to about 7,000,000g/mol, or from about 80,000g/mol to about 700,000g/mol, or from about 100,000g/mol to about 500,000 g/mol.

The propylene-based elastomer may have a molecular weight distribution ("MWD") of from about 1.5 to about 20, or from about 1.5 to about 15, or from about 1.5 to about 5, or from about 1.8 to about 3, or from about 1.8 to about 2.5.

In some embodiments, the propylene-based elastomer is an elastomer comprising propylene crystallinity, a melting point equal to or less than 105 ℃ as measured by DSC, and a heat of fusion of from about 5J/g to about 45J/g. The propylene-derived units are present in an amount of about 80 wt% to about 95 wt%, based on the total weight of the propylene-based elastomer. Ethylene-derived units are present in an amount of about 5 wt% to about 18 wt%, e.g., about 8 wt% to about 18 wt%, about 8.5 to about 17.5 wt%, about 9 wt% to about 16.5 wt%, about 10 wt% to about 16 wt%, about 10.5 wt% to 15.5 wt%, e.g., about 11 wt% to about 15 wt%, based on the total weight of the propylene-based elastomer.

The compositions disclosed herein may include one or more different propylene-based elastomers, i.e., propylene-based elastomers each having one or more different properties, e.g., different comonomer or comonomer content. These combinations of various propylene-based elastomers are within the scope of the present disclosure.

The propylene-based elastomer may comprise a copolymer prepared according to the procedures described in WO 02/36651, U.S. patent No. 6,992,158, and/or WO 00/01745. Preferred methods for the preparation of propylene-based elastomers can be found in U.S. Pat. nos. 7,232,871 and 6,881,800. The present disclosure is not limited by any particular polymerization process for preparing the propylene-based elastomer, and the polymerization process is not limited by any particular type of reaction vessel.

Suitable propylene-based elastomers may be sold under the trade name VISTA MAXX^TM(ExxonMobil Chemical Company)、VERSIFY^TM(The Dow Chemical Company), some grades of TAFMER^TMXM or NOTIO^TM(Mitsui Company) and certain grades of SOFTEL^TM(Basell polyoffs) are commercially available.

In at least one embodiment, the addition of the propylene-based elastomer can reduce the low temperature tensile elasticity of the composition by 25% or more, such as 50% or more, such as 75% or more, such as 85% or more, and up to 95%. The tensile elasticity values provided herein were determined according to the procedure provided in the test methods section below. Additionally, in at least one embodiment, the polymer composition comprising the propylene-based elastomer and the ethylene-based plastomer may have a tensile elasticity at a temperature determined at 23 ℃ of 1000 megapascals (MPa) or less, 900MPa or less, 800MPa or less, 700MPa or less, 600MPa or less, 500MPa or less, 300MPa or less, or 200MPa or less, or 150MPa or less. In such embodiments, the polymer composition may have a minimum temperature tensile elasticity of 600MPa or greater. Tensile elasticity was measured at 2in/min according to ASTM D638, type IV, 0.075 inch specimen.

In at least one embodiment, VISTAMAXX^TMAs propylene-based elastomers, e.g. Vistamaxx^TM3020、Vistamaxx^TM 6102、Vistamaxx^TM6202 and VISTA MAXX^TM 6502。VISTAMAXX^TMThe propylene-based elastomer is a copolymer of propylene and ethylene. VISTA MAX^TMIs rich in propylene>80%) and is a semi-crystalline material with a high amorphous content. Their synthesis is based on EXXPOL from ExxonMobil Chemical Company^TMProvided is a technique.

VISTAMAXX^TM3020 propylene-ethylene Performance Polymer ("VM 3020") is available from ExxonMobil Chemical Company. VM3020 had an ethylene content of 11 wt%, with the remainder being propylene. Typical performances of VM3020 include: 0.874g/cm³Density of (ASTM D1505); a melt index of 1.2g/10min (ASTM D1238; 190 ℃, 2.16 kg); a melt mass flow rate of 3g/10min (230 ℃, 2.16 kg); a Shore D hardness of 34 (ASTM D2240) and a Vicat Softening Temperature (VST) of 67 ℃.

VISTAMAXX^TM6102 propylene-ethylene performance polymers ("VM 6102") are available from ExxonMobil Chemical Company. VM6102 had an ethylene content of 16 wt%, the remainder being propylene. Typical performances of VM6102 include: 0.862g/cm³Density of (ASTM D1505); a melt index of 1.4g/10min (ASTM D1238; 190 ℃, 2.16 kg); a melt mass flow rate of 3g/10min (230 ℃, 2.16 kg); a Shore A hardness of 66 (ASTM D2240) and a Vicat softening temperature of 52.2 ℃ (ASTM D1525).

VISTAMAXX^TM6202 propylene-ethylene performance polymer ("VM 6202") is available from ExxonMobil Chemical Company. VM6202 had an ethylene content of 15 wt%, the remainder being propylene. Typical performance of VM6202 includes:0.863g/cm³density of (ASTM D1505); a melt index of 9.1g/10min (ASTM D1238; 190 ℃, 2.16 kg); a melt mass flow rate of 20g/10min (230 ℃, 2.16 kg); a Shore A hardness of 66 (ASTM D2240) and a Vicat softening temperature of 47.2 ℃. VM6202 is a substantially amorphous HMW SSC-PP copolymer having a weight average molecular weight (Mw) of about 144,700g/mol, a DSC melting point of about 101 ℃, and a DSC melting enthalpy of about 11.4J/g.

VISTAMAXX^TM6502 propylene-ethylene performance polymer ("VM 6502") is available from ExxonMobil Chemical Company, Houston, TX. VM6502 is an amorphous HMW SSC-PP copolymer containing about 13 wt% ethylene comonomer and having a weight average molecular weight (Mw) of about 119,000g/mol, a DSC melting point of about 64 ℃, a DSC melting enthalpy of about 9J/g, about 0.865g/cm³A density at 23 ℃ according to ASTM D1505 and a melt flow rate at about 48g/10min according to ASTM D1238 at 230 ℃/2.16kg test conditions.

Ethylene-based plastomers

The compositions of the present disclosure include an ethylene plastomer ("ethylene-based plastomer"). The ethylene-based plastomer comprises a blend having from about 15 wt% to about 35 wt% derived from C₄-C₁₀Those of units of alpha-olefins, which may have, based on the total weight of the ethylene-based plastomer: an ethylene content of 50 wt% to 90 wt% (e.g., 60 wt% to 85 wt%, or 65 wt% to 80 wt%, or 65 wt% to 75 wt%); an ethylene content of 80 mol% to 96 mol% (e.g., 82 mol% to 92 mol%, or 82 mol% to 88 mol%, or 84 mol% to 86 mol%); a 1-butene content of 15 wt% or more (e.g., 20 wt% or more, or 25 wt% or more); a 1-hexene content of 20 wt% or more (e.g., 25 wt% or more, or 30 wt% or more); and/or a 1-octene content of 25 wt% or more (e.g., 30 wt% or more, or 35 wt% or more).

