COMPOSIÇÕES E FILMES DE POLÍMEROS DE ETILENO EM MISTURAS DE REATOR
Patent Information
- Authority / Receiving Office
- BR · BR
- Patent Type
- Applications
- Current Assignee / Owner
- NOVA CHEM (INT) SA
- Filing Date
- 2024-03-19
- Publication Date
- 2026-08-04
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Abstract
Description
1 / 123 “ETHYLENE POLYMER COMPOSITIONS AND FILMS IN REACTOR MIXTURES TECHNICAL FIELD
[001] This disclosure provides ethylene polymer compositions in reactor mix form and films prepared therefrom. The ethylene polymer compositions include at least two distinguishable ethylene polymer components with defined architectural features. BACKGROUND OF THE TECHNIQUE
[002] A heat-sealable film structure is a single or multi-layer structure capable of forming a bond when, in a partially molten state, placed in intimate contact with itself or with a substrate (e.g., another film structure or a rigid / semi-rigid structure). Based on functional requirements, the variables of the heat-sealing process and heat-sealable film structures can be designed to produce two types of bonds, namely: locking seals and removable seals.
[003] Locking seals are preferred in hermetic sealing applications, and removable seals are preferred in applications involving easy-open packaging systems. Commonly known technologies for easy-open seals include cohesive, adhesive, and delaminated seals. Regardless of the technology employed, heat-sealable and easy-open film structures incorporate one or more non-polyethylene thermoplastic polymers, including polypropylene resins, polybutene-1 resins, ethylene-vinyl acetate copolymers, ethylene-acrylic acid copolymers, ethylene-methyl acrylate copolymers, and ionomers. Multilayer films containing more than 10% by weight of non-polyethylene materials are known to present challenges in the mechanical recycling processes of polyethylene. Therefore, there is still a need for polyethylene compositions. Petition 870250084786, dated 09 / 19 / 2025, page 10 / 154 2 / 123 leno for applications requiring easy-to-open, single-material packaging systems. SUMMARY OF THE INVENTION
[004] In a first aspect, a reactor mixture ethylene polymer composition is provided, comprising from 30 to 70 percent by weight of a first ethylene polymer, the first ethylene polymer comprising ethylene and optionally at least one α-olefin, the first ethylene polymer having a weight average molecular weight Mw of 70 kg / mol to 250 kg / mol, a number of short-chain branches per thousand carbon atoms of 0 to 6, and a polydispersity index Mw / Mn of 1.7 to 2.3; and 30 to 70 percent by weight of a second ethylene interpolymer, the second ethylene interpolymer comprising ethylene and at least one α-olefin, the second ethylene interpolymer having a weight-average molecular weight Mw of 20 kg / mol to 75 kg / mol, a number of short-chain branches per thousand carbon atoms of 25 to 55 and a polydispersity index Mw / Mn of 1.7 to 2.3;wherein the weight-average molecular weight of the second ethylene interpolymer is less than the weight-average molecular weight of the first ethylene polymer; and wherein the ethylene polymer composition is produced in a continuous solution polymerization process, the continuous solution polymerization process comprising: forming the first ethylene polymer in a first solution polymerization reactor by polymerizing ethylene and, optionally, at least one α-olefin with a first homogeneous catalyst formulation; and forming the second ethylene interpolymer in a second solution polymerization reactor by polymerizing ethylene and at least one α-olefin with a second homogeneous catalyst formulation.
[005] In some embodiments, the ethylene polymer composition exhibits a comonomer distribution profile in a GPC-FTIR analysis, in which the comonomer distribution profile exhibits a greater secant slope or Petition 870250084786, dated 09 / 19 / 2025, page 11 / 154 3 / 123 equals -55 short-chain branches per 1000 carbons and less than or equal to -20 short-chain branches per 1000 carbons, where the secant slope is defined as the number of short-chain branches per 1000 carbons at a molecular weight of 300 kg / mol minus the number of short-chain branches per 1000 carbons at a molecular weight of 30 kg / mol.
[006] In some embodiments, the comonomer distribution profile is a normal comonomer distribution profile.
[007] In some embodiments, one or both of the first homogeneous catalyst formulation and the second homogeneous catalyst formulation comprise a bridged metallocene catalyst having Formula (I): Ri Q M Q G (I) where M is a group 4 metal selected from titanium, zirconium, or hafnium; G is a group 14 element selected from carbon, silicon, germanium, tin, or lead; Ri is a hydrogen atom, a C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, or a C6-10 aryl oxide radical; R2 and R3 are independently selected from a hydrogen atom, a C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, or a C6-10 aryl oxide radical; R4 and R5 are independently selected from a hydrogen atom, an unsubstituted C1-20 hydrocarbyl radical, a substituted C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, or a C6-10 aryl oxide radical; and Q is independently an activatable leaving group ligand. Petition 870250084786, dated 09 / 19 / 2025, p. 12 / 154 4 / 123
[008] In some embodiments, one or both of the first homogeneous catalyst and the second homogeneous catalyst comprise a phosphinimine catalyst.
[009] In some embodiments, the first ethylene polymer is a first ethylene homopolymer.
[010] In some embodiments, the ethylene polymer composition has a density from 0.880 g / cm3 to 0.920 g / cm3, as determined in accordance with ASTM D792-13.
[011] In some embodiments, the ethylene polymer composition has a density from 0.900 g / cm3 to 0.920 g / cm3, as determined in accordance with ASTM D792-13.
[012] In some embodiments, the ethylene polymer composition has a melt index I2 of from 2 dg / min to 10 dg / min, as determined in accordance with ASTM D1238-13 at 190°C using a weight of 2.16 kg.
[013] In some embodiments, the ethylene polymer composition has a molecular weight distribution with a polydispersity index Mw / Mn from 2.3 to 6.0.
[014] In some embodiments, the ethylene polymer composition has a molecular weight distribution with a polydispersity index Mw / Mn from 2.3 to 4.5.
[015] In some embodiments, the ethylene polymer composition has a unimodal molecular weight distribution.
[016] In some embodiments, the ratio between the weight-average molecular weight of the first ethylene polymer and the weight-average molecular weight of the second ethylene interpolymer is greater than or equal to 1.5 and less than or equal to 6. Petition 870250084786, dated 09 / 19 / 2025, page 13 / 154 5 / 123
[017] In some embodiments, the ratio between the weight-average molecular weight of the first ethylene polymer and the weight-average molecular weight of the second ethylene interpolymer is greater than or equal to 2 and less than or equal to 4.
[018] In some embodiments, the ethylene polymer composition contains detectable levels of long-chain branching as characterized according to a long-chain branching factor, LCBF, greater than or equal to 0.001.
[019] In some embodiments, the second ethylene interpolymer is present in the ethylene polymer composition in an amount from 50 to 65 percent by weight.
[020] In some embodiments, the first ethylene polymer is present in the ethylene polymer composition in an amount from 35 to 50 percent by weight.
[021] In some embodiments, the ethylene polymer composition has a number average molecular weight Mn from 10 kg / mol to 35 kg / mol.
[006] In some embodiments, the ethylene polymer composition has a number average molecular weight Mn from 15 kg / mol to 30 kg / mol.
[022] In some embodiments, the ethylene polymer composition has a weight-average molecular weight Mw from 65 kg / mol to 100 kg / mol.
[023] In some embodiments, the ethylene polymer composition has a weight-average molecular weight Mw from 70 kg / mol to 95 kg / mol.
[024] In some embodiments, the second ethylene interpolymer has a number average molecular weight from 10 kg / mol to 38 kg / mol.
[025] In some embodiments, the second ethylene interpolymer has a number average molecular weight from 15 kg / mol to 34 kg / mol. Petition 870250084786, dated 09 / 19 / 2025, p. 14 / 154 6 / 123
[026] In some embodiments, the second ethylene interpolymer has a weight-average molecular weight from 30 kg / mol to 65 kg / mol.
[027] In some embodiments, the second ethylene interpolymer has a number of short-chain branches per thousand carbon atoms from 27 to 48.
[028] In some embodiments, the first ethylene polymer has a weight-average molecular weight from 70 kg / mol to 160 kg / mol.
[029] In some embodiments, the first ethylene polymer has a weight-average molecular weight from 100 kg / mol to 160 kg / mol.
[030] In some embodiments, the ethylene polymer composition has a melt flow ratio I21 / I2 of from 15 to 40, as determined in accordance with ASTM D1238-13 at 190°C using weights of 2.16 kg and 21.6 kg.
[031] In some embodiments, the ethylene polymer composition further comprises from greater than 0 to 20 percent by weight of a third ethylene interpolymer comprising ethylene and at least one α-olefin, the third ethylene interpolymer having a polydispersity index Mw / Mn of from 1.7 to 2.3 and a weight-average molecular weight less than the weight-average molecular weight of the first ethylene polymer and the weight-average molecular weight of the second ethylene interpolymer.
[032] In some embodiments, the third ethylene interpolymer has a weight-average molecular weight of from 20 kg / mol to 50 kg / mol and a number of short-chain branches per 1000 carbon atoms of from 25 to 50.
[033] In some embodiments, the continuous solution polymerization process further comprises a step of forming the third ethylene interpolymer in a third solution polymerization reactor by polymerizing ethylene and at least one α-olefin with a third homogeneous catalyst formulation. Petition 870250084786, dated 09 / 19 / 2025, page 15 / 154 7 / 123 neo, in which the first, second and third solution-phase polymerization reactors are configured in series with respect to each other.
[034] In some embodiments, the third homogeneous catalyst formulation comprises a bridged metallocene catalyst having Formula (I): Q (I) wherein M is a group 4 metal selected from titanium, zirconium, or hafnium; G is a group 14 element selected from carbon, silicon, germanium, tin, or lead; Ri is a hydrogen atom, a C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, or a C6-10 aryl oxide radical; R2 and R3 are independently selected from a hydrogen atom, a C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, or a C6-10 aryl oxide radical; R4 and R5 are independently selected from a hydrogen atom, an unsubstituted C1-20 hydrocarbyl radical, a substituted C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, or a C6-10 aryl oxide radical; and Q is independently an activatable leaving group ligand.
[035] In some embodiments, the third homogeneous catalyst comprises a phosphinimine catalyst.
[036] In some embodiments, at least one α-olefin is selected from the group consisting of C3 to C10 α-olefins.
[037] In some embodiments, at least one α-olefin is selected from the group consisting of hexene-1, octene-1, and a mixture of hexene-1 and octene-1. Petition 870250084786, dated 09 / 19 / 2025, p. 16 / 154 8 / 123
[038] In some embodiments, at least one α-olefin is octene-1.
[039] Provided in a second aspect is a film layer entirely of polyethylene comprising the ethylene polymer composition as defined in the first aspect.
[040] In some embodiments, the film layer is a film formed via a blowing system.
[041] In some embodiments, the film layer is a cast film.
[042] In some embodiments, the film layer additionally comprises a linear low-density polyethylene (LLDPE) having a density from 0.910 g / cm3 to 0.940 g / cm3 and a melt index I2 from 0.1 to 10 dg / min.
[043] In some embodiments, the film layer comprises from 10 to 40 percent by weight of LLDPE and from 60 to 90 percent by weight of the ethylene polymer composition, according to any one of claims 1-32.
[044] Provided in a third aspect is a multilayer film structure made entirely of polyethylene, wherein the film structure has at least one surface layer comprising the ethylene polymer composition as defined in the first aspect.
[045] In some embodiments, the film structure has a sublayer adjacent to at least one surface layer; the sublayer comprising a high-density polyethylene HDPE having a density of at least 0.945 g / cm3 and a melt index I2 from 0.1 to 10 dg / min.
[046] In some embodiments, HDPE is a mixture of at least two ethylene homopolymer blend components; the mixture comprising: from 30 to 95 percent by weight of a first ethylene homopolymer blend component having a density from 0.950 to 0.975 g / cm3; and Petition 870250084786, dated 09 / 19 / 2025, p. 17 / 154 9 / 123 from 5 to 70 percent by weight of a second component ethylene homopolymer mixture having a density from 0.950 to 0.975 g / cm3; wherein the ratio of the melt index I2 of the second component ethylene homopolymer mixture to the melt index I2 of the first component ethylene homopolymer mixture is at least 10.
[047] In some embodiments, HDPE comprises from 100 to 3000 parts per million of a nucleating agent or a mixture of nucleating agents.
[048] In some modalities, HDPE has a polydispersity index Mw / Mn of from 7 to 18.
[049] In some embodiments, at least one additional surface layer comprises linear low-density polyethylene (LLDPE) having a density of from 0.910 g / cm3 to 0.940 g / cm3 and a melt index I2 of from 0.1 to 10.0 dg / min.
[050] In some embodiments, at least one surface layer comprises from 10 to 40 percent by weight of LLDPE and from 60 to 90 percent by weight of the ethylene polymer composition as defined in the first aspect.
[051] In some modalities, the film structure comprises at least three layers.
[052] In some formats, the film structure comprises between three and nine layers.
[053] In some embodiments, at least one surface layer is a sealant layer.
