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WO2025003837A1 - Polymères polaires utilisés en tant qu'auxiliaires de traitement dans du polyéthylène - Google Patents

Polymères polaires utilisés en tant qu'auxiliaires de traitement dans du polyéthylène Download PDF

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WO2025003837A1
WO2025003837A1 PCT/IB2024/055996 IB2024055996W WO2025003837A1 WO 2025003837 A1 WO2025003837 A1 WO 2025003837A1 IB 2024055996 W IB2024055996 W IB 2024055996W WO 2025003837 A1 WO2025003837 A1 WO 2025003837A1
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mol
weight
evoh
ethylene
polyethylene
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Derek Wasylenko
Joshua HEIDEBRECHT
Jared Taylor
Tony Tikuisis
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Nova Chemicals International SA
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Nova Chemicals International SA
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/04—Homopolymers or copolymers of ethene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2205/00—Polymer mixtures characterised by other features
    • C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2205/00—Polymer mixtures characterised by other features
    • C08L2205/03—Polymer mixtures characterised by other features containing three or more polymers in a blend

Definitions

  • U.S. Pat. No. 3,222,314 discloses blends of polyethylene and low molecular weight polyethylene glycol to provide heat sealable film which is suitable for printing.
  • Fluoroelastomers and fluoropolymers are expensive materials so there is an economic incentive to avoid their use. Further, perfluorinated alkanes and perfluorinated surfactant compounds, such as for example, perfluoroctane sulfonate and perfluorooctanoic acid, which are used during the production of fluoropolymers, are increasingly being recognized for possible negative environmental impacts.
  • EVOH ethylene vinyl alcohol copolymer
  • a poly(oxyalkylene) polymer works well as a polymer processing aid during the extrusion of thermoplastic polyolefins and in the absence of fluoropolymer processing aids.
  • the present disclosure provides a useful alternative to fluorinated alkene-based polymer processing aids.
  • An embodiment is a process for preparing a thermoplastic composition extrudate, the process comprising extruding a thermoplastic composition in a melt extrusion process; the thermoplastic composition comprising i) a linear polyethylene; ii) from 200 to 5,000 parts per million (based on the weight the linear polyethylene) of an ethylene vinyl alcohol copolymer (EVOH); and iii) 200 to 5,000 parts per million (based on the weight of the linear polyethylene) of a polyethylene glycol (PEG); wherein the linear polyethylene is selected from the group consisting of LLDPE, MDPE, VLDPE, HDPE, and mixtures thereof.
  • the linear polyethylene is selected from the group consisting of LLDPE, MDPE, VLDPE, HDPE, and mixtures thereof.
  • An embodiment is a process for preparing a thermoplastic composition extrudate, the process comprising extruding a thermoplastic composition in a melt extrusion process; the thermoplastic composition comprising i) a linear polyethylene; ii) from 200 to 5,000 parts per million (based on the weight the linear polyethylene) of an ethylene vinyl alcohol copolymer (EVOH); and iii) 200 to 5,000 parts per million (based on the weight of the linear polyethylene) of a polyethylene glycol (PEG); wherein the linear polyethylene is selected from the group consisting of LLDPE, MDPE, VLDPE, HDPE, and mixtures thereof; wherein the thermoplastic composition is substantially free of fluoropolymers; and wherein the melt extrusion process is carried out in the absence of fluoropolymers.
  • the thermoplastic composition comprising i) a linear polyethylene; ii) from 200 to 5,000 parts per million (based on the weight the linear polyethylene) of an ethylene vinyl alcohol copolymer (EVOH); and
  • An embodiment is an extrudable thermoplastic composition
  • a linear polyethylene comprising i) a linear polyethylene; ii) from 200 to 5,000 parts per million (based on the weight the linear polyethylene) of an ethylene vinyl alcohol copolymer (EVOH); and iii) 200 to 5,000 parts per million (based on the weight of the linear polyethylene) of a polyethylene glycol (PEG); wherein the linear polyethylene is selected from the group consisting of LLDPE, MDPE, VLDPE, HDPE, and mixtures thereof.
  • EVOH ethylene vinyl alcohol copolymer
  • PEG polyethylene glycol
  • An embodiment is an extrudable thermoplastic composition
  • a linear polyethylene comprising i) a linear polyethylene; ii) from 200 to 5,000 parts per million (based on the weight the linear polyethylene) of an ethylene vinyl alcohol copolymer (EVOH); and iii) 200 to 5,000 parts per million (based on the weight of the linear polyethylene) of a polyethylene glycol (PEG); wherein the linear polyethylene is selected from the group consisting of LLDPE, MDPE, VLDPE, HDPE, and mixtures thereof; wherein the thermoplastic composition is substantially free of fluoropolymers.
  • EVOH ethylene vinyl alcohol copolymer
  • PEG polyethylene glycol
  • An embodiment is a method for reducing melt extrusion defects during the extrusion of a thermoplastic composition comprising a linear polyethylene, the method comprising: adding from 200 to 5,000 parts per million (based on the weight the linear polyethylene) of an ethylene vinyl alcohol copolymer (EVOH) to the linear polyethylene; and extruding the thermoplastic composition in a melt extrusion process; wherein the linear polyethylene is selected from the group consisting of LLDPE, MDPE, VLDPE, HDPE, and mixtures thereof.
  • EVOH ethylene vinyl alcohol copolymer
  • An embodiment is a method for reducing melt extrusion defects during the extrusion of a thermoplastic composition comprising a linear polyethylene, the method comprising: adding from 200 to 5,000 parts per million (based on the weight the linear polyethylene) of an ethylene vinyl alcohol copolymer (EVOH) to the linear polyethylene; adding from 200 to 5,000 parts per million (based on the weight of the linear polyethylene) of a polyethylene glycol to the linear polyethylene; and extruding the thermoplastic composition in a melt extrusion process; wherein the linear polyethylene is selected from the group consisting of LLDPE, MDPE, VLDPE, HDPE, and mixtures thereof.
  • EVOH ethylene vinyl alcohol copolymer
  • an (extrudable) thermoplastic composition is substantially free of fluoropolymers.
  • an (extrudable) thermoplastic composition is substantially free of a polyolefm/EVOH compatibilizer.
  • a melt extrusion process is carried out in the absence of fluoropolymers.
  • a melt extrusion process is conducted at a shear rate which would produce a thermoplastic composition extrudate having melt fracture defects if carried out using a thermoplastic composition consisting essentially of a linear polyethylene.
  • a melt extrusion process is a blown fdm extrusion process carried out at a temperature of from 180°C to 275°C.
  • An embodiment is an extrudable thermoplastic composition having a time to clear melt fracture of fewer than about 60 minutes when extruded in a melt extrusion process on a blown film line at a temperature of from 180°C to 275°C.
  • Figure 1 shows the results of experiments (Examples 1 to 7) which assess the ability of various polymer processing aids to clear melt extrusion defects when extruding a thermoplastic composition comprising a linear low density polyethylene (LLDPE) in a blown film line melt extrusion process.
  • LLDPE linear low density polyethylene
  • the term “monomer” refers to a small molecule that may chemically react and become chemically bonded with itself or other monomers to form a polymer.
  • a -olefin or “alpha-olefin” is used to describe a monomer having a linear hydrocarbon chain containing from 3 to 20 carbon atoms having a double bond at one end of the chain; an equivalent term is “linear a-olefin”.
  • An alpha-olefin may also be referred to as a comonomer.
  • polyethylene or “ethylene polymer”, refers to macromolecules produced from ethylene monomers and optionally one or more additional monomers; regardless of the specific catalyst or specific process used to make the ethylene polymer.
  • the one or more additional monomers are often called “comonomer(s)” and typically include a -olefins.
  • homopolymer generally refers to a polymer that contains only one type of monomer.
  • copolymer refers to a polymer that contains two or more types of monomer.
  • polyethylene types include high pressure low density polyethylene (LDPE), high density polyethylene (HDPE); medium density polyethylene (MDPE); linear low density polyethylene (LLDPE); and very low density polyethylene (VLPDE) or ultralow density polyethylene (ULPDE) which are also known as plastomers and elastomers.
  • LDPE high pressure low density polyethylene
  • HDPE high density polyethylene
  • MDPE medium density polyethylene
  • LLDPE linear low density polyethylene
  • VLPDE very low density polyethylene
  • ULPDE ultralow density polyethylene
  • polyethylene also includes polyethylene terpolymers which may include two or more comonomers in addition to ethylene.
  • polyethylene also includes combination of, or blends of, the polyethylene types described above.
  • fluoropolymers in the present disclosure refers to homopolymers and copolymers of fluorinated olefins.
  • fluoropolymer includes fluoroelastomers.
  • the fluorinated olefins may have a fluorine atom to carbon ratio of at least 1:2, or in some embodiments at least 1: 1.
  • Homopolymers include for example, those derived from vinylidene fluoride and vinyl fluoride.
  • Copolymers include, for example those derived from vinylidene fluoride and one or more additional olefins, which can be fluorinated, such as for example hexafluoropropylene or non-fluorinated, such as for example propylene.
  • fluoropolymers as the term is used in the present disclosure include those described, for example, in U.S. Pat. Nos. 2,968,649; 3,051,677; 3,318,854; 5,015,693; 4,855,360; U.S. Pat. No. 5,710,217; U.S. Pat. No. 6,277,919; U.S. Pat. No. 7,375,157; and U.S. Pat. Appl. Pub. No. 2010/0311906.
  • fluoropolymers include for example, copolymers of hexafluoropropylene and vinylidene fluoride which are available under the tradenames “DYNAMAR® FX 9613” and “DYNAMAR FX 9614”; and copolymers of vinylidene fluoride, tetrafluoroethylene, and hexafluoropropylene available under the tradenames “DYNAMAR FX 5911” and “DYNAMAR FX 5912”.
  • Other commercially available fluoropolymers include “VITON® A”, “VITON FREEFLOW”, “DAI-EL®”, and “KYNAR®” all of which are available in various grades.
  • polyalkylene oxide, poly(oxyalkylene), and polyalkylene glycol are used interchangeably. Accordingly, the terms polyethylene oxide, poly(oxyethylene), and polyethylene glycol are also used interchangeably; as are the terms polypropylene oxide, poly(oxypropylene) and polypropylene glycol.
  • film is used herein to mean a fdm having one or more layers which is formed by the extrusion of a polymer through one or more die openings.
  • film structure is used to connote that a film has more than one layer (i.e. a film structure may have at least two layers, at least three layers, at least four layers, at least five layers, etc.).
  • Alkyl group and the prefix “alk-” are inclusive of both straight chain and branched chain groups and of cyclic groups having up to 30 carbons unless otherwise specified. Cyclic groups can be monocyclic or polycyclic and, in some embodiments, have from 3 to 10 ring carbon atoms.
  • ether linkages for example, with regard to an alkyl, alkylene, or arylalkylene refers to having part of the alkyl, alkylene, or arylalkylene on both sides of the functional group.
  • An example of an alkylene that is interrupted with — O — is — CEL — CEL — O — CEL — CH2 — .
  • aryl as used herein includes carbocyclic aromatic rings or ring systems, for example, having 1, 2, or 3 rings, optionally containing at least one heteroatom (e.g., O, S, or N) in the ring, and optionally substituted by up to five substituents including one or more alkyl groups having up to 4 carbon atoms (e.g., methyl or ethyl), alkoxy having up to 4 carbon atoms, halo (i.e., fluoro, chloro, bromo or iodo), hydroxy, or nitro groups.
  • heteroatom e.g., O, S, or N
  • substituents including one or more alkyl groups having up to 4 carbon atoms (e.g., methyl or ethyl), alkoxy having up to 4 carbon atoms, halo (i.e., fluoro, chloro, bromo or iodo), hydroxy, or nitro groups.
  • aryl groups include phenyl, naphthyl, biphenyl, fluorenyl as well as furyl, thienyl, oxazolyl, and thiazolyl.
  • Arylalkylene refers to an “alkylene” moiety to which an aryl group is attached.
  • Alkylarylene refers to an “arylene” moiety to which an alkyl group is attached.
  • substituted or similar (e.g. “substituent”) means that one or more nonhydrogen radicals (or non-hydrogen moieties or non-hydrogen groups) have replaced one or more hydrogen radicals in any position within the group being referred to.
  • the extrusion of a thermoplastic polyolefin is improved (“aided”) by using a polymer processing aid (PPA).
  • PPA polymer processing aid
  • one or more components of a polymer processing aid can be admixed (e.g. pre-mixed), or pre-blended (e.g. dry blended or melt blended) with a thermoplastic polyolefin followed by extrusion of the polyolefin.
  • one or more components of a polymer processing aid can be co-fed with a thermoplastic polyolefin to an extruder.
  • one or more components of a polymer processing aid can be added to a thermoplastic polyolefin to prepare a masterbatch of the polyolefin containing the one or more components of a polymer processing aids.
  • the resulting polyolefin masterbatch can then be used to introduce the one or more components of a polymer processing aid into a thermoplastic polyolefin in any conventional manner prior to extrusion of the polyolefin (e.g. dry blending or melt blending) or during the extrusion of the polyolefin (e.g. co-feeding with a polyolefin to an extruder).
  • the Polymer Processing Aid (the PPA)
  • a polymer processing aid used to aid the extrusion of a thermoplastic polyolefin, comprises an ethylene vinyl alcohol copolymer (EVOH).
  • EVOH ethylene vinyl alcohol copolymer
  • an EVOH copolymer which is commercially available under the tradenames EVAL® (from Kuraray), EVASIN® (from SK Functional Polymer) and SOARNOL® (from Mitsubishi Chemical) is used as a polymer processing aid.
  • a polymer processing aid used to aid the extrusion of a thermoplastic polyolefin, comprises i) an ethylene vinyl alcohol copolymer (EVOH), and ii) a poly(oxyalkylene) polymer, also known as polyalkylene glycol (PAG).
  • PPA polymer processing aid
  • a polymer processing aid used to aid the extrusion of a thermoplastic polyolefin, comprises i) an ethylene vinyl alcohol copolymer (EVOH), and ii) a poly(oxyethylene) polymer, also known as polyethylene glycol or polyethylene oxide.
  • EVOH ethylene vinyl alcohol copolymer
  • a poly(oxyethylene) polymer also known as polyethylene glycol or polyethylene oxide.
  • a polymer processing aid used to aid the extrusion of a thermoplastic polymer is further characterized by the substantial absence of perfluoroalkane compounds, fluoroelastomers, and fluoropolymers.
  • An embodiment of the disclosure is characterized by the substantial absence of perfluoroalkane compounds, fluoroelastomers, and fluoropolymers in an extrudable thermoplastic composition.
  • An embodiment of the disclosure is a process for preparing a thermoplastic composition extrudate which comprises melt extruding the thermoplastic composition in a melt extrusion process; where the thermoplastic composition is characterized by the substantial absence of perfluoroalkane compounds, fluoroelastomers, and fluoropolymers and where the melt extrusion process is carried out in the absence of perfluoroalkane compounds, fluoroelastomers, and fluoropolymers.
  • melt extrusion processes include film extrusion (blown or cast film extrusion), extrusion blow molding, injection molding, pipe extrusion, wire extrusion, cable extrusion, and fiber extrusion, all of which are well known to persons skilled in the art.
  • a polymer processing aid will comprise an ethylene vinyl alcohol copolymer (abbreviated herein as EVOH).
  • EVOH ethylene vinyl alcohol copolymer
  • Ethylene vinyl alcohol is copolymer of ethylene and vinyl alcohol, can be made by copolymerization of ethylene and vinyl acetate followed by hydrolysis, and is generally further defined by the mole percent of ethylene content.
  • vinyl alcohol polymers including ethylene vinyl alcohol copolymers (EVOHs) see “Vinyl Alcohol Polymers” by F. L. Marten in the Kirk-Othmer Encyclopedia of Chemical Technology; CopyrightOJohn Wiley & Sons; First Published: 10 June 2002; https://doi.org/10.1002/0471238961.2209142513011820.a01.pub2.