The ethylene-based plastomer may have one or more of the following properties: 0.91g/cm³Or lower (e.g., 0.905 g/cm)³Or less, or 0.902g/cm³Or less, or 0.85g/cm³Or higher, or 0.86g/cm³Or higher, or 0.87g/cm³Or higher, or 0.88g/cm³Or higher, or 0.885g/cm³Or higher, or 0.85g/cm³-0.91g/cm³Or 0.86g/cm³-0.91g/cm³Or 0.87g/cm³-0.91g/cm³Or 0.88g/cm³-0.905g/cm³Or 0.88g/cm³-0.902g/cm³Or 0.885g/cm³-0.902g/cm³) (ii) a density of (d); a heat of fusion (Hf) of 90J/g or less (e.g., 70J/g or less, or 50J/g or less, or 30J/g or less, or 10J/g to 70J/g, or 10J/g to 50J/g, or 10J/g to 30J/g); a crystallinity of 40% or less (e.g., 30% or less, or 20% or less, e.g., at least 5%, or 5% to 30%, or 5% to 20%); a melting point (Tm, first melting peak) of 100 ℃ or less (e.g., 95 ℃ or less, or 90 ℃ or less, or 80 ℃ or less, or 70 ℃ or less, or 60 ℃ or less, or 50 ℃ or less); a crystallization temperature (Tc, peak) of 90 ℃ or less (e.g., 80 ℃ or less, or 70 ℃ or less, or 60 ℃ or less, or 50 ℃ or less, or 40 ℃ or less); -a glass transition temperature (Tg) of 20 ℃ or less (e.g. -30 ℃ or less, or-40 ℃ or less); an Mw of from 30kg/mol to 2,000kg/mol (e.g., from 50kg/mol to 1,000kg/mol, or from 90kg/mol to 500 kg/mol); an Mw/Mn of 1 to 40 (e.g., 1.4 to 20, or 1.6 to 10, or 1.8 to 3.5, or 1.8 to 2.5); a branching index (g') of from 1.4 to 20 (e.g., from 1.6 to 10, or from 1.8 to 10); a melt index (MI, 2.16kg, 190 ℃) of 0.1 to 100g/10min (e.g., 0.3 to 60g/10min, or 0.5 to 40g/10min, or 0.7 to 20g/10 min); and/or a composition distribution breadth index ("CDBI") of at least 60 wt% (e.g., at least 70 wt%, or at least 80 wt%, or at least 90 wt%, or at least 95 wt%).

Test methods for measuring crystallinity, heat of fusion, reactivity ratio, proportion of reverse propylene units, and branching index derived from ethylene are disclosed in U.S. application serial No. 62/268,112 filed 12, 16/2015, incorporated herein by reference.

The branching index is an indicator of the amount of branching of the polymer and is defined as g' ═ Rg]² _Branching/[Rg]² _Linearity. "Rg" represents radius of gyration and uses W equipped with a multi-angle laser light Scattering ("MALLS") detector, a viscometry detector, and a differential refractive index detectoraters 150 gel permeation chromatography. "[ Rg ]]_Branching"radius of gyration of branched Polymer sample," [ Rg]_Linearity"is the radius of gyration of a linear polymer sample.

The method of making the ethylene-based plastomer may be via a slurry, solution, gas phase, high pressure or other suitable process using a catalyst system suitable for polyolefin polymerization, such as a ziegler-natta catalyst, a metallocene catalyst, other suitable catalyst system, or a combination thereof.

Ethylene copolymers can be prepared in solution, slurry, high pressure, or gas phase using a metallocene catalyst system (i.e., a mono-or bis-cyclopentadienyl transition metal catalyst) in combination with an alumoxane and/or a non-coordinating anion activator. The catalyst and activator may be supported or unsupported and the cyclopentadienyl ring may be substituted or unsubstituted. Information on the process and catalyst/activator for preparing such mPE homopolymers and copolymers can be found in WO 94/26816; WO 94/03506; EPA277,003; EPA277,004; U.S. Pat. nos. 5,153,157; U.S. Pat. nos. 5,198,401; U.S. Pat. nos. 5,240,894; U.S. patent nos. 5,017,714; CA1,268,753; U.S. Pat. nos. 5,324,800; EPA129,368; U.S. patent nos. 5,264,405; EPA520,732; WO 92/00333; U.S. patent nos. 5,096,867; 5,507,475, respectively; EPA 426637; EPA 573403; EPA 520732; EPA 495375; EPA 500944; EPA 570982; WO 91/09882; WO94/03506 and U.S. Pat. No. 5,055,438. In general, exemplary plastomers are prepared using single site catalysts (whether metallocene or not) and have a Mw/Mn from 1.5 to 3 (e.g., from 1.8 to 2.5) and a CDBI of 70% or greater (e.g., 80% or greater, or 90% or greater).

Plastomers useful in the compositions of the present disclosure include those available under the trade designation EXACT^TM(ExxonMobil Chemical Company)、AFFINITY^TM、ENGAGE^TM、FLEXOMER^TM(The Dow Chemical Company)、QUEO^TM(Borealis AG, Austria) and TAFMER^TM(Mitsui Company) commercially available.

In at least one embodiment, ENGAGE^TMAs second olefin elastomers, e.g. ENGAGE^TM8100 and ENGAGE^TM 8411。ENGAGE^TM8100 is available from The Dow Chemical Company. ENGAGE^TM8100 is an ethylene-octene copolymer containing 35.5 wt% octene. ENGAGE^TMTypical properties of 8100 include: 0.870g/cm³Density of (ASTM D1505); a melt index of 1.0g/10min (ASTM D1238; 190 ℃, 2.16 kg); a Shore D hardness of 22 (ASTM D2240); a Shore A hardness of 73 (ASTM D2240); and a Vicat Softening Temperature (VST) of 113 ℃ (ASTM D1525).

ENGAGE^TM8411 is available from The Dow Chemical Company. ENGAGE^TM8411 is an ethylene-octene copolymer containing 35.5 wt% octene. ENGAGE^TM8411 typical properties include: 0.880g/cm³Density of (ASTM D1505); a melt index of 18.0g/10min (ASTM D1238; 190 ℃, 2.16 kg); a Shore A hardness of 81 (ASTM D2240); a Shore D hardness of 27 (ASTM D2240); and a DSC melting peak at 72 deg.C (rate 10 deg.C/min).

Composition comprising a metal oxide and a metal oxide

The compositions of the present disclosure are compositions comprising a first polymer (polyethylene), a second polymer (polypropylene), a propylene-based elastomer, and an ethylene-based plastomer. In at least one embodiment, the amount of first polymer (polyethylene) + second polymer (polypropylene) in the composition is from 10 wt% to 99 wt%, based on the weight of the composition, for example from 20 wt% to 95 wt%, such as from 30 wt% to 90 wt%, such as from 40 wt% to 90 wt%, such as from 50 wt% to 90 wt%, such as from 60 wt% to 90 wt%, such as from 70 wt% to 90 wt%. In at least one embodiment, the amount of propylene-based elastomer in the composition is from 0.1 wt% to 50 wt%, based on the weight of the composition, for example from 0.2 wt% to 20 wt%, such as from 0.3 wt% to 10 wt%, such as from 0.4 wt% to 9 wt%, such as from 0.5 wt% to 8 wt%, such as from 1 wt% to 7 wt%, such as from 2 wt% to 5 wt%. In at least one embodiment, the amount of ethylene-based plastomer in the composition is from 0.1 wt% to 50 wt%, based on the weight of the composition, such as from 0.2 wt% to 20 wt%, such as from 0.3 wt% to 10 wt%, such as from 0.4 wt% to 9 wt%, such as from 0.5 wt% to 8 wt%, such as from 1 wt% to 7 wt%, such as from 2 wt% to 5 wt%.

In at least one embodiment, the ratio (by weight) of propylene-based elastomer to ethylene-based plastomer in the composition is about 90:10, or about 80:20 to 10:90, or 70:30 to 20:80, or 60:40 to 30:70 or 50:50 to 40:60, for example about 50: 50.

In at least one embodiment, the ratio (by weight) of ethylene polymer to propylene polymer in the composition is about 90:10, or about 80:20 to 10:90, or 70:30 to 20:80, or 60:40 to 30:70, or 50:50 to 40:60, for example about 50: 50.

The compositions (also referred to as "blends") of the present disclosure may be prepared as follows: the first polymer (polyethylene), the second polymer (polypropylene), the propylene-based elastomer, and the ethylene-based plastomer are mixed together, reactors are connected together in series to make a reactor blend or by using more than one catalyst, e.g., two metallocene catalysts, in the same reactor to produce multiple polymer species. The polymers may be mixed together prior to being fed into the extruder or the polymers may be mixed in the extruder.