[054] In some embodiments, the film structure has a sealing start temperature greater than or equal to 70°C to 115°C, where the sealing start temperature is the minimum sealing temperature at which the Petition 870250084786, dated 09 / 19 / 2025, page 18 / 154 The 10 / 123 film structure has a sealing strength greater than 3.4 N per 25.4 mm sealing width.
[055] In some embodiments, the film structure has a sealing strength from 3.4 to 15.0 N per 25.4 mm sealing width at a sealing temperature from SIT to SIT + 40°C.
[056] In some embodiments, the film structure has a sealing strength from 3.4 to 15.0 N per 25.4 mm sealing width at a sealing temperature from SIT to SIT + 25°C. BRIEF DESCRIPTION OF THE DRAWINGS
[057] Figure 1a shows the gel permeation chromatogram with Fourier transform infrared detection (GPC-FTIR) obtained for the ethylene polymer composition produced in Example 1. The comonomer content is shown on the secondary y-axis as the number of short-chain branches per 1000 carbon atoms as a function of molecular weight.
[058] Figure 1b shows the fusion endotherms obtained during the second heating cycle for Example 1. The dashed line is an imaginary baseline drawn from 20 °C to the end of fusion.
[059] Figure 2a shows the gel permeation chromatogram with Fourier transform infrared detection (GPC-FTIR) obtained for the ethylene polymer composition produced in Example 2. The comonomer content is shown on the secondary y-axis as the number of short-chain branches per 1000 carbon atoms as a function of molecular weight.
[060] Figure 2b shows the fusion endotherms obtained during the second heating cycle for Example 2. The dashed line is an imaginary baseline drawn from 20 °C to the end of fusion.
[061] Figure 3a shows the gel permeation chromatogram with Fourier transform infrared (GPC-FTIR) detection obtained for the with Petition 870250084786, dated 09 / 19 / 2025, page 19 / 154 11 / 123 position of ethylene polymer produced in Example 3. The comonomer content is shown on the secondary y-axis as the number of short-chain branches per 1000 carbon atoms as a function of molecular weight.
[062] Figure 3b shows the fusion endotherms obtained during the second heating cycle for Example 3. The dashed line is an imaginary baseline drawn from 20 °C to the end of fusion.
[063] Figures 4a, 4b, and 4c illustrate the seal strength of multilayer film structures prepared in Examples 1F-3F and 1FB-2FB, and in Comparative Examples 1F and 3F-6F as a function of seal temperature. The dashed horizontal lines represent the upper and lower limits of the seal strength range from 3.4 to 15 N / 25 mm. The error bars indicate the range of ± standard deviation for five seal strength measurements at each seal temperature.
[064] Figure 5 illustrates the seal strength of multilayer film structures prepared in Examples 4F-6F as a function of seal temperature. The dashed horizontal lines represent the upper and lower limits of the seal strength range from 3.4 to 15 N / 25 mm. The error bars indicate the range of ± standard deviation for five seal strength measurements at each seal temperature. Definition of Terms
[065] Except in examples or where otherwise indicated, all numbers or expressions referring to quantities of ingredients, extrusion conditions, etc., used in the specification and claims should be understood as modified in all cases by the term “approximately”. Consequently, unless otherwise indicated, the numerical parameters set forth in the specification and claims appended below are approximations that may vary depending on the desired properties of the various embodiments. Petition 870250084786, dated 09 / 19 / 2025, page 20 / 154 12 / 123 obtain. At a minimum, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should be interpreted in light of the number of significant digits reported and by applying common rounding techniques. The numerical values set forth in the specific examples are reported to the greatest extent possible. Any numerical values, however, inherently contain certain errors necessarily resulting from the standard deviation found in their respective test measurements.
[066] It should be understood that any numerical range mentioned here is intended to include all subranges contained therein. For example, a range of “1 to 10” is intended to include all subranges between and including the stated minimum value of 1 and the stated maximum value of 10; that is, having a minimum value equal to or greater than 1 and a maximum value equal to or less than 10. As the disclosed numerical ranges are continuous, they include all values between the minimum and maximum values. Unless expressly stated otherwise, the various numerical ranges specified in this application are approximations.
[067] All compositional ranges expressed herein are limited in total to, and do not exceed, 100% (percentage by volume or percentage by weight) in practice. Where multiple components may be present in a composition, the sum of the maximum quantities of each component may exceed 100%, with the understanding that, and as experts in the field readily understand, the quantities of the components actually used will conform to the maximum of 100%.
[068] For a more complete understanding of this disclosure, the following terms are defined and should be used with the attached figures and the description of the various modalities throughout the text.
[069] As used in this document, the term “monomer” refers to a small molecule that can react chemically and bind chemically to you. Petition 870250084786, dated 09 / 19 / 2025, p. 21 / 154 13 / 123 same or other monomers to form a polymer. As used in this document, the term “α-olefin” or “alpha-olefin” is used to describe a monomer with a linear hydrocarbon chain with a double bond at one end of the chain and containing n = 3 to 20 carbon atoms with the chemical formula CnH2n; an equivalent term is “linear α-olefin”.
[070] As used in this document, the terms “polyethylene,” “polyethylene polymer,” or “ethylene polymer” refer to macromolecules produced from ethylene monomer and, optionally, at least one αolefin monomer; regardless of the specific catalyst or process used to produce the ethylene polymer. An ethylene polymer in its polymerized form will include more than 50% by weight (based on the weight of the ethylene polymer) of ethylene monomeric units. Common polyethylenes include high-density polyethylene (HDPE), medium-density polyethylene (MDPE), linear low-density polyethylene (LLDPE), very low-density polyethylene (LLDPE), ultra-low-density polyethylene (ULDPE), plastomers, and elastomers. The term polyethylene also includes combinations or mixtures of the polyethylenes described above.
[071] As used herein, the term “ethylene homopolymer” refers to a subset of polymers within the “ethylene polymer” group that are produced using only ethylene as a polymerizable monomer.
[072] The term “ethylene interpolymer” refers to a subset of polymers within the “ethylene polymer” group that are produced from ethylene and at least one α-olefin. Thus, as used herein, the term “ethylene interpolymer” includes ethylene polymers prepared from two polymerizable monomeric units (i.e., ethylene and one α-olefin) and ethylene polymers prepared from more than two polymerizable monomeric units (i.e., ethylene and two or more α-olefins). Petition 870250084786, dated 09 / 19 / 2025, p. 22 / 154 14 / 123
[073] The term “heterogeneously branched ethylene interpolymer” refers to a subset of ethylene interpolymers produced using a heterogeneous catalytic system; non-limiting examples of which include Ziegler-Natta or chromium catalysts, both well known in the art.
[074] The term “homogeneously branched ethylene interpolymer” refers to a subset of groups of ethylene interpolymers produced using single-site catalysts; non-limiting examples of which include metallocene catalysts, phosphinimine catalysts and restricted geometry catalysts, all well known in the art.
[075] Typically, homogeneously branched ethylene interpolymers exhibit narrow molecular weight distributions, for example, gel permeation chromatography (GPC) Mw / Mn values less than about 2.8, especially less than about 2.3, although exceptions may occur; Mw and Mn refer to weight-average and number-average molecular weights, respectively. In contrast, the Mw / Mn of heterogeneously branched ethylene interpolymers is typically higher than the Mw / Mn of homogeneously branched ethylene interpolymers. In general, homogeneously branched ethylene interpolymers also exhibit a narrow compositional distribution, i.e., each macromolecule within the molecular weight distribution has a similar αolefin comonomer content.
[076] A mixture of two or more homogeneously branched ethylene interpolymers, which differ in weight-average molecular weight (Mw), may have an Mw / Mn greater than or equal to 2.8; In this disclosure, such a mixture has been defined as a homogeneous mixture or homogeneous composition.
[077] The term “thermoplastic polymer” refers to a polymer that becomes liquid when heated, flows under pressure, and solidifies when cooled. Thermoplastic polymers include ethylene polymers, as well as other polymers used in Petition 870250084786, dated 09 / 19 / 2025, page 23 / 154 15 / 123 plastics industry; non-limiting examples of other polymers commonly used in film applications include barrier resins (e.g., EVOH), bonding resins, polyethylene terephthalate (PET), polyamides, ethylene-vinyl acetate (EVA) copolymers, and the like.
[078] As used herein, the term “monolayer film” refers to a film containing a single layer of one or more thermoplastic polymers.
[079] As used herein, the term “multilayer film” or “multilayer film structure” refers to a film composed of more than one thermoplastic layer or, optionally, non-thermoplastic layers. Non-limiting examples of non-thermoplastic materials include metal products (metal foil) or cellulosic products (paper). One or more thermoplastic layers within a multilayer film (or film structure) may be composed of more than one thermoplastic.
[080] As used in this document, the term “all-polyethylene film layer” refers to a monolayer film containing more than or equal to 90% of one or more ethylene polymers based on the total weight of the film layer.
[081] As used in this document, the term “all-polyethylene multilayer film structure” refers to a multilayer film structure containing more than or equal to 90% of one or more ethylene polymers based on the total weight of the multilayer film structure, excluding non-thermoplastic layers (if present).
[082] As used herein, the term “bonding resin” refers to a thermoplastic that, when formed into an intermediate layer, or a “bonding layer” within a multilayer film structure, promotes adhesion between adjacent film layers that are different in chemical composition. Petition 870250084786, dated 09 / 19 / 2025, page 24 / 154 16 / 123
[083] As used herein, the term “seal layer” refers to a layer of thermoplastic film that is capable of being bonded to a second substrate, forming a leak-proof seal. A “seal layer” can be a surface layer or the innermost layer in a multilayer film structure.
[084] As used herein, the term “adhesive lamination” and the term “extrusion lamination” describe continuous processes through which two or more substrates, or sheets of material, are combined to form a multilayer product or sheet; wherein the two or more sheets are joined together using an adhesive or a molten thermoplastic film, respectively.
[085] As used herein, the term “extrusion coating” describes a continuous process whereby a molten thermoplastic layer is combined with, or deposited onto, a moving solid network or substrate. Non-limiting examples of substrates include paper, cardboard, metal foil, single-layer plastic film, multi-layer plastic film, or fabric. The molten thermoplastic layer may be single-layer or multi-layer.
[086] As used herein, the terms “hydrocarbyl”, “hydrocarbyl radical” or “hydrocarbyl group” refer to linear or cyclic, aliphatic, olefinic, acetylenic and aryl (aromatic) radicals comprising hydrogen and carbon that are deficient in one hydrogen.
[087] As used herein, an “alkyl radical” includes linear, branched, and cyclic paraffinic radicals that are deficient in a hydrogen radical; non-limiting examples include methyl (-CH3) and ethyl (-CH2CH3) radicals. The term “alkenyl radical” refers to linear, branched, and cyclic hydrocarbons containing at least one carbon-carbon double bond deficient in a hydrogen radical.
[088] As used herein, the term “aryl” group includes phenyl, naphthyl, pyridyl and other radicals whose molecules have an aromatic ring structure; Petition 870250084786, dated 09 / 19 / 2025, page 25 / 154 17 / 123 Non-limiting examples include naphthylene, phenanthrene, and anthracene. An “arylalkyl” group is an alkyl group with a pendant aryl group; non-limiting examples include benzyl, phenethyl, and tolylmethyl; an “alkylaryl” is an aryl group with one or more pendant alkyl groups; non-limiting examples include tolyl, xylyl, mesityl, and cumyl.
[089] As used herein, the term “heteroatom” includes any atom other than carbon and hydrogen that can be bonded to carbon. A “heteroatom-containing group” is a hydrocarbon radical containing a heteroatom and may contain one or more identical or different heteroatoms. In one embodiment, a heteroatom-containing group is a hydrocarbyl group containing 1 to 3 atoms selected from the group consisting of boron, aluminum, silicon, germanium, nitrogen, phosphorus, oxygen, and sulfur. Non-limiting examples of heteroatom-containing groups include imine, amine, oxide, phosphine, ether, ketone, heterocyclic oxoazoline, oxazoline, thioethers, and the like. The term “heterocyclic” refers to ring systems with a carbon backbone comprising 1 to 3 atoms selected from the group consisting of boron, aluminum, silicon, germanium, nitrogen, phosphorus, oxygen, and sulfur.
[090] As used herein, the term “unsubstituted” means that the hydrogen radicals are attached to the molecular group following the term unsubstituted. The term “substituted” means that the group following this term has one or more moieties (non-hydrogen radicals) that have substituted one or more hydrogen radicals at any position within the group; non-limiting examples of moieties include halogen radicals (F, Cl, Br), hydroxyl groups, carbonyl groups, carboxyl groups, silyl groups, amine groups, phosphine groups, alkoxy groups, phenyl groups, naphthyl groups, C1 to C30 alkyl groups, C2 to C30 alkenyl groups, and combinations thereof. Non-limiting examples of substituted alkyls and aryls include: acyl radicals, alkylsilyl radicals, alkylamino radicals, alkoxy radicals, aryloxy radicals, radicals Petition 870250084786, dated 09 / 19 / 2025, page 26 / 154 18 / 123 alkylthio, dialkylamino radicals, alkoxycarbonyl radicals, aryloxycarbonyl radicals, carbomoyl radicals, alkyl- and dialkyl-carbamoyl radicals, acyloxy radicals, acylamino radicals, arylamino radicals and combinations thereof. DESCRIPTION OF THE MODALITIES
[091] In the present disclosure, an ethylene polymer composition in reactor mixture shall comprise at least two identifiable components; namely: a first ethylene polymer having a defined weight-average molecular weight Mw, a defined short-chain branching content and a defined polydispersity index Mw / Mn; and a second ethylene interpolymer having a defined weight-average molecular weight Mw, a defined short-chain branching content and a defined polydispersity index Mw / Mn. In some embodiments, the ethylene polymer composition further includes a third ethylene interpolymer.