  • an ethylene vinyl alcohol copolymer may be represented by the following general formula: where n indicates the length of a polyvinylalcohol block and, m indicates the length of a polyethylene block.
  • EVOH is an ethylene vinyl alcohol copolymer having 20 to 60 mol % ethylene, and is prepared by, for example, hydrolysis of ethylene vinyl acetate copolymers.
  • EVOH is an ethylene vinyl alcohol copolymer having 20 to 50 mol % ethylene, and is prepared by, for example, hydrolysis of ethylene vinyl acetate copolymers. In an embodiment of the disclosure, EVOH is an ethylene vinyl alcohol copolymer having 22 to 48 mol % ethylene, and is prepared by, for example, hydrolysis of ethylene vinyl acetate copolymers.
  • EVOH is an ethylene vinyl alcohol copolymer having 20 to 50 mol % ethylene, including subranges or any values within this range.
  • EVOH is an ethylene vinyl alcohol copolymer having from 22 to 49 mol % ethylene, or from 22 to 48 mol % ethylene, or from 27 to 44 mol % ethylene, or from 25 to 35 mol % ethylene, or about 24 mol% ethylene, or about 25 mol % ethylene, or about 26 mol % ethylene, or about 27 mol% ethylene, or about 28 mol % ethylene, or about 29 mol % ethylene, or about 30 mol % ethylene, or about 31 mol % ethylene, or about 32 mol % ethylene, or about 33 mol % ethylene, or about 34 mol % ethylene, or about 35 mol % ethylene, or about 36 mol % ethylene, or about 37 mol % ethylene, or about 38
  • the EVOH copolymer is a commercially available copolymer and is sold under the tradename SOARNOL.
  • the EVOH copolymer is a commercially available copolymer (from for example the Mitsubishi Chemical Group) selected from the group consisting of: SOARNOL D2908, SOARNOL DT2904, SOARNOL DC3212, SOARNOL DC3203, SOARNOL E3808, SOARNOL ET3803, SOARNOL A4412, SOARNOL AT4403, and mixtures thereof.
  • the EVOH copolymer is the commercially available copolymer, SOARNOL DT2904.
  • the EVOH copolymer is a commercially available copolymer and is sold under the tradename EVAL.
  • the EVOH copolymer is a commercially available copolymer (from for example Kuraray) selected from the group consisting of: EVAL® M type, EVAL T type, EVAL L type, EVAL F type, EVAL J type, EVAL C type, EVAL H type, EVAL E type, EVAL G type, EVAL SP type, and mixtures thereof.
  • the EVOH copolymer is a commercially available copolymer (from for example Kuraray) selected from the group consisting of: EVAL® L171B, EVAL F101A, EVAL F101B, EVAL F171B, EVAL F104B, EVAL FP101B, EVAL FP104B, EVAL T101A, EVAL J102B, EVAL C109B, EVAL H171B, EVAL E171B, EVAL E105B, EVAL G156B, EVAL SP521B, EVAL SP482B, EVAL SP292B, and mixtures thereof.
  • EVAL® L171B EVAL F101A
  • EVAL F101B EVAL F171B
  • EVAL F104B EVAL FP101B
  • EVAL FP104B EVAL T101A
  • EVAL J102B EVAL C109B
  • EVAL H171B EVAL E171B
  • EVAL E105B EVAL G156B
  • EVAL SP521B EVAL SP48
  • the EVOH copolymer is a commercially available copolymer and is sold under the tradename EVASIN®.
  • the EVOH copolymer is a commercially available copolymer (from for example SK Functional Polymer) selected from the group consisting of: EVASIN® EV 295 IF, EVASIN EV 325 IF, EVASIN EV 3251FT, EVASIN EV 3851F/V, EVASIN EV 4405F, EVASIN EV 445 IF, EVASIN EV 445 IV, and mixtures thereof.
  • SK Functional Polymer commercially available copolymer selected from the group consisting of: EVASIN® EV 295 IF, EVASIN EV 325 IF, EVASIN EV 3251FT, EVASIN EV 3851F/V, EVASIN EV 4405F, EVASIN EV 445 IF, EVASIN EV 445 IV, and mixtures thereof.
  • a polymer processing aid used to aid the extrusion of a thermoplastic polyolefin, comprises an ethylene vinyl alcohol polymer (EVOH).
  • a polymer processing aid used to aid the extrusion of a thermoplastic polyolefin, comprises an ethylene vinyl alcohol polymer (EVOH) having an ethylene content of from about 20 mol percent to about 60 mol percent.
  • EVOH ethylene vinyl alcohol polymer
  • a polymer processing aid used to aid the extrusion of a thermoplastic polyolefin, comprises an ethylene vinyl alcohol polymer (EVOH) having an ethylene content of from about 25 mol percent to about 50 mol percent.
  • EVOH ethylene vinyl alcohol polymer
  • a polymer processing aid used to aid the extrusion of a thermoplastic polyolefin, comprises an ethylene vinyl alcohol polymer (EVOH) having an ethylene content of from about 22 mol percent to about 48 mol percent.
  • EVOH ethylene vinyl alcohol polymer
  • a polymer processing aid used to aid the extrusion of a thermoplastic polyolefin, comprises an ethylene vinyl alcohol polymer (EVOH) having an ethylene content of from about 27 mol percent to about 48 mol percent.
  • EVOH ethylene vinyl alcohol polymer
  • a polymer processing aid used to aid the extrusion of a thermoplastic polyolefin, comprises an ethylene vinyl alcohol polymer (EVOH) having an ethylene content of from about 25 mol percent to about 35 mol percent.
  • EVOH ethylene vinyl alcohol polymer
  • a polymer processing aid used to aid the extrusion of a thermoplastic polyolefin, comprises an ethylene vinyl alcohol polymer (EVOH) having an ethylene content of about 29 mol percent.
  • EVOH ethylene vinyl alcohol polymer
  • the amount of EVOH used as a polymer processing aid will be from 100 to 10,000 parts per million by weight (based on the weight of a thermoplastic polyolefin such as a linear polyethylene) including any sub range within this range and any value within this range. Further optimized PPA addition levels and ranges for a given extrusion process may be readily determined by those skilled in the art.
  • the amount of EVOH used as a polymer processing aid will be from 100 to 7,500 parts per million by weight, or from 100 to 5,000 parts per million by weight, or from 200 to 4,000 parts per million by weight, or from 100 to 3,000 parts per million by weight, or from 200 to 3,000 parts per million by weight, or from 100 to 2,000 parts per million by weight, or from 200 to 2,500 parts per million by weight, or from 300 to 2,500 parts per million by weight, or from 300 to 2,500 parts per million by weight, or from 400 to 2,500 parts per million by weight, or from 500 to 2,500 parts per million by weight, or from 750 to 4,000 parts per million by weight, or from 750 to 3,000 parts per million by weight, or from 750 to 2,500 parts per million by weight, or from 1,000 to 4,000 parts per million by weight, or from 1,000 to 3,000 parts per million by weight, or from 1,000 to 2,500 parts per million by weight, or from 1,000 to 2,250 parts per million by weight, or from 1,000 to 2,000 parts per million
  • PPA polymer processing aid
  • the amount of EVOH used as a polymer processing aid will be from 200 to 1,500 parts per million by weight, or from 300 to 1,500 parts per million, or from 400 to 1,500 parts per million by weight, or from 500 to 1,500 parts per million by weight, or from 750 to 1,500 parts per million by weight, or from 300 to 1,250 parts per million by weight, or from 400 to 1,250 parts per million by weight, or from 500 to 1,250 parts per million by weight, or from 750 to 1,250 parts per million by weight, or from 200 to 1,000 parts per million by weight, or from 300 to 1,000 parts per million, or from 500 to 1,000 parts per million by weight, or from 750 to 1,000 parts per million by weight (based on the weight of the thermoplastic polyolefin such as a linear polyethylene).
  • the amount of EVOH used as a polymer processing aid will be fewer than 1,500 parts per million by weight (based on the weight of the thermoplastic polyolefin), or fewer than 1,250 parts per million by weight, or fewer than 1,000 parts per million by weight, or fewer than 750 parts per million by weight, or fewer than 500 parts per million by weight, or equal to or fewer than 1,000 parts per million by weight, or equal to or fewer than 750 parts per million by weight, or equal to or fewer than 500 parts per million by weight (based on the weight of the thermoplastic polyolefin such as a linear polyethylene).
  • an EVOH copolymer is added to a thermoplastic polyolefin (e.g. a linear polyethylene) using a masterbatch formulation containing the EVOH copolymer.
  • a masterbatch is well known to persons skilled in the art.
  • the term “masterbatch” refers to the practice of first melt mixing an additive, for example, an EVOH copolymer, with a small amount of a given thermoplastic polyolefin (e.g. a linear polyethylene), followed by blending (by for example melt mixing or dry blending) the resulting “masterbatch” with the remaining bulk of the thermoplastic polyolefin (e.g. the linear polymer).
  • from about 0.1 to about 15.0 weight percent, or from about 0.5 to about 15.0 weight percent, or from about 0.5 to about 10.0 weight percent, or from about 0. 1 to about 10.0 weight percent, or from about 0.1 to about 7.5 weight percent, or from about 0.5 to about 7.5 weight percent or from about 0.5 to about 5.0 weight percent, or from about 0.1 to about 5.0 weight percent, or from about 1.0 to about 15.0 weight percent, or from about 1.0 to about 5.0 weight percent, or from about 1.0 to about 7.5 weight percent, or from about 1.0 to about 5.0 weight percent, or from about 0.1 to about 2.5 weight percent, or from about 0.5 to about 2.5 weight percent of a masterbatch will be used in a blend with the bulk polymer (where weight percent of the masterbatch is based on the combined weight of the masterbatch and the bulk polymer).
  • a masterbatch e.g. of a linear polyethylene
  • a masterbatch may contain an amount of EVOH copolymer of up to 10 weight percent (based on the weight of the masterbatch), or from 500 to 75,000 parts per million by weight (based on the weight of the masterbatch) including subranges within this range and any number within this range.
  • a masterbatch may contain an amount of EVOH copolymer in the range of from 500 to 50,000 ppm, or from 500 to 40,000 ppm, or from 500 to 35,000 ppm, or from 500 to 40,000 ppm, or from 500 to 25,000 ppm, or from 1,000 to 40,000 ppm, or from 1,000 to 35,000 ppm, or from 1,000 to 30,000 ppm, or from 1,000 to 25,000 parts per million by weight (based on the weight of the masterbatch), or from 5,000 to 25,000 ppm, or from 1,000 to 20,000 ppm, or from 2,000 to 20,000 ppm, or from 3,000 to 20,000, or from 4,000 to 20,000 ppm, or from 5,000 to 20,000 ppm, or from 5,000 to 17,500, or from 5,000 to 15,000 or from 5,000 to 12,500 ppm, or from 2,500 to 15,000 ppm, or from 5,000 to 15,000 ppm, or from 7,500 to 15,000 ppm, or
  • a polymer processing aid will comprise a poly(oxyalkylene) polymer, also known as polyalkylene glycol (PAG) or polyalkylene oxide.
  • PAG polyalkylene glycol
  • a polymer processing aid will comprise a poly(oxyethylene) polymer, also known as polyethylene glycol (PEG) or polyethylene oxide.
  • PEG polyethylene glycol
  • a polymer processing aid will comprise a poly(oxypropylene) glycol, also known as polypropylene glycol or polypropylene oxide.
  • a poly(oxyalkylene) polymer can in embodiments of the disclosure be represented by formula A[(OR 1 ) x OR 2 ] y , wherein A is typically alkylene interrupted by one or more ether linkages, y is 2 or 3, (OR J ) X is a poly(oxyalkylene) chain having a plurality (x) of oxyalkylene groups, OR 1 , wherein each R 1 is independently C2 to C5 alkylene, in some embodiments, C2 to C3 alkylene, R 2 is hydrogen, alkyl, aryl, arylalkenyl, alkylarylenyl, — C(O)-alkyl, — C(O)-aryl, — C(O)-arylalkenyl, or — C(O)-alkylarylenyl, wherein — C(O) — is bonded to the O of OR 2 .
  • a poly(oxyalkylene) polymer can be a homopolymer such as a poly(oxyethylene) polymer (also called a polyethylene glycol in the present disclosure) in which each R 1 is — CH2CH2 — , or a homopolymer such as a poly(oxypropylene) polymer in which each R 1 is — C3H6 — .
  • a poly(oxyalkylene) polymer is a poly(oxyalkylene) polymer comprising a chain of randomly distributed oxyalkylene groups (e.g., a copolymer comprising — OC2H4 — and — OC3H6 — units) or having alternating blocks of repeating oxyalkylene groups (e.g., a copolymer comprising ( — OC2H4 — )a and ( — OC3H6 — )b blocks, wherein a+b is x).
  • a copolymer comprising ( — OC2H4 — )a and ( — OC3H6 — )b blocks, wherein a+b is x.
  • Poly(oxyalkylene) copolymers comprising randomly distributed, or alternating units of ( — OC2H4 — ) and ( — OC3H6 — ) or blocks of ( — OC2H4 — )a and ( — OC3H6 — )b are sometimes referred to as “poloxamers” and are available commercially under the tradenames PLURONIC®, KOLLIPHOR® and SYNPERONIC®.
  • A is ethylene, — CH2 — CH( — ) — CH2 — (derived from glycerol), CH3CH2C(CH2 — (derived from 1,1,1 -trimethylol propane), poly(oxypropylene), — CH2CH2 — O — CH2CH2 — , or — CH2CH2 — O — CH2CH2 — O — CH2CH2— .
  • R 2 is hydrogen, methyl, butyl, phenyl, benzyl, acetyl, benzoyl, or stearyl.
  • poly(oxyalkylene) polymers are polyesters prepared, for example, from dicarboxylic acids and poly(oxyalkylene) polymers represented by formula A[(OR 1 ) x OR 2 ] y , wherein A, R 1 , and x are as defined above, R 2 is hydrogen, and y is 2.
  • the major proportion of a poly(oxyalkylene) polymer by weight will be the repeating oxyalkylene groups, (OR 1 ).
  • poly(oxyalkylene) polymer is a polyethylene glycol (PEG).
  • PEG polyethylene glycol
  • Polyethylene glycol (PEG) can be represented by formula H(O — CH2CH2 — )xOH.
  • Many polyethylene glycols, as well as their ethers, and their esters are commercially available and they are all contemplated for use in embodiments of the present disclosure.
  • the weight average molecular weights (e.g. Mn and Mw) of a polyalkylene glycol such as a polyethylene glycol (PEG) can be measured, for example, by gel permeation chromatography (i.e., size exclusion chromatography) using narrow molecular weight distribution poly(oxyalkylene) polymers (e.g. polyethylene glycols) as standards with techniques known in the art.
  • a polyalkylene glycol such as a polyethylene glycol (PEG)
  • PEG polyethylene glycol
  • a polyalkylene glycol has a value of x such that the weight average molecular weight, Mw of the polyalkylene glycol polymer is at least about 20,000 g/mol, or at least about 30,000 g/mol, or at least about 40,000 g/mol, or at least about 50,000 g/mol, or at least about 60,000 g/mol.
  • a polyalkylene glycol has a value of x such that the weight average molecular weight, Mw of the polyalkylene glycol polymer has an upper limit of about 500,000 g/mol, or about 450,000 g/mol, or about 400,000 g/mol, or about 350,000 g/mol, or about 300,000 g/mol.