The composition may be formed as follows: the polymers are dry blended and then melt mixed in a mixer, or the polymers are directly mixed together in a mixer such as a Banbury mixer, a Haake mixer, a Brabender internal mixer, or a single or twin screw extruder, which may include compounding extruders and side arm extruders used directly downstream of the polymerization process, which may include blending powders or pellets of the resin at the feed hopper of a film extruder. Further, additives may be included in the composition, in one or more components of the composition, and/or in a product formed from the composition, such as a film, as desired. These additives may include, for example: a filler; antioxidants (e.g., hindered phenols such as IRGANOX, available from Ciba-Geigy^TM1010 or IRGANOX^TM1076) (ii) a Phosphites (e.g., IRGAFOS available from Ciba-Geigy^TM168) (ii) a An anti-stiction additive; tackifiers such as polybutene, terpene resins, aliphatic and aromatic hydrocarbon resins, alkali metal and glycerol stearates and hydrogenated rosin; a UV stabilizer; a heat stabilizer; an anti-blocking agent; a release agent; an antistatic agent; a pigment; a colorant;a dye; a wax; silicon dioxide; fillers and talc.

In at least one embodiment, the amount of additive in the composition is less than 10 wt%, such as less than 5 wt%, such as less than 1 wt%, such as about 0 wt%.

The polymers and components of the present disclosure may be blended by any suitable means, and are typically blended to produce an intimately mixed composition, which may be a homogeneous single phase mixture. For example, they may be blended in a static mixer, batch mixer, extruder, or combinations thereof sufficient to obtain adequate dispersion of the composition components.

The mixing step may comprise a first dry blending, for example using a drum blender, in which the polymers (and optional additives) are first contacted without thorough mixing, and then may be melt blending in an extruder. Another method of component blending is to melt blend the first polymer as pellets and the second polymer as pellets directly in an extruder or batch mixer. It is also possible to include a "masterbatch" process, in which the final modifier concentration is obtained by combining the neat polymer with an appropriate amount of modified polymer that has been previously prepared at a higher additive concentration. The mixing may be performed as part of a processing method for manufacturing the article, for example in an extruder on an injection molding machine or a blown film line or a fiber line.

In at least one embodiment of the present disclosure, the first polymer (polyethylene), the second polymer (polypropylene), the propylene-based elastomer, and/or the ethylene-based plastomer may be "melt blended" in equipment such as an extruder (single or twin screw) or batch mixer. The first polymer (polyethylene), the second polymer (polypropylene), the propylene-based elastomer, and/or the ethylene-based plastomer may also be "dry blended" with one another using a tumbler (tubbler), a double cone blender, a ribbon blender, or other suitable blender. In yet another embodiment, the first polymer (polyethylene), the second polymer (polypropylene), the propylene-based elastomer, and/or the ethylene-based plastomer are blended by a process, such as a combination of a tumbler followed by an extruder. One suitable blending process is to include a final blending stage as part of the article manufacturing step, for example in an extruder used to melt and convey the composition to a molding step such as injection molding or blow molding. This may include injecting the one or more polymers, elastomers, and/or plastomers directly into the extruder before or after the different one or more polymers, elastomers, and/or plastomers are completely melted. EXTRUSION techniques for polymers are described in more detail, for example, PLASTIC EXTRUSION TECHNOLOGY p.26-37(Friedhelm Hensen, ed. Hanser Publishers 1988).

In another aspect of the present disclosure, the first polymer (polyethylene), the second polymer (polypropylene), the propylene-based elastomer, and/or the ethylene-based plastomer may be blended in the form of a solution by any suitable means using a solvent that dissolves the components of the composition to a significant extent. Blending can be carried out at any temperature or pressure wherein the components are maintained in solution. Suitable conditions include blending at elevated temperatures, for example at a temperature of 10 ℃ or more, for example 20 ℃ or more, above the melting point of the one or more polymers, elastomers and/or plastomers. Such solution blending would be particularly useful in processes where one or more polymers, elastomers and/or plastomers are prepared by a solution process and the modifier is added directly to the finishing train, rather than being added together in another blending step to the dry polymer, elastomer and/or plastomer. Such solution blending would also be particularly useful in processes where one or more polymers, elastomers and/or plastomers are prepared in bulk or high pressure processes and where one or more polymers, elastomers and/or modifiers are all soluble in the monomer. As with the solution process, the one or more polymers, elastomers and/or plastomers may be added directly to the finishing train rather than being added together in another blending step to the dried one or more polymers, elastomers and/or plastomers.

Accordingly, in the case of articles manufactured using processes involving extruders, such as injection molding or blow molding, any suitable manner of combining one or more polymers, elastomers, and/or plastomers to obtain the desired composition is equally effective as well as fully formulated pre-blended pellets, as the molding process may involve pre-melting and mixing of the raw materials; example combinations include neat polymer, elastomer, and/or plastomer pellets (and optional additive (s)), neat polymer, elastomer, and/or plastomer particles, and simple blends of neat polymer, elastomer, and/or plastomer pellets and pre-blended pellets. However, in the compression molding process, little mixing of the molten components occurs, and pre-blended pellets will be preferred over simple blends that make up pellets.

In another embodiment, the composition of the present disclosure is combined with one or more additional polymers prior to forming a film, molded part, or other article. Other useful polymers include polyethylene, isotactic polypropylene, highly isotactic polypropylene, syndiotactic polypropylene, random copolymers of propylene and ethylene and/or butene and/or hexene, polybutene, ethylene-vinyl acetate, LDPE, LLDPE, HDPE, ethylene-vinyl acetate, ethylene methyl acrylate, copolymers of acrylic acid, polymethyl methacrylate or any other polymer polymerizable by the high pressure free radical process, polyvinyl chloride, polybutene-1, isotactic polybutene, ABS resins, ethylene-propylene rubbers (EPR), vulcanized EPR, EPDM, block copolymers, styrenic block copolymers, polyamides, polycarbonates, PET resins, crosslinked polyethylene, copolymers of ethylene and vinyl alcohol (EVOH), polymers of aromatic monomers such as polystyrene, poly-1 esters, polyacetals, polyvinylidene fluoride, polyethylene glycol and/or polyisobutylene.

The above blends can be prepared as follows: the polymers of the present disclosure are mixed with one or more polymers (as described above), reactors are connected together in series to produce a reactor blend or more than one catalyst is used in the same reactor to produce multiple polymer species. The polymers may be mixed together prior to being fed into the extruder or may be mixed in the extruder.

The multiphase polymer blends described herein can be formed into desired end use products by any suitable method. They are also particularly useful for making articles by blow molding, extrusion, injection molding, thermoforming, gas foaming, elastic welding (elastowelding) and compression molding techniques.

For example, blow molding processes include injection blow molding, multilayer blow molding, extrusion blow molding, and stretch blow molding, and are particularly well suited for substantially enclosed or hollow objects, such as gas tanks and other fluid containers. Blow molding is described in more detail in, for example, Concise Encyclopedia of Polymer Science and Engineering, pp.90-92 (Jacqeline I. Kroschwitz, ed., John Wiley & Sons 1990).

In at least one embodiment of the forming and shaping process, profile coextrusion (profile coextrusion) may be used. The process parameters of profile coextrusion are as for the blow molding process described above, except that the die temperature (top and bottom of the dual zone) is in the range of 150 ℃ to 235 ℃, the feed zone is 90 ℃ to 250 ℃, and the water cooling tank temperature is 10 ℃ to 40 ℃.