[092] The first ethylene polymer, the second ethylene interpolymer, and the optional third ethylene interpolymer are identifiable using known fractionation techniques (e.g., thermal fractionation) and / or using reaction simulation deconvolution. Each of the first ethylene polymers, the second ethylene interpolymer, and the optional third ethylene interpolymer, and the ethylene polymer composition of which they are part, are described in more detail below. First ethylene polymer
[093] The first ethylene polymer comprises ethylene and optionally at least one α-olefin. In embodiments of the disclosure, the optional at least one α-olefin that can be polymerized with ethylene to form the first ethylene polymer can be selected from the group comprising propene-1, butene-1, pentene-1, hexene-1 and octene-1 and mixtures thereof.
[094] In one embodiment of the disclosure, the first ethylene polymer is a first ethylene homopolymer. Petition 870250084786, dated 09 / 19 / 2025, page 27 / 154 19 / 123
[095] In one embodiment of the disclosure, the first ethylene polymer is a first ethylene interpolymer.
[096] In one embodiment of the disclosure, the first ethylene polymer is a first ethylene / octene-1 interpolymer.
[097] In one embodiment of the disclosure, the first ethylene interpolymer is a homogeneously branched first ethylene interpolymer.
[098] In one embodiment of the disclosure, the first ethylene polymer is produced with a homogeneous first catalyst, non-limiting examples of which include phosphinimine catalysts and metallocene bridge catalysts, all of which are well known in the art.
[099] In one embodiment of the disclosure, the first ethylene polymer is produced with a homogeneous first catalyst, having hafnium, Hf, as the active metal center (i.e., the catalyst is a hafnocene catalyst).
[0100] In one embodiment of the disclosure, the first ethylene polymer is produced with a bridging metallocene catalyst.
[0101] In one embodiment of the disclosure, the first ethylene polymer is produced with a bridge metallocene catalyst having Formula (I): (I)
[0102] In Formula (I): M is a group 4 metal selected from titanium, zirconium, or hafnium; G is a group 14 element selected from carbon, silicon, germanium, tin, or lead; Ri is a hydrogen atom, a C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, or a C6-10 aryl oxide radical; R2 and Petition 870250084786, dated 09 / 19 / 2025, p. 28 / 154 20 / 123 R3 are independently selected from a hydrogen atom, a C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, or a C6-10 aryl oxide radical; R4 and R5 are independently selected from a hydrogen atom, an unsubstituted C1-20 hydrocarbyl radical, a substituted C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, or a C6-10 aryl oxide radical; and Q is independently an activatable leaving group ligand.
[0103] In one embodiment, R4 and R5 are independently an aril group.
[0104] In one embodiment, R4 and R5 are independently a phenyl group or a substituted phenyl group.
[0105] In one embodiment, R4 and R5 are a phenyl group.
[0106] In one embodiment, R4 and R5 are independently a substituted phenyl group.
[0107] In one embodiment, R4 and R5 are a substituted phenyl group, wherein the phenyl group is replaced with a substituted silyl group.
[0108] In one embodiment, R4 and R5 are a substituted phenyl group, wherein the phenyl group is substituted with a trialkyl silyl group.
[0109] In one embodiment, R4 and R5 are a substituted phenyl group, wherein the phenyl group is substituted in the para position with a trialkylsilyl group. In one embodiment, R1 and R2 are a substituted phenyl group, wherein the phenyl group is substituted in the para position with a trimethylsilyl group. In one embodiment, R1 and R2 are a substituted phenyl group, wherein the phenyl group is substituted in the para position with a triethylsilyl group.
[0110] In one embodiment, R4 and R5 are independently an alkyl group.
[0111] In one embodiment, R4 and R5 are independently an alkenyl group.
[0112] In one embodiment, R1 is hydrogen. Petition 870250084786, dated 09 / 19 / 2025, p. 29 / 154 21 / 123
[0113] In one embodiment, Ri is an alkyl group.
[0114] In one embodiment, R1 is an aril group.
[0115] In one embodiment, R1 is an alkenyl group.
[0116] In one embodiment, R2 and R3 are independently a hydrocarbyl group having from 1 to 30 carbon atoms.
[0117] In one embodiment, R2 and R3 are independently an aril group.
[0118] In one embodiment, R2 and R3 are independently an alkyl group.
[0119] In one embodiment, R2 and R3 are independently an alkyl group having from 1 to 20 carbon atoms.
[0120] In one embodiment, R2 and R3 are independently a phenyl group or a substituted phenyl group.
[0121] In one embodiment, R2 and R3 are a tert-butyl group.
[0122] In one embodiment, R2 and R3 are hydrogen.
[0123] In one modality, M is haphnic, Hf.
[0124] In one embodiment of the disclosure, the first ethylene polymer is produced with a bridge metallocene catalyst having Formula (Ia): (Ia)
[0125] In Formula (Ia): G is a group 14 element selected from carbon, silicon, germanium, tin, or lead; R1 is a hydrogen atom, a C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, or a C6-10 aryl oxide radical; R2 and R3 are independently selected from a hydrogen atom, Petition 870250084786, dated 09 / 19 / 2025, p. 30 / 154 22 / 123 a C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, or a C6-10 aryl oxide radical; R4 and R5 are independently selected from a hydrogen atom, an unsubstituted C1-20 hydrocarbyl radical, a substituted C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, or a C6-10 aryl oxide radical; and Q is independently an activatable leaving group ligand.
[0126] In this disclosure, the term “activatable” means that the ligand Q can be cleaved from the metal center M via a proteolysis reaction or abstracted from the metal center M by suitable acidic or electrophilic catalyst activating compounds (also known as “co-catalyst” compounds) respectively, examples of which are described below. The activatable ligand Q can also be transformed into another ligand that is cleaved or abstracted from the metal center M (for example, a halide can be converted into an alkyl group). Without adhering to any single theory, the protonolysis or abstraction reactions generate an active “cationic” metal center that can polymerize olefins.
[0127] In embodiments of the present disclosure, the activatable linker, Q, is independently selected from the group consisting of a hydrogen atom; a halogen atom; a C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, and a C6-10 aryl or aryloxy radical, where each of the hydrocarbyl, alkoxy, aryl or aryl oxide radicals may be unsubstituted or additionally substituted by one or more halogen groups or other; a C1-8 alkyl; a C1-8 alkoxy; a C6-10 aryl or aryloxy; an amido or phosphide radical, but where Q is not a cyclopentadienyl. Two linkers Q may also be joined to each other and form, for example, a substituted or unsubstituted diene linker (e.g., 1,3-butadiene); or a delocalized heteroatom containing a group such as an acetate or acetamidinate group.In a convenient embodiment of the disclosure, each Q is independently selected from the group consisting of a halide atom, a C14 alkyl radical, and a benzyl radical. Particularly suitable activatable Q ligands are mono. Petition 870250084786, dated 09 / 19 / 2025, page 31 / 154 23 / 123 anionic compounds such as a halide (e.g., chloride) or a hydrocarbyl (e.g., methyl, benzyl).
[0128] In one embodiment of the disclosure, the first homogeneous catalyst used to form the first ethylene polymer is diphenylmethylene(cyclopentadienyl)(2,7-di-t-butylfluorenyl)hafnium dichloride having the molecular formula: [(2,7-tBu2Flu)Ph2C(Cp)HfCl2].
[0129] In one embodiment of the disclosure, the first homogeneous catalyst used to form the first ethylene polymer is diphenylmethylene(cyclopentadienyl)(2,7-di-t-butylfluorenyl)hafnium dimethyl having the molecular formula: [(2,7-tBu2Flu)Ph2C(Cp)HfMe2].
[0130] In one embodiment of the disclosure, the first homogeneous catalyst is a phosphinimine catalyst represented by formula (II): (LA)aM*(PI)b(Q)n (II) where (LA) represents a bulky ligand; M* represents a metal atom; PI represents a phosphinimine ligand; Q is independently an activatable leaving group ligand; a is 0 or 1; b is 1 or 2; (a + b) = 2; n is 1 or 2; and the sum of (a + b + n) is equal to the valence of the metal M*.
[0131] In one embodiment of the disclosure, LA is selected from the group consisting of unsubstituted cyclopentadienyl, substituted cyclopentadienyl, unsubstituted indenyl, substituted indenyl, unsubstituted fluorenyl and substituted fluorenyl.
[0132] In one embodiment of the disclosure, M* is a metal selected from the group consisting of titanium, hafnium, and zirconium.
[0133] In additional non-limiting embodiments of the disclosure, the bulk linker LA in formula (II) includes unsubstituted or substituted cyclopentadienyl linkers or cyclopentadienyl type linkers, substituted cyclopentadienyl type linkers Petition 870250084786, dated 09 / 19 / 2025, p. 32 / 154 24 / 123 heteroatom-linked and / or heteroatom-containing ligands. In further non-limiting embodiments, the bulky ligand LA in formula (II) includes cyclopentaphenanthreneyl ligands, unsubstituted or substituted indenyl ligands, benzindenyl ligands, unsubstituted or substituted fluorenyl ligands, octahydrofluorenyl ligands, cyclooctatetraendyl ligands, cyclopentacyclododecene ligands, azenyl ligands, azulene ligands, pentalene ligands, phosphoyl ligands, phosphinimine ligands, pyrrolyl ligands, pyrozolyl ligands, carbazolyl ligands, borabenzene ligands and the like, including hydrogenated versions thereof, for example, tetrahydroindenyl ligands. In other embodiments, LA may be any other ligand structure capable of η-linking to metal M*, such embodiments include both η3-linking and η5-linking to metal M*.In other embodiments, LA may comprise one or more heteroatoms, for example, nitrogen, silicon, boron, germanium, sulfur, and phosphorus, in combination with carbon atoms to form an open, acyclic, or fused ring, or a system of rings, for example, a heterocyclopentadienyl auxiliary ligand. Other non-limiting embodiments for LA include bulky amides, phosphides, alkoxides, aryloxides, imides, carbolites, borolides, porphyrins, phthalocyanines, corrins, and other polyazomacrocycles.
[0134] In one embodiment of the disclosure, the metal M* is titanium, Ti.
[0135] The phosphinimine ligand, PI, is defined by formula (III): (Rp)3 P = N (III) where the Rp groups are independently selected from: a hydrogen atom; a halogen atom; C1-20 hydrocarbyl radicals that are unsubstituted or substituted with one or more halogen atom(s); a C1-8 alkoxy radical; a C6-10 aryl radical; a C6-10 aryloxy radical; an amido radical; a silyl radical of formula -Si(Rs)3, wherein the Rp groups are independently selected from, a hydrogen atom, a C1-8 alkyl or alkoxy radical, a Petition 870250084786, dated 09 / 19 / 2025, p. 33 / 154 25 / 123 aryl radical C6-10, an aryloxy radical C6-10, or a germanyl radical of formula Ge(RG)3, wherein the RG groups are defined as Rs defined in this paragraph.
[0136] In addition to the first homogeneous catalyst molecule per se, an active homogeneous catalyst system may further comprise one or more of the following: an alkylaluminoxane cocatalyst and an ionic activator. The homogeneous catalyst system may also optionally comprise a hindered phenol.
[0137] Although the exact structure of alkylaluminoxane is uncertain, experts in the field generally agree that it is an oligomeric species containing repeating units of the general formula: (R)2AlO-(Al(R)-O)n-Al(R)2 where the R groups can be identical or different linear, branched, or cyclic hydrocarbyl radicals containing 1 to 20 carbon atoms and n is from 0 to about 50. A non-limiting example of an alkylaluminoxane is methylaluminoxane (or MAO) in which each R group is a methyl radical.
[0138] In one embodiment of the disclosure, R of alkylaluminoxane, is a methyl radical in e from 10 to 40.
[0139] In one embodiment of the disclosure, the cocatalyst is modified methylaluminoxane (MMAO).
[0140] It is well known in the art that alkylaluminoxane can play dual roles not only as an alkylator but also as an activator. Therefore, an alkylaluminoxane cocatalyst is frequently used in combination with activatable ligands such as halogens.