  • a polyalkylene glycol has a value of x such that the weight average molecular weight, Mw of the polyethylene glycol polymer is from about 60,000 g/mol to about 500,000 g/mol, or from about 75,000 g/mol to about 500,000 g/mol, or from about 60,000 g/mol to about 450,000 g/mol, or from about 75,000 g/mol to about 450,000 g/mol, or from about 80,000 g/mol to about 500,000 g/mol, or from about 80,000 g/mol to about 450,000 g/mol, or from about 85,000 g/mol to about 500,000 g/mol, or from about 60,000 g/mol to about 400,000 g/mol, or from about 60,000 g/mol, to about 350,000 g/mol, or from about 70,000 g/mol to about 400,000 g/mol, or from about 70,000 g/mol to about 350,000 g/mol, or from about 100,000 g/mol to about
  • a polyalkylene glycol has a value of x such that the weight average molecular weight, Mw of the polyalkylene glycol polymer is less than 20,000 g/mol, or less than 15,000 g/mol, or less than 10,000 g/mol, or less than 5,000 g/mol.
  • a polyalkylene glycol has a value of x such that the weight average molecular weight, Mw of the polyalkylene glycol polymer is from about 200 g/mol to about 20,000 g/mol, or from about 400 g/mol to about 15,000 g/mol, or from about 400 g/mol to about 10,000 g/mol, or from about 400 g/mol to about 7,500 g/mol, or from about 400 g/mol to about 5,000 g/mol.
  • a polyalkylene glycol has a value of x such that the weight average molecular weight, Mw of the polyalkylene glycol polymer is from about 1,000 g/mol to about 20,000 g/mol, or from about 2,000 g/mol to about 20,000 g/mol, or from about 1,000 g/mol to about 15,000 g/mol, or from about 2,000 g/mol to about 15,000 g/mol, or from about 1,000 g/mol to about 10,000 g/mol, or from about 2,000 g/mol to about 10,000 g/mol.
  • a polyalkylene glycol has a value of x such that the weight average molecular weight, Mw of the polyalkylene glycol polymer is from about 10,000 g/mol to about 50,000 g/mol, or from about 15,000 g/mol to about 50,000 g/mol, or from about 20,000 g/mol to about 50,000 g/mol, or from about 25,000 g/mol to about 50,000 g/mol, or from about 20,000 g/mol to about 40,000 g/mol, or from about 25,000 g/mol to about 35,000 g/mol, or from about 15,000 g/mol to about 35,000 g/mol, or from about 15,000 g/mol to about 30,000 g/mol, or from about 15,000 g/mol to about 25,000 g/mol.
  • a polyethylene glycol (PEG) has a value of x such that the weight average molecular weight, Mw of the polyethylene glycol polymer is at least about 20,000 g/mol, or at least about 30,000 g/mol, or at least about 40,000 g/mol, or at least about 50,000 g/mol, or at least about 60,000 g/mol.
  • a polyethylene glycol (PEG) has a value of x such that the weight average molecular weight, Mw of the polyethylene glycol polymer has an upper limit of about 500,000 g/mol, or about 450,000 g/mol, or about 400,000 g/mol, or about 350,000 g/mol, or about 300,000 g/mol.
  • a polyethylene glycol (PEG) has a value of x such that the weight average molecular weight, Mw of the polyethylene glycol polymer is from about 60,000 g/mol to about 500,000 g/mol, or from about 75,000 g/mol to about 500,000 g/mol, or from about 60,000 g/mol to about 450,000 g/mol, or from about 75,000 g/mol to about 450,000 g/mol, or from about 80,000 g/mol to about 500,000 g/mol, or from about 80,000 g/mol to about 450,000 g/mol, or from about 85,000 g/mol to about 500,000 g/mol, or from about 60,000 g/mol to about 400,000 g/mol, or from about 60,000 g/mol, to about 350,000 g/mol, or from about 70,000 g/mol to about 400,000 g/mol, or from about 70,000 g/mol to about 350,000 g/mol, or from about 100,000 g/mol to about 350,000
  • a polyethylene glycol (PEG) has a value of x such that the weight average molecular weight, Mw of the polyethylene glycol polymer is less than 20,000 g/mol, or less than 15,000 g/mol, or less than 10,000 g/mol, or less than 5,000 g/mol.
  • a polyethylene glycol (PEG) has a value of x such that the weight average molecular weight, Mw of the polyethylene glycol polymer is from about 200 g/mol to about 20,000 g/mol, or from about 400 g/mol to about 15,000 g/mol, or from about 400 g/mol to about 15,000 g/mol, or from about 400 g/mol to about 10,000 g/mol, or from about 400 g/mol to about 7,500 g/mol, or from about 400 g/mol to about 5,000 g/mol.
  • a polyethylene glycol (PEG) has a value of x such that the weight average molecular weight, Mw of the polyethylene glycol polymer is from about 1,000 g/mol to about 20,000 g/mol, or from about 2,000 g/mol to about 20,000 g/mol, or from about 1,000 g/mol to about 15,000 g/mol, or from about 2,000 g/mol to about 15,000 g/mol, or from about 1,000 g/mol to about 10,000 g/mol, or from about 2,000 g/mol to about 10,000 g/mol, 2,000 g/mol to about 8,000 g/mol, 2,000 g/mol to about 5,000 g/mol.
  • a polyethylene glycol (PEG) has a weight average molecular weight, Mw of about 3,350 g/mol.
  • a polyethylene glycol (PEG) has a value of x such that the weight average molecular weight, Mw of the polyethylene glycol polymer is from about 10,000 g/mol to about 50,000 g/mol, or from about 15,000 g/mol to about 50,000 g/mol, or from about 20,000 g/mol to about 50,000 g/mol, or from about 25,000 g/mol to about 50,000 g/mol, or from about 20,000 g/mol to about 40,000 g/mol, or from about 25,000 g/mol to about 35,000 g/mol, or from about 15,000 g/mol to about 35,000 g/mol, or from about 15,000 g/mol to about 30,000 g/mol, or from about 15,000 g/mol to about 25,000 g/mol.
  • a polyethylene glycol has a weight average molecular weight, Mw of at least 20,000 g/mol, or at least 25,000 g/mol.
  • a polyethylene glycol has a weight average molecular weight, Mw of from about 20,000 g/mol to about 50,000 g/mol.
  • a polyethylene glycol has a weight average molecular weight, Mw of about 35,000 g/mol.
  • a polyethylene glycol has a weight average molecular weight, Mw of from about 100,000 g/mol to about 500,000 g/mol, or from about 150,000 g/mol to about 450,000 g/mol, or from about 200,000 g/mol to about 400,000 g/mol.
  • a polyethylene glycol has a weight average molecular weight, Mw of about 300,000 g/mol.
  • a polyethylene glycol (PEG) commercially available under the trademark POLYGLYKOLTM is used as a polymer processing aid.
  • a polyethylene glycol (PEG) commercially available under the trademark CARBOWAX® or PLURIOL® is used as a polymer processing aid.
  • a polymer processing aid will comprise at least two polyalkylene glycols of different weight average molecular weight, M w .
  • a polymer processing aid will comprise at least two polyethylene glycols of different weight average molecular weight, Mw.
  • a polymer processing aid will comprise at least two polyethylene glycols of different weight average molecular weight, M w , where a first polyethylene glycol has a weight average molecular weight, M w , of less than 10,000 g/mol, and a second polyethylene glycol has weight average molecular weight, M w of greater than 25,000 g/mol.
  • a polymer processing aid will comprise at least two polyethylene glycols of different weight average molecular weight, M w , where a first polyethylene glycol has a weight average molecular weight, M w , of less than 25,000 g/mol, and a second polyethylene glycol has weight average molecular weight, Mw of at least 25,000 g/mol.
  • a polymer processing aid will comprise at least two polyethylene glycols of different weight average molecular weight, M w , where a first polyethylene glycol has a weight average molecular weight, M w , of less than 25,000 g/mol, and a second polyethylene glycol has weight average molecular weight, M w of at least 250,000 g/mol.
  • a polymer processing aid will comprise at least two polyethylene glycols of different weight average molecular weight, M w , where a first polyethylene glycol has a weight average molecular weight, M w , of less than 10,000 g/mol, and a second polyethylene glycol has weight average molecular weight, Mw of at least 250,000 g/mol.
  • a polymer processing aid will comprise at least two polyethylene glycols of different weight average molecular weight, M w , where a first polyethylene glycol has a weight average molecular weight, M w , of from about 2,000 to about 10,000 g/mol, and a second polyethylene glycol has weight average molecular weight, Mw of from about 25,000 to about 350,000 g/mol.
  • a polymer processing aid will comprise at least two polyethylene glycols of different weight average molecular weight, M w , where a first polyethylene glycol has a weight average molecular weight, M w , of from about 2,000 to about 10,000 g/mol, and a second polyethylene glycol has weight average molecular weight, M w of from about 15,000 to about 50,000 g/mol.
  • a polymer processing aid will comprise at least two polyethylene glycols of different weight average molecular weight, M w , where a first polyethylene glycol has a weight average molecular weight, Mw, of from about 2,000 to about 10,000 g/mol, and a second polyethylene glycol has weight average molecular weight, M w of from about 15,000 to about 25,000 g/mol.
  • a polymer processing aid will comprise at least two polyethylene glycols of different weight average molecular weight, M w , where a first polyethylene glycol has a weight average molecular weight, M w , of from about 2,000 to about 10,000 g/mol, and a second polyethylene glycol has weight average molecular weight, M w of from about 25,000 to about 50,000 g/mol.
  • a polymer processing aid will comprise at least two polyethylene glycols of different weight average molecular weight, Mw, where a first polyethylene glycol has a weight average molecular weight, M w , of from about 2,000 to about 10,000 g/mol, and a second polyethylene glycol has weight average molecular weight, M w of from about 250,000 to about 350,000 g/mol.
  • a polymer processing aid will comprise at least two polyethylene glycols of different weight average molecular weight, M w , where a first polyethylene glycol has a weight average molecular weight, M w , of less than 10,000 g/mol, and a second polyethylene glycol has weight average molecular weight, M w of greater than 10,000 g/mol.
  • a polymer processing aid will comprise at least two polyethylene glycols of different weight average molecular weight, Mw, where a first polyethylene glycol has a weight average molecular weight, M w , of less than about 10,000 g/mol, and a second polyethylene glycol has weight average molecular weight, M w of at least about 50,000 g/mol.
  • a polymer processing aid will comprise at least two polyethylene glycols of different weight average molecular weight, Mw, where a first polyethylene glycol has a weight average molecular weight, Mw, of from about 2,000 to about 8,000 g/mol, or a first polyethylene glycol has a weight average molecular weight, M w of from 2,000 to 5,000 g/mol; and a second polyethylene glycol has weight average molecular weight, M w of from about 25,000 to about 50,000 g/mol, or a second polyethylene glycol has weight average molecular weight, M w of from 15,000 to 25,000 g/mol.
  • a polymer processing aid will comprise at least two polyethylene glycols of different weight average molecular weight, M w , and the difference in weight average molecular weight, Mw between the at least two polyethylene glycols will be in the range of from 2: 1 to 100,000: 1 including any sub range encompassed within this range and any value within this range.
  • a polymer processing aid will comprise at least two polyethylene glycols of different weight average molecular weight, M w , and the difference in weight average molecular weight, M w between the at least two polyethylene glycols will be in the range of from 5: 1 to 100,000: 1, or from 2: 1 to 1000: 1, or from 5: 1 to 1000: 1, or from 2: 1 to 500: 1, or from 5: 1 to 500: 1, or from 2: 1 to 100: 1, or from 5: 1 to 100: 1.
  • a polymer processing aid will comprise at least two polyethylene glycols of different weight average molecular weight, Mw, and the at least two polyethylene glycols having different M w , will be present in a mole ratio of from 1 :99 to 99: 1 including any sub range encompassed within this range and any value within this range.
  • a polymer processing aid will comprise at least two polyethylene glycols of different weight average molecular weight, M w , in a mole ratio of from 5:95 to 95:5, or from 10:90 to 90: 10, or from 20:80 to 80:20, or from 25:75 to 75:25, or from 35:65 to 65:35, or from 40:60 to 60:40, or about 50:50.
  • the amount of polyalkylene glycol (PAG) or the amount of polyethylene glycol (PEG) used as a polymer processing aid (PPA) will be from 100 to 10,000 parts per million by weight (based on the weight of a thermoplastic polyolefin such as a linear polyethylene) including any sub range within this range and any value within this range. Further optimized PPA addition levels and ranges for a given extrusion process may be readily determined by those skilled in the art.
  • the amount of polyalkylene glycol (PAG) or the amount of polyethylene glycol (PEG) used as a polymer processing aid (PPA) will be from 100 to 7,500 parts per million by weight, or from 100 to 5,000 parts per million by weight, or from 100 to 4,000 parts per million by weight, or 100 to 3,000 parts per million by weight, or from 200 to 3,000 parts per million by weight, or from 100 to 2,000 parts per million by weight, or from 200 to 2,000 parts per million by weight, or from 300 to 2,000 parts per million by weight, or from 400 to 2,000 parts per million by weight, or from 200 to 1,500 parts per million by weight, or from 300 to 1,500 parts per million by weight, or from 400 to 1,500 parts per million by weight, or from 200 to 1,200 parts per million by weight, or from 300 to 1,200 parts per million by weight, or from 400 to 1,200 parts per million by weight (based on the weight of the thermoplastic polyolefin such as a linear polyethylene).
  • a polyalkylene glycol (PAG) or a polyethylene glycol (PEG) is added to a thermoplastic polyolefin (e.g. a linear polyethylene) using a masterbatch formulation containing the PAG or PEG.
  • the term masterbatch is well known to persons skilled in the art.
  • the term “masterbatch” refers to the practice of first melt mixing an additive, for example, a PEG, with a small amount of a given thermoplastic polyolefin (e.g. a linear polyethylene), followed by blending (by for example melt mixing or dry blending) the resulting “masterbatch” with the remaining bulk of the thermoplastic polyolefin (e.g. the linear polymer).
  • from about 0.1 to about 15.0 weight percent, or from about 0.5 to about 15.0 weight percent, or from about 0.5 to about 10.0 weight percent, or from about 0. 1 to about 10.0 weight percent, or from about 0.1 to about 7.5 weight percent, or from about 0.5 to about 7.5 weight percent or from about 0.5 to about 5.0 weight percent, or from about 0.1 to about 5.0 weight percent, or from about 1.0 to about 15.0 weight percent, or from about 1.0 to about 5.0 weight percent, or from about 1.0 to about 7.5 weight percent, or from about 1.0 to about 5.0 weight percent, or from about 0.1 to about 2.5 weight percent, or from about 0.5 to about 2.5 weight percent of a masterbatch will be used in a blend with the bulk polymer (where weight percent of the masterbatch is based on the combined weight of the masterbatch and the bulk polymer).
  • a masterbatch e.g. of a linear polyethylene
  • a masterbatch may contain an amount of PAG or PEG of up to 10 weight percent (based on the weight of the masterbatch) or in the range of from 500 to 75,000 parts per million by weight (based on the weight of the masterbatch) including subranges within this range and any number within this range.
  • a masterbatch may contain an amount of PAG or PEG in the range of from 500 to 50,000 ppm, or from 500 to 40,000 ppm, or from 500 to 35,000 ppm, or from 500 to 40,000 ppm, or from 500 to 25,000 ppm, or from 1,000 to 40,000 ppm, or from 1,000 to 35,000 ppm, or from 1,000 to 30,000 ppm, or from 1,000 to 25,000 parts per million by weight (based on the weight of the masterbatch), or from 5,000 to 25,000 ppm, or from 1,000 to 20,000 ppm, or from 2,000 to 20,000 ppm, or from 3,000 to 20,000, or from 4,000 to 20,000 ppm, or from 5,000 to 20,000 ppm, or from 5,000 to 17,500, or from 5,000 to 15,000 or from 5,000 to 12,500 ppm, or from 2,500 to 15,000 ppm, or from 5,000 to 15,000 ppm, or from 7,500 to 15,000 ppm, or from 7,
  • the polyalkylene glycol or the polyethylene glycol used as a polymer processing aid (PPA) may be used in the form of a semi solid or a viscous liquid, or as powders, pellets, or granules.