One embodiment of the injection molding process is described below. The shaped laminate is placed in an injection molding tool. The mold is closed and the substrate material is injected into the mold. The substrate material has a melt temperature of 200 ℃ to 300 ℃, for example 215 ℃ to 250 ℃, and is injected into the mold at an injection rate of 2 to 10 seconds. After injection, the material is compacted or held at a predetermined time and pressure to make the part correct in size and appearance. Typical times are 5 to 25 seconds and pressures are 1,380kPa to 10,400 kPa. The mold is cooled to 10-70 ℃ to cool the substrate. The temperature depends on the desired gloss and the desired appearance. Typical cooling times are 10 to 30 seconds, depending in part on thickness. Finally, the mold is opened and the shaped composite article is removed. Similarly, molded articles can be made by injecting molten polymer into a mold that shapes and solidifies the molten polymer into a desired geometry and thickness of the molded article. The sheet can be prepared by extruding a substantially flat profile from a die onto a chill roll or by calendering. The sheet will generally be considered to have a thickness of 10 mils to 100 mils (254 μm to 2540 μm), but the sheet may be significantly thicker. Tubing (tubing) or pipe (pipe) may be obtained by profile extrusion for medical, drinking water, land drainage applications or similar applications. Profile extrusion processes include extruding molten polymer through a die. The extruded tubing or pipe is then cured by cooling water or cooling air into a continuous extruded article. Sheets made from the compositions of the present disclosure can be used to form containers. Such containers may be formed by thermoforming, solid-phase pressure forming (pressing), stamping, and other forming techniques. Sheets may also be formed to cover floors or walls or other surfaces.

In one embodiment of the thermoforming process, the oven temperature is 160 ℃ to 195 ℃, the time in the oven is 10 to 20 seconds, and the die temperature, typically the male die, is 10 ℃ to 71 ℃.

In one embodiment of the injection molding process, wherein the substrate material is injection molded into a tool comprising a shaped laminate, the substrate material has a melt temperature in one embodiment in the range of from 230 ℃ to 255 ℃, in another embodiment in the range of from 235 ℃ to 250 ℃, in one embodiment in a fill time in the range of from 2 to 10 seconds, in another embodiment in the range of from 2 to 8 seconds, in another embodiment in the range of from 25 ℃ to 65 ℃, in another embodiment in the range of from 27 ℃ to 60 ℃. In at least one embodiment, the temperature of the substrate material is sufficiently high to melt any tie layer material or backing layer to effect adhesion between the layers.

In yet another embodiment of the present disclosure, the composition is secured to a substrate material using a blow molding operation. Blow molding is particularly useful in applications for making closed articles such as fuel tanks and other fluid containers, playground facilities, outdoor furniture, and small enclosed structures. In one embodiment of the method, the composition of the present disclosure is extruded through a multi-layer head, followed by placing the uncooled laminate within a parison in a mold. The mold, with the male or female mold pattern inside, is then closed and air is blown into the mold to form the part. It will be appreciated by those of ordinary skill in the art that the steps described above may be varied depending on the desired results. For example, extruded sheets formed from the compositions of the present disclosure can be thermoformed or blow molded directly without cooling, thereby skipping the cooling step. Other parameters may also be varied in order to achieve a final composite article having the desired characteristics.

In at least one embodiment, the compositions of the present disclosure are formed into articles, such as weatherable seals, hoses, belts, gaskets, molded articles, covers, elastomeric fibers, and the like. Foamed end use articles are also contemplated. More specifically, the blends of the present disclosure may be formed as part of a vehicle component, such as a weather strip, a brake component including, but not limited to, cups, coupling discs, diaphragm cups, boots (e.g., constant velocity joints) and rack and pinion joints, tubing, gaskets, components of hydraulic or pneumatic devices, O-rings, pistons, valves, valve seats, valve conduits, and other elastomeric polymer-based components or elastomeric polymers in combination with other materials (e.g., metals, plastic composite materials) as will be known to those of ordinary skill in the art. Also contemplated are drive belts comprising V-belts, toothed belts with truncated ribs containing fabric-facing V, ground short fiber reinforced V or molding compound with short fiber flocked V. The cross-section of such belts and the number of ribs thereof may vary depending on the end use, market type and power transmission of the belt. They may also be flat, made of a textile reinforcement material with discrete outer surfaces. Vehicles to which these components are expected to be applicable include, but are not limited to, passenger cars, motorcycles, trucks, boats, and other vehicles.

Notched impact strength after seizing: the charpy impact test (also known as the charpy V-notch test) is a standardized high strain rate test that determines the energy absorbed by a material during fracture. The quantitative results of the impact test the energy required to fracture the material and can be used to measure the toughness of the material. Notched Charpy impact strength was measured according to ISO 179-1/1eA using equipment manufactured by Empire Technologies Inc. In at least one embodiment, the composition of the present disclosure has 8kJ/m²Or greater, e.g. 10kJ/m²Or greater, e.g. 12kJ/m²Or greater, e.g. 14kJ/m²Or larger, e.g.E.g. 20kJ/m²Or greater, e.g. 30kJ/m²Or greater, e.g. 40kJ/m²Or greater (or at 8 kJ/m)²Or 25kJ/m²Or 30kJ/m²To 16kJ/m²Or 20kJ/m²Or 30kJ/m²Or 40kJ/m²Or 50kJ/m²Or 60kJ/m²Or 70kJ/m²Or 80kJ/m²In the range of (1) a notched charpy impact strength at 23 ℃.

Notched Izod impact strength: notched Izod impact strength was measured according to ASTM D256 using equipment made by Empire Technologies Inc. In at least one embodiment, the compositions of the present disclosure have a 23 ℃ notched Izod impact strength of 2ft-lb/in or greater, such as 3ft-lb/in or greater, such as 4ft-lb/in or greater, such as 5ft-lb/in or greater, e.g., 6ft-lb/in or greater (or in the range of 2ft-lb/in or 5ft-lb/in to 6ft-lb/in or 7ft-lb/in or 8ft-lb/in or 9ft-lb/in or 10ft-lb/in or 11 ft-lb/in).

Submicron domains: atomic force microscopy can be used to determine the size and concentration of the microdomains of the second polymer (polypropylene) formed in the bulk domain (first polymer (polyethylene)).

For atomic force microscopy, samples were cryomicrotomed prior to scanning to form a smooth surface at-125 ℃ and N in a desiccator prior to AFM imaging₂And (5) performing lower purging. Imaging was performed according to EM-120 on an Icon AFM. The scan sizes were 85 μm and 45 μm over the body area of the two regions, respectively. The TESPA tip is used for scanning, and the data channels monitored are height and phase.

The compositions of the present disclosure have a submicron domain content, defined as the percentage of domains having a diameter of 1 micron or less, as determined by atomic force microscopy, based on the amount of total microdomains of the second polymer for a given region of the composition sample. In at least one embodiment, at least a portion (e.g., 1 mm) of the composition of the present disclosure²Area) has 50% or more, such as 60% or more, such as 70% or more, such as 80% or more, such as 90% or more per mm²Sub-micron domain content.

Film

The compositions of the present disclosure may be used in monolayer films or multilayer films. These films may be formed by any suitable extrusion or coextrusion technique. The film may be non-oriented, uniaxially oriented, or biaxially oriented. The physical properties of the film may vary depending on the film-forming technique used.