[0141] In general, ionic activators comprise a bulky cation and anion; wherein the latter is substantially uncoordinated. Non-limiting examples of ionic activators are boron ionic activators which are tetracoordinated with four ligands bonded to the boron atom. Examples not Petition 870250084786, dated 09 / 19 / 2025, page 34 / 154 26 / 123 limiting compounds of boron ionic activators include the following formulas shown below: [R5]+[B(R7)4] - where B represents a boron atom, R5 is an aromatic hydrocarbyl (e.g., triphenylmethyl cation), and each R7 is independently selected from phenyl radicals that are unsubstituted or substituted with 3 to 5 substituents selected from fluorine atoms, C1-4 alkyl or alkoxy radicals that are unsubstituted or substituted by fluorine atoms; and a silyl radical of formula -Si(R9)3, where each R9 is independently selected from hydrogen atoms and C1-4 alkyl radicals, and [(R8)tZH]+[B(R7)4]-where B is a boron atom, H is a hydrogen atom, Z is a nitrogen or phosphorus atom, t is 2 or 3 and R8 is selected from C1-8 alkyl radicals, phenyl radicals that are unsubstituted or substituted by up to three C1-4 alkyl radicals, or an R8 taken together with the nitrogen atom can form an aniline radical and R7 is as defined above.
[0142] In both formulas, a non-limiting example of R7 is a pentafluorophenyl radical. In general, ionic boron activators can be described as tetra(perfluorophenyl) boron salts; non-limiting examples include aniline, carbonium, oxonium, phosphonium and sulfonium salts of tetra(perfluorophenyl) boron with aniline and trityl (or triphenylmethyl). Additional non-limiting examples of ionic activators include: triethylammonium tetra(phenyl)boron, tripropylammonium tetra(phenyl)boron, tri(n-butyl)ammonium tetra(phenyl)boron, trimethylammonium tetra(p-tolyl)boron, trimethylammonium tetra(o-tolyl)boron, tributylammonium tetra(pentafluorophenyl)boron, tripropylammonium tetra(o,p-dimethylphenyl)boron, tributylammonium tetra(m,m-dimethylphenyl)boron, tributylammonium tetra(p-trifluoromethylphenyl)boron, tributylammonium tetra(pentafluorophenyl)boron, tri(n-butyl)ammonium tetra(o-tolyl)boron, N,N Petition 870250084786, dated 09 / 19 / 2025, page 35 / 154 27 / 123 dimethylaniline tetra(phenyl)boron, N,N-diethylaniline tetra(phenyl)boron, N,N-diethylaniline tetra(phenyl)n-butylboron, N,N-2,4,6-pentamethylaniline tetra(phenyl)boron, di-(isopropyl)ammonium tetra(pentafluorophenyl)boron, dicyclohexylammonium tetra(phenyl)boron, triphenylphosphonium tetra(phenyl)boron, tri(methylphenyl)phosphonium tetra(phenyl)boron, tri(dimethylphenyl)phosphonium tetra(phenyl)boron, tropylium tetrakispentafluorophenyl borate, triphenylmethyl tetrakispentafluorophenyl borate, benzene(diazonium)tetrakispentafluorophenyl borate, tropylium tetrakis(2,3,5,6-tetrafluorophenyl)borate, triphenylmethyl tetrakis(2,3,5,6-tetrafluorophenyl)borate, benzene(diazonium) tetrakis(3,4,5-trifluorophenyl)borate, tropylium tetrakis(3,4,5-trifluorophenyl)borate, benzene(diazonium) tetrakis(3,4,5-trifluorophenyl)borate, tropylium tetrakis(1,2,2-trifluoroethenyl)borate, triphenylmethyl tetrakis(1,2,2-trifluoroethenyl)borate, benzene(diazonium) tetrakis(1,2,2-trifluoroethenyl)borate, tropylium tetrakis(2,3,4,5-tetrafluorophenyl)borate, triphenylmethyl tetrakis(2,3,4,5-tetrafluorophenyl)borate, and benzene(diazonium) tetrakis(2,3,4,5-tetrafluorophenyl)borate. Readily available commercial ionic activators include N,N-dimethylaniline tetrakispentafluorophenylborate and triphenylmethyl tetrakispentafluorophenylborate.
[0143] Non-limiting examples of hindered phenols include butylated phenolic antioxidants, butylated hydroxytoluene, 2,6-di-tert-butyl-4-ethylphenol, 4,4'-methylenebis(2,6-di-tert-butylphenol), 1,3,5-trimethyl-2,4,6-tris(3,5-di-tert-butyl-4-hydroxybenzyl)benzene and octadecyl-3-(3',5'-di-tert-butyl-4'-hydroxyphenyl)propionate.
[0144] To produce an active homogeneous catalyst system, the amount and molar ratios of the three or four components—the first homogeneous catalyst, the alkylaluminoxane, the ionic activator, and the optional hindered phenol—are optimized.
[0145] In one embodiment of the disclosure, the first homogeneous catalyst used to form the first ethylene polymer does not produce branching of Petition 870250084786, dated 09 / 19 / 2025, page 36 / 154 28 / 123 long chain, and / or the first ethylene polymer will not contain measurable amounts of long chain branching.
[0146] In one embodiment of the disclosure, the first homogeneous catalyst used to form the first ethylene polymer produces long-chain branches, and the first ethylene polymer will contain long-chain branches, hereafter referred to as “LCB”. LCB is a well-known structural phenomenon in ethylene polymers and well known to those with common knowledge in the art.
[0147] In one embodiment of the disclosure, the first ethylene polymer contains long-chain branching characterized by the LCBF disclosed in this document. In embodiments of the disclosure, the upper limit on the LCBF of the first ethylene polymer may be about 0.5, in other cases about 0.4, and in still other cases about 0.3 (dimensionless). In embodiments of the disclosure, the lower limit on the LCBF of the first ethylene polymer may be about 0.001, in other cases about 0.0015, and in still other cases about 0.002 (dimensionless).
[0148] In some embodiments of the disclosure, the upper limit of the molecular weight distribution (Mw / Mn) of the first ethylene polymer is about 2.3, or about 2.2, or about 2.1, or about 2.0. In some embodiments of the disclosure, the lower limit of the molecular weight distribution (Mw / Mn) of the first ethylene polymer is about 1.7, or about 1.8, or about 1.9.
[0149] In some embodiments of the disclosure, the first ethylene polymer has a molecular weight distribution (Mw / Mn) of < 2.3, or < 2.3, or < 2.2, or < 2.2, or < 2.1, or < 2.1. In some embodiments of the disclosure, the first ethylene polymer has a molecular weight distribution (Mw / Mn) from about 1.7 to about 2.3, or from about 1.8 to about 2.3, or from about 1.8 to about 2.2.
[0150] In one embodiment, the first ethylene polymer has a number of short-chain branches per thousand carbon atoms from 0 to 10. In Petition 870250084786, dated 09 / 19 / 2025, p. 37 / 154 29 / 123 additional embodiments, the first ethylene polymer has from greater than (>) 0 to 10 short-chain branches per thousand carbon atoms, or from 0 to 6 short-chain branches per thousand carbon atoms, or greater than (>) 0 to 6 short-chain branches per thousand carbon atoms, or from 0 to 5 short-chain branches per thousand carbon atoms, or from greater than (>) 0 to 5 short-chain branches per thousand carbon atoms, or from 0.005 to 6 short-chain branches per thousand carbon atoms. Still in additional embodiments, the first ethylene polymer has from 0.01 to 6 short-chain branches per thousand carbon atoms, or from 0.1 to 6 short-chain branches per thousand carbon atoms, or from 0.5 to 6 short-chain branches per thousand carbon atoms.
[0151] In some embodiments, the first ethylene polymer contains 0 short-chain branches per thousand carbon atoms.
[0152] Short chain branching (i.e., short chain branching per thousand carbon atoms) is branching by virtue of the presence of at least one optional α-olefin in the first ethylene polymer and, if present, will have, for example, two carbon atoms for butene-1, or four carbon atoms for hexene-1, or six carbon atoms for octene-1, etc.
[0153] In one embodiment of the disclosure, the first ethylene polymer has a weighted average molecular weight, Mw, of from 70 kg / mol to 250 kg / mol, or from 70 kg / mol to 200 kg / mol, or from 70 kg / mol to 180 kg / mol, or from 70 kg / mol to 160 kg / mol, or from 75 kg / mol to 160 kg / mol, or from 80 kg / mol to 160 kg / mol, or from 85 kg / mol to 160 kg / mol, or from 90 kg / mol to 160 kg / mol, or from 100 kg / mol to 160 kg / mol.
[0154] In some embodiments of the disclosure, the upper limit of the weight percentage of the first ethylene polymer in the ethylene polymer composition (i.e., the weight percentage of the first ethylene polymer based on the pe Petition 870250084786, dated 09 / 19 / 2025, page 38 / 154 30 / 123 so total of the ethylene polymer composition) is about 70 percent by weight, or about 65 percent by weight, or about 60 percent by weight, or about 55 percent by weight, or about 52 percent by weight, or about 50 percent by weight. In some embodiments of the disclosure, the lower limit of the percentage by weight of the first ethylene polymer in the ethylene polymer composition is about 30 percent by weight, or about 35 percent by weight, or about 40 percent by weight, or about 45 percent by weight, or about 50 percent. In one embodiment, the first ethylene polymer is present in the ethylene polymer composition in an amount from 30 to 70 percent by weight. In another embodiment, the ethylene homopolymer is present in the ethylene polymer composition in an amount from 40 to 60 percent by weight.In yet another embodiment, the ethylene homopolymer is present in the ethylene polymer composition in an amount ranging from 35 to 50 percent by weight. Second Ethylene Interpolymer
[0155] The second ethylene interpolymer comprises ethylene and at least one α-olefin. In embodiments of the disclosure, the at least one α-olefin that can be polymerized with ethylene to form the second ethylene interpolymer can be selected from the group comprising propene-1, butene-1, pentene-1, hexene-1 and octene-1 and mixtures thereof.
[0156] In one embodiment of the disclosure, the second ethylene interpolymer is a second ethylene interpolymer.
[0157] In one embodiment of the disclosure, the second ethylene interpolymer is a second ethylene / octene-1 interpolymer.
[0158] In one embodiment of the disclosure, the second ethylene interpolymer is a homogeneously branched second ethylene interpolymer.
[0159] In one embodiment of the disclosure, the second ethylene interpolymer is produced with a second homogeneous catalyst, non-limiting examples Petition 870250084786, dated 09 / 19 / 2025, page 39 / 154 31 / 123 of which include phosphinimine catalysts and metallocene catalysts in bridges, all of which are well known in the art.
[0160] In one embodiment of the disclosure, the second ethylene interpolymer is produced with a second homogeneous catalyst, having hafnium, Hf, as the active metal center (i.e., the catalyst is a hafnocene catalyst).
[0161] In one embodiment of the disclosure, the second ethylene interpolymer is produced with a bridging metallocene catalyst.
[0162] In one embodiment of the disclosure, the second ethyl interpolymer is produced with a bridged metallocene catalyst having Formula (I): Q (I)
[0163] In Formula (I): M is a group 4 metal selected from titanium, zirconium, or hafnium; G is a group 14 element selected from carbon, silicon, germanium, tin, or lead; Ri is a hydrogen atom, a C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, or a C6-10 aryl oxide radical; R2 and R3 are independently selected from a hydrogen atom, a C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, or a C6-10 aryl oxide radical; R4 and R5 are independently selected from a hydrogen atom, an unsubstituted C1-20 hydrocarbyl radical, a substituted C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, or a C6-10 aryl oxide radical; and Q is independently an activatable leaving group ligand.
[0164] In one embodiment, R4 and R5 are independently an aril group. Petition 870250084786, dated 09 / 19 / 2025, p. 40 / 154 32 / 123
[0165] In one embodiment, R4 and R5 are independently a phenyl group or a substituted phenyl group.
[0166] In one embodiment, R4 and R5 are a phenyl group.
[0167] In one embodiment, R4 and R5 are independently a substituted phenyl group.
[0168] In one embodiment, R4 and R5 are a substituted phenyl group, wherein the phenyl group is replaced with a substituted silyl group.
[0169] In one embodiment, R4 and R5 are a substituted phenyl group, wherein the phenyl group is substituted with a trialkyl silyl group.
[0170] In one embodiment, R4 and R5 are a substituted phenyl group, wherein the phenyl group is substituted in the para position with a trialkylsilyl group. In one embodiment, R1 and R2 are a substituted phenyl group, wherein the phenyl group is substituted in the para position with a trimethylsilyl group. In one embodiment, R1 and R2 are a substituted phenyl group, wherein the phenyl group is substituted in the para position with a triethylsilyl group.
[0171] In one embodiment, R4 and R5 are independently an alkyl group.
[0172] In one embodiment, R4 and R5 are independently an alkenyl group.
[0173] In one embodiment, Ri is hydrogen.
[0174] In one embodiment, Ri is an alkyl group.
[0175] In one embodiment, R1 is an aril group.
[0176] In one embodiment, R1 is an alkenyl group.
[0177] In one embodiment, R2 and R3 are independently a hydrocarbyl group having from 1 to 30 carbon atoms.
[0178] In one embodiment, R2 and R3 are independently an aril group. Petition 870250084786, dated 09 / 19 / 2025, p. 41 / 154 33 / 123
[0179] In one embodiment, R2 and R3 are independently an alkyl group.