  • PPA polymer processing aid
  • LDPE High Pressure Low Density Polyethylene
  • a polymer processing aid will comprise a high pressure low density polyethylene, LDPE.
  • high pressure low density polyethylene is an ethylene homopolymer and is prepared by the free radical homopolymerization of ethylene.
  • LDPE has high degrees of so called long chain branching (which may be as long as the main polymer backbone) and which gives the LDPE a non-linear microstructure.
  • high pressure low density polyethylene LDPE
  • linear polyethylene which is made using ethylene polymerization catalysts, as further described below, and which has a linear polymer microstructure. Further description of the high pressure low density polyethylene, LDPE used in the present disclosure is found in the Kirk-Othmer Encyclopedia of Chemical Technology, in the chapter titled Polyethylene, Low Density by Norma Maraschin, First Published March 18, 2005, which description is incorporated herein in its entirety by reference.
  • a high pressure low density polyethylene is prepared in either a tubular reactor or an autoclave reactor.
  • a tubular reactor operates in a continuous mode and at high pressures and temperatures.
  • Typical operating pressures for a tubular reactor are from 2000 to 3500 bar. Operating temperatures can range from 140 to 340°C.
  • the reactor is designed to have a large length to diameter ratio (for example, from 400 to 40,000) and may have multiple reaction zones which take the shape of an elongated coil. High gas velocities (at least 10 m/s) are used to provide optimal heat transfer. Conversions for multi-zone systems are typically 22 to 30% per pass but can be as high as 36 to 40%.
  • Tubular reactors may have multiple injection points for the addition of monomer or initiators to different reaction zones having different temperatures.
  • An autoclave reactor may have a length to diameter ratio of between 2 and 20 and may be single stage or multistage.
  • low temperature ethylene is passed into a hot reaction zone and conversion may be controlled by the temperature differential between the incoming ethylene gas and the temperature of the autoclave reactor. Conversions are usually lower in an autoclave reactor, up to 23% per pass, than in a tubular reactor which has a higher capacity to remove the heat of polymerization.
  • Typical operating pressures for autoclave reactors are from 1,100 to 2,000 bar. Average operating temperatures are from 220 to 300°C, but temperatures can be as high as 340°C.
  • a wide variety of initiators may be used with each type of reactor to initiate the free radical polymerization of ethylene.
  • Initiators may include oxygen or one or more organic peroxides such as but not limited to di-tert-butylperoxide, cumuyl peroxide, tert-butyl- peroxypivalate, tert-butyl hydroperoxide, benzoyl peroxide, tert-amyl peroxypivalate, tertbutyl -peroxy-2 -ethylhexanoate, and decanoyl peroxide.
  • Chain transfer reagents may also be used with each type of reactor to control the polymer melt index. Chain transfer reagents include but are not limited to propane, n-butane, n-hexane, cyclohexane, propylene, 1-butene, and isobutylene.
  • the LDPE has a density of from about 0.910 g/cm 3 to about 0.940 g/cm 3 , including sub ranges within this range or any value within this range.
  • the LDPE has a density of from about 0.914 g/cm 3 to about 0.930 g/cm 3 , or from about 0.916 g/cm 3 to about 0.930 g/cm 3 , or from about 0.920 g/cm 3 to about 0.940 g/cm 3 , or from about 0.920 g/cm 3 to about 0.930 g/cm 3 .
  • the LDPE used in the present disclosure will have a melt index, h of from 0.1 to 20.0 g/lOmin, or from 0.1 to 15.0 g/lOmin, or from 0.1 to 10.0 g/10 min.
  • the LDPE used in the present disclosure will have a melt index, h of at least 1.0 g/lOmin, or at least 2.0 g/lOmin, or at least 2.5 g/lOmin, or at least 3.0 g/lOmin.
  • the LDPE used in the present disclosure will have a melt index, h of from 1.0 to 10.0 g/lOmin, or from 1.5 to 10.0 g/lOmin, or from 2.0 to 10 g/lOmin, or from 2.5 to 10.0 g/lOmin, or from 3.0 to 10.0 g/lOmin, or from 3.5 to 10.0 g/lOmin, or from 4.0 to 10.0 g/lOmin, or from 2.5 to 9.0 g/lOmin, or from 2.5 to 8.5 g/lOmin, or from 2.5 to 8.0 g/lOmin, or from 3.0 to 9.0 g/lOmin, or from 3.0 to 8.5 g/lOmin, or from 3.0 to 8.0 g/lOmin, or from 3.5 to 9.0 g/lOmin, or from 3.5 to 8.5 g/lOmin, or from 3.5 to 8.0 g/lOmin, or from 4.0 to 9.0 g/lOmin, or from
  • the LDPE used in the present disclosure will have a melt index, h of below 1.0 g/10 min. Such a LDPE may be referred to as a “frac melt” LDPE material. In further embodiments, the LDPE used in the present disclosure will have a melt index, h of from 0.01 to 1.0 g/10 min, or from 0.01 to below 1.0 g/10 min.
  • a high pressure low density polyethylene is a blend of LDPE materials having different densities and/or different melt indices, h’s.
  • low density polyethylene LDPE is a blend of LDPE made in a tubular reactor and LDPE made in an autoclave reactor.
  • a LDPE polymer blend is prepared by physically blending different high pressure LDPEs (e.g. a LDPE produced in a tubular reactor with the LDPE produced in an autoclave reactor). Physically blending is meant to encompass those processes in which two or more individual ethylene homopolymers are mixed after they are removed from a polymerization reaction zone. Physically blending of the individual LDPEs may be accomplished by dry blending (e.g. tumble blending), extrusion blending (coextrusion), solution blending, melt blending or any other similar blending technique known to those skilled in the art.
  • MWD molecular weight distribution
  • M w /M n also known as molecular weight distribution (MWD)
  • MWD is defined as the weight average molecular weight, M w divided by the number average molecular weight, M n .
  • the MWD of LDPE may in embodiments the disclosure be determined by gel permeation chromatography (GPC)-viscometry.
  • GPC-viscometry technique was based on the method of ASTM D6474-99 and uses a dual refractometer/viscometer detector system to analyze polymer samples. This approach allows for the online determination of intrinsic viscosities and is well known to those skilled in the art.
  • the LDPE has a MWD of greater than about 5.0. In embodiments of the disclosure, the LDPE has a MWD of from about 8.0 to about 30.0.
  • the molecular weight of the of the LDPE or blends thereof can further be described as unimodal, bimodal or multimodal.
  • unimodal it is meant that the molecular weight distribution, can be said to have only one maximum in a molecular weight distribution curve.
  • a molecular weight distribution curve can be generated according to the method of ASTM D6474-99.
  • bimodal it is meant that the molecular weight distribution, can be said to have two maxima in a molecular weight distribution curve.
  • multi-modal denotes the presence of more than two maxima in such a curve.
  • the LDPE used has a unimodal, bimodal or multimodal molecular weight distributions.
  • the LDPE used is made in a tubular reactor and has a multimodal molecular weight distribution.
  • the LDPE used is made in an autoclave reactor and has a bimodal or multimodal molecular weight distribution.
  • a blend of LDPEs is used and the blend has a multimodal molecular weight distribution.
  • Antioxidants packages for stabilizing LDPE in embodiments of the disclosure are well known in the art and may include a phenolic and a phosphite compound.
  • Two nonlimiting examples of a phenolic and phosphite stabilizer which may be added to a LDPE in embodiments of the disclosure are sold under the trade names IRGANOX® 1076 and IRGAFOS® 168 respectively.
  • the phenolic compound is sometimes referred to as the “primary” antioxidant.
  • the phosphite compound is sometimes referred to as the “secondary” antioxidant.
  • the levels of antioxidant present in a LDPE are from 0 to 2,000 parts per million, ppm, by weight (based on the weight of the LDPE). In further embodiments, the amounts of antioxidant present in a LDPE are from 0 to 1,000 ppm, or from 0 to 500 ppm, or from 0 to 300 ppm, by weight (based on the weight of the LDPE).
  • the LDPE may be used in the form of powders, pellets, granules, or in any other extrudable form.
  • the amount of LDPE used as a polymer processing aid is relatively low relative to the weight of the bulk thermoplastic polyolefin material (e.g. the linear polyethylene). Accordingly, in embodiments of the disclosure, the LDPE is used in an amount which makes up from 1.0 to 25.0 weight percent of the total weight of the LDPE and the bulk thermoplastic polyolefin (e.g. a linear polyolefin), including sub ranges within this range and any value within this range.
  • the amount of LDPE will make up from 1.0 to 20.0 weight percent, or from 3.0 to 20.0 weight percent, or from 5.0 to 20.0 weight percent, or from 5.0 to 15.0 weight percent, or from 5.0 to 12.5 weight percent, or from 7.5 to 12.5 weight percent, or from 7.5 to 15.0 weight percent, or from 7.5 to 20.0 weight percent, or from 3.0 to 17.5 weight percent, or from 3.0 to 15.0 weight percent, or from 2.5 to 20.0 weight percent, or from 2.5 to 15.0 weight percent, or from 2.5 to 12.5 weight percent, or from 3.0 to 12.5 weight percent, or from greater than 0 to 20.0 weight percent, or from greater than 0 to 15.0 weight percent of from greater than 0 to 12.5 weight percent, of the total weight of the LDPE and the thermoplastic polyolefin (e.g. the linear polyethylene).
  • the thermoplastic polyolefin e.g. the linear polyethylene
  • Thermoplastic Polyolefin (E.g, A Linear Polyethylene)
  • an extrudable or extruded thermoplastic composition comprises: a linear polyethylene; and an ethylene vinyl alcohol copolymer (EVOH).
  • an extrudable or extruded thermoplastic composition comprises: a linear polyethylene; an ethylene vinyl alcohol copolymer (EVOH); and one or more of: a poly(oxyalkylene) polymer, also known as polyalkylene glycol (PAG); and a high pressure low density polyethylene (LDPE).
  • a poly(oxyalkylene) polymer also known as polyalkylene glycol (PAG)
  • PAG polyalkylene glycol
  • LDPE high pressure low density polyethylene
  • an extrudable or extruded thermoplastic composition comprises: a linear polyethylene; an ethylene vinyl alcohol copolymer (EVOH); and a poly(oxyalkylene) polymer, also known as polyalkylene glycol (PAG).
  • an extrudable or extruded thermoplastic composition comprises: a linear polyethylene; an ethylene vinyl alcohol copolymer (EVOH); and a poly(oxyethylene) polymer, also known as polyethylene glycol (PEG).
  • EVOH ethylene vinyl alcohol copolymer
  • PEG poly(oxyethylene) polymer
  • an extrudable or extruded thermoplastic composition comprises: a linear polyethylene; and an ethylene vinyl alcohol copolymer (EVOH); but is substantially free of fluoropolymers, fluoroelastomers, and other perfluorinated alkane or alkene derivatives.
  • EVOH ethylene vinyl alcohol copolymer
  • an extrudable or extruded thermoplastic composition comprises: a linear polyethylene; an ethylene vinyl alcohol copolymer (EVOH); and one or more of: a poly(oxyalkylene) polymer, also known as polyalkylene glycol (PAG); and a high pressure low density polyethylene (LDPE); but is substantially free of fluoropolymers, fluoroelastomers, and other perfluorinated alkane or alkene derivatives.
  • a poly(oxyalkylene) polymer also known as polyalkylene glycol (PAG)
  • LDPE high pressure low density polyethylene
  • an extrudable or extruded thermoplastic composition comprises: a linear polyethylene; an ethylene vinyl alcohol copolymer (EVOH); and a poly(oxyalkylene) polymer, also known as polyalkylene glycol (PAG); but is substantially free of fluoropolymers, fluoroelastomers, and other perfluorinated alkane or alkene derivatives.
  • an extrudable or extruded thermoplastic composition comprises: a linear polyethylene; an ethylene vinyl alcohol copolymer (EVOH); and a poly(oxyethylene) polymer, also known as polyethylene glycol (PEG); but is substantially free of fluoropolymers, fluoroelastomers, and other perfluorinated alkane or alkene derivatives.
  • substantially free it is meant that fluoropolymers, fluoroelastomers, and other perfluorinated alkane or alkene derivatives will be present in amounts below that which can improve the melt defect (e.g. melt fracture) performance of a thermoplastic composition during a melt extrusion process.
  • melt defect e.g. melt fracture
  • fluoropolymers, fluoroelastomers, and other perfluorinated alkane or alkene derivatives will be less than about 1 percent by weight, or less than about 0.5 percent by weight, or less than 0.1 percent by weight, or less than 500 parts per million, or less than 100 ppm, or less than 90 ppm, or less than 75 ppm, or less than 50 ppm, or less than 25 ppm, or less than 10 ppm, or about 0 weight percent, or about 0 ppm, of an extrudable or extruded thermoplastic composition.
  • the extrudable or extruded thermoplastic composition will have 0 percent by weight of fluoropolymers, fluoroelastomers, and other perfluorinated alkane or alkene derivatives (based on the weight of an extrudable or extruded thermoplastic composition).
  • a major or predominant component in an extrudable or extruded thermoplastic composition will be a linear polyethylene.
  • such an “extrudate” will comprise a linear polyethylene in an amount of at least about 70% by weight, or at least about 75% by weight, or at least about 80% by weight, or at least about 85% by weight, or at least about 90% by weight, or at least about 95% by weight, of the extrudate composition.
  • extrudable or extruded thermoplastic composition may, in embodiments of the disclosure, comprise a mixture of more than one different type of linear polyethylene.
  • a linear polyethylene is distinct from a high pressure low density polyethylene, LDPE, which (by virtue of the presence of large amounts of long chain branching) has a branched polymer microstructure and is made in a high pressure free radical polymerization process.
  • Linear polyethylene is made using transition metal based olefin polymerization catalysts and has a linear polymer microstructure.
  • Olefin polymerization catalysts for use in the preparation of linear polyethylene are well known in the art: linear polyethylene can be made using so called single site polymerization catalysts, or multi-site polymerization catalysts. Multi-site polymerization catalysts, such as Ziegler-Natta catalysts and Phillips (chromium based) catalysts are well known by persons skilled in the art.
  • Single site catalysts such as metallocene catalysts, constrained geometry catalysts, phosphinimine catalysts, and catalysts having tetradentate ligands, are also well known by persons skilled in the art.
  • Linear polyethylenes include homogeneously branched linear ethylene polymers such as those described in U.S. Pat. No. 3,645,992; heterogeneously branched linear ethylene polymers such as those described in U.S. Pat. No. 4,076,698; and homogeneously branched linear ethylene polymers containing long chain branching (but less long chain branching than a LDPE), sometimes referred to as “substantially linear ethylene polymers” which are described in U.S. Pat. Nos. 5,272,236, 5,278,272, 5,582,923, and 5,733,155; and/or blends thereof.
  • homogeneously branched refers to linear ethylene copolymers in which the a-olefin comonomer is randomly distributed within the copolymer molecule, substantially all of the copolymer molecules have the same ethylene-to-a-olefin monomer ratio, and the ethylene copolymer is characterized by a relatively narrow short chain branching distribution as indicated by, for example, a composition distribution index, CDBLo of greater than about 50 percent by weight, or in some embodiments greater than about 75 percent by weight, or greater than about 80 percent by weight, or greater than about 90 percent by weight.
  • Homogeneously branched ethylene copolymers are generally prepared using single site olefin polymerization catalysts.
  • heterogeneously branched is used herein to refer to linear ethylene copolymers characterized by a relatively broad short chain branching distribution as indicated by, for example, a composition distribution index, CDBLo of less than about 75 percent by weight, or in some embodiments less than about 50 percent by weight.
  • CDBLo composition distribution index
  • Heterogeneously branched ethylene copolymers are generally prepared using multi-site olefin polymerization catalysts.