One or more of the above polymers, such as their above blends, can be used in various end use applications, such as single-or multilayer blown, extruded and/or shrink films. These films can be formed by a number of well-known extrusion or coextrusion techniques, such as the blown film processing technique, in which the composition can be extruded in a molten state through an annular die, then expanded to form a uniaxially or biaxially oriented melt, then cooled to form a tubular, blown film, and then can be axially cut and unfolded to form a flat film. The film may be subsequently unoriented, uniaxially oriented, or biaxially oriented to the same or different degrees. One or more of the film layers may be oriented in the transverse and/or machine direction to the same or different extents. Uniaxial orientation can be performed using typical cold or hot stretching methods. Biaxial orientation may be performed using a tenter apparatus or a double bubble process, and may be performed before or after the individual layers are assembled together. For example, a polyethylene layer may be extrusion coated or laminated onto an oriented polypropylene layer or the polyethylene and polypropylene may be coextruded together into a film and then oriented. Also, oriented polypropylene may be laminated to oriented polyethylene or oriented polyethylene may be coated onto polypropylene, and then optionally the assembly may be even further oriented. Typically, the film is oriented in the Machine Direction (MD) in a proportion of up to 15, such as 5 to 7, and in the Transverse Direction (TD) in a proportion of up to 15, such as 7 to 9. However, in at least one embodiment, the film is oriented to the same extent in both the MD and TD directions.

The thickness of the film may vary depending on the intended application; however, films of thickness from 1 μm to 50 μm are generally suitable. Films intended for packaging are typically 10 μm to 50 μm thick. The thickness of the sealing layer is typically 0.2 μm to 50 μm. The sealant layer may be present on both the inner and outer surfaces of the film or the sealant layer may be present only on the inner or outer surface.

In at least one embodiment, one or more layers may be modified by corona treatment, electron beam radiation, gamma radiation, flame treatment, or microwave. In at least one embodiment, one or both of the surface layers are modified by corona treatment.

The films of the present disclosure include any suitable film structure and film applications. Specific end use films include, for example, blown films, cast films, stretched/cast films, stretch cling films, stretch hand wrap films, mechanical stretch wraps, shrink films, shrink wrap films, greenhouse films, laminates, and laminated films. Exemplary films can be prepared by any suitable technique, such as by techniques for preparing blown, extruded and/or cast stretch and/or shrink films (including shrink-on-shrink applications).

In one embodiment, a multilayer film (or multilayer film) may be formed by a suitable method. The overall thickness of the multilayer film may vary based on the desired application. A total film thickness of about 5 μm to 100 μm, more typically about 10 μm to 50 μm, is suitable for most applications. One skilled in the art will appreciate that the thickness of the various layers of the multilayer film can be adjusted depending on the desired end use properties, the resin or copolymer used, the equipment throughput, and other factors. The materials forming each layer may be coextruded through a coextrusion feed block and die assembly to produce a film having two or more layers adhered together but of different composition. Coextrusion may be suitable for use in cast film or blown film processes. Exemplary multilayer films have at least two, at least three, or at least four layers. In one embodiment, the multilayer film is comprised of five to ten layers.

To facilitate discussion of the different membrane structures, the following notation is used herein. Each layer of the film is designated as "a" or "B". Where the film includes more than one a layer or more than one B layer, one or more prime symbols (', "," ", etc.) are appended to the a or B symbols to indicate the same type of layer, which may be the same or may differ in one or more properties such as chemical composition, density, melt index, thickness, etc. Finally, the symbols of adjacent layers are separated by slashes (/). Using this notation, a three-layer film having an inner layer disposed between two outer layers will be denoted as a/B/a'. Similarly, five layers of film of alternating layers will be denoted as A/B/A '/B'/A ". Unless otherwise indicated, the left-to-right or right-to-left order of layers is immaterial for the purposes described herein, as is the order of the prime; for example, an A/B membrane is equivalent to a B/A membrane, and an A/A '/B/A ' membrane is equivalent to an A/B/A ' membrane. The relative thickness of each film layer is similarly expressed, where the thickness (dimensionless) of each layer relative to the total film thickness 100 is numerically represented and separated by slashes, for example the relative thickness of an a/B/a 'film with a and a' layers (each 10 μm) and a 30 μm B layer is represented as 20/60/20.

In some embodiments, and using the nomenclature described above, the present disclosure provides a multilayer film having any of the following exemplary structures: (a) bilayer membranes, such as A/B and B/B'; (b) three layer films, such as A/B/A ', A/A'/B, B/A/B ', and B/B'/B "; (c) four-layer membranes, such as A/A '/A "/B, A/A'/B/A", A/A '/B/B', A/B/A '/B', A/B/B '/A', B/A/A '/B', A/B/B '/B ", B/A/B'/B", and B/B '/B "/B'; (d) five layer membranes, such as A/A '/B, A/A'/B/A '″, A/A'/B/A '/B', A/A '/B', A/A '/B/B'/A ', A/B/A'/B, B/A/A '/B', A/A '/B/B', A/B/A '/B', A/B/B '/A'), B/A/A '/B', B/A/B '/A'/B ', B/A/B'/A ', A/B/B', B/A/B ', B/B'/A/B ', and B/B'; and similar structures having 6, 7, 8, 9, 24, 48, 64, 100 or any other number of layers of film. It goes without saying that the film may have more layers.

In any of the embodiments described above, one or more a layers may be replaced with a substrate layer, e.g., glass, plastic, paper, metal, etc., or the entire film may be coated or laminated onto the substrate. Thus, while the discussion herein focuses on multilayer films, the films may also be used as coatings for substrates such as paper, metal, glass, plastic, and any other suitable material.

The film may be further embossed, or produced, or processed according to other known film processes. The film can be tailored to a specific application by adjusting the thickness, materials, and order of the various layers, as well as additives in or modifiers applied to each layer.

In at least one embodiment, the melt strength of the film may be from about 1 to about 100cN, from about 1 to about 50cN, from about 1 to about 25cN, from about 3 to about 15cN, from about 4 to about 12cN, or from about 5 to about 10cN, or from about 5 to about 15cN, when measured at 190 ℃. In some embodiments, the film has a melt strength of at least about 5cN, at least about 10cN, or at least about 15cN, and 30 up to about 20cN when measured at 190 ℃. The melt strength of the film at a particular temperature can be measured using a Gottfert Rheotens melt strength apparatus. To determine melt strength, the melt strand of film extruded from the capillary die was sandwiched between two counter-rotating wheels on the apparatus. At 2.4mm/sec²The constant acceleration of (2) increases the take-up speed. The maximum tensile force (in cN) reached before the threadline broke or began to exhibit tensile resonance was determined as the melt strength. The temperature of the rheometer was set at 190 ℃. The capillary die had a length of 30mm and a diameter of 2 mm. The film melt was extruded from the die at a speed of 10 mm/sec. The distance between the die exit and the contact point of the wheels should be 122 mm.

In at least one embodiment, the films of the present disclosure have an average 1% secant modulus (M) at 23 ℃ according to ASTM D790 procedure B of from about 10,000psi to about 250,000 pounds per square inch (psi). In at least one embodiment, the membrane has an average 1% secant modulus (M) at 23 ℃ according to ASTM D790, procedure B of from about 20,000psi to about 40,000psi, such as from about 20,000 to about 35,000psi, or from about 25,000psi to about 35,000psi, such as from about 30,000psi to about 35,000 psi. In at least one embodiment, the membrane has a TD 1% secant modulus of from about 20,000psi to about 40,000psi, such as from about 20,000 to about 35,000psi, or from about 30,000psi to about 35,000psi, such as from about 33,000psi to about 35,000 psi.

The film of the present disclosure also has an elmendorf tear value according to ASTM D-1922. In at least one embodiment, the film has an Elmendorf tear (MD) of at least 100g/mil, such as at least 120g/mil, such as at least 125g/mil, or such as at least 130 g/mil. For example, the Elmendorf tear (MD) can be from about 100g/mil to about 200g/mil, from about 100g/mil to about 150g/mil, from about 100g/mil to about 130g/mil, from about 120 to about 130g/mil, or from about 125 to about 130 g/mil.

The film of the present disclosure also has an elmendorf tear value according to ASTM D-1922. In at least one embodiment, the film has an Elmendorf Tear (TD) of at least 200g/mil, such as at least 250g/mil, such as at least 300g/mil, or such as at least 350 g/mil. For example, the Elmendorf Tear (TD) may be from about 200g/mil to about 600g/mil, from about 250g/mil to about 500g/mil, from about 300g/mil to 400g/mil, from about 300 to about 350g/mil, or from about 320g/mil to about 340 g/mil.