[0180] In one embodiment, R2 and R3 are independently an alkyl group having from 1 to 20 carbon atoms.
[0181] In one embodiment, R2 and R3 are independently a phenyl group or a substituted phenyl group.
[0182] In one embodiment, R2 and R3 are a tert-butyl group.
[0183] In one embodiment, R2 and R3 are hydrogen.
[0184] In one modality, M is haphnic, Hf.
[0185] In one embodiment of the disclosure, the second ethylene interpolymer is produced with a bridged metallocene catalyst having Formula (Ia): (Ia)
[0186] In Formula (Ia): G is a group 14 element selected from carbon, silicon, germanium, tin, or lead; Ri is a hydrogen atom, a C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, or a C6-10 aryl oxide radical; R2 and R3 are independently selected from a hydrogen atom, a C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, or a C6-10 aryl oxide radical; R4 and R5 are independently selected from a hydrogen atom, an unsubstituted C1-20 hydrocarbyl radical, a substituted C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, or a C6-10 aryl oxide radical; and Q is independently an activatable leaving group ligand. Petition 870250084786, dated 09 / 19 / 2025, p. 42 / 154 34 / 123
[0187] In this disclosure, the term “activatable” means that the ligand Q can be cleaved from the metal center M via a proteolysis reaction or abstracted from the metal center M by suitable acidic or electrophilic catalyst activating compounds (also known as “co-catalyst” compounds) respectively, examples of which are described below. The activatable ligand Q can also be transformed into another ligand that is cleaved or abstracted from the metal center M (for example, a halide can be converted into an alkyl group). Without adhering to any single theory, the protonolysis or abstraction reactions generate an active “cationic” metal center that can polymerize olefins.
[0188] In embodiments of the present disclosure, the activatable linker, Q, is independently selected from the group consisting of a hydrogen atom; a halogen atom; a C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, and a C6-10 aryl or aryloxy radical, where each of the hydrocarbyl, alkoxy, aryl or aryl oxide radicals may be unsubstituted or additionally substituted by one or more halogen groups or other; a C1-8 alkyl; a C1-8 alkoxy; a C6-10 aryl or aryloxy; an amido or phosphide radical, but where Q is not a cyclopentadienyl. Two linkers Q may also be joined to each other and form, for example, a substituted or unsubstituted diene linker (e.g., 1,3-butadiene); or a delocalized heteroatom containing a group such as an acetate or acetamidinate group.In a convenient embodiment of the disclosure, each Q is independently selected from the group consisting of a halide atom, a C14 alkyl radical, and a benzyl radical. Particularly suitable activatable Q ligands are monoanionic, such as a halide (e.g., chloride) or a hydrocarbyl (e.g., methyl, benzyl).
[0189] In one embodiment of the disclosure, the second homogeneous catalyst used to form the second ethylene interpolymer is diphenylmethylene(cyclopentadienyl)(2,7-di-t-butylfluorenyl)hafnium dichloride having the molecular formula: Petition 870250084786, dated 09 / 19 / 2025, page 43 / 154 35 / 123 [(2,7-tBu2Flu)Ph2C(Cp)HfCl2].
[0190] In one embodiment of the disclosure, the second homogeneous catalyst used to form the second ethylene interpolymer is diphenylmethylene(cyclopentadienyl)(2,7-di-t-butylfluorenyl)hafnium dimethyl having the molecular formula: [(2,7-tBu2Flu)Ph2C(Cp)HfMe2].
[0191] In one embodiment of the disclosure, the second homogeneous catalyst is a phosphinimine catalyst represented by formula (II): (LA)aM*(PI)b(Q)n (II)
[0192] where (LA) represents a bulky ligand; M* represents a metal atom; PI represents a phosphinimine ligand; Q is independently an activatable leaving group ligand; a is 0 or 1; b is 1 or 2; (a + b) = 2; n is 1 or 2; and the sum of (a + b + n) is equal to the valence of the metal M*.
[0193] In one embodiment of the disclosure, LA is selected from the group consisting of unsubstituted cyclopentadienyl, substituted cyclopentadienyl, unsubstituted indenyl, substituted indenyl, unsubstituted fluorenyl and substituted fluorenyl.
[0194] In one embodiment of the disclosure, M* is a metal selected from the group consisting of titanium, hafnium, and zirconium.
[0195] In further non-limiting embodiments of the disclosure, the bulky LA ligand in formula (II) includes unsubstituted or substituted cyclopentadienyl ligands or cyclopentadienyl-type ligands, heteroatom-substituted and / or heteroatom-containing cyclopentadienyl-type ligands. In further non-limiting embodiments, the bulky LA ligand in formula (II) includes cyclopentaphenanthreneyl ligands, unsubstituted or substituted indenyl ligands, benzindenyl ligands, unsubstituted or substituted fluorenyl ligands, octahydrofluorenyl ligands, cyclooctatetraenyl ligands, cyclopentacyclododecene ligands, azenyl ligands, azulene ligands, Petition 870250084786, dated 09 / 19 / 2025, p. 44 / 154 36 / 123 pentalene ligands, phosphoyl ligands, phosphinimine ligands, pyrrolyl ligands, pyrozolol ligands, carbazolyl ligands, borabenzene ligands and the like, including hydrogenated versions thereof, for example tetrahydroindenyl ligands. In other embodiments, LA may be any other ligand structure capable of η-bonding to the M* metal, such embodiments include both η3-bonding and η5-bonding to the M* metal. In other embodiments, LA may comprise one or more heteroatoms, for example nitrogen, silicon, boron, germanium, sulfur and phosphorus, in combination with carbon atoms to form an open, acyclic or fused ring, or a system of rings, for example, a heterocyclopentadienyl auxiliary ligand. Other non-limiting forms of LA include bulky amides, phosphides, alkoxides, aryloxides, imides, carbolites, borolides, porphyrins, phthalocyanines, corrins, and other polyazomacrocycles.
[0196] In one embodiment of the disclosure, the metal M* is titanium, Ti.
[0197] The phosphinimine ligand, PI, is defined by formula (III): (Rp)3 P = N (III) wherein the Rp groups are independently selected from: a hydrogen atom; a halogen atom; C1-20 hydrocarbyl radicals that are unsubstituted or substituted with one or more halogen atom(s); a C1-8 alkoxy radical; a C6-10 aryl radical; a C6-10 aryloxy radical; an amido radical; a silyl radical of formula -Si(Rs)3, wherein the Rs groups are independently selected from, a hydrogen atom, a C1-8 alkyl or alkoxy radical, a C6-10 aryl radical, a C6-10 aryloxy radical, or a germanyl radical of formula Ge(RG)3, wherein the RG groups are defined as Rs defined in this paragraph.
[0198] In addition to the second homogeneous catalyst molecule per se, an active homogeneous catalyst system may additionally comprise one or more of the following: an alkylaluminoxane cocatalyst and an ionic activator. The Petition 870250084786, dated 09 / 19 / 2025, p. 45 / 154 37 / 123 homogeneous catalyst system may also optionally comprise a hindered phenol.
[0199] Although the exact structure of alkylaluminoxane is uncertain, experts in the field generally agree that it is an oligomeric species containing repeating units of the general formula: (R)2AlO-(Al(R)-O)n-Al(R)2 where the R groups can be identical or different linear, branched, or cyclic hydrocarbyl radicals containing 1 to 20 carbon atoms and is from 0 to about 50. A non-limiting example of an alkylaluminoxane is methylaluminoxane (or MAO) where each R group is a methyl radical.
[0200] In one embodiment of the disclosure, Rdo alkylaluminoxane, is a methyl radical in e from 10 to 40.
[0201] In one embodiment of the disclosure, the cocatalyst is modified methylaluminoxane (MMAO).
[0202] It is well known in the art that alkylaluminoxane can play dual roles not only as an alkylator but also as an activator. Therefore, an alkylaluminoxane cocatalyst is frequently used in combination with activatable ligands such as halogens.
[0203] In general, ionic activators comprise a bulky cation and anion; wherein the latter is substantially uncoordinated. Non-limiting examples of ionic activators are boron ionic activators which are tetra-coordinated with four ligands bonded to the boron atom. Non-limiting examples of boron ionic activators include the following formulas shown below: [R5]+[B(R7)4] - where B represents a boron atom, R5 is an aromatic hydrocarbyl (e.g., triphenylmethyl cation), and each R7 is independently selected from Petition 870250084786, dated 09 / 19 / 2025, page 46 / 154 38 / 123 of phenyl radicals that are unsubstituted or substituted with 3 to 5 substituents selected from fluorine atoms, C1-4 alkyl or alkoxy radicals that are unsubstituted or substituted by fluorine atoms; and a silyl radical of formula -Si(R9)3, where each R9 is independently selected from hydrogen atoms and C1-4 alkyl radicals, and [(R8)tZH]+[B(R7)4]-where B is a boron atom, H is a hydrogen atom, Z is a nitrogen or phosphorus atom, t is 2 or 3 and R8 is selected from C1-8 alkyl radicals, phenyl radicals that are unsubstituted or substituted by up to three C1-4 alkyl radicals, or an R8 taken together with the nitrogen atom can form an aniline radical and R7 is as defined above.
[0204] In both formulas, a non-limiting example of R7 is a pentafluorophenyl radical. In general, ionic boron activators can be described as tetra(perfluorophenyl)boron salts; non-limiting examples include aniline, carbonium, oxonium, phosphonium and sulfonium salts of tetra(perfluorophenyl)boron with aniline and trityl (or triphenylmethyl).Additional non-limiting examples of ionic activators include: triethylammonium tetra(phenyl)boron, tripropylammonium tetra(phenyl)boron, tri(n-butyl)ammonium tetra(phenyl)boron, trimethylammonium tetra(p-tolyl)boron, trimethylammonium tetra(o-tolyl)boron, tributylammonium tetra(pentafluorophenyl)boron, tripropylammonium tetra(o,p-dimethylphenyl)boron, tributylammonium tetra(m,m-dimethylphenyl)boron, tributylammonium tetra(p-trifluoromethylphenyl)boron, tributylammonium tetra(pentafluorophenyl)boron, tri(n-butyl)ammonium tetra(o-tolyl)boron, N,N-dimethylaniline tetra(phenyl)boron, N,N-diethylaniline tetra(phenyl)boron, N,N-diethylaniline tetra(phenyl)n-butylboron, N,N-2,4,6-pentamethylaniline tetra(phenyl)boron, di-(isopropyl)ammonium tetra(pentafluorophenyl)boron, dicyclohexylammonium tetra(phenyl)boron, triphenylphosphonium tetra(phenyl)boron, tri(methylphenyl)phosphonium tetra(phenyl)boron, tri(dimethylphenyl)phosphonium tetra(phenyl)boron, tropylium tetraquispentafluorophenyl borate, triphenylmethyl tetraquispentaflu. Petition 870250084786, dated 09 / 19 / 2025, page 47 / 154 39 / 123 orophenyl borate, benzene(diazonium) tetrakispentafluorophenyl borate, tropylium tetrakis(2,3,5,6-tetrafluorophenyl)borate, triphenylmethyl tetrakis(2,3,5,6-tetrafluorophenyl)borate, benzene(diazonium) tetrakis(3,4,5-trifluorophenyl)borate, tropylium tetrakis(3,4,5-trifluorophenyl)borate, benzene(diazonium) tetrakis(3,4,5-trifluorophenyl)borate, tropylium tetrakis(1,2,2-trifluoroethenyl)borate, triphenylmethyl tetrakis(1,2,2-trifluoroethenyl)borate, benzene(diazonium) tetrakis(1,2,2-trifluoroethenyl)borate, tropylium tetrakis(2,3,4,5-tetrafluorophenyl)borate, triphenylmethyl tetrakis(2,3,4,5-tetrafluorophenyl)borate, and benzene(diazonium) tetrakis(2,3,4,5-tetrafluorophenyl)borate. Readily available commercial ionic activators include N,N-dimethylaniline tetrakispentafluorophenylborate and triphenylmethyl tetrakispentafluorophenylborate.
[0205] Non-limiting examples of hindered phenols include butylated phenolic antioxidants, butylated hydroxytoluene, 2,6-di-tert-butyl-4-ethyl phenol, 4,4'-methylenebis(2,6-di-tert-butylphenol), 1,3,5-trimethyl-2,4,6-tris(3,5-di-tert-butyl-4-hydroxybenzyl)benzene and octadecyl-3-(3',5'-di-tert-butyl-4'-hydroxyphenyl)propionate.
[0206] To produce an active homogeneous catalyst system, the amount and molar ratios of the three or four components—the first homogeneous catalyst, the alkylaluminoxane, the ionic activator, and the optional hindered phenol—are optimized.
[0207] In one embodiment of the disclosure, the second homogeneous catalyst used to form the second ethylene interpolymer does not produce long-chain branches, and / or the second ethylene interpolymer will not contain measurable amounts of long-chain branches.