  • R 3 is a hydrocarbon group having up to 10 carbon atoms.
  • R 3 is a hydrocarbon group having from one to six carbon atoms, and may for example be an aromatic group such as a phenyl group (i.e. styrene as alpha olefin), or a n-hexyl group (i.e. 1 -octene as alpha olefin).
  • a linear polyethylene is an ethylene homopolymer or an ethylene copolymer.
  • an ethylene copolymer comprises polymerized ethylene and one or more than one polymerized alpha olefin selected from the group comprising C3-C12 alpha olefins.
  • an ethylene copolymer comprises polymerized ethylene and one or more than one polymerized alpha olefin selected from the group comprising C3-C12 alpha olefins, and polymerized ethylene comprises at least 85 weight percent of the ethylene copolymer.
  • an ethylene copolymer comprises polymerized ethylene and one or more than one polymerized alpha olefin selected from the group comprising C3-C12 alpha olefins, and polymerized ethylene comprises at least 90 weight percent of the ethylene copolymer.
  • an ethylene copolymer comprises polymerized ethylene and one or more than one polymerized alpha olefin selected from the group comprising propylene, 1-butene, 1-hexene, 1-octene, I -decene, 4-methyl-l -pentene, and 1 -octadecene.
  • an ethylene copolymer comprises polymerized ethylene and one or more than one polymerized alpha olefin selected from the group comprising 1-butene, 1-hexene, and 1-octene.
  • an ethylene copolymer comprises polymerized ethylene and one or more than one alpha olefin selected from the group comprising 1- butene, 1-hexene, and 1-octene, and polymerized ethylene comprises at least 85 weight percent of the ethylene copolymer.
  • an ethylene copolymer comprises polymerized ethylene and one or more than one polymerized alpha olefin selected from the group comprising 1-butene, 1-hexene, and 1-octene, and polymerized ethylene comprises at least 90 weight percent of the ethylene copolymer.
  • the linear polyethylene may be prepared by using one or more olefin polymerization catalysts in any conventionally known processes, such as gas phase polymerization, slurry phase polymerization or solution phase polymerization.
  • a transition metal polymerization catalyst may be immobilized on a suitable support material, and the resulting particulate catalyst may be employed in a fluidized bed polymerization process.
  • a fluidized bed gas phase polymerization reactor employs a “bed” of polymer and catalyst particles which is fluidized by a flow of monomer and other optional components which are at least partially gaseous. Heat is generated by the enthalpy of polymerization of the monomer (and optional comonomer(s)) flowing through the bed.
  • Un-reacted monomer and other optional gaseous components exit the fluidized bed and are contacted with a cooling system to remove this heat.
  • the cooled gas stream including monomer, and optional other components (such as condensable liquids), is then re-circulated through the polymerization zone, together with “make-up” monomer to replace that which was polymerized on the previous pass. Simultaneously, polymer product is withdrawn from the reactor.
  • the “fluidized” nature of the polymerization bed helps to evenly distribute/mix the heat of reaction and thereby minimize the formation of localized temperature gradients.
  • the reactor pressure in a gas phase process may vary from about atmospheric to about 600 psig. In another embodiment, the pressure can range from about 100 psig (690 kPa) to about 500 psig (3448 kPa). In yet another embodiment, the pressure can range from about 200 psig (1379 kPa) to about 400 psig (2759 kPa). In still another embodiment, the pressure can range from about 250 psig (1724 kPa) to about 350 psig (2414 kPa).
  • a transition metal polymerization catalyst may be immobilized on a suitable support material, and the resulting particulate catalyst may be employed in a slurry phase polymerization process.
  • Slurry phase polymerization processes are conducted in the presence of a hydrocarbon diluent such as an alkane (including for example isoalkanes), an aromatic or a cycloalkane.
  • the diluent may also be the alpha olefin comonomer used in copolymerizations.
  • alkane diluents include propane, butanes, (i.e.
  • the polymerization temperature is from about 5°C to about 200°C, or less than about 120°C, or from about 10°C to about 100°C.
  • the reaction temperature is selected so that an ethylene or alpha olefin homopolymer or copolymer is produced in the form of solid particles.
  • the reaction pressure is influenced by the choice of diluent and reaction temperature.
  • the pressures may range from 15 to 45 atmospheres (about 220 to 660 psi or about 1,500 to about 4,600 kPa) when isobutane is used as diluent to approximately twice that (i.e. from 30 to 90 atmospheres - about 440 to 1,300 psi or about 3,000-9,100 kPa) when propane is used.
  • the pressure in a slurry process must be kept sufficiently high to keep at least part of the ethylene and/or alpha olefin to be polymerized in the liquid phase.
  • the reaction typically takes place in a jacketed closed loop reactor having an internal stirrer (e.g. an impeller) and at least one settling leg.
  • Catalyst, monomers and diluents are fed to the reactor as liquids or suspensions.
  • the slurry circulates through the reactor and the jacket is used to control the temperature of the reactor.
  • the slurry enters a settling leg and then is let down in pressure to flash the diluent and unreacted monomers and recover the polymer generally in a cyclone.
  • the diluent and unreacted monomers are recovered and recycled back to the reactor.
  • Solution polymerization processes for the polymerization or copolymerization of olefins such as ethylene and alpha olefins are well known in the art. Solution processes are generally conducted in the presence of an inert hydrocarbon solvent in which the resultant polyolefin is soluble under the polymerization conditions employed.
  • the solvent used in a solution phase polymerization process is selected from the group consisting of C5-12 hydrocarbons which may be unsubstituted or substituted by C1-4 alkyl group, and include hydrocarbon solvents such as pentane, methyl pentane, hexane, heptane, octane, cyclohexane, methylcyclohexane and hydrogenated naphtha.
  • a suitable solvent for use in embodiments of the present disclosure and which is commercially available is “ISOPAR® E” (Cs-12 aliphatic solvent, Exxon Chemical Co.).
  • the polymerization temperature in a conventional solution process may be from about 80°C to about 300°C.
  • the polymerization temperature in a solution process is from about 120°C to about 250°C.
  • the polymerization pressure in a solution process may be a “medium pressure process”, meaning that the pressure in the reactor is less than about 6,000 psi (about 42,000 kiloPascals or kPa).
  • the polymerization pressure in a solution process may be from about 10,000 to about 40,000 kPa, or from about 14,000 to about 22,000 kPa (i.e. from about 2,000 psi to about 3,000 psi).
  • the monomers are dissolved/dispersed in the solvent either prior to being fed to the reactor (or for gaseous monomers the monomer may be fed to the reactor so that it will dissolve in the reaction mixture).
  • the solvent and monomers Prior to mixing, are generally purified to remove potential catalyst poisons such as water, oxygen or metal impurities.
  • the feedstock purification follows standard practices in the art, e.g. molecular sieves, alumina beds and oxygen removal catalysts are used for the purification of monomers.
  • the solvent itself as well e.g. methyl pentane, cyclohexane, hexane or toluene
  • the feedstock may be heated or cooled prior to feeding to the reactor.
  • the olefin polymerization catalyst components may be premixed in the solvent for the reaction or fed as separate streams to a solution phase polymerization reactor. In some instances, premixing may be desirable to provide a reaction time for the catalyst components prior to entering the reaction.
  • premixing may be desirable to provide a reaction time for the catalyst components prior to entering the reaction.
  • Solution phase polymerization processes can be carried out in one or more stirred tank reactors (e.g. a continuously stirred tank reactor), loop reactors or the like, and these reactors can be configured in series or in parallel with one another.
  • stirred tank reactors e.g. a continuously stirred tank reactor
  • loop reactors or the like e.g. a continuously stirred tank reactor
  • these reactors can be configured in series or in parallel with one another.
  • linear polyethylenes employed in embodiments of the present disclosure include, linear low density polyethylene (LLDPE), medium density polyethylene (MDPE), high density polyethylene (HDPE), and very low density polyethylene (VLDPE).
  • LLDPE linear low density polyethylene
  • MDPE medium density polyethylene
  • HDPE high density polyethylene
  • VLDPE very low density polyethylene
  • a high density polyethylene is an ethylene homopolymer or an ethylene copolymer with another alpha olefin (such as, for example, 1- butene, 1-hexene, and/or 1-octene) and has a density of about 0.949 g/cm 3 or greater.
  • a HDPE is an ethylene homopolymer or an ethylene copolymer with another alpha olefin (such as, for example, 1 -butene, 1-hexene, and/or 1-octene) having a density of at least 0.950 g/cm 3 , or at least 0.951 g/cm 3 , or at least 0.952 g/cm 3 , or at least 0.953 g/cm 3 .
  • alpha olefin such as, for example, 1 -butene, 1-hexene, and/or 1-octene
  • a HDPE is an ethylene homopolymer or an ethylene copolymer with another alpha olefin (such as, for example, 1-butene, 1-hexene, and/or 1-octene) having a density of from about 0.950 g/cm 3 to about 0.970 g/cm 3 , or from about 0.950 g/cm 3 to about 0.965 g/cm 3 .
  • alpha olefin such as, for example, 1-butene, 1-hexene, and/or 1-octene
  • linear low density polyethylene is an ethylene copolymer with another alpha olefin (such as, for example, 1-butene, 1-hexene, and/or 1- octene) and has a density of from about 0.910 g/cm 3 to about 0.940 g/cm 3 including subranges within this range or any value within this range.
  • a LLDPE has a density of from 0.910 to 0.936 g/cm 3 , or from 0.912 to 0.936 g/cm 3 , or from 0.910 to 0.932 g/cm 3 , or from 0.912 to 0.932 g/cm 3 .
  • medium density polyethylene is an ethylene copolymer with another alpha olefin (such as, for example, 1 -butene, 1 -hexene, and/or 1- octene) and has a density of from about 0.940 g/cm 3 to about 0.949 g/cm 3 including subranges within this range or any value within this range.
  • alpha olefin such as, for example, 1 -butene, 1 -hexene, and/or 1- octene
  • very low density polyethylene is an ethylene copolymer with another alpha olefin (such as propylene, 1 -butene, 4-methyl-l -pentene, 1 -hexene, and/or 1-octene) and has a density of less than about 0.910 g/cm 3 and may include so called elastomers and plastomers.
  • alpha olefin such as propylene, 1 -butene, 4-methyl-l -pentene, 1 -hexene, and/or 1-octene
  • a VLDPE is an ethylene copolymer with another alpha olefin (such as, for example, propylene, 1 -butene, 4-methyl-l -pentene 1- hexene, and/or 1-octene) having a density of from about 0.880 g/cm 3 to about 0.910 g/cm 3 , or from about 0.880 g/cm 3 to about 0.905 g/cm 3 , or from about 0.880 g/cm 3 to about 0.902 g/cm 3 .
  • another alpha olefin such as, for example, propylene, 1 -butene, 4-methyl-l -pentene 1- hexene, and/or 1-octene
  • a linear polyethylene has a density of from 0.900 to 0.955 g/cm 3 , or from 0.900 to 0.950 g/cm 3 .
  • a linear polyethylene is selected from the group consisting of linear low density polyethylene (LLDPE), medium density polyethylene (MDPE), high density polyethylene (HDPE), very low density polyethylene (VLDPE) and mixtures thereof.
  • LLDPE linear low density polyethylene
  • MDPE medium density polyethylene
  • HDPE high density polyethylene
  • VLDPE very low density polyethylene
  • the linear polyethylene may have a weight average molecular weight, M w of at least about 10,000 g/mol, and up to about 1,500,000 g/mol including any sub range within this range or any value within this range.
  • the linear polyethylene has a weight average molecular weight, Mw, of from about 50,000 to about 1,000,000 g/mol, or from about 100,000 to about 1,000,000 g/mol, or from about 75,000 to about 750,000 g/mol, or from about 100,000 to about 750,000 g/mol, or from about 75,000 to about 500,000 g/mol, or from about 100,000 to about 500,000 g/mol, or from about 50,000 to about 350,000 g/mol, or from about 75,000 to about 350,000 g/mol, or from about 100,000 to about 350,000 g/mol, or from about 50,000 to about 300,000 g/mol, or from about 75,000 to about 300,000 g/mol, or from about 100,000 to about 300,000 g/mol, or from about 50,000 to about 250,000 g/mol, or from about 75,000 to about 250,000 g/mol, or from about 100,000 to about 250,000 g/mol.
  • Mw weight average molecular weight
  • the linear polyethylene has a molecular weight distribution, M w /M n of from about 2.0 to about 12.0, including sub ranges within this range or any value within this range.
  • the linear polyethylene has a M w /M n value of from about 2.0 to about 10.0, or from about 2.0 to about 8.0, or from about 2.0 to about 5.0.
  • a linear polyethylene is characterized by its melt index, h, as determined by ASTM D1238, Condition E, at 190°C.
  • a linear polyethylene has a melt index, h of from 0.1 to 20.0 g/lOmin, including any sub range within this range or any value within this range.
  • a linear polyethylene has a melt index, h of from 0.
  • 1 to 15.0 g/lOmin or from 0.1 to 10.0 g/lOmin, or from 0.3 to 15.0 g/lOmin, or from 0.3 to 10.0 g/lOmin, or from 0.1 to 5.0 g/lOmin or from 0.3 to 5.0 g/lOmin, or from 0.5 to 15.0 g/lOmin, or from 0.5 to 10.0 g/lOmin, or from 0.5 to 5.0 g/lOmin.
  • a linear polyethylene selected from the group consisting of LLDPE, MDPE, HDPE, VLPDE and mixtures thereof, may be used in the form of powders, pellets, granules, or in any other extrudable form.
  • a linear polyethylene is a LLDPE.
  • a linear polyethylene is a LLDPE having a melt index, h of from 0.1 to 10.0 g/lOmin, or from 0.5 to 5.0 g/lOmin.
  • a linear polyethylene is a LLDPE having a density of from about 0.910 g/cm 3 to about 0.936 g/cm 3 and a melt index, h of from 0. 1 to 10.0 g/lOmin.
  • a linear polyethylene is a LLDPE having a density of from about 0.910 g/cm 3 to about 0.936 g/cm 3 and a melt index, h of from 0. 1 to 5.0 g/lOmin.
  • a linear polyethylene is a LLDPE having a molecular weight distribution, M w /M n of from about 2.0 to about 12.0, including sub ranges within this range or any value within this range.
  • a LLDPE has a Mw/Mn value of from about 2.0 to about 10.0, or from about 2.0 to about 8.0, or from about 2.0 to about 5.0.
  • a linear polyethylene will comprise small amounts, defined as ⁇ 3.0 weight percent (wt%, based on the total weight of the linear polymer and the LDPE) of a high pressure low density polyethylene, LDPE having a melt index of below about 1.0 g/lOmin.
  • a homogeneously branched linear polyethylene will comprise small amounts, defined as ⁇ 3.0 weight percent (wt%, based on the total weight of the linear polymer and the LDPE), of a high pressure low density polyethylene, LDPE having a melt index of below about 1.0 g/lOmin.
  • the presence of small amounts of a LDPE having a melt index of below about 1.0 g/lOmin may be useful in various end use applications.
  • thermoplastic compositions in a wide variety of extrusion processes such as profile extrusion in which an extruded part such as a pipe or profiled part is prepared by extruding molten plastic through a shaped die) and film extrusion (in which plastic film is prepared by extruding molten plastic through a slit or annular die).
  • a film extrusion process such as for example, a “blown film” extrusion process is employed.
  • a blown film extrusion process is described in more detail below in the Examples section.
  • a cast extrusion process such as for example, a “cast film” extrusion process is employed.
  • the polyolefin e.g. the linear polyethylene
  • the polyolefin may contain a pigment/filler such as carbon black and other adjuvants.
  • thermoplastic polyolefin such as a linear polyethylene
  • used in the present disclosure may further include fillers, antioxidants (such as a primary and optionally a secondary antioxidant), pigments, opacifying agents, static control agents such as glycerol monostearate, lubricants such as fatty acid esters, light stabilizers (such as hindered amine light stabilizers), zinc oxide, antiblock agents and other adjuvants.