The films of the present disclosure also have a dart drop impact (or dart drop F50 or dart Drop Impact Strength (DIS)) reported in grams (g) or grams/mil (g/mil) according to ASTM D-1709, method a. The films of the present disclosure may have a dart impact of about 50g/mil to about 600 g/mil. In at least one embodiment, the film has a dart drop of at least about 200g/mil, such as at least about 250g/mil, such as at least about 300g/mil, such as at least about 350 g/mil. For example, the dart can be from about 200g/mil to about 550g/mil, from about 250g/mil to about 400g/mil, from about 300g/mil to about 350 g/mil. Alternatively, the film has a dart drop of at least about 100g/mil, such as at least about 110g/mil, such as at least about 120g/mil, such as at least about 130 g/mil. For example, the dart can be from about 100g/mil to about 300g/mil, from about 110g/mil to about 200g/mil, from about 120g/mil to about 150 g/mil.

The shrinkage (in percent) of the film can be measured by cutting a circular sample from the film using a 100 mm die. They can be marked in the respective direction of the sample, dusted with talc and placed on preheated talc-covered tiles. The sample may then be heated using a heat gun (e.g., model HG-501A) for approximately 10-45 seconds, or until any dimensional change ceases. The values are the average of three samples. The negative shrinkage value indicates the dimensional expansion after heating when compared to its pre-heated dimension.

In at least one aspect, the film has a TD shrinkage at 150 ℃ of at least about 20%, such as at least about 25%. For example, the film has a TD shrinkage at 130 ℃ of at least about 20%, such as at least about 30%, such as at least about 35%. For example, the film has a TD shrinkage at 120 ℃ of at least about 20%, such as at least about 25%.

In at least one aspect, the film has a 150 ℃ MD shrinkage of at least about 50%, such as at least about 60%. For example, the film has a 130 ℃ MD shrinkage of at least about 40%, such as at least about 50%, such as at least about 60%. For example, the film has a 120 ℃ MD shrinkage of at least about 30%, such as at least about 40%.

In at least one embodiment, the film has a combination of the various dart and TD shrink properties given herein. For example, the film may have a dart drop of at least about 200g/mil, and a TD shrinkage at 150 ℃ of at least about 50%, or a dart drop of at least about 250g/mil and a TD shrinkage at 130 ℃ of at least about 40%, or a dart drop of at least 100g/mil, such as at least about 300g/mil and a TD shrinkage at 120 ℃ of at least about 30%.

In at least one embodiment, the film has a total MD/TD shrinkage (i.e., the sum of MD shrinkage and TD shrinkage) at 150 ℃ of greater than about 100%, such as greater than about 110%, such as greater than about 120%, such as greater than about 130%. For example, the film has a 130 ℃ total MD/TD shrinkage of greater than about 100%, such as greater than about 110%, such as greater than about 120%, such as greater than about 130%. For example, the film has a total MD/TD shrinkage at 120 ℃ of greater than about 100%, such as greater than about 110%.

The Strain Hardening Ratio (SHR) is used to characterize the rise in elongational viscosity and is defined as the ratio of the maximum transient elongational viscosity to three times the transient zero shear rate viscosity value at the same strain. When the ratio is greater than 1, strain hardening is present in the material. In at least one embodiment, the film has a strain hardening ratio of about 1 to about 8, such as about 1 to about 5, such as about 2 to about 5.

The properties of the shaped film-forming polymer composition can be characterized by a maximum die rate. The "maximum die rate" is the extrusion rate normalized by die size as is commonly used in the blown film industry. The maximum die rate as used herein is expressed as: the maximum die speed [ lb/in-hr ] -the extrusion rate [ lb/hr ]/die circumference [ inch ]. The maximum die speed measurement is defined as: maximum die rate [ kg/mm-hr ] ═ extrusion rate [ kg/hr ]/die diameter [ mm ]. The maximum die rate at which the film is formed may be greater than about 13lb/in-hr (0.73kg/mm-hr) or about 16lb/in-hr (0.90kg/mm-hr) or about 24lb/in-hr (1.34kg/mm-hr), in any embodiment, or in the range of from about 13lb/in-hr (0.73kg/mm-hr), or about 16lb/in-hr (0.90kg/mm-hr), or about 24lb/in-hr (1.34kg/mm-hr) to about 30(1.69kg/mm-hr), or about 40lb/in-hr (2.25 kg/mm-hr); and for example, the maximum extrusion rate is in the range of about 350lb/hr (159kg/hr) to about 500lb/hr (227 kg/hr). It should be noted that for "maximum die rate" in English units, the die size is the die circumference, and in metric units, the die size is the die diameter. Thus, for a die factor in lb/in-hr, the complete expression is lb/die circumference (in inches)/hr; for a die factor in kg/mm-hr, the complete expression is kg/die diameter (in mm)/hr.

Stretched film

The compositions of the present disclosure may be used to prepare stretch films. The stretch film may be used in various bundling and packaging applications. The term "stretched film" refers to a film that is capable of being stretched and exerting a bundling force and includes films that are stretched at the time of application as well as "pre-stretched", i.e., films that are provided in a pre-stretched form for use without additional stretching. The stretched film may be a monolayer film or a multilayer film and may include conventional additives, such as adhesion enhancing additives, e.g., tackifiers, and non-stick or slip additives, to tailor the slip/stick properties of the film.

Shrink film

The compositions of the present disclosure may be used to prepare shrink films. Shrink films (also known as heat shrinkable films) are widely used in industrial and retail bundling and packaging applications. Such films are capable of shrinking upon the application of heat to relieve stresses imparted to the film during or after extrusion. The shrinkage may occur in one direction or in both the longitudinal and transverse directions. Conventional shrink films are described, for example, in WO 2004/022646.

Industrial shrink films can be used to bundle articles on pallets. Typical industrial shrink films are formed in a single bubble blown extrusion process to a thickness of about 80-200 μm and provide shrinkage in two directions, typically at a Machine Direction (MD) to Transverse Direction (TD) ratio of about 60: 40.

Retail films may be used to package and/or bundle articles for consumer use, such as for supermarket merchandise. Such films are typically formed in a single bubble blown extrusion process to a thickness of about 35-80 μm with a typical MD: TD shrink ratio of about 80: 20.

The film may be used in "shrink-on-shrink" applications. As used herein, "shrink-on" refers to a method of applying an outer shrink-wrap layer around one or more articles that have been individually shrink-wrapped (herein, the "inner layer" of the wrap). In these processes, it is desirable that the film used to wrap the individual articles have a higher melting (or shrink) point than the film used for the outer layer. When such a configuration is used, a desired level of shrinkage can be achieved in the outer layer while preventing the inner layer from melting, shrinking further, or distorting during shrinkage of the outer layer. Some of the films described herein have been observed to have sharp shrink points when subjected to heat from a heat gun at high heat-set, indicating that they may be particularly suitable for use as an inner layer in various shrink-on-shrink applications.

Greenhouse film

The compositions of the present disclosure can be used to make greenhouse films. Greenhouse films are usually heat-insulating films, which, depending on the climate requirements, retain different amounts of heat. Films that are less demanding of heat retention are used in warmer areas or for spring applications. Films that require more heat retention are used in winter months and in colder areas.

Bag (bag)

Bags include those bag structures and bag applications known to those skilled in the art. Exemplary bags include shipping sacks, grocery bags and liners, industrial liners, production bags, and heavy duty bags.

