# US 10,865,281 B2 · Polyethylene films

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- Number: US 10,865,281 B2
- Document ID: US10865281B2
- Status: Granted
- Kind: B2
- Application number: 16/068,767
- Filed: 2017-02-08
- Published: 2019-10-03
- Granted: 2020-12-15
- Earliest claimed: 2016-03-25
- Assignees: ExxonMobil Chemical Patents Inc.
- Applicants: ExxonMobil Chemical Patents Inc.
- Inventors: Etienne R. H. Lernoux; Wen Li; Achiel J. M. Van Loon; Steven A. Best; Xiao-Chuan Wang
- Web page: https://patentgrep.com/patent/US10865281B2

## CPC

- C08J 5/18: Manufacture of films or sheets
- B32B 27/08: of synthetic resin
- B32B 27/20: using fillers, pigments, thixotroping agents
- B32B 27/28: comprising synthetic resins not wholly covered by any one of the sub-groups {B32B27/30 - B32B27/42}
- B32B 27/281: {comprising polyimides}
- B32B 27/285: {comprising polyethers}
- B32B 27/286: {comprising polysulphones; polysulfides}
- B32B 27/302: {comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers}
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 27/306: {comprising vinyl acetate or vinyl alcohol (co)polymers}
- B32B 27/308: {comprising acrylic (co)polymers}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/322: {comprising halogenated polyolefins, e.g. PTFE}
- B32B 27/325: {comprising polycycloolefins}
- B32B 27/327: {comprising polyolefins obtained by a metallocene or single-site catalyst}
- B32B 27/34: comprising polyamides
- B32B 2250/02: 2 layers
- B32B 2250/03: 3 layers
- B32B 2250/04: 4 layers
- B32B 2250/05: 5 or more layers
- B32B 2250/242: All polymers belonging to those covered by group B32B27/32
- B32B 2270/00: Resin or rubber layer containing a blend of at least two different polymers
- B32B 2307/54: Yield strength; Tensile strength
- B32B 2307/546: Flexural strength; Flexion stiffness
- B32B 2307/558: Impact strength, toughness
- B32B 2307/72: Density
- B32B 2307/732: Dimensional properties
- B32B 2410/00: Agriculture-related articles
- B32B 2439/46: Bags
- B32B 2439/70: Food packaging
- B32B 2439/80: Medical packaging
- C08J 2323/06: Polyethene
- C08J 2323/08: Copolymers of ethene (C08J2323/16 takes precedence)
- C08J 2423/06: Polyethene
- C08J 2423/08: Copolymers of ethene (C08J2423/16 takes precedence)
- C08J 2423/14: Copolymers of propene (C08J2423/16 takes precedence)
- C08L 2203/16: used for films
- C08L 2314/02: Ziegler natta catalyst
- C08L 2314/06: Metallocene or single site catalysts
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)

## Abstract

Films made from metallocene-catalyzed polyethylene polymers, optionally, with other polymers, are disclosed.

## Claims

### Claim 1

A film made from at least one polyethylene polymer comprising from 75.0 mol % to 100.0 mol % ethylene derived units and having:
a density of from 0.910 g/cm3 to 0.923 g/cm3,
a melt index (I2.16) of from 0.1 g/10 min to 1.2 g/10 min,
a melt index ratio (I21.6/I2.16) of from 20 to 35, and
a weight average molecular weight (Mw) of from 150,000 g/mol to 400,000 g/mol;
wherein the film has a dart drop impact strength (DIS) of ≥40 g/μm and flex crack resistance of ≤5 holes/10,000 cycles;
and,
wherein the film comprises two or more layers, wherein the two or more layers comprise at least one skin layer, a core layer, and optionally one or more intermediary layers; and, wherein at least one of the skin layer, the core layer, or optional intermediary layer comprises from 30 wt % to 100 wt % of the polyethylene polymer, based upon the total weight of the skin layer, the core layer, or optional intermediary layer; and,
wherein at least one of the skin layer, the core layer, or optional intermediary layer, comprises a blend of the polyethylene polymer and at least one different polyethylene polymer, wherein the at least one different polyethylene polymer is a Ziegler-Natta linear low density polyethylene polymer.

### Claim 2 (depends on 1)

The film of claim 1, wherein the film has a flex crack resistance of ≤4 holes/10,000 cycles.

### Claim 3 (depends on 1)

The film of claim 1, wherein the film has a flex crack resistance of ≤3 holes/10,000 cycles.

### Claim 4 (depends on 1)

The film of claim 1, wherein the film has a dart drop impact strength (DIS) of ≥60 g/μm.

### Claim 5 (depends on 1)

The film of claim 1, wherein the film has a dart drop impact strength (DIS) of ≥80 g/μm.

### Claim 6 (depends on 1)

The film of claim 1, wherein the film has a film thickness of from ≥1 mil.

### Claim 7 (depends on 1)

The film of claim 1, wherein the film has a film thickness of from ≥3 mil.

### Claim 8 (depends on 1)

The film of claim 1, wherein the polyethylene polymer has a density of from 0.910 g/cm3 to 0.920 g/cm3.

### Claim 9 (depends on 1)

The film of claim 1, wherein the polyethylene polymer has a density of from 0.912 g/cm3 to 0.918 g/cm3.

### Claim 10 (depends on 1)

The film of claim 1, wherein the polyethylene polymer has a melt index (I2.16) of from 0.2 g/10 min to 1.1 g/10 min.

### Claim 11 (depends on 1)

The film of claim 1, wherein the polyethylene polymer has a melt index (I2.16) of from 0.4 g/10 min to 1.0 g/10 min.

### Claim 12 (depends on 1)

The film of claim 1, wherein the polyethylene polymer has a melt index ratio (I21.6/I2.16) of from 25 to 32.

### Claim 13 (depends on 1)

The film of claim 1, wherein the polyethylene polymer has a melt index ratio (I21.6/I2.16) of from 28 to 31.

### Claim 14 (depends on 1)

The film of claim 1, wherein the polyethylene polymer has an orthogonal comonomer distribution and/or has at least a first peak and at least a second peak in a comonomer distribution analysis.

### Claim 15 (depends on 1)

The film of claim 1, wherein the polyethylene polymer has a hafnium to zirconium ratio (ppm/ppm) ≥1.0.

### Claim 16 (depends on 1)

The film of claim 1, wherein the polyethylene polymer composition has at least a first peak and a second peak in a comonomer distribution analysis and wherein the first peak has a maximum at a log(Mw) value of 4.0 to 5.4 and a TREF elution temperature of 70.0° C. to 100.0° C. and the second peak has a maximum at a log(Mw) value of 5.0 to 6.0 and a TREF elution temperature of 40.0° C. to 70.0° C.

### Claim 17 (depends on 1)

The film of claim 1, wherein the ethylene-based polymer composition has at least a first peak and a second peak in a comonomer distribution analysis, wherein the first peak has a maximum at a log(Mw) value of 4.3 to 5.0 and a TREF elution temperature of 80.0° C. to 95.0° C. and the second peak has a maximum at a log(Mw) value of 5.3 to 5.7 and a TREF elution temperature of 45.0° C. to 60.0° C.

### Claim 18 (depends on 1)

The film of claim 1, wherein the ethylene-based polymer composition has at least a first peak and a second peak in a comonomer distribution analysis, wherein the first peak has a maximum at a log(Mw) value of 4.5 to 4.7 and a TREF elution temperature of 85.0° C. to 90.0° C. and the second peak has a maximum at a log(Mw) value of 5.4 to 5.6 and a TREF elution temperature of 48.0° C. to 54.0° C.

### Claim 19 (depends on 1)

The film of claim 1, wherein at least one of the skin layer, the core layer, or optional intermediary layer comprises from 50 wt % to 100 wt % of the polyethylene polymer, based upon the total weight of the skin layer, the core layer, or optional intermediary layer.

### Claim 20

A multilayer film comprising a core layer with a subskin layer located on each side of the core layer and a skin layer on the outer side of each subskin layer, where the core layer comprises i) from 50 wt % to 100 wt % of a first polyethylene polymer comprising from 75.0 mol % to 100.0 mol % ethylene derived units and having:
a density of from 0.910 g/cm3 to 0.923 g/cm3,
a melt index (I2.16) of from 0.1 g/10 min to 1.2 g/10 min,
a melt index ratio (I21.6/I2.16) of from 20 to 35, and
a weight average molecular weight (Mw) of from 150,000 g/mol to 400,000 g/mol; ii) a second polyethylene polymer comprising a Ziegler-Natta linear low density polyethylene polymer;
the skin and subskin layers comprise i) from 50 wt % to 100 wt % of the first polyethylene polymer and ii) the second polyethylene polymer;
wherein the wt % of first polyethylene polymer in the core layer is greater than or equal to the wt % of first polyethylene polymer in the skin and subskin layers; and
wherein the film has a dart drop impact strength (DIS) of ≥40 g/μm and flex crack resistance of ≤5 holes/10,000 cycles.