  • antioxidants such as a primary and optionally a secondary antioxidant
  • pigments such as a primary and optionally a secondary antioxidant
  • static control agents such as glycerol monostearate
  • lubricants such as fatty acid esters
  • light stabilizers such as hindered amine light stabilizers
  • zinc oxide antiblock agents and other adjuvants.
  • an antioxidant (a primary antioxidant alone or optionally a primary antioxidant in combination with a secondary antioxidant) is added to a polyolefin (e.g. a linear polyethylene) and is added in an amount from about 0.01 to about 2 weight percent, or from about 0.01 to about 1 weight percent.
  • a linear polyethylene comprises a primary antioxidant, and a secondary antioxidant.
  • a linear polyethylene comprises a hindered phenol primary antioxidant, and a phosphorus-containing secondary antioxidant.
  • additives which may in embodiments be added to a thermoplastic polyolefin, such as a linear polyethylene is provided below, including: primary antioxidants; secondary antioxidants; UV absorbers and light stabilizers; polyamide stabilizers; basic co-stabilizers; nucleating agents; slip agents; fillers, antiblocking agents, and reinforcing agents, and various further miscellaneous additives.
  • the additives added to a thermoplastic polyolefin may be used in an amount of from 100 to 5,000 ppm, or from 100 to 3,000 ppm, or from 200 to 3,000 ppm, or from 200 to 2,000 ppm, or from 300 to 1,500 ppm, or from 400 to 1,200 ppm (based on the weight of the thermoplastic polyolefin).
  • a thermoplastic polyolefin e.g. a linear polyethylene
  • a primary antioxidant is selected from alkylated mono-phenols (also described herein as “hindered phenol primary antioxidants”), such as, for example, 2,6-di-tert-butyl-4-methylphenol; 2-tert-butyl-4,6-dimethylphenol; 2,6-di-tert- butyl-4-ethylphenol; 2,6-di-tert-butyl-4-n-butylphenol; 2,6-di-tert-butyl-4isobutylphenol; 2,6-dicyclopentyl-4-methylphenol; 2-(alpha.-methylcyclohexyl)-4,6 dimethylphenol; 2,6-di- octadecyl-4-methylphenol; 2,4,6,-tricyclohexyphenol; and 2,6-di-tert-butyl-4- methoxymethylphenol.
  • alkylated mono-phenols also described herein as “hindered phenol primary antioxidants”
  • Suitable hindered phenolic antioxidants which can be used in embodiments of the disclosure, are sold under the trademarks IRGANOX® 1010 (CAS Registry number 6683-19-8) and IRGANOX 1076 (CAS Registry number 2082-79-3) by BASF Corporation.
  • a primary antioxidant is selected from alkylated hydroquinones, such as, for example, 2,6-di-tert-butyl-4-methoxyphenol; 2,5-di-tert- butylhydroquinone; 2,5-di-tert-amyl-hydroquinone; and 2,6-diphenyl-4- octadecyloxyphenol .
  • a primary antioxidant is selected from hydroxylated thiodiphenyl ethers, such as, for example, 2,2'-thio-bis-(6-tert-butyl-4- methylphenol); 2,2'-thio-bis-(4-octylphenol); 4,4'thio-bis-(6-tertbutyl-3-methylphenol); and 4, 4'-thio-bis-(6-tert-butyl-2 -methylphenol).
  • hydroxylated thiodiphenyl ethers such as, for example, 2,2'-thio-bis-(6-tert-butyl-4- methylphenol); 2,2'-thio-bis-(4-octylphenol); 4,4'thio-bis-(6-tertbutyl-3-methylphenol); and 4, 4'-thio-bis-(6-tert-butyl-2 -methylphenol).
  • a primary antioxidant is selected from alkylidenebisphenols, such as, for example, 2,2'-methylene-bis-(6-tert-butyl-4-methylphenol); 2,2'- methylene-bis-(6-tert-butyl-4-ethylphenol); 2,2'-methylene-bis-(4-methyl-6-(alpha- methylcyclohexyl)phenol); 2,2'-methylene-bis-(4-methyl-6-cyclohexyiphenol); 2,2'- methylene-bis-(6-nonyl-4-methylphenol); 2,2'-methylene-bis-(6-nonyl-4methylphenol); 2,2'-methylene-bis-(6-(alpha-methylbenzyl)-4-nonylphenol); 2,2'-methylene-bis-(6-(alpha-methylbenzyl)-4-nonylphenol); 2,2'-methylene-bis-(6-(alpha, alpha-dimethylbenzyl)-4-n
  • a primary antioxidant is selected from benzyl compounds, such as for example, l,3,5-tris-(3,5-di-tert-butyl-4-hydroxybenzyl)-2,4,6- trimethylbenzene; bis-(3, 5 -di -tert-butyl -4-hydroxybenzyl)sulfide; isooctyl 3,5-di-tert-butyl- 4-hydroxybenzyl-mercaptoacetate; bis-(4-tert-butyl-3hydroxy-2,6-dimethylbenzyl)dithiol- terephthalate; l,3,5-tris-(3,5-di-tert-butyl-4,10 hydroxybenzyl)isocyanurate; 1 ,3,5-tris-(4- tert-butyl-3 -hydroxy-2, 6-dimethylbenzyl)isocyanurate ; dioctadecyl 3 ,5 -d
  • a primary antioxidant is selected from acvlaminophenols, such as for example, 4-hydroxy-lauric acid anilide; 4-hydroxy-stearic acid anilide; 2,4-bis-octylmercapto-6-(3,5-tert-butyl-4-hydroxyanilino)-s-triazine; and octyl- N-(3 ,5 -di-tert-butyl-4-hydroxyphenyl)-carbamate .
  • acvlaminophenols such as for example, 4-hydroxy-lauric acid anilide; 4-hydroxy-stearic acid anilide; 2,4-bis-octylmercapto-6-(3,5-tert-butyl-4-hydroxyanilino)-s-triazine; and octyl- N-(3 ,5 -di-tert-butyl-4-hydroxyphenyl)-carbamate .
  • a primary antioxidant is selected from esters of beta-(5-tert-butyl-4-hydroxy-3-methylphenyl)-propionic acid with monohydric or polyhydric alcohols, such as for example, methanol; diethyleneglycol; octadecanol; triethyleneglycol; 1,6-hexanediol; pentaerythritol; neopentylglycol; tris-hydroxyethyl isocyanurate; thidiethyleneglycol; and dihydroxy ethyl oxalic acid diamide.
  • monohydric or polyhydric alcohols such as for example, methanol; diethyleneglycol; octadecanol; triethyleneglycol; 1,6-hexanediol; pentaerythritol; neopentylglycol; tris-hydroxyethyl isocyanurate; thidiethyleneglycol; and dihydroxy e
  • a primary antioxidant is selected from amides of beta-(3,5-di-tert-butyl-4-hydroxyphenol)-propionic acid, such as for example, N,N'-di-(3,5- di-tert-butyl-4-hydroxyphenylpropionyl)-hexamethylendiamine; N,N'-di-(3,5-di-tert-butyl- 4-hydroxyphenylpropionyl) trimethylenediamine; and N,N'-di(3, 5 -di -tert-butyl -4- hy droxypheny Iprop iony 1) -hydrazine .
  • beta-(3,5-di-tert-butyl-4-hydroxyphenol)-propionic acid such as for example, N,N'-di-(3,5- di-tert-butyl-4-hydroxyphenylpropionyl)-hexamethylendiamine; N,N'-di-(3,5-
  • the primary antioxidant may be used in an amount of from 100 to 5,000 ppm, or from 100 to 3,000 ppm, or from 200 to 3,000 ppm, or from 200 to 2,000 ppm, or from 300 to 1,500 ppm, or from 400 to 1,200 ppm (based on the weight of the thermoplastic polyolefin).
  • a secondary antioxidant is selected from phosphites and phosphonites (also described herein as “phosphorus containing secondary antioxidants”), such as, for example, triphenyl phosphite; diphenylalkyl phosphites; phenyldialkyl phosphites; tris (nonyl-phenyl)phosphite [WESTON® 399, available from SI Group]; phosphorous acid, mixed 2,4-bis(l,l-dimethylpropyl)phenyl and 4-(l , 1 - dimethylpropyl)phenyl triesters [WESTON 705, CAS Reg. No.
  • a secondary antioxidant is selected from alkylphenol free, polymeric polyphosphites, examples of which are disclosed in U.S. Pat. No. 8,563,637.
  • a secondary antioxidant is selected from peroxide scavengers, such as, for example, esters of betathiodipropionic acid.
  • Esters betathiodipropionic acid may be selected from the group consisting of lauryl, stearyl, myristyl or tridecyl esters.
  • peroxide scavengers for use as a secondary antioxidant in certain embodiments may be selected from the group consisting of mercaptobenzimidazole; or the zinc salt of 2-mercaptobenzimidazole; zinc-dibutyidithiocarbamate; dioctadecyidisulfide; and pentaerythritottetrakis-(beta-dodecylmercapto)-propionate.
  • a secondary antioxidant is selected from hydroxylamines and amine oxides, such as, for example, N,N-dibenzylhydroxylamine; N,N- diethylhydroxylamine; N,N-dioctylhydroxylamine; N,N-dilaurylhydroxylamine; N,N- ditetradecylhydroxylamine; N,N-dihexadecylhydroxylamine; N,N- dioctadecylhydroxylamine; N-hexadecyl-N-octadecylhydroxylamine; N-heptadecyl-N- octadecylhydroxylamine; and N,N-dialkylhydroxylamine derived from hydrogenated tallow amine.
  • hydroxylamines and amine oxides such as, for example, N,N-dibenzylhydroxylamine; N,N- diethylhydroxylamine; N,N-dioctylhydroxylamine; N
  • analogous amine oxides are also suitable.
  • a commercially available example of hydroxylamine which may be used in embodiments of the disclosure is the N,N- di(alkyl)hydroxylamine sold as IRGASTAB® FS 042 (by BASF) and which is reported to be prepared by the direct oxidation of N,N - di (hydrogenated) tallow amine.
  • a secondary antioxidant is selected from nitrones, such as, for example, N-benzyl-alpha-phenyl nitrone; N-ethyl-alpha-methyl nitrone; N- octyl-alpha-heptyl nitrone; N-lauryl-alpha-undecyl nitrone; N-tetradecyl-alpha-tridecyl nitrone; N-hexadecyl-alpha-pentadecyl nitrone; N-octadecyl-alpha-heptadecylnitrone; N- hexadecyl-alpha-heptadecyl nitrone; N-octadecyl-alpha-pentadecyl nitrone; N-heptadecyl- alpha-heptadecyl nitrone; N-octadecyl-o-pent
  • the secondary antioxidant may also be used in an amount of from 100 to 5,000 ppm, or from 100 to 3,000 ppm, or from 200 to 3,000 ppm, or from 200 to 2,000 ppm, or from 300 to 1,500 ppm, or from 400 to 1,200 ppm (based on the weight of the thermoplastic polyolefin).
  • a UV absorber or light stabilizer is selected from 2-(2'-hydroxyphenyl)-benzotriazoles, such as, for example, the 5'-methyl-; 3',5'-di-tert- butyl-; 5'-tert-butyl-; 5'(l,l,3,3-tetramethylbutyl)-; 5-chloro-3',5'-di-tert-butyl-; 5-chloro-3'- tert-butyl-5'-methyl-; 3'-sec-butyl-5'-tert-butyl-; 4'-octoxy,3',5'-di-tert-amyl-; and 3',5'-bis- (alpha, alpha - dimethylbenzyl) derivatives.
  • 2-(2'-hydroxyphenyl)-benzotriazoles such as, for example, the 5'-methyl-; 3',5'-di-tert- butyl-; 5'-tert
  • a UV absorber or light stabilizer is selected from 2-hydroxy-benzophenones, such as, for example, the 4-hydroxy-; 4-methoxy-; 4-octoxy; 4- decyloxy-; 4-dodecyloxy-; 4-benzyloxy-; 4,2',4'-trihydroxy-; and 2'-hydroxy-4,4'-dimethoxy derivative.
  • a UV absorber or light stabilizer is selected from sterically hindered amines, such as, for example, bis (2,2,6,6-tetramethylpiperidyl)- sebacate; bis-5(l,2,2,6,6-pentamethylpiperidyl)-sebacate; n-butyl-3, 5 -di -tert-butyl -4- hydroxybenzyl malonic acid bis(l,2,2,6,6,-pentamethylpiperidyl)ester; condensation product of l-hydroxyethyl-2,2,6,6-tetramethyl-4-hydroxy-piperidine and succinic acid; condensation product of N,N'-(2,2,6,6-tetramethylpiperidyl)-hexamethylendiamine and 4- tert-octylamino-2,6-dichloro-l,3,5-s-triazine; tris-(2,2,6,6-tetramethylpiperidyl)- ni
  • HALS Hindered Amines Light Stabilizing
  • amines include butane tetracarboxylic acid 2,2,6,6-tetramethyl piperidinol esters.
  • Such amines include hydroxylamines derived from hindered amines, such as di(l -hydroxy-2, 2, 6, 6-tetramethylpiperidin-4-yl) sebacate; 1- hydroxy 2,2,6,6-tetramethyl-4-benzoxypiperidine; 1 -hydroxy-2, 2,6, 6-tetramethyl-4-(3, 5 -di- tert-butyl -4-hydroxy hydrocinnamoyloxy) -piperdine; and N-( 1 -hydroxy-2, 2,6,6- tetramethyl-piperidin-4-yl)-epsiloncaprolactam.
  • hindered amines such as di(l -hydroxy-2, 2, 6, 6-tetramethylpiperidin-4-yl) sebacate; 1- hydroxy 2,2,6,6-tetra
  • Suitable commercially available HALS which may be used in embodiments of the disclosure include those sold under the trademarks CHIMASSORB® 119; CHIMASSORB 944; CHIMASSORB 2020; TINUVIN® 622 and TINUVIN 770 from BASF, and CYASORB® UV 3346, CYASORB UV 3529, CYASORB UV 4801, and CYASORB UV 4802 from Solvay. In other embodiments of the disclosure, the use of mixtures of more than one HALS are also contemplated.
  • a UV absorber or light stabilizer is selected from esters of substituted and unsubstituted benzoic acids, such as for example, phenyl salicilate; 4-tertbutylphenyl-salicilate; octylphenyl salicylate; dibenzoylresorcinol; bis-(4-tert- butylbenzoyl) -resorcinol; benzoylresorcinol; 2,4-di-tert-butyl-phenyl-3,5-di-tert-butyl-4- hydroxybenzoate; and hexadecyl-3, 5 -di -tert-butyl -4-hydroxybenzoate.
  • esters of substituted and unsubstituted benzoic acids such as for example, phenyl salicilate; 4-tertbutylphenyl-salicilate; octylphenyl salicylate; dibenzoylresorcinol;
  • a UV absorber or light stabilizer is selected from acrylates, such as, for example, alpha-cyano-beta,beta-diphenylacrylic acid-ethyl ester or isooctyl ester; alpha-carbomethoxy-cinnamic acid methyl ester; alpha-cyano-beta-methyl- p-methoxy-cinnamic acid methyl ester or butyl ester; alpha-carbomethoxy-p-methoxy- cinnamic acid methyl ester; and N-(beta-carbomethoxy-beta-cyano-vinyl)-2-methyl- indoline.