[0208] In one embodiment of the disclosure, the second homogeneous catalyst used to form the second ethylene interpolymer produces long-chain branches, and the second ethylene interpolymer will contain long-chain branches, hereafter referred to as “LCB”. LCB is a well-known structural phenomenon in Petition 870250084786, dated 09 / 19 / 2025, page 48 / 154 40 / 123 ethylene polymers and well known to those with common knowledge in the art.
[0209] In one embodiment of the disclosure, the second ethylene interpolymer contains long-chain branching characterized by the LCBF disclosed in this document. In embodiments of the disclosure, the upper limit on the LCBF of the second ethylene interpolymer may be about 0.5, in other cases about 0.4, and in still other cases about 0.3 (dimensionless). In embodiments of the disclosure, the lower limit on the LCBF of the second ethylene interpolymer may be about 0.001, in other cases about 0.0015, and in still other cases about 0.002 (dimensionless).
[0210] In some embodiments of the disclosure, the upper limit of the molecular weight distribution (Mw / Mn) of the second ethylene interpolymer is about 2.3, or about 2.2, or about 2.1, or about 2.0. In some embodiments of the disclosure, the lower limit of the molecular weight distribution (Mw / Mn) of the second ethylene interpolymer is about 1.7, or about 1.8, or about 1.9.
[0211] In some embodiments of the disclosure, the second ethylene interpolymer has a molecular weight distribution (Mw / Mn) of < 2.3, or < 2.3, or < 2.2, or < 2.2, or < 2.1, or < 2.1. In some embodiments of the disclosure, the second ethylene interpolymer has a molecular weight distribution (Mw / Mn) from about 1.7 to about 2.3, or from about 1.8 to about 2.3, or from about 1.8 to about 2.2.
[0212] In one embodiment, the second ethylene interpolymer has a number of short-chain branches per thousand carbon atoms from 25 to 55. In further embodiments, the second ethylene interpolymer has from 30 to 50 short-chain branches per thousand carbon atoms, or from 30 to 45 short-chain branches per thousand carbon atoms, or from 30 to 40 short-chain branches per thousand carbon atoms, or from 31 to 55 short-chain branches per thousand carbon atoms. Petition 870250084786, dated 09 / 19 / 2025, p. 49 / 154 41 / 123 short-chain branches per thousand carbon atoms, or from 31 to 50 short-chain branches per thousand carbon atoms, or from 33 to 45 short-chain branches per thousand carbon atoms, or from 33 to 40 short-chain branches per thousand carbon atoms. In further embodiments, the second ethylene interpolymer has from 25 to 50 short-chain branches per thousand carbon atoms, or from 27 to 48 short-chain branches per thousand carbon atoms, or from 27 to 45 short-chain branches per thousand carbon atoms.
[0213] It is recognized by those skilled in the art that short-chain branching (i.e., short-chain branching by one thousand carbon atoms) is branching by virtue of the presence of at least one α-olefin in the second ethylene interpolymer and will have, for example, two carbon atoms for butene-1, or four carbon atoms for hexene-1, or six carbon atoms for octene-1, etc.
[0214] In one embodiment of the disclosure, the second ethylene interpolymer has a weighted average molecular weight, Mw, of from 20 kg / mol to 75 kg / mol, or from 20 kg / mol to 70 kg / mol, or from 30 kg / mol to 65 kg / mol, or from 35 kg / mol to 60 kg / mol, or from 40 kg / mol to 60 kg / mol, or from 40 kg / mol to 55 kg / mol.
[0215] The weight-average molecular weight of the second ethylene interpolymer is less than the weight-average molecular weight of the first ethylene polymer. In some embodiments, the ratio of the weight-average molecular weight of the first ethylene polymer to the weight-average molecular weight of the second ethylene interpolymer is greater than or equal to 1.5 and less than or equal to 6. In some embodiments, the ratio of the weight-average molecular weight of the first ethylene polymer to the weight-average molecular weight of the second ethylene interpolymer is greater than or equal to 2 and less than or equal to 4. In some embodiments Petition 870250084786, dated 09 / 19 / 2025, page 50 / 154 42 / 123 embodiments, a ratio of the weight-average molecular weight of the first ethylene polymer to the weight-average molecular weight of the second ethylene interpolymer is greater than or equal to 2.5 and less than or equal to 4.0. In some embodiments, a ratio of the weight-average molecular weight of the first ethylene polymer to the weight-average molecular weight of the second ethylene interpolymer is greater than or equal to 2 and less than or equal to 3.
[0216] In one embodiment of the disclosure, the second ethylene interpolymer has a number average molecular weight, Mn, of from 10 kg / mol to 40 kg / mol, or from 15 kg / mol to 40 kg / mol, or from 15 kg / mol to 34 kg / mol, or from 15 kg / mol to 30 kg / mol.
[0217] In some embodiments of the disclosure, the upper limit of the weight percentage of the second ethylene interpolymer in the ethylene polymer composition (i.e., the weight percentage of the second ethylene interpolymer based on the total weight of the ethylene polymer composition) is about 70 percent by weight, or about 65 percent by weight, or about 60 percent by weight, or about 55 percent by weight, or about 52 percent by weight, or about 50 percent by weight. In some embodiments of the disclosure, the lower limit of the weight percentage of the second ethylene interpolymer in the ethylene polymer composition is about 30 percent by weight, or about 35 percent by weight, or about 40 percent by weight, or about 45 percent by weight, or about 50 percent. In one embodiment, the second ethylene interpolymer is present in the ethylene polymer composition in an amount ranging from 30 to 70 percent by weight.In another embodiment, the second ethylene interpolymer is present in the ethylene polymer composition in an amount ranging from 40 to 60 percent by weight. In yet another embodiment, the second ethylene interpolymer is present in the ethylene polymer composition in an amount ranging from 50 to 65 percent by weight. Petition 870250084786, dated 09 / 19 / 2025, page 51 / 154 43 / 123 Third Ethylene Interpolymer
[0218] The third ethylene interpolymer comprises ethylene and at least one α-olefin. In embodiments of the disclosure, the at least one α-olefin that is polymerized with ethylene to form the third ethylene interpolymer may be selected from the group comprising propene-1, butene-1, pentene-1, hexene-1 and octene-1 and mixtures thereof.
[0219] In one embodiment of the disclosure, the third ethylene interpolymer is a third ethylene / octene-1 interpolymer.
[0220] In one embodiment of the disclosure, the third ethylene interpolymer is a homogeneously branched third ethylene interpolymer.
[0221] In one embodiment of the disclosure, the third ethylene interpolymer is produced with a third homogeneous catalyst, non-limiting examples of which include phosphinimine catalysts and metallocene catalysts in bridging, all of which are well known in the art.
[0222] In one embodiment of the disclosure, the third ethylene interpolymer is produced with a third homogeneous catalyst, having hafnium, Hf, as the active metal center (i.e., the catalyst is a hafnocene catalyst).
[0223] In one embodiment of the disclosure, the third ethylene interpolymer is produced with a bridging metallocene catalyst.
[0224] In one embodiment of the disclosure, the third ethylene interpolymer is produced with a bridged metallocene catalyst having Formula (I): G M Q Q (I) Petition 870250084786, dated 09 / 19 / 2025, p. 52 / 154 44 / 123
[0225] In Formula (I): M is a group 4 metal selected from titanium, zirconium, or hafnium; G is a group 14 element selected from carbon, silicon, germanium, tin, or lead; Ri is a hydrogen atom, a C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, or a C6-10 aryl oxide radical; R2 and R3 are independently selected from a hydrogen atom, a C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, or a C6-10 aryl oxide radical; R4 and R5 are independently selected from a hydrogen atom, an unsubstituted C1-20 hydrocarbyl radical, a substituted C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, or a C6-10 aryl oxide radical; and Q is independently an activatable leaving group ligand.
[0226] In one embodiment, R4 and R5 are independently an aril group.
[0227] In one embodiment, R4 and R5 are independently a phenyl group or a substituted phenyl group.
[0228] In one embodiment, R4 and R5 are a phenyl group.
[0229] In one embodiment, R4 and R5 are independently a substituted phenyl group.
[0230] In one embodiment, R4 and R5 are a substituted phenyl group, wherein the phenyl group is replaced with a substituted silyl group.
[0231] In one embodiment, R4 and R5 are a substituted phenyl group, wherein the phenyl group is substituted with a trialkylsyl group.
[0232] In one embodiment, R4 and R5 are a substituted phenyl group, wherein the phenyl group is substituted in the para position with a trialkylsilyl group. In one embodiment, R1 and R2 are a substituted phenyl group, wherein the phenyl group is substituted in the para position with a trimethylsilyl group. In one embodiment, R1 and R2 are a substituted phenyl group, wherein the phenyl group is substituted in the para position with a triethylsilyl group. Petition 870250084786, dated 09 / 19 / 2025, p. 53 / 154 45 / 123
[0233] In one embodiment, R4 and R5 are independently an alkyl group.
[0234] In one embodiment, R4 and R5 are independently an alkenyl group.
[0235] In one embodiment, Ri is hydrogen.
[0236] In one embodiment, Ri is an alkyl group.
[0237] In one modality, Ri is an arila group.
[0238] In one embodiment, Ri is an alkenyl group.
[0239] In one embodiment, R2 and R3 are independently a hydrocarbyl group having from 1 to 30 carbon atoms.
[0240] In one embodiment, R2 and R3 are independently an aril group.
[0241] In one embodiment, R2 and R3 are independently an alkyl group.
[0242] In one embodiment, R2 and R3 are independently an alkyl group having from 1 to 20 carbon atoms.
[0243] In one embodiment, R2 and R3 are independently a phenyl group or a substituted phenyl group.
[0244] In one embodiment, R2 and R3 are a tert-butyl group.
[0245] In one embodiment, R2 and R3 are hydrogen.
[0246] In one modality, M is haphnic, Hf.
[0247] In one embodiment of the disclosure, the third ethylene interpolymer is produced with a bridged metallocene catalyst having Formula (Ia): Petition 870250084786, dated 09 / 19 / 2025, p. 54 / 154 46 / 123 (Ia)
[0248] In Formula (Ia): G is a group 14 element selected from carbon, silicon, germanium, tin, or lead; Ri is a hydrogen atom, a C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, or a C6-10 aryl oxide radical; R2 and R3 are independently selected from a hydrogen atom, a C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, or a C6-10 aryl oxide radical; R4 and R5 are independently selected from a hydrogen atom, an unsubstituted C1-20 hydrocarbyl radical, a substituted C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, or a C6-10 aryl oxide radical; and Q is independently an activatable leaving group ligand.
[0249] In the present disclosure, the term “activatable” means that the ligand Q can be cleaved from the metal center M via a proteolysis reaction or abstracted from the metal center M by suitable acidic or electrophilic catalyst activating compounds (also known as “co-catalyst” compounds) respectively, examples of which are described below. The activatable ligand Q can also be transformed into another ligand that is cleaved or abstracted from the metal center M (for example, a halide can be converted into an alkyl group). Without adhering to any single theory, the protonolysis or abstraction reactions generate an active “cationic” metal center that can polymerize olefins.
[0250] In embodiments of the present disclosure, the activatable ligand, Q is independently selected from the group consisting of a hydrogen atom; a halogen atom; a C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, Petition 870250084786, dated 09 / 19 / 2025, p. 55 / 154 47 / 123 and an aryl Ce-io or aryloxy radical, where each of the hydrocarbyl, alkoxy, aryl or aryl oxide radicals may be unsubstituted or additionally substituted by one or more halogen groups or other; a C1-8 alkyl; a C1-8 alkoxy; a C1-io or aryloxy aryl; an amido or phosphide radical, but where Q is not a cyclopentadienyl. Two Q ligands may also be joined to each other and form, for example, a substituted or unsubstituted diene ligand (e.g., 1,3-butadiene); or a delocalized heteroatom containing a group such as an acetate or acetamidinate group. In a convenient embodiment of the disclosure, each Q is independently selected from the group consisting of a halide atom, a C14 alkyl radical and a benzyl radical. Particularly suitable Q-activatable ligands are monoanionic ligands such as a halide (e.g., chloride) or a hydrocarbyl (e.g., methyl, benzyl). [025I] In one embodiment of the disclosure, the third homogeneous catalyst used to form the third ethylene interpolymer is diphenylmethylene(cyclopentadienyl)(2,7-di-t-butylfluorenyl)hafnium dichloride having the molecular formula: [(2,7-tBu2Flu)Ph2C(Cp)HfCl2].
[0252] In one embodiment of the disclosure, the third homogeneous catalyst used to form the third ethylene interpolymer is diphenylmethylene(cyclopentadienyl)(2,7-di-t-butylfluorenyl)hafnium dimethyl having the molecular formula: [(2,7-tBu2Flu)Ph2C(Cp)HfMe2].
[0253] In one embodiment of the disclosure, the third homogeneous catalyst is a phosphinimine catalyst represented by formula (II): (LA)aM*(PI)b(Q)n (II) where (LA) represents a bulky ligand; M* represents a metal atom; PI represents a phosphinimine ligand; Q is independently a ligand of Petition 870250084786, dated 09 / 19 / 2025, page 56 / 154 48 / 123 activatable leaving group; a is 0 or 1; b is 1 or 2; (a + b) = 2; n is 1 or 2; and the sum of (a + b + n) is equal to the valence of the metal M*.
