Interpolymers suitable for multilayer films
The present invention relates to compositions and processes of making and using interpolymers having a controlled molecular weight distribution. Multilayer films and film layers derived from novel ethylene/α-olefin interpolymers are also disclosed.
1. A multilayer film comprising:
i. a base layer comprising a first polymer;
ii. a tie layer comprising a second polymer; and
iii. a sealant layer comprising an ethylene/α-olefin interpolymer,
wherein the tie layer is between the base layer and the sealant layer and wherein the ethylene/α-olefin interpolymer of the sealant layer has
(a) a DSC curve characterized by an area under the DSC curve from the melting peak temperature to the end of melting is at least about 17% of the total area under the DSC melting curve from −20° C. to the end of melting;
(b) a multi-modal molecular weight distribution;
(c) a density of from about 0.875 g/cc to about 0.915 g/cc;
(d) a I 10 /I 2 from 5.5 to 6.5;
(e) a molecular weight distribution in the range from about 2.0 to about 3.8; and
(f) less than 0.01 long chain branches per 1000 carbon atoms.
2. The multilayer film of claim 1 , wherein the interpolymer has a DSC curve characterized by an area under the DSC curve from the melting peak temperature to the end of melting is at least about 18% of the total area under the DSC melting curve from −20° C. to the end of melting.
3. The multilayer film of claim 1 , wherein the interpolymer has a B value of greater than 0.98.
4. The multilayer film of claim 1 , wherein the interpolymer has a density in the range from about 0.895 g/cc to about 0.910 g/cc.
5. The multilayer film of claim 1 , wherein the interpolymer has a molecular weight distribution in the range from about 2.2 to about 2.8.
6. The multilayer film of claim 1 , wherein the interpolymer has a I 10 /I 2 in the range from about 5.6 to about 6.3.
7. The multilayer film of claim 1 , wherein the first polymer is selected from the group consisting of polyethylene, polypropylene, polybutadiene, polystyrene, polyesters, polycarbonates, polyamides and combinations thereof.
8. The multilayer film of claim 1 , wherein the first polymer is a polyamide.
9. The multilayer film of claim 1 , wherein the second polymer is selected from the group consisting of polyethylene, poly(ethylene vinyl acetate), anhydride-modified polyolefin polymers, blends of EVA and anhydride-modified polyolefin polymers, anhydride-modified EVA polymers, acid-modified EVA polymers, acid-modified polyolefin polymers, amorphous polyolefin-modified EVA polymers, blends of any of the above materials with polyester or copolyester, blends of polyolefins with polyester or copolyester and combinations thereof.
10. The multilayer film of claim 1 , wherein the thickness ratio of the sealant layer to the tie layer to the base layer is about 1:2:1.
11. An article comprising the multilayer film of claim 1 .
12. The multilayer film of claim 2 , wherein the interpolymer has a DSC curve characterized by an area under the DSC curve from the melting peak temperature to the end of melting is from at least about 18 to about 25% of the total area under the DSC melting curve from −20° C. to the end of melting.
13. The multilayer film of claim 12 , wherein the interpolymer has a B value of greater than 0.98.
14. The multilayer film of claim 3 , wherein the interpolymer has a B value of greater than 0.99.
15. The multilayer film of claim 14 , wherein the interpolymer has a B value of greater than 1.0.
16. The multilayer film of claim 15 , wherein the interpolymer has a B value of greater than 1.02.
17. The multilayer film of claim 1 , wherein the interpolymer has an I 2 melt index in the range from about 0.2 to about 20.
18. The multilayer film of claim 9 , wherein the second polymer is a maleic anhydride-modified polyolefin polymer.
19. The article of claim 11 , wherein the interpolymer has a DSC curve characterized by an area under the DSC curve from the melting peak temperature to the end of melting is at least about 17% of the total area under the DSC melting curve from −20° C. to the end of melting.
20. The article of claim 11 , wherein the first polymer is selected from the group consisting of polyethylene, polypropylene, polybutadiene, polystyrene, polyesters, polycarbonates, polyamides and combinations thereof.
21. The article of claim 11 , wherein the second polymer is selected from the group consisting of polyethylene, poly(ethylene vinyl acetate), anhydride-modified polyolefin polymers, blends of EVA and anhydride-modified polyolefin polymers, anhydride-modified EVA polymers, acid-modified EVA polymers, acid-modified polyolefin polymers, amorphous polyolefin-modified EVA polymers, blends of any of the above materials with polyester or copolyester, blends of polyolefins with polyester or copolyester and combinations thereof.
22. The article of claim 11 , wherein the article is a package material.
23. The article of claim 19 , wherein the interpolymer has a DSC curve characterized by an area under the DSC curve from the melting peak temperature to the end of melting is at least about 18% of the total area under the DSC melting curve from −20° C. to the end of melting.
24. The article of claim 20 , wherein the first polymer is a polyamide.
25. The article of claim 21 , wherein the second polymer is a maleic anhydride-modified polyolefin polymer.
26. The article of claim 22 , wherein the package material is a food package material.
27. A film layer comprising:
an ethylene/α-olefin interpolymer having
(i) a DSC curve characterized by an area under the DSC curve from the melting peak temperature to the end of melting is at least about 17% of the total area under the DSC melting curve from −20° C. to the end of melting;
(ii) a multi-modal molecular weight distribution;
(iii) a density of from about 0.875 g/cc to about 0.915 g/cc;
(iv) a I 10 /I 2 from 5.5 to 6.5;
(v) the interpolymer has a molecular weight distribution in the range from about 2.0 to about 3.8; and
(vi) less than 0.01 long chain branches per 1000 carbon atoms.
28. The film layer of claim 27 , wherein the interpolymer has a DSC curve characterized by an area under the DSC curve from the melting peak temperature to the end of melting is at least about 18% of the total area under the DSC melting curve from −20° C. to the end of melting.
29. The film layer of claim 27 , wherein the interpolymer has a B value of greater than 0.98.
30. The film layer of claim 27 , wherein the interpolymer has a B value of greater than 0.99.
31. The film layer of claim 27 , wherein the interpolymer has a B value of greater than 1.0.
32. The film layer of claim 27 , wherein the interpolymer has a B value of greater than 1.02.
33. The film layer of claim 27 , wherein the interpolymer has a density in the range from about 0.895 g/cc to about 0.910 g/cc.
34. The film layer of claim 27 wherein the average hot tack (ASTM F 1921, Method B, dwell time of 500 ms, seal pressure of 27.5 N/cm 2 ) is at least 10 N over a temperature range of at least 20° C.
35. The film layer of claim 27 wherein the average hot tack (ASTM F 1921, Method B, dwell time of 500 ms, seal pressure of 27.5 N/cm 2 ) is at least 10 N over a temperature range of at least 25° C.
36. The film layer of claim 27 wherein the average hot tack (ASTM F 1921, Method B, dwell time of 500 ms, seal pressure of 27.5 N/cm 2 ) is at least 10 N over a temperature range of at least 28° C.
37. The film layer of claim 28 , wherein the interpolymer has a DSC curve characterized by an area under the DSC curve from the melting peak temperature to the end of melting is from at least about 18 to about 25% of the total area under the DSC melting curve from −20° C. to the end of melting.
38. An ethylene/α-olefin interpolymer which has
(i) a DSC curve characterized by an area under the DSC curve from the melting peak temperature to the end of melting is at least about 17% of the total area under the DSC melting curve from −20° C. to the end of melting;
(ii) a multi-modal molecular weight distribution;
(iii) a density of from about 0.875 g/cc to about 0.915 g/cc;
(iv) a I 10 /I 2 from 5.5 to 6.5; and
(v) the interpolymer has a molecular weight distribution in the range from about 2.0 to about 3.8; and
(vi) less than 0.01 long chain branches per 1000 carbon atoms.
39. The ethylene/α-olefin interpolymer of claim 38 which has a DSC curve characterized by an area under the DSC curve from the melting peak temperature to the end of melting is at least about 18% of the total area under the DSC melting curve from −20° C. to the end of melting.
40. The ethylene/α-olefin interpolymer of claim 38 which has a B value of greater than about 0.98.
41. The ethylene/α-olefin interpolymer of claim 38 which has a DSC curve characterized by an area under the DSC curve from the melting peak temperature to the end of melting is from at least about 18 to about 35% of the total area under the DSC melting curve from −20° C. to the end of melting.
42. The ethylene/α-olefin interpolymer of claim 38 which has a DSC curve characterized by an area under the DSC curve from the melting peak temperature to the end of melting is at least about 20% of the total area under the DSC melting curve from −20° C. to the end of melting.
43. The ethylene/α-olefin interpolymer of claim 38 which has a B value of greater than about 0.99.
44. The ethylene/α-olefin interpolymer of claim 38 which has a B value of greater than about 1.0.
45. The ethylene/α-olefin interpolymer of claim 38 which has a B value of greater than about 1.02.
46. The ethylene/α-olefin interpolymer of claim 38 which has a density of from about 0.895 g/cc to about 0.910 g/cc.
47. The ethylene/α-olefin interpolymer of claim 38 wherein the interpolymer has a molecular weight distribution in the range from about 2.2 to about 3.5.
48. The ethylene/α-olefin interpolymer of claim 38 wherein the interpolymer has a molecular weight distribution in the range from about 2.2 to about 3.3.