  • acrylates such as, for example, alpha-cyano-beta,beta-diphenylacrylic acid-ethyl ester or isooctyl ester; alpha-carbomethoxy-cinnamic acid methyl ester; alpha-cyano-
  • a UV absorber or light stabilizer is selected from nickel compounds, such as, for example, nickel complexes of 2,2'-thio-bis(4-(l, 1,1,3- tetramethylbutyl)-phenol), such as the 1: 1 or 1:2 complex, optionally with additional ligands such as n-butylamine, triethanolamine or N-cyclohexyl-diethanolamine; nickel dibutyldithiocarbamate; nickel salts of 4-hydroxy-3,5-di-tert-butylbenzylphosphonic acid monoalkyl esters, such as of the methyl, ethyl, or butyl ester; nickel complexes of ketoximes such as of 2-hydroxy-4-methyl-penyl undecyl ketoxime; and nickel complexes of 1-phenyl- 4-lauroyl-5-hydroxy-pyrazole, optionally with additional ligands.
  • nickel compounds such as, for example, nickel complexes of 2,2'-thio-bis(4
  • a UV absorber or light stabilizer is selected from hydroxyphenyl-s-triazines, such as, for example, 2,6-bis-(2,4-dimethylphenyl)-4-(2- hydroxy-4octyloxyphenyl)-s-triazine; 2,6-bis(2,4-dimethylphenyl)-4-(2,4- dihydroxyphenyl)-s-triazine; 5 2,4-bis(2,4-dihydroxyphenyl)-6-(4-chlorophenyl)-s-triazine; 2, 4-bis(2-hydroxy4-(2 -hydroxyethoxy )phenyl)-6-(4-chlorophenyl)-s-triazine; 2,4- bis(2hydroxy4-(2 -hydroxyethoxy )phenyl)-6-phenyl-s-triazine; 2,4-bis(2-hydroxy4-(2- hydroxyethoxy)-phenyl)-6-(2,4-bis(2-hydroxy4
  • a polyamide stabilizer is selected from for example, copper salts in combination with iodides and/or phosphorus compounds and salts of divalent manganese.
  • a hydrotalcite has the formula: [M 2+ i- x M 3+ x(OH)2] x+ [(A“')x/n TMH20] X ’ where M 2+ is divalent Mg, Ni, Zn, Cu, or Mn; M 3+ is trivalent Al, Fe, or Cr; A n ’ is an anion such as for examples, CO3 2 -, or SO4 2 -, NO3 2 -, Cl 1 ’, or OH 1 ’; and x is from 0.1 to 0.5.
  • a hydrotalcite has the formula: MgeAh (OHfieCCh wHzO.
  • hydrotalcite is the mineral hydrotalcite (MgeAh (OH)ieCO3’4H2O).
  • Hydrotalcites which may be used in embodiments of the disclosure, include materials commercially available under the general tradenames DHT®-4 (A, C, or V), ZHT®-4V HYCITE® 713, and AC-207TM.
  • nucleating agent is meant to convey its conventional meaning to those skilled in the art of preparing nucleated polyolefin compositions, namely an additive that changes the crystallization behavior of a polymer as the polymer melt is cooled.
  • nucleating agents which are commercially available and which may be added to a thermoplastic polyolefin are dibenzylidene sorbital esters.
  • Further examples of nucleating agents which may be added to thermoplastic polyolefins include the cyclic organic structures disclosed in U.S. Patent No. 5,981,636 (and salts thereof, such as disodium bicyclo [2.2.1] heptene dicarboxylate); the saturated versions of the structures disclosed in U.S. Patent No. 5,981,636 (as disclosed in U.S. Patent No.
  • the HHPA structure comprises a ring structure with six carbon atoms in the ring and two carboxylic acid groups which are substituents on adjacent atoms of the ring structure.
  • the other four carbon atoms in the ring may be substituted, as disclosed in U.S. Patent No. 6,599,971.
  • An example is 1,2- cyclohexanedicarboxylicacid, calcium salt (CAS registry number 491589-22-1).
  • nucleating agents which may be added to a thermoplastic polyolefin (e.g. a linear polyethylene) include those disclosed in WO2015042561, WO2015042563, WO2015042562 and WO2011050042.
  • the amount of nucleating agent used is comparatively small— from 100 to 3,000 parts per million by weight (based on the weight of the thermoplastic polyolefin) so it will be appreciated by those skilled in the art that some care should be taken to ensure that the nucleating agent is well dispersed.
  • the nucleating agent is added in finely divided form (less than 50 microns, especially less than 10 microns) to the thermoplastic polyolefin (e.g. a linear polyethylene) to facilitate mixing. This type of “physical blend” (i.e.
  • a mixture of the nucleating agent and the resin in solid form is in some embodiments preferable to the use of a “masterbatch” of the nucleator (where the term “masterbatch” refers to the practice of first melt mixing the additive— the nucleator, in this case— with a small amount of the thermoplastic polyolefin —then melt mixing the “masterbatch” with the remaining bulk of the thermoplastic polyolefin).
  • an additive such as nucleating agent may be added to the thermoplastic polyolefin by way of a “masterbatch”, where the term “masterbatch” refers to the practice of first melt mixing the additive (e.g. a nucleator) with a small amount of the thermoplastic polyolefin, followed by melt mixing the “masterbatch” with the remaining bulk of the thermoplastic polyolefin.
  • masterbatch refers to the practice of first melt mixing the additive (e.g. a nucleator) with a small amount of the thermoplastic polyolefin, followed by melt mixing the “masterbatch” with the remaining bulk of the thermoplastic polyolefin.
  • a filler, an antiblocking agent, or a reinforcing agents is selected from calcium carbonate; diatomaceous earth; natural and synthetic silica; silicates; glass fibers; asbestos; talc; kaolin; mica; barium sulfate; metal oxides and hydroxides; carbon black; and graphite.
  • a miscellaneous additive is selected from plasticizers; epoxidized vegetable oils, such as epoxidized soybean oils; lubricants; emulsifiers; pigments; optical brighteners; flameproofing agents; anti-static agents; anti-fog agents; blowing agents; and thiosynergists, such as dilaurylthiodipropionate or distearylthiodipropionate .
  • the thermoplastic compositions are substantially free of (i.e. have less than about 2 weight percent) or free of (i.e. have zero weight percent) of a compound or composition which serves as a compatibilizer between the linear polyethylene and the ethylene vinyl alcohol copolymer (EVOH).
  • a compatibilizer compound or composition and which is referred to herein as an “polyolefin/EVOH compatibilizer” can stabilize blends of or facilitate the blending of two otherwise immiscible polymers such as a non-polar polyolefin, including a linear polyethylene, and a polar polymer, including an ethylene vinyl alcohol copolymer (EVOH).
  • Some non-limiting examples of compounds and compositions which may be used as a polyolefin/EVOH compatibilizer include maleic acid; maleic anhydride; acid or anhydride modified polyolefins such as maleic anhydride modified polyethylene (MAH-graft-PE), or maleic anhydride modified polypropylene (MAH-graft-PP), or maleic anhydride modified copolymers of ethylene with propylene, and/or styrene and/or other alpha-olefins (e.g.
  • MAH-graft-SEBS ethylene vinyl acetate copolymer
  • EVA ethylene vinyl acetate copolymer
  • MAH-graft-EVA acid or anhydride modified ethylene vinyl acetate copolymers
  • MAH-graft-EVOH acid or anhydride modified ethylene vinyl alcohol copolymers
  • MAH- graft-EVOH maleic anhydride modified ethylene vinyl alcohol copolymer
  • ethylene acrylic acid copolymers ethylene methacrylic acid copolymers; acid or anhydride modified ethylene acrylic acid or ethylene methacrylic acid copolymers
  • GMA-graft-PE glycidyl methacrylate modified polyolefins, such as glycidyl methacrylate modified polyethylene
  • Non-limiting examples of compounds and compositions which may be used as a polyolefin/EVOH compatibilizer include copolymers of ethylene and unsaturated acids or unsaturated anhydrides or esters of unsaturated acids, such as copolymers of ethylene and maleic anhydride. Copolymers of ethylene and unsaturated acids, or unsaturated anhydrides, or esters of unsaturated acids are described, in for example, U.S. Pat. No. 8,431,650.
  • compatibilizer compounds and compositions which may be used as a polyolefin/EVOH compatibilizer include those sold under the tradenames BYNEL® and RETAIN® (Dow Chemical, USA); NOVACOM- PTM (Polygroup, USA); ADMER® (Mitsui Chemicals), and FUSABOND® (E. I. du Pont de Nemours and Company).
  • thermoplastic composition is substantially free of a polyolefin/EVOH compatibilizer.
  • the thermoplastic composition is substantially free of a polyolefin/EVOH compatibilizer selected from the group consisting of maleic acid; maleic anhydride; acid or anhydride modified polyolefins such as maleic anhydride modified polyethylene (MAH-graft-PE), or maleic anhydride modified polypropylene (MAH-graft-PP), or maleic anhydride modified copolymers of ethylene with propylene, and/or styrene and/or other alpha-olefins (e.g.
  • a polyolefin/EVOH compatibilizer selected from the group consisting of maleic acid; maleic anhydride; acid or anhydride modified polyolefins such as maleic anhydride modified polyethylene (MAH-graft-PE), or maleic anhydride modified polypropylene (MAH-graft-PP), or maleic anhydride modified copolymers of ethylene with propylene, and/or styrene and/or other alpha-olefin
  • MAH-graft-SEBS ethylene vinyl acetate copolymer
  • EVA ethylene vinyl acetate copolymer
  • MAH-graft-EVA acid or anhydride modified ethylene vinyl acetate copolymers
  • MAH-graft-EVOH acid or anhydride modified ethylene vinyl alcohol copolymers
  • ethylene acrylic acid copolymers ethylene methacrylic acid copolymers
  • glycidyl methacrylate modified polyolefins such as glycidyl methacrylate modified polyethylene (GMA-graft-PE)
  • copolymers of ethylene and unsaturated acids or unsaturated anhydrides or esters of unsaturated acids such as for example copolymers of ethylene and maleic anhydride; and mixtures thereof.
  • the thermoplastic composition is substantially free of a polyolefin/EVOH compatibilizer selected from the group consisting of maleic anhydride, maleic anhydride modified polyethylene (MAH-graft-PE), ethylene vinyl acetate copolymer (EVA), maleic anhydride modified ethylene vinyl acetate copolymer (MAH- graft-EVA), maleic anhydride modified ethylene vinyl alcohol copolymer (MAH-graft- EVOH), and mixtures thereof.
  • a polyolefin/EVOH compatibilizer selected from the group consisting of maleic anhydride, maleic anhydride modified polyethylene (MAH-graft-PE), ethylene vinyl acetate copolymer (EVA), maleic anhydride modified ethylene vinyl acetate copolymer (MAH- graft-EVA), maleic anhydride modified ethylene vinyl alcohol copolymer (MAH-graft- EVOH), and mixtures thereof.
  • the extrudable or extruded thermoplastic composition will have 0 percent by weight of a polyolefin/EVOH compatibilizer (based on the weight of an extrudable or extruded thermoplastic composition).
  • Extrudable thermoplastic compositions according to the present disclosure can be prepared by any one or a variety of ways.
  • the polymer processing aid components can be mixed with a thermoplastic polyolefin during a melt extrusion process.
  • one or more of the polymer processing aid components can be formulated with a polyolefin, in a so called “masterbatch”. Such a masterbatch may be used to deliver a useful, diluted amount of one or more of the polymer processing aid components.
  • the masterbatch may be added to the bulk thermoplastic polyolefin for extrusion in a melt extrusion process into an extruded article.
  • thermoplastic polyolefin to be extruded and the polymer processing aid components can be combined using any of the blending means well known to persons skilled in the art, such as for example, using a compounding mill, a Banbury mixer, or a mixing extruder in which the polymer processing aid components are uniformly distributed within the thermoplastic polyolefin.
  • Such mixing may be carried out at a temperature above the melting point, or the softening point of the polyolefin, or such mixing may simply be a dry blend mixing of solid thermoplastic polyolefin with polymer process aid components.
  • an extrudable thermoplastic composition of the present disclosure will be prepared by melt blending a thermoplastic polyolefin (e.g. a linear polyethylene) with polymer processing aids prior to final extrusion in a melt extrusion process (such as for example a blown film extrusion process).
  • a thermoplastic polyolefin e.g. a linear polyethylene
  • polymer processing aids prior to final extrusion in a melt extrusion process (such as for example a blown film extrusion process).
  • thermoplastic polyolefin masterbatch is then fed to an extruder and melt blended with other components as desired including for example bulk polyolefin, polymer processing aids or other additives.
  • each of the components used to make up the extrudable thermoplastic composition may be metered directly into an extruder used for the melt extrusion process.
  • melt extrusion processes are well known to persons skilled in the art, non-limiting examples of which include, cast film extrusion, blown film extrusion, extrusion blow molding, injection molding, pipe extrusion, wire extrusion, cable extrusion, and fiber extrusion.
  • the extruder employed in embodiments of the present disclosure may be a twin or single screw extruder. If it a twin-screw extruder is employed it may be operated in a corotating mode (i.e. both screws turning in the same direction) or in a counter rotating mode (i.e. the screws rotate in opposite directions).
  • a twin screw extruder optionally a laboratory scale, twin screw extruder, will operate within the following envelope of conditions: the barrel will be heated to atemperature from about 175 to about 275°C, or from about 180 to about 210°C, or from about 190 to about 200°C; the screw speed will operate at from about 50 to about 175 rpm, or from about 50 to about 150 rpm, or from about 100 to about 130 rpm.
  • any specific extruder can readily be determined by one skilled in the art by non-inventive testing in view of the foregoing envelope of conditions.
  • the extruder will typically extrude a thermoplastic composition as strands which are then cooled and cut into pellets for subsequent use, such as for use in a film extrusion.
  • the extruder used for the final extrusion may also be a single or twin-screw extruder.
  • the die In blown film extrusion, the die may be a slot die or it may be an annular ring die extruding a film of the polyolefin about a stable bubble of air. In blown film extrusion, the film is collapsed after passing over or about the bubble.
  • a typical extruder contains one (or two) flighted screws which rotate within a cylinder or “barrel”.
  • a thermoplastic polyolefin is sheared between the barrel and the screw by the stresses caused by the rotation of the screw.
  • the barrel of the extruder may be heated. The shear and/or heat cause the thermoplastic polyolefin to melt and the action of the flighted screw transports it along the length of the extruder. The molten thermoplastic polyolefin extrudate is then forced through a die to form the desired plastic part.
  • a melt extrusion process is a blown film melt extrusion process.
  • thermoplastic polyolefin composition In a blown film melt extrusion process an extruder heats, melts, mixes and conveys a thermoplastic polyolefin composition. Once molten, the thermoplastic composition is forced through an annular die to produce a thermoplastic tube. In the case of co-extrusion, multiple extruders are employed to produce a multilayer thermoplastic tube.
  • the temperature of the extrusion process is primarily determined by the thermoplastic polyolefin composition being processed, for example the melting temperature or glass transition temperature of the thermoplastic polyolefin composition and the desired viscosity of the melt. In the case of thermoplastic polyolefins, typical extrusion temperatures may be from 330°F to 550°F (166°C to 288°C).
  • the thermoplastic tube Upon exit from the annular die, the thermoplastic tube is inflated with air, cooled, solidified and pulled through a pair of nip rollers. Due to air inflation, the tube increases in diameter forming a bubble of desired size. Due to the pulling action of the nip rollers the bubble is stretched in the machine direction. Thus, the bubble is stretched in two directions: the transverse direction (TD) where the inflating air increases the diameter of the bubble; and the machine direction (MD) where the nip rollers stretch the bubble. In the blown film process, air is also blown on the external bubble circumference to cool the thermoplastic polyolefin as it exits the annular die.
  • TD transverse direction
  • MD machine direction
  • the final width of the film is determined by controlling the inflating air or the internal bubble pressure; in other words, increasing or decreasing bubble diameter.
  • Film thickness is controlled primarily by increasing or decreasing the speed of the nip rollers to control the draw-down rate.
  • the bubble or tube is collapsed and may be slit in the machine direction thus creating sheeting.
  • Each sheet may be wound into a roll of film.