[0254] In one embodiment of the disclosure, LA is selected from the group consisting of unsubstituted cyclopentadienyl, substituted cyclopentadienyl, unsubstituted indenyl, substituted indenyl, unsubstituted fluorenyl and substituted fluorenyl.
[0255] In one embodiment of the disclosure, M* is a metal selected from the group consisting of titanium, hafnium, and zirconium.
[0256] In further non-limiting embodiments of the disclosure, the bulky linker LA in formula (II) includes unsubstituted or substituted cyclopentadienyl ligands or cyclopentadienyl type ligands, heteroatom substituted and / or heteroatom containing cyclopentadienyl type ligands. In additional non-limiting embodiments, the bulky linker LA in formula (II) includes cyclopentaphenanthreneyl linkers, unsubstituted or substituted indenyl linkers, benzindenyl linkers, unsubstituted or substituted fluorenyl linkers, octahydrofluorenyl linkers, cyclooctatetraendyl linkers, cyclopentacyclododecene linkers, azenyl linkers, azulene linkers, pentalene linkers, phosphoyl linkers, phosphinimine linkers, pyrrolyl linkers, pyrozolyl linkers, carbazolyl linkers, borabenzene linkers and the like, including hydrogenated versions thereof, for example, tetrahydroindenyl linkers.In other embodiments, LA may be any other ligand structure capable of η-bonding to the M* metal; such embodiments include both η3-bonding and η5-bonding to the M* metal. In other embodiments, LA may comprise one or more heteroatoms, for example, nitrogen, silicon, boron, germanium, sulfur, and phosphorus, in combination with carbon atoms to form an open, acyclic, or fused ring, or a system of rings, for example, a heterocyclopentadienyl auxiliary ligand. Other non-limiting embodiments for LA include bulky amides, phosphides, alkoxides, aryloxides, imides, carbolites, borolides, porphyrins, phthalocyanines, corrins, and other polyazomacrocycles. Petition 870250084786, dated 09 / 19 / 2025, p. 57 / 154 49 / 123
[0257] In one embodiment of the disclosure, the metal M* is titanium, Ti.
[0258] The phosphinimine ligand, PI, is defined by formula (III): (RP)3 P = N - (III) wherein the Rp groups are independently selected from: a hydrogen atom; a halogen atom; C1-20 hydrocarbyl radicals that are unsubstituted or substituted with one or more halogen atom(s); a C1-8 alkoxy radical; a C6-10 aryl radical; a C6-10 aryloxy radical; an amido radical; a silyl radical of formula -Si(Rs)3, wherein the Rs groups are independently selected from, a hydrogen atom, a C1-8 alkyl or alkoxy radical, a C6-10 aryl radical, a C6-10 aryloxy radical, or a germanyl radical of formula Ge(RG)3, wherein the RG groups are defined as Rs defined in this paragraph.
[0259] In addition to the first homogeneous catalyst molecule per se, an active homogeneous catalyst system may further comprise one or more of the following: an alkylaluminoxane cocatalyst and an ionic activator. The homogeneous catalyst system may also optionally comprise a hindered phenol.
[0260] Although the exact structure of alkylaluminoxane is uncertain, experts in the field generally agree that it is an oligomeric species containing repeating units of the general formula: (R)2AlO-(Al(R)-O)n-Al(R)2 where the R groups can be identical or different linear, branched, or cyclic hydrocarbyl radicals containing 1 to 20 carbon atoms and is from 0 to about 50. A non-limiting example of an alkylaluminoxane is methylaluminoxane (or MAO) where each R group is a methyl radical.
[0261] In one embodiment of the disclosure, R of alkylaluminoxane, is a methyl radical in e from 10 to 40. Petition 870250084786, dated 09 / 19 / 2025, p. 58 / 154 50 / 123
[0262] In one embodiment of the disclosure, the cocatalyst is modified methylaluminoxane (MMAO).
[0263] It is well known in the art that alkylaluminoxane can play dual roles not only as an alkylator but also as an activator. Therefore, an alkylaluminoxane cocatalyst is frequently used in combination with activatable ligands such as halogens.
[0264] In general, ionic activators comprise a bulky cation and anion; wherein the latter is substantially uncoordinated. Non-limiting examples of ionic activators are boron ionic activators which are tetra-coordinated with four ligands bonded to the boron atom. Non-limiting examples of boron ionic activators include the following formulas shown below: [R5r[B(R7)4]—where B represents a boron atom, R5 is an aromatic hydrocarbyl (e.g., triphenylmethyl cation), and each R7 is independently selected from phenyl radicals that are unsubstituted or substituted with 3 to 5 substituents selected from fluorine atoms, C1-4 alkyl or alkoxy radicals that are unsubstituted or substituted with fluorine atoms; and a silyl radical of formula -Si(R9)3, where each R9 is independently selected from hydrogen atoms and C1-4 alkyl radicals, and [(R8)tZH]+[B(R7)4]-where B is a boron atom, H is a hydrogen atom, Z is a nitrogen or phosphorus atom, t is 2 or 3 and R8 is selected from C1-8 alkyl radicals, phenyl radicals that are unsubstituted or substituted by up to three C1-4 alkyl radicals, or an R8 taken together with the nitrogen atom can form an aniline radical and R7 is as defined above. Petition 870250084786, dated 09 / 19 / 2025, p. 59 / 154 51 / 123
[0265] In both formulas, a non-limiting example of R7 is a pentafluorophenyl radical. In general, ionic boron activators can be described as tetra(perfluorophenyl) boron salts; non-limiting examples include aniline, carbonium, oxonium, phosphonium and sulfonium salts of tetra(perfluorophenyl) boron with aniline and trityl (or triphenylmethyl). Additional non-limiting examples of ionic activators include: triethylammonium tetra(phenyl)boron, tripropylammonium tetra(phenyl)boron, tri(n-butyl)ammonium tetra(phenyl)boron, trimethylammonium tetra(p-tolyl)boron, trimethylammonium tetra(o-tolyl)boron, tributylammonium tetra(pentafluorophenyl)boron, tripropylammonium tetra(o,p-dimethylphenyl)boron, tributylammonium tetra(m,m-dimethylphenyl)boron, tributylammonium tetra(p-trifluoromethylphenyl)boron, tributylammonium tetra(pentafluorophenyl)boron, tri(n-butyl)ammonium tetra(o-tolyl)boron, N,N-dimethylaniline tetra(phenyl)boron, N,N-diethylaniline tetra(phenyl)boron, N,N-diethylaniline tetra(phenyl)n-butylboron, N,N-2,4,6-pentamethylaniline tetra(phenyl)boron, di-(isopropyl)ammonium tetra(pentafluorophenyl)boron, dicyclohexylammonium tetra(phenyl)boron, triphenylphosphonium tetra(phenyl)boron, tri(methylphenyl)phosphonium tetra(phenyl)boron, tri(dimethylphenyl)phosphonium tetra(phenyl)boron, tropylium tetrakispentafluorophenyl borate, triphenylmethyl tetrakispentafluorophenyl borate, benzene(diazonium)tetrakispentafluorophenyl borate, tropylium tetrakis(2,3,5,6-tetrafluorophenyl)borate, triphenylmethyl tetrakis(2,3,5,6-tetrafluorophenyl)borate, benzene(diazonium) tetrakis(3,4,5-trifluorophenyl)borate, tropylium tetrakis(3,4,5-trifluorophenyl)borate, benzene(diazonium) tetrakis(3,4,5-trifluorophenyl)borate, tropylium tetrakis(1,2,2-trifluoroethenyl)borate, triphenylmethyl tetrakis(1,2,2-trifluoroethenyl)borate, benzene(diazonium) tetrakis(1,2,2-trifluoroethenyl)borate, tropylium tetrakis(2,3,4,5-tetrafluorophenyl)borate, triphenylmethyl tetrakis(2,3,4,5-tetrafluorophenyl)borate, and benzene(diazonium) tetrakis(2,3,4,5-tetrafluorophenyl)borate. Readily available commercial ionic activators include N,N-dimethylaniline tetraquispentafluorophenyl borate and triphenylmethyl tetraquispentafluorophenyl borate. Petition 870250084786, dated 09 / 19 / 2025, page 60 / 154 52 / 123
[0266] Non-limiting examples of hindered phenols include butylated phenolic antioxidants, butylated hydroxytoluene, 2,6-di-tert-butyl-4-ethyl phenol, 4,4'-methylenebis(2,6-di-tert-butylphenol), 1,3,5-trimethyl-2,4,6-tris(3,5-di-tert-butyl-4-hydroxybenzyl)benzene and octadecyl-3-(3',5'-di-tert-butyl-4'-hydroxyphenyl)propionate.
[0267] To produce an active homogeneous catalyst system, the amount and molar ratios of the three or four components—the first homogeneous catalyst, the alkylaluminoxane, the ionic activator, and the optional hindered phenol—are optimized.
[0268] In one embodiment of the disclosure, the homogeneous third catalyst used to form the third ethylene interpolymer does not produce long-chain branches, and / or the third ethylene interpolymer will not contain measurable amounts of long-chain branches.
[0269] In one embodiment of the disclosure, the homogeneous third catalyst used to form the third ethylene interpolymer produces long-chain branches, and the third ethylene interpolymer will contain long-chain branches, hereafter referred to as “LCB”. LCB is a well-known structural phenomenon in ethylene polymers and well known to those with common knowledge in the art.
[0270] In one embodiment of the disclosure, the third ethylene interpolymer contains long-chain branching characterized by the LCBF disclosed in this document. In embodiments of the disclosure, the upper limit on the LCBF of the third ethylene interpolymer may be about 0.5, in other cases about 0.4, and in still other cases about 0.3 (dimensionless). In embodiments of the disclosure, the lower limit on the LCBF of the third ethylene interpolymer may be about 0.001, in other cases about 0.0015, and in still other cases about 0.002 (dimensionless).
[0271] In some embodiments of the disclosure, the upper limit of the molecular weight distribution (Mw / Mn) of the third ethylene interpolymer is about 2.3, Petition 870250084786, dated 09 / 19 / 2025, p. 61 / 154 53 / 123 or about 2.2, or about 2.1, or about 2.0. In some embodiments of the disclosure, the lower limit of the molecular weight distribution (Mw / Mn) of the third ethylene interpolymer is about 1.7, or about 1.8, or about 1.9.
[0272] In some embodiments of the disclosure, the third ethylene interpolymer has a molecular weight distribution (Mw / Mn) of < 2.3, or < 2.3, or < 2.2, or < 2.2, or < 2.1, or < 2.1. In some embodiments of the disclosure, the third ethylene interpolymer has a molecular weight distribution (Mw / Mn) from about 1.7 to about 2.3, or from about 1.8 to about 2.3, or from about 1.8 to about 2.2.
[0273] In one embodiment, the third ethylene interpolymer has a number of short-chain branches per thousand carbon atoms from 25 to 50. In further embodiments, the third ethylene interpolymer has from 30 to 50 short-chain branches per thousand carbon atoms, or from 30 to 45 short-chain branches per thousand carbon atoms, or from 30 to 40 short-chain branches per thousand carbon atoms, or from 31 to 55 short-chain branches per thousand carbon atoms, or from 31 to 50 short-chain branches per thousand carbon atoms, or from 33 to 45 short-chain branches per thousand carbon atoms, or from 33 to 40 short-chain branches per thousand carbon atoms.In further variations, the third ethylene interpolymer has either 25 to 55 short-chain branches per thousand carbon atoms, or 27 to 48 short-chain branches per thousand carbon atoms, or 27 to 45 short-chain branches per thousand carbon atoms.
[0274] It is recognized by those skilled in the art that short-chain branching (i.e., short-chain branching by one thousand carbon atoms) is branching by virtue of the presence of at least one α-olefin in the third ethylene interpolymer and will have, for example, two carbon atoms for butene-1, or qua Petition 870250084786, dated 09 / 19 / 2025, p. 62 / 154 54 / 123 three carbon atoms for a hexene-1, or six carbon atoms for an octene-1, etc.
[0275] In embodiments of the disclosure, the third ethylene interpolymer has a number of short-chain branches per thousand carbon atoms that is greater than the number of short-chain branches of the second ethylene interpolymer—that is, the number of short-chain branches per thousand carbon atoms of the third ethylene interpolymer (SCB3) and the number of short-chain branches per thousand carbon atoms of the second ethylene interpolymer (SCB2) satisfy the inequality SCB3 > SCB2.
[0276] In one embodiment of the disclosure, the third ethylene interpolymer has a weighted average molecular weight, Mw, of from 20 kg / mol to 50 kg / mol, or from 20 kg / mol to 48 kg / mol, or from 20 kg / mol to 46 kg / mol, or from 23 kg / mol to 48 kg / mol, or from 24 kg / mol to 46 kg / mol, or from 25 kg / mol to 45 kg / mol.
