Ethylene-based polymer compositions for improved extrusion coatings

• US 10,457,799 B2
• Filed: 06/30/2015
• Issued: 10/29/2019
• Est. Priority Date: 06/30/2015
• Status: Active Grant

• Current Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Original Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Inventors: Demirors, Mehmet, Karjala, Teresa P., Lin, Yijian, Cooper, James L.
• Primary Examiner(s): Nutter, Nathan M
• Application Number:
  US15/574,261
• Publication Number:
  US 20180134881A1
• Time in Patent Office: 1,582 Days
• CPC Class Codes: C08L 2205/025 containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
• CPC Class Codes: C08L 2207/062 HDPE
• CPC Class Codes: C08L 2207/066 LDPE (radical process)
• CPC Class Codes: C08L 23/06 Polyethene
• CPC Class Codes: C08L 23/0815 Copolymers of ethene with aliphatic 1-olefins
• CPC Class Codes: C09D 123/06 Polyethene

Abstract

The invention provides a composition comprising at least the following: a) a first composition comprising at least one first ethylene-based polymer, formed by high pressure, free-radical polymerization, and wherein the first composition comprises the following properties: a melt index (I2) from 1.0 to 15.0 g/10 min, and density from 0.910 to 0.940 g/cc; b) a second composition comprising at least one second ethylene-based polymer, and wherein the second composition comprises the following properties; a melt index (I2) from 1.0 to 1000 g/10 min, a density greater than 0.940 g/cc; wherein the composition comprises the following properties: melt index (I2) from 2.0 to 20.0 g/10 min, and a density from 0.915 to 0.940 g/cc; and wherein the first composition is present in an amount from 65 to 95 wt %, based on the weight of the composition.

Claims

1. A composition comprising at least the following:

a) a first composition comprising at least one first ethylene-based polymer, formed by high pressure, free-radical polymerization, and wherein the first composition comprises the following properties;

a melt index (I2) from 1.0 to 15.0 g/10 min, and density from 0.910 to 0.940 g/cc;

b) a second composition comprising at least one second ethylene-based polymer, and wherein the second composition comprises the following properties;

a melt index (I2) from 1.0 to 1000 g/10 min, and a density greater than 0.940 g/cc;

wherein the melt index (I2) ratio of the melt index (I2) of the second composition to the melt index (I2) of the first composition is from 0.50 to 2.70;

wherein the composition comprises the following properties;

melt index (I2) from 2.0 to 20.0 g/10 min, and a density from 0.915 to 0.940 g/cc; and

wherein the first composition is present in an amount from 65 to 95 wt %, based on the weight of the composition.

2. The composition of claim 1, wherein the melt index (I2) ratio of “

the composition”

to “

the second composition”

is from 0.30 to 2.00.

3. The composition of claim 1, wherein the first ethylene-based polymer is prepared in a tubular reactor.

4. The composition of claim 1, wherein the first composition comprises ≥

95 wt % of the first ethylene-based polymer, based on the weight of the first composition.

5. The composition of claim 1, wherein the first ethylene-based polymer is a low density polyethylene (LDPE).

6. The composition of claim 1, wherein the second composition comprises ≥

95 wt % of the second ethylene-based polymer, based on the weight of the second composition.

7. The composition of claim 1, wherein the second composition has a density from 0.940 to 0.966 g/cc.

8. The composition of claim 1, wherein the second ethylene-based polymer is a high density polyethylene (HDPE).

9. The composition of claim 1, wherein the melt index (I2) ratio of the composition to the first composition is from 0.50 to 3.00.

10. The composition of claim 1, wherein the first composition has a melt index (I2) from 3.0 to 10.0 g/10 min.

11. The composition of claim 1, wherein the first composition is present in an amount from 75 to 95 wt %, based on the weight of the composition.

12. The composition of claim 1, wherein the second composition has a melt index (I2) from 4.0 to 40.0 g/10 min.

13. The composition of claim 1, wherein the composition has a density from 0.910 to 0.930 g/cc.

14. The composition of claim 1, wherein the first composition, is prepared in a tubular reactor, and has a melt index (I2) from 3.0 to 10.0 g/10 min, and a G′

value (at G″

=500 Pa, 170°

C.)≥

127.5 Pa-1.25 Pa/(g/10 min)×

I2.

15. The composition of claim 1, wherein the first composition is prepared in a tubular reactor, and has a melt index (I2) from 3.0 to 10.0 g/min, a density from 0.916 to 0.928 g/cc;

the second composition has a melt index (I2) from 4.0 to 20.0 g/10 min, a density from 0.955 to 0.970 g/cc; and

wherein the composition has a melt index (I2) from 3.0 to 10.0 g/10 min, and a G′

(at G″

=500 Pa, 170°

C.) from 100 to 200 Pa; and

wherein the second composition is present in an amount from 10 to 20 wt %, based on the weight of the composition.

16. The composition of claim 1, wherein a coating the composition has a Water Vapor Transmission Rate, WVTR (38°

C. 100% RH according to ASTM1249-06, 1 mil coating)≤

1.8 (g/100 in2/day.

17. An article comprising at least one component formed from the composition of claim 1.

18. The article of claim 17, wherein the article is a coating, a film, a foam, a laminate, a fiber, or a tape.