Package (I)

Packaging includes those packaging structures and packaging applications known to those skilled in the art. Exemplary packaging includes flexible packaging, food packaging, such as newcut packaging, frozen food packaging, bundling, packaging, and unitizing various products. Applications for such packaging include various food products, rolls of carpet, liquid containers, and various similar items that are containerized and/or palletized for shipping, storage, and/or display.

Blow molded articles

The compositions of the present disclosure may be used in suitable blow molding processes and applications. Such processes include those that inflate a hot, hollow thermoplastic preform (or parison) inside a closed mold. In this way, the shape of the parison conforms to the shape of the mold cavity, thereby enabling the production of a wide variety of hollow parts and containers.

In a typical blow molding process, a parison is formed between mold halves and the mold is closed around the parison, sealing one end of the parison and closing the parison around a mandrel at the other end. Air is then blown through the mandrel (or through a needle) to inflate the parison inside the mold. The mold is then cooled and the part formed inside the mold is solidified. Finally, the mold is opened and the molded part is ejected. The method can be performed to provide any suitable design having a hollow shape, including but not limited to bottles, jars, toys, household goods, automotive parts, and other hollow containers and/or parts.

Blow molding processes may include extrusion and/or injection blow molding, as described above. Extrusion blow molding is typically suitable for forming articles having a relatively heavy weight, e.g., greater than about 12 ounces, including but not limited to food, clothing, or waste containers. Injection blow molding is typically used to obtain precise and uniform wall thicknesses, high quality neck finishes, and to process polymers that cannot be extruded. Typical injection blow molding applications include, but are not limited to, pharmaceutical, cosmetic, and single serve containers, typically weighing less than 12 ounces.

Injection molded article

The compositions of the present disclosure may also be used in injection molding applications. Injection molding is a process generally known in the art and is a process that typically occurs in a cyclic manner. The cycle time is generally from 10 to 100 seconds and is controlled by the cooling time of the polymer or polymer blend used.

In a typical injection molding cycle, polymer pellets or powder are fed from a hopper and melted in a reciprocating screw-type injection molding machine. The screw in the machine rotates forward, filling the mold with melt and holding the melt under high pressure. As the melt cools and shrinks in the mold, the machine adds more melt to the mold to compensate. Once the mold is filled, it is separated from the injection unit and the melt cools and solidifies. The solidified part is ejected from the mold, which is then closed in preparation for the next injection of melt from the injection unit.

Injection molding processes offer high productivity, good reproducibility, minimized waste losses, and little to no need for part refurbishment. Injection molding is suitable for a wide variety of applications, including containers, commodity goods, automotive components, electronic parts, and many other solid articles.

Extrusion coating

The compositions of the present disclosure may be used in extrusion coating processes and applications. Extrusion coating is a plastic manufacturing process in which a molten polymer is extruded and applied onto a non-plastic carrier or substrate, such as paper or aluminum, in order to obtain a multi-material composite structure. Such composite structures typically combine the toughness, sealability, and resistance properties of the polymeric formulation with the barrier, rigidity, or aesthetic properties of the non-polymeric substrate. In this process, the substrate is typically fed from a web into the molten polymer as it is extruded from a slot die, similar to cast film processes. The resulting structure is cooled, typically with chill rolls, and formed into a finished roll.

Extrusion coated materials can be used, for example, in food and non-food packaging, pharmaceutical packaging, and in the manufacture of goods for the construction (insulating elements) and photographic industry (paper).

Foam product

The compositions of the present disclosure may be used in foam applications. In the extrusion foaming process, a blowing agent, for example carbon dioxide, nitrogen or a compound which decomposes to form carbon dioxide or nitrogen, is injected into the polymer melt by means of a metering unit. The blowing agent is then dissolved in the polymer in the extruder and the pressure is maintained throughout the time in the extruder. The rapid pressure drop rate upon exiting the extruder produces a foamed polymer having a homogeneous pore structure. The resulting foamed products are typically lightweight, strong, and suitable for use in a wide range of applications in industry such as packaging, automotive, aerospace, transportation, electrical and electronic instruments and manufacturing.

Wire and cable applications

Also provided are electrical articles and devices comprising one or more layers formed from or comprising the compositions of the present disclosure. Such devices include, for example, electronics cables, computers and computer-related equipment, marine cables, power cables, communication cables or data transmission cables, and hybrid power/communication cables.

The appliance may be formed by methods well known in the art, for example by one or more extrusion coating steps in a reactor/extruder equipped with a cable die. Such cable extrusion apparatus and methods are well known. In a typical extrusion process, an optionally heated conductive core is pulled through a hot extrusion die, typically a cross-head die, where a layer of molten polymer composition is applied. The multiple layers may be applied by successive extrusion steps with additional layers added, or the multiple layers may be added simultaneously, using a suitable type of die. The cable may be placed in a moisture curing environment or allowed to cure under ambient conditions.

Rotomoulded product

Also provided are rotomoulded products comprising one or more layers formed from or comprising the compositions of the present disclosure. Rotational molding or rotational molding involves adding a quantity of material to a mold, heating and slowly rotating the mold so that the softened material covers the walls of the mold. The mould is kept rotating throughout the heating phase, thus maintaining a uniform thickness throughout the part and preventing any deformation during the cooling phase. Examples of rotomoulded products include, but are not limited to, furniture, toys, pots, road signs tornado shelters, containers, including containers approved by the united nations for transporting nuclear fissile material.

Environmental Stress Cracking Resistance (ESCR)

ESCR can be used, for example, in the blow molding or extrusion industries, in household/industrial chemical containers, liquid food packaging, and pipes. ESCR was measured according to ASTM D-1693, condition B using 100% Igepal CO-630.

In at least one embodiment of the present disclosure, when VISTAMAXX is present^TMThe composition has an ESCR greater than the ESCR of the first PE. In at least one embodiment of the present disclosure, for the compounds having VISTAMAXX^TMHas a ratio of the ESCR value measured with respect to a composition having only the first polymer and the second polymer without VISTA MAXX^TMIs 1.5 times, e.g. 2 times or more, e.g. 2.5 times or more, e.g. 3 times or more, e.g. 3.5 times or more larger.

In other embodiments, the composition of the present disclosure has about 0.945g/cm³-about 0.960g/cm³For example, about 0.948g/cm³-about 0.957g/cm³E.g. about 0.950g/cm³-about 0.960g/cm³E.g., about 0.955g/cm³-about 0.960g/cm³(iii) density (190 ℃/2.16kg based on ASTM D4883).

Examples

Test method

The properties cited below were determined according to the following test procedure. When any of these properties are mentioned in the appended claims, they will be measured according to the specified test procedures.

The elongation at break was measured as specified in ASTM D-882 and reported as a percentage (%).

The 1% secant modulus (M) was measured at 0.5in/min as specified in ASTM D790 procedure B, in pounds per square inch (lb/in)²Or psi).

Izod impact (method of determining impact resistance of a material) is reported in foot-pounds per inch, as determined by ASTM D-4812.

Elasticity under tension (kinetic analysis)

Tensile elasticity was measured at 2in/min according to ASTM D638, type IV, 0.075 inch specimen.

Tensile elasticity (E '), which may also be referred to as the real or elastic component of young's modulus, can be measured by testing a compression molded plate using a DMA Q800 manufactured by TA Instruments inc. Data was collected using a dynamic analysis ("DMA") bend test procedure (using a single cantilever device) in which one end of the sample was mounted to a stationary fixture and the other end was mounted to a movable fixture. The movable clamp then caused the sample to bend in a sinusoidal motion by applying a small percentage strain of 0.025% during the test. The frequency of the bending movement is 1 Hz. When the sample is bent, it undergoes a temperature variation sequence from-30 ℃ to +90 ℃ via an increase rate of 3 ℃/minute. The measurements obtained were then processed by standard machine software and the E' (and E ", viscosity analog) data were reported. In a bending DMA procedure, the machine would apply a specified force and then directly measure the magnitude of the sample deformation and the phase angle in response to the force. In its simplest form (i.e., as a function of time rather than frequency), the stiffness of a material can be calculated according to the following equation:

k-the magnitude of the applied force/deformation

The geometric form factor (GF) of a material is defined as:

GF＝L/A

where L is the length of the sample, a is the cross-sectional area of the sample, and the young's modulus is then calculated as:

E＝K*(GF)

however, it is also possible to re-express the young's modulus as a function of the dynamic modulus E (function of frequency) or ω constituted by its in-phase and out-of-phase components (E' and E ", as mentioned above) in order to be able to calculate those elasticity and viscosity specific parameters.

The tensile elasticity (E') can be calculated, for example, by the following first formula, where δ is the phase angle of the response force from the experiment:

e ═ (stress/strain) cos (δ)

E ═ (stress/strain) sin (δ)

E*(ω)＝E'(ω)+iE”(ω)

Then, in the bending deformation test, tan δ is related to the dynamic modulus according to the following formula:

Tan(δ)＝E”/E'

as technical references for the above discussion, see, for example: young, r.j. and Lovell, p.a, Introduction to Polymers, second edition, CRC press, 1991, chapter 5.

Notched impact strength after seizing:

notched Charpy impact strength was measured at 23 ℃ according to ISO 179 using equipment manufactured by Empire Technologies Inc.

Notched Izod impact strength:

notched Izod impact strength was measured according to ASTM D256 using equipment made by Empire Technologies Inc.

Atomic Force Microscopy (AFM)

Cryomicrotomy of each sample was performed prior to scanning to form a smooth surface at-125 deg.C and N in a desiccator prior to AFM imaging₂And (5) performing lower purging. Imaging was performed according to EM-120 on an Icon AFM. The scan size includes 85 μm and 45 μm over the bulk region of the two regions. The TESPA tip is used for scanning, and the data channels monitored are height and phase.

The incompatibility tendency of HDPE and PP results in blends with limited properties, thus leading to the need to incorporate a small weight percentage (5-15%) of VISTA MAX^TMTo improve performance. It has been found that the impact, flow and Environmental Stress Crack Resistance (ESCR) properties of post-consumer polyolefin materials are greatly improved. Because of VISTA MAX^TMContains both ethylene and propylene, so it bridges the gap between the polypropylene and polyethylene materials, thereby improving impact properties and even surrounding the contaminating domains. High temperature¹³C NMR was used to determine the approximate level of polyolefin contamination. In addition, VISTA MAX^TMAnd ENGAGE^TMThe effect of both additions to the PCR material tends to produce even better impact results. Atomic force microscope images show that HDPE-rich PCR Material (with VISTA MAXX)^TMAnd ENGAGE^TMBlends of (a) have a synergistic effect in which the PP domains are significantly smaller and more rounded. In contrast to contamination, such domains instead are more like impact modifiers. These small spherical domains are capable of absorbing impact energyNot due to incompatibility. These materials are in pellet form and can be compounded or dry blended into HDPE or PP post-consumer recycle batches at the supplier/compounding equipment or molding machine prior to final part manufacture.

All of the following samples were prepared using a large scale roller mill to mix the materials, compression molded, and then die cut to produce samples for testing. This method is mainly used to reduce the risk of damaging any equipment due to unknown contamination (rocks, PET, film and copper wires found during the roller milling).

HDPE Studies

The study was conducted to test for possible increases in melt flow and impact resistance (fig. 1). This material was a 3MFR material obtained from commercial sources which appeared to be heavily contaminated. Polyethylene terephthalate powder is sometimes added to such materials as a filler, which significantly reduces performance. The right is a photograph of contaminants in the material after rolling. The specifications given are as follows: 1) > 60% PE; 2) < 30% PP; 3) < 5% other polymers; 4) < 5% mineral filler; 5) < 3% "others".

The synergy trend using the composition is shown in figure 2. The percent increase in notched Izod results is shown as a percentage above each bar. With, for example, 100% PE control sample, or using 5% -10% VISTA MAX^TMOr even using 2.5% VISTA MAXX^TM6102 and 2.5% ENGAGE^TM8100 mixture of 5% VISTAMAXX^TM6102 and 5% ENGAGE^TM8100 the composition provides an increase in physical properties. Overall, 5% VISTA MAX^TM6102 and 5% ENGAGE^TM8100 compositions give the best results and provide a tensile (Young's) modulus value of 659MPa, tensile strength (about 0.28MPa), 23 ℃ impact notched Izod (about 8ft-lb/in), 23 ℃ impact unnotched Izod (about 15ft-lb/in) and-40 ℃ impact unnotched Izod (about 3.4 ft-lb/in).

Using VISTA MAXX^TM6102 and VISTA MAX^TM3020, and comparative materials additional HDPE (fractional melt 0.6) grade materials were tested. FIG. 3 shows AFM results showing VISTA MAXX^TMThe polymer helps to blend PPDispersed in the PE matrix and creating more rounded domains and surrounding the PP, contributing to impact resistance. This particular material contained 17.6% PP and 81.7% PE¹³C NMR measurement. The compositions have better dispersion of contaminating domains, just like impact modifying materials.

FIG. 4 illustrates the use of (1) a 5% VISTA MAX with 90% HDPE^TM6102 and 5% ENGAGE^TM8100 composition, (2) having 90% HDPE, 5% VISTA MAX^TM6102 and 5% ENGAGE^TM8100 for the composition. As shown in fig. 4, with 5% VISTAMAXX^TM6102 and 5% ENGAGE^TM8100 the composition provides 37.909kJ/m at 23 deg.C²The highest impact notched charpy value and the highest elongation at break value.

Overall, it has been observed that the performance of the composition can be improved for both polypropylene and polyethylene rich PCR materials. For example, in HDPE-rich materials, VISTA MAXX^TMTends to surround PP domains to help improve physical properties. In addition, VISTA MAX is shown^TMAnd ENGAGE^TMThe unique blend of (50/50) further modifies the HDPE-rich PCR, which results in very high impact strength. In the HDPE-rich PCR material, VISTA MAXX is present^TMAnd ENGAGE^TMThe blends of (a) have a synergistic behavior in which the PP domains are significantly smaller and rounder. In contrast to contaminants, these domains instead more like impact modifiers.

In general, the compositions and methods of the present disclosure can provide compositions comprising a propylene-based elastomer and an ethylene-based plastomer to provide enhanced composition properties, such as flow modification and impact properties.

For the sake of brevity, only certain numerical ranges are explicitly disclosed herein. However, a certain lower limit may be combined with any other upper limit to define a range not explicitly recited, similarly, a certain lower limit may be combined with any other lower limit to define a range not explicitly recited, and similarly, a certain upper limit may also be combined with any upper limit to define a range not explicitly recited. In addition, each point or individual value between two endpoints is included in a range, even if not explicitly recited. Thus, each point or individual value can serve as a lower or upper limit on its own, in combination with other points or individual values or other lower or upper limits, to define a range not explicitly recited.

All documents described herein, including any priority documents and/or test procedures, are incorporated by reference in their entirety for all jurisdictions in which the present invention is not inconsistent with this disclosure. It will be apparent from the foregoing summary and the specific embodiments that, while forms of the disclosure have been illustrated and described, various modifications can be made without departing from the spirit and scope of the disclosure. Accordingly, it is not intended that the disclosure be limited thereby. Likewise, the term "comprising" is considered synonymous with the term "including" by U.S. law. Likewise, whenever a composition, element, or group of elements precedes the transitional term "comprising," it is understood that the transitional term "consisting essentially of," consisting of, "selected from" or "being" the same composition or group of elements precedes the recited composition, element, or elements, and vice versa, is also contemplated.

While the present disclosure has been described in terms of a number of embodiments and examples, those skilled in the art, upon reading this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope and spirit of the present disclosure.