[0277] In some embodiments, the third ethylene interpolymer has a weighted average molecular weight that is less than the weighted average molecular weight of the first ethylene polymer and the weighted average molecular weight of the second ethylene interpolymer—that is, the weighted average molecular weights of the first ethylene polymer, the second ethylene interpolymer, and the third ethylene interpolymer (Mw1, Mw2, and Mw3, respectively) satisfy the inequalities Mw3 < Mw1 and Mw3 < Mw2.
[0278] In some embodiments of the disclosure, the upper limit of the weight percent of the third ethylene interpolymer in the ethylene polymer composition (i.e., the weight percent of the third ethylene interpolymer based on the total weight of the ethylene polymer composition) is about 20 percent by weight, or about 15 percent by weight, or about 12 percent by weight, or about 10 percent by weight, or about 8 percent by weight, or about 5 percent Petition 870250084786, dated 09 / 19 / 2025, p. 63 / 154 55 / 123 by weight. In some embodiments of the disclosure, the lower limit of the weight percentage of the third ethylene interpolymer in the ethylene polymer composition is 0 percent by weight, or greater than 0 percent by weight, or about 1 percent by weight, or about 3 percent by weight, or about 5 percent by weight. In one embodiment, the third ethylene interpolymer is present in the ethylene polymer composition in an amount from 0 to 20 percent by weight. In another embodiment, the third ethylene interpolymer is present in the ethylene polymer composition in an amount from greater than (>) 0 to 20 percent by weight. In another embodiment, the third ethylene interpolymer is present in the ethylene polymer composition in an amount from 0 to 10 percent by weight.In yet another embodiment, the third ethylene interpolymer is present in the ethylene polymer composition in an amount greater than (>) 0 to 10 percent by weight. Ethylene Polymer Composition
[0279] The ethylene polymer composition disclosed in this document is a reactor mixture of a first ethylene polymer, a second ethylene interpolymer, and optionally a third ethylene interpolymer. The term “reactor mixture” refers to a mixture that is formed while polymerization is occurring and is distinguished in this document from a post-reactor physical mixture. The term “post-reactor mixture” refers to a mixture formed by combining two or more than two mixture components, wherein each of the mixture components is already polymerized and recovered from the polymerization process—recovery operations may include catalyst deactivation, phase separation, devolatilization of unreacted monomers and / or process solvent, pelletization, etc.—before being combined with the other mixture component(s). Petition 870250084786, dated 09 / 19 / 2025, page 64 / 154 56 / 123
[0280] In one embodiment, the ethylene polymer composition of the present disclosure is produced using a first homogeneous catalyst in a first reactor to obtain a first ethylene polymer, and a second homogeneous catalyst is used in a second reactor to obtain a second ethylene interpolymer.
[0281] In one embodiment, the ethylene polymer composition of the present disclosure is produced using a first homogeneous catalyst in a first reactor to obtain a first ethylene polymer, a second homogeneous catalyst is used in a second reactor to obtain a second ethylene interpolymer, and a third homogeneous catalyst is used in a third reactor to obtain a third ethylene interpolymer.
[0282] In one embodiment, the ethylene polymer composition of the present disclosure is produced by forming a first ethylene polymer in a first reactor by polymerizing ethylene and optionally at least one α-olefin with a first homogeneous catalyst; and forming a second ethylene interpolymer in a second reactor by polymerizing ethylene and at least one α-olefin with a second homogeneous catalyst.
[0283] In one embodiment, the ethylene polymer composition of the present disclosure is produced by forming a first ethylene homopolymer in a first reactor by polymerizing ethylene with a first homogeneous catalyst; and forming a second ethylene interpolymer in a second reactor by polymerizing ethylene and at least one α-olefin with a second homogeneous catalyst.
[0284] In one embodiment, the ethylene polymer composition of the present disclosure is produced by forming a first ethylene homopolymer in a first reactor by polymerizing ethylene with a first homogeneous catalyst; and forming a second ethylene interpolymer in a second reactor by polymerizing ethylene and at least one α-olefin with a second homogeneous catalyst. Petition 870250084786, dated 09 / 19 / 2025, page 65 / 154 57 / 123
[0285] In one embodiment, the ethylene polymer composition of the present disclosure is produced by forming a first ethylene interpolymer in a first reactor by polymerizing ethylene and at least one α-olefin with a first homogeneous catalyst; and forming a second ethylene interpolymer in a second reactor by polymerizing ethylene and at least one α-olefin with a second homogeneous catalyst.
[0286] In one embodiment, the ethylene polymer composition of the present disclosure is produced by forming a first ethylene polymer in a first reactor by polymerizing ethylene and optionally at least one α-olefin with a first homogeneous catalyst; forming a second ethylene interpolymer in a second reactor by polymerizing ethylene and at least one α-olefin with a second homogeneous catalyst; and forming a third ethylene interpolymer in a third reactor by polymerizing ethylene and at least one α-olefin with a third homogeneous catalyst.
[0287] In one embodiment, the ethylene polymer composition of the present disclosure is produced by forming a first ethylene homopolymer in a first reactor by polymerizing ethylene with the first homogeneous catalyst; forming a second ethylene interpolymer in a second reactor by polymerizing ethylene and at least one α-olefin with a second homogeneous catalyst; and forming a third ethylene interpolymer in a third reactor by polymerizing ethylene and at least one α-olefin with a third homogeneous catalyst.
[0288] In one embodiment, the ethylene polymer composition of the present disclosure is produced by forming a first ethylene polymer in a first solution-phase polymerization reactor by polymerizing ethylene and optionally at least one α-olefin with a first homogeneous catalyst; and forming a second ethylene interpolymer in a second solution-phase polymerization reactor. Petition 870250084786, dated 09 / 19 / 2025, page 66 / 154 58 / 123 of solution when polymerizing ethylene and at least one α-olefin with a second homogeneous catalyst.
[0289] In one embodiment, the ethylene polymer composition of the present disclosure is produced by forming a first ethylene homopolymer in a first solution-phase polymerization reactor by polymerizing ethylene with a first homogeneous catalyst; and forming a second ethylene interpolymer in a second solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a second homogeneous catalyst.
[0290] In one embodiment, the ethylene polymer composition of the present disclosure is produced by forming a first ethylene polymer in a first solution-phase polymerization reactor by polymerizing ethylene and optionally at least one α-olefin with a first homogeneous catalyst; forming a second ethylene interpolymer in a second solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a second homogeneous catalyst; and forming a third ethylene interpolymer in a third solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a third homogeneous catalyst.
[0291] In one embodiment, the ethylene polymer composition of the present disclosure is produced by forming a first ethylene homopolymer in a first solution-phase polymerization reactor by polymerizing ethylene with a first homogeneous catalyst; forming a second ethylene interpolymer in a second solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a second homogeneous catalyst; and forming a third ethylene interpolymer in a third solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a third homogeneous catalyst. Petition 870250084786, dated 09 / 19 / 2025, page 67 / 154 59 / 123
[0292] In one embodiment, the ethylene polymer composition of the present disclosure is produced by forming a first ethylene polymer in a first solution-phase polymerization reactor by polymerizing ethylene and optionally at least one α-olefin with a first homogeneous catalyst; and forming a second ethylene interpolymer in a second solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a second homogeneous catalyst, wherein the first and second solution-phase polymerization reactors are configured in series with respect to each other.
[0293] In one embodiment, the ethylene polymer composition of the present disclosure is produced by forming a first ethylene homopolymer in a first solution-phase polymerization reactor by polymerizing ethylene with a first homogeneous catalyst; and forming a second ethylene interpolymer in a second solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a second homogeneous catalyst, wherein the first and second solution-phase polymerization reactors are configured in series with respect to each other.
[0294] In one embodiment, the ethylene polymer composition of the present disclosure is produced by forming a first ethylene polymer in a first solution-phase polymerization reactor by polymerizing ethylene and optionally at least one α-olefin with a first homogeneous catalyst; and forming a second ethylene interpolymer in a second solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a second homogeneous catalyst, wherein the first and second solution-phase polymerization reactors are configured in parallel with respect to each other.
[0295] In one embodiment, the ethylene polymer composition of the present disclosure is produced by forming a first ethylene homopolymer in a first solution-phase polymerization reactor by polymerizing ethylene with a Petition 870250084786, dated 09 / 19 / 2025, page 68 / 154 60 / 123 first homogeneous catalyst; and form a second ethylene interpolymer in a second solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a second homogeneous catalyst, wherein the first and second solution-phase polymerization reactors are configured in parallel with respect to each other.
[0296] In one embodiment, the ethylene polymer composition of the present disclosure is produced by forming a first ethylene polymer in a first solution-phase polymerization reactor by polymerizing ethylene and optionally at least one α-olefin with a first homogeneous catalyst; forming a second ethylene interpolymer in a second solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a second homogeneous catalyst; and forming a third ethylene interpolymer in a third solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a third homogeneous catalyst, wherein the first and second solution-phase polymerization reactors are configured in series with respect to each other.
[0297] In one embodiment, the ethylene polymer composition of the present disclosure is produced by forming a first ethylene homopolymer in a first solution-phase polymerization reactor by polymerizing ethylene with a first homogeneous catalyst; forming a second ethylene interpolymer in a second solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a second homogeneous catalyst; and forming a third ethylene interpolymer in a third solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a third homogeneous catalyst, wherein the first and second solution-phase polymerization reactors are configured in series with respect to each other. Petition 870250084786, dated 09 / 19 / 2025, page 69 / 154 61 / 123
[0298] In one embodiment, the ethylene polymer composition of the present disclosure is produced by forming a first ethylene polymer in a first solution-phase polymerization reactor by polymerizing ethylene and optionally at least one α-olefin with a first homogeneous catalyst; forming a second ethylene interpolymer in a second solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a second homogeneous catalyst; and forming a third ethylene interpolymer in a third solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a third homogeneous catalyst, wherein at least two of the first, second, and third solution-phase polymerization reactors are configured in series with respect to each other.
[0299] In one embodiment, the ethylene polymer composition of the present disclosure is produced by forming a first ethylene homopolymer in a first solution-phase polymerization reactor by polymerizing ethylene with a first homogeneous catalyst; forming a second ethylene interpolymer in a second solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a second homogeneous catalyst; and forming a third ethylene interpolymer in a third solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a third homogeneous catalyst, wherein at least two of the first, second, and third solution-phase polymerization reactors are configured in series with respect to each other.
[0300] In one embodiment, the ethylene polymer composition of the present disclosure is produced by forming a first ethylene polymer in a first solution-phase polymerization reactor by polymerizing ethylene and optionally at least one α-olefin with a first homogeneous catalyst; forming a second ethylene interpolymer in a second solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a second catalyst. Petition 870250084786, dated 09 / 19 / 2025, page 70 / 154 62 / 123 homogeneous lysator, and form a third ethylene interpolymer in a third solution-phase polymerization reactor by polymerizing ethylene and at least one αolefin with a third homogeneous catalyst, wherein the first, second, and third solution-phase polymerization reactors are configured in series with respect to each other.
[0301] In one embodiment, the ethylene polymer composition of the present disclosure is produced by forming a first ethylene homopolymer in a first solution-phase polymerization reactor by polymerizing ethylene with a first homogeneous catalyst; forming a second ethylene interpolymer in a second solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a second homogeneous catalyst; and forming a third ethylene interpolymer in a third solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a third homogeneous catalyst, wherein the first, second, and third solution-phase polymerization reactors are configured in series with respect to each other.
[0302] In one embodiment, the ethylene polymer composition of the present disclosure is produced by forming a first ethylene polymer in a first solution-phase polymerization reactor by polymerizing ethylene and optionally at least one α-olefin with a first homogeneous catalyst; forming a second ethylene interpolymer in a second solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a second homogeneous catalyst; and forming a third ethylene interpolymer in a third solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a third homogeneous catalyst, wherein each of the first, second, and third solution-phase polymerization reactors are configured in series with respect to each other. Petition 870250084786, dated 09 / 19 / 2025, page 71 / 154 63 / 123
[0303] In one embodiment, the ethylene polymer composition of the present disclosure is produced by forming a first ethylene polymer in a first solution-phase polymerization reactor by polymerizing ethylene and optionally at least one α-olefin with a first homogeneous catalyst; forming a second ethylene interpolymer in a second solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a second homogeneous catalyst; and forming a third ethylene interpolymer in a third solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a third homogeneous catalyst, wherein each of the first, second, and third solution-phase polymerization reactors are configured in parallel with respect to each other.
[0304] In one embodiment, the ethylene polymer composition of the present disclosure is produced by forming a first ethylene homopolymer in a first solution-phase polymerization reactor by polymerizing ethylene with a first homogeneous catalyst; forming a second ethylene interpolymer in a second solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a second homogeneous catalyst; and forming a third ethylene interpolymer in a third solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a third homogeneous catalyst, wherein each of the first, second, and third solution-phase polymerization reactors are configured in parallel with respect to each other.
[0305] In one embodiment, the ethylene polymer composition of the present disclosure is produced by forming a first ethylene polymer in a first solution-phase polymerization reactor by polymerizing ethylene and optionally at least one α-olefin with a first homogeneous catