# US 11,299,607 B2 · Polyethylene sheets

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- Number: US 11,299,607 B2
- Document ID: US11299607B2
- Status: Granted
- Kind: B2
- Application number: 16/082,026
- Filed: 2017-02-08
- Published: 2020-09-17
- Granted: 2022-04-12
- Earliest claimed: 2016-04-22
- Assignees: Exxon Mobil Chemical Patents Inc.
- Applicants: ExxonMobil Chemical Patents Inc.
- Inventors: Giriprasath Gururajan; Wen Li; David B. Dunaway; Steven A. Best; Etienne R. H. Lernoux
- Web page: https://patentgrep.com/patent/US11299607B2

## CPC

- C08L 23/0815: {with aliphatic 1-olefins containing one carbon-to-carbon double bond}
- B32B 27/08: of synthetic resin
- B32B 27/20: using fillers, pigments, thixotroping agents
- B32B 27/205: {the fillers creating voids or cavities, e.g. by stretching}
- B32B 27/22: using plasticisers
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/327: {comprising polyolefins obtained by a metallocene or single-site catalyst}
- C08J 5/18: Manufacture of films or sheets
- C08L 23/12: Polypropene
- 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 2262/101: Glass fibres
- B32B 2264/102: Oxide or hydroxide
- B32B 2270/00: Resin or rubber layer containing a blend of at least two different polymers
- B32B 2274/00: Thermoplastic elastomer material
- B32B 2307/54: Yield strength; Tensile strength
- B32B 2307/558: Impact strength, toughness
- B32B 2307/7145: Rot proof, resistant to bacteria, mildew, mould, fungi
- B32B 2307/7246: Water vapor barrier
- B32B 2307/7265: Non-permeable
- B32B 2307/732: Dimensional properties
- B32B 2419/00: Buildings or parts thereof
- C08J 2323/08: Copolymers of ethene (C08J2323/16 takes precedence)
- C08J 2423/04: Homopolymers or copolymers of ethene
- C08J 2423/08: Copolymers of ethene (C08J2423/16 takes precedence)
- C08L 2205/025: containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
- C08L 2207/066: LDPE (radical process)
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- 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)

## Abstract

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

## Claims

### Claim 1

A sheet made from at least one metallocene-catalyzed 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 28 to 35,
a CDBI of 20% to <50%;
an orthogonal comonomer distribution, wherein the polyethylene polymer has a molecular weight range and polymer fractions across the molecular weight range vary by more than 10 wt %, and/or at least a first peak and at least a second peak in a comonomer distribution analysis, wherein the first peak has a maximum at a log (Mw) value of 4.0 to 5.4, and the second peak has a maximum at a log (Mw) value of 5.0 to 6.0, and
a weight average molecular weight (Mw) of from 150,000 g/mol to 400,000 g/mol;
wherein:
the sheet has a thickness of ≥20 mil (508 μm), has a dart drop impact strength (DIS) of ≥2,200 g, a permeance of ≤0.1 perms, and comprises a blend of the polyethylene polymer and at least one additional polymer, wherein the at least one additional polymer is a Ziegler-Natta linear low density polyethylene polymer having a density of from 0.915 g/cm3 to 0.940 g/cm3 and a melt index (I2.16) of from 0.1 g/10 min to 1.0 g/10 min.

### Claim 2 (depends on 1)

The sheet of claim 1, wherein the sheet has a tensile strength of ≥45 lbf/in (7.9 kN/m).

### Claim 3 (depends on 1)

The sheet of claim 1, wherein the sheet has a tensile strength of ≥61.9 lbf/in (10.84 kN/m).

### Claim 4 (depends on 1)

The sheet of claim 1, wherein the sheet has a dart drop impact strength (DIS) of ≥2,500 g.

### Claim 5 (depends on 1)

The sheet of claim 1, wherein the sheet has a dart drop impact strength (DIS) of ≥3,000 g.

### Claim 6 (depends on 1)

The sheet of claim 1, wherein the sheet has zero failures (F=0) at a dart drop impact strength (DIS) of at least 2,200 g or greater.

### Claim 7 (depends on 1)

The sheet of claim 1, wherein the sheet has a permeance of ≤0.05 perms.

### Claim 8 (depends on 1)

The sheet 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 sheet 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 10 (depends on 1)

The sheet 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 11 (depends on 1)

The sheet of claim 1, wherein the polyethylene polymer has a melt index ratio (I21.6/I2.16) of from 28 to 32.

### Claim 12 (depends on 1)

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

### Claim 13 (depends on 1)

The sheet of claim 1, wherein the polyethylene polymer has a melt strength of from 1 to 25 cN.

### Claim 14 (depends on 1)

The sheet of claim 1, wherein the polyethylene polymer has a melt strength of from 3 to 15 cN.

### Claim 15 (depends on 1)

The sheet of claim 1, wherein the sheet comprises two or more layers.

### Claim 16 (depends on 15)

The sheet of claim 15, wherein the two or more layers comprise at least one skin layer, a core layer, and optionally, one or more intermediary layers.

### Claim 17 (depends on 16)

The sheet of claim 16, 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.

### Claim 18 (depends on 16)

The sheet of claim 16, 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 19 (depends on 1)

An industrial or construction liner comprising the sheet of any one of claim 1.