  • Each roll may be further slit to create film of the desired width.
  • Each roll of film may be further processed into a variety of consumer products.
  • the melt extrusion process is a blown film extrusion process carried out at a temperature of from 180°C to 275°C including subranges within this range and any number within this range.
  • the melt extrusion process is a blown film extrusion process carried out at a temperature of from 180°C to 250°C, or from 190°C to 275°C, or 190°C to 250°C.
  • a melt extrusion process is a cast film melt extrusion process.
  • the cast film process is similar in that a single or multiple extruder(s) may be used; however the various thermoplastic materials are metered into a flat die and extruded into a monolayer or multilayer sheet, rather than a tube. In the cast film process the extruded sheet is solidified on a chill roll.
  • the melt extrusion process is a cast film extrusion process carried out at a temperature of from 180°C to 300°C including subranges within this range and any number within this range.
  • the melt extrusion process is a cast film extrusion process carried out at a temperature of from 180°C to 275°C, or from 180°C to 250°C, or from 190°C to 275°C, or 190°C to 250°C.
  • the extruder pressure employed during a melt extrusion process or during a melt compounding process can range from 0.1 MPa to 10 MPa or any value or range therebetween, depending on the melt extrusion or compounding process, such as for example, 0.1 MPa, 1 MPa, 2 MPa, 3 MPa, 4 MPa, 5 MPa, 6 MPa, 7 MPa, 8 MPa, 9 MPa, 10 MPa.
  • a polymer processing aid is used during the melt extrusion of a thermoplastic polyolefin into a thermoplastic polyolefin extrudate.
  • the use of a polymer processing aid during the melt extrusion of a thermoplastic polyolefin into a thermoplastic polyolefin extrudate decreases melt defects during the extrusion of the thermoplastic polyolefin.
  • the use of a polymer processing aid during the melt extrusion of a thermoplastic polyolefin clears melt fracture (i.e. the observable melt fracture in the thermoplastic extrudate is about zero percent) in fewer than 70 minutes, or fewer than 60 minutes, or fewer than 50 minutes, when the thermoplastic polyolefin is extruded in a melt extrusion process which is a blown film extrusion process carried out at a temperature of from 180°C to 275°C.
  • an extrudable thermoplastic composition comprising: a linear polyethylene; an ethylene vinyl alcohol copolymer (EVOH); and a poly(oxyethylene) polymer, also known as polyethylene glycol (PEG); has a time to clear melt fracture (i.e. the observable melt fracture in the thermoplastic extrudate is about zero percent) of fewer than 70 minutes, or fewer than 60 minutes, or fewer than 50 minutes when extruded in a melt extrusion process on a blown film line at a temperature of from 180°C to 275°C.
  • a time to clear melt fracture i.e. the observable melt fracture in the thermoplastic extrudate is about zero percent
  • an extrudable thermoplastic composition comprising: a linear polyethylene; an ethylene vinyl alcohol copolymer (EVOH); and a poly(oxyethylene) polymer, also known as polyethylene glycol (PEG); but is substantially free of fluoropolymers, fluoroelastomers, and other perfluorinated alkane or alkene derivatives; has a time to clear melt fracture (i.e. the observable melt fracture in the thermoplastic extrudate is about zero percent) of fewer than 70 minutes, or fewer than 60 minutes, or fewer than 50 minutes when extruded in a melt extrusion process on a blown fdm line at a temperature of from 180°C to 275°C.
  • a time to clear melt fracture i.e. the observable melt fracture in the thermoplastic extrudate is about zero percent
  • the use of a polymer processing aid during the melt extrusion of a thermoplastic polyolefin into a thermoplastic polyolefin extrudate increases the shear rate at which the melt extrusion process may be operated without melt defects, such as melt fracture, in the thermoplastic polyolefin extrudate, compared to the shear rate at which melt defects occur in the thermoplastic polyolefin extrude in the absence of the polymer processing aid.
  • the use of a polymer processing aid during the melt extrusion of a thermoplastic polyolefin into a thermoplastic polyolefin extrudate increases the shear rate at which the melt extrusion process may be operated without melt defects, such as melt fracture, in the thermoplastic polyolefin extrudate, by at least 10 percent, or at least 25 percent, or at least 50 percent, or at least 75 percent, or at least 100 percent, or at least 200 percent, or at least 300 percent, or at least 400 percent, or at least 500 percent, compared to the shear rate at which melt defects occur in the thermoplastic polyolefin extrudate in the absence of the polymer processing aid.
  • An embodiment of the disclosure is a method to reduce melt defects, such as melt fracture, during the extrusion of a thermoplastic composition comprising a linear polyethylene, the method comprising: combining the linear polyethylene with an ethylene vinyl alcohol copolymer (EVOH); and extruding the thermoplastic polyolefin.
  • EVOH ethylene vinyl alcohol copolymer
  • melt extrusion defects indicates that observable and/or quantifiable melt defects, such as melt fracture defects, occurring during an extrusion process are diminished, relative to a control experiment (for example, a control experiment in which a melt extrusion process is carried out on a thermoplastic polyolefin in which no PPA has been added to the thermoplastic polyolefin).
  • An embodiment of the disclosure is a method to reduce melt defects, such as melt fracture, during the extrusion of a thermoplastic composition comprising a linear polyethylene, the method comprising: combining the linear polyethylene with an ethylene vinyl alcohol copolymer (EVOH); and a poly(oxyalkylene) polymer, also known as polyalkylene glycol (PAG); and extruding the thermoplastic composition.
  • EVOH ethylene vinyl alcohol copolymer
  • PAG poly(oxyalkylene) polymer
  • An embodiment of the disclosure is a method to reduce melt defects, such as melt fracture, during the extrusion of a thermoplastic composition comprising a linear polyethylene, the method comprising: combining the linear polyethylene with an ethylene vinyl alcohol copolymer (EVOH); and a poly(oxyethylene) polymer, also known as polyethylene glycol (PEG); and extruding the thermoplastic composition.
  • EVOH ethylene vinyl alcohol copolymer
  • PEG poly(oxyethylene) polymer
  • a polymer processing aid comprising an ethylene vinyl alcohol copolymer (EVOH); and one or more of: a poly(oxyalkylene) polymer, also known as polyalkylene glycol (PAG); and a high pressure low density polyethylene (LDPE); during the melt extrusion of a thermoplastic polyolefin (e.g. a linear polyethylene) into a thermoplastic polyolefin extrudate also helps to reduce extruder die lip build up (DLBU).
  • a poly(oxyalkylene) polymer also known as polyalkylene glycol (PAG)
  • LDPE high pressure low density polyethylene
  • a polymer processing aid comprising an ethylene vinyl alcohol copolymer (EVOH) and a poly(oxyalkylene) polymer, also known as polyalkylene glycol (PAG); during the melt extrusion of a thermoplastic polyolefin (e.g. a linear polyethylene) into a thermoplastic polyolefin extrudate also helps to reduce extruder die lip build up (DLBU).
  • a thermoplastic polyolefin e.g. a linear polyethylene
  • DLBU extruder die lip build up
  • a polymer processing aid comprising an ethylene vinyl alcohol copolymer (EVOH) and a poly(oxyethylene) polymer, also known as polyethylene glycol (PEG); during the melt extrusion of a thermoplastic polyolefin (e.g. a linear polyethylene) into a thermoplastic polyolefin extrudate also helps to reduce extruder die lip build up (DLBU).
  • a thermoplastic polyolefin e.g. a linear polyethylene
  • DLBU extruder die lip build up
  • a polymer processing aid comprising an ethylene vinyl alcohol copolymer (EVOH) during the melt extrusion of a thermoplastic polyolefin (e.g. a linear polyethylene) into a thermoplastic polyolefin extrudate also helps to reduce extruder die lip build up (DLBU).
  • a thermoplastic polyolefin e.g. a linear polyethylene
  • DLBU extruder die lip build up
  • each polymer specimen was conditioned for at least 24 hours at 23 ⁇ 2°C and 50 ⁇ 10% relative humidity and subsequent testing was conducted at 23 ⁇ 2°C and 50 ⁇ 10% relative humidity.
  • ASTM conditions refers to a laboratory that is maintained at 23 ⁇ 2°C and 50 ⁇ 10% relative humidity; and specimens to be tested were conditioned for at least 24 hours in this laboratory prior to testing.
  • ASTM refers to the American Society for Testing and Materials. Density
  • Polymer e.g. of the linear polyethylene densities were determined using ASTM D792-13 (January 1, 2013). Melt Index
  • Polyethylene melt index was determined using ASTM D1238 (August 1, 2013). Melt indexes, h, k, Iio and hi were measured at 190°C, using weights of 2.16 kg, 6.48 kg, 10 kg and a 21.6 kg respectively.
  • GPC Gel Permeation Chromatography
  • Polyethylene samples (polymer) solutions (1 to 3 mg/mL) were prepared by heating the polymer in 1,2,4-trichlorobenzene (TCB) and rotating on a wheel for 4 hours at 150°C in an oven.
  • An antioxidant (2,6-di-tert-butyl-4-methylphenol (BHT)) was added to the mixture in order to stabilize the polymer against oxidative degradation.
  • the BHT concentration was 250 ppm.
  • Polymer solutions were chromatographed at 140°C on a PL 220 high-temperature chromatography unit equipped with four SHODEX® columns (HT803, HT804, HT805 and HT806) using TCB as the mobile phase with a flow rate of 1.0 mL/minute, with a differential refractive index (DRI) as the concentration detector.
  • BHT was added to the mobile phase at a concentration of 250 ppm to protect GPC columns from oxidative degradation.
  • the sample injection volume was 200 pL.
  • the GPC columns were calibrated with narrow distribution polystyrene standards.
  • the polystyrene molecular weights were converted to polyethylene molecular weights using the Mark-Houwink equation, as described in the ASTM standard test method D6474-12 (December 2012).
  • the GPC raw data were processed with the Cirrus GPC software, to produce molar mass averages (M n , M w , M z , each in units of g/mol) and molar mass distribution (e.g. Polydispersity, M w /M n ).
  • M n , M w , M z molar mass averages
  • M w /M n Polydispersity
  • a generally accepted estimate of density for molten polyethylene is 0.76 grams per cubic centimeter (g/cm 3 ) and this value was used for all calculations.
  • a generally accepted value for power law index is 0.5 and this value was used in all calculations.
  • Extrudable thermoplastic polyolefin compositions for blown film extrusion were prepared by melt compounding a linear polyethylene with polymer processing aids and other additives on a Leistritz twin-screw pelletizer under mild conditions with nitrogen purge; see Table 1 for conditions.
  • the elastomeric fluoropolymer, VITON Z110 used in an admixture with a linear polyethylene is commercially available from 3M.
  • VITON Z110 is known to also contain a polyethylene glycol.
  • the potassium stearate, PSV-10 used in an admixture with a linear polyethylene is commercially available from PMC Crystal.
  • EVOH ethylene vinyl alcohol copolymer
  • the ethylene vinyl acetate copolymer (EVA) used in an admixture with a linear polyethylene was ULTRATHENE® UE62400-EVA-NT commercially available from LyondellBasell. This EVA material is believed to have a vinyl acetate content of 17.9 weight percent.
  • PEG 3350 used in an admixture with a linear polyethylene is believed to have a weight average molecular weight, M w of about 3350 g/mol.
  • M w weight average molecular weight
  • PEG 3350 is commercially available from Clariant and is sold under the tradename of POLYGLYKOL 3350.
  • the linear polyethylene used in the present examples was a linear low density polyethylene, LLDPE having a density of 0.914 g/cm 3 and a melt index, L of about 0.85 g/10 min sold under the tradename VPsK914 (or VPsK914-A, or VPsK914-A04, or VPsK914-C) by NOVA Chemicals.
  • the “VPsK914” used in the examples is copolymer of ethylene and 1 -octene and is made in a solution phase polymerization process using a dual reactor single site catalyst and Ziegler-Natta catalyst technology.
  • a specialty antioxidant 500 ppm SUMILIZER® GP
  • hindered amine light stabilizer 17 ppm TINUVIN 622
  • hydrotalcite 800 ppm
  • Monolayer blown fdm was prepared on a 3 -inch Macro blown film line which had a standard output of greater than 60 pounds per hour and was equipped with a 15 horsepower motor (manufactured by Macro Engineering & Technology Inc. based in Ontario, CA).
  • the feed-screw had a 1.5 inch diameter and a length/diameter (L/D) ratio of 24/1.
  • the feedscrew was a barrier design and was fitted with a mixing element on the end of the screw.
  • the film bubble was air cooled using chilled air, and the line was operated at a blow up ratio (BUR) of between 2/1 and 4/1.
  • BUR blow up ratio
  • the blown film line was fitted with a 3 inch diameter annular die. A die pin was utilized resulting in a die gap of 35 mils for the experiments.
  • PEG 3350 polyethylene glycol with M w ⁇ 3350 g/mol
  • PEG 35000 polyethylene glycol with
  • the blown film line was purged using a LLDPE or a LDPE containing 30 - 40% of diatomaceous earth which was free of any polymer processing aids to clean the die by abrasion.
  • a PPA free LLDPE with a density of about 0.92 g/cm 3 and a melt index of 0.8 g/10 min was introduced to produce an extrudate having 100% hard melt fracture across the entire width of the film (e.g. to produce film having gross surface defects with similar appearance to shark skin).
  • the target thermoplastic composition was introduced and this was recoded as time zero.
  • the target thermoplastic composition was extruded under constant conditions and swatches of the extrudate film were collected every ten minutes to measure melt fracture defects as a percentage of the width of the swatch.
  • the melt extrusion process was continued for 60 to 90 minutes for each experiment, and the melt fracture percentage was recorded in 10 minute intervals.
  • the extrudate was considered to be clear of melt fracture, when the melt fracture percentage reached zero.
  • a polymer processing aid (a PPA) may be regarded as providing good performance if melt fracture clears at or before about 60 minutes of extruder operation.
  • the results of the melt fracture clearing experiments are shown in Figure 1 and in Table 3.
  • thermoplastic composition comprising a linear polyethylene and only an ethylene vinyl alcohol copolymer (EVOH) as a polymer processing aid, even at relatively high loading (e.g. 1,500 ppm of SOARNOL) was not able to clear melt fracture completely within about 80 minutes (see Example 4).
  • EVOH ethylene vinyl alcohol copolymer
  • Example 4 when an EVOH copolymer was used in combination with a polyethylene glycol (PEG 3350), even at much lower loading (750 ppm SOARNOL), the thermoplastic composition was able to completely clear melt fracture within about 50 minutes (see Example 5).
  • thermoplastic composition comprising a linear polyethylene, an elastomeric fluoropolymer and a polyethylene glycol (e.g. VITON Z110 in VPs914; see Example 1) and similar to that observed for a thermoplastic composition comprising a linear polyethylene, a metal stearate and a polyethylene glycol (see Example 3). That the mixture of an EVOH copolymer and a polyethylene glycol polymer worked better as a polymer processing aid than a mixture of high and low molecular weight polyethylene glycol polymers is evidenced by comparing Example 3 with Example 5 in Figure 1 and Table 3.
  • EVOH ethylene vinyl alcohol copolymer
  • PEG 3350 polyethylene glycol
  • EVOH ethylene vinyl alcohol copolymer

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  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
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  • Organic Chemistry (AREA)
  • Compositions Of Macromolecular Compounds (AREA)

Abstract

Lorsqu'elle est ajoutée à un polyéthylène linéaire en quantités relativement faibles (moins d'environ 5 000 parties par million), un copolymère d'éthylène-alcool vinylique (EVOH) réduit les défauts de fusion pendant les processus d'extrusion, même en l'absence de polymères fluorés.
PCT/IB2024/055996 2023-06-26 2024-06-19 Polymères polaires utilisés en tant qu'auxiliaires de traitement dans du polyéthylène Pending WO2025003837A1 (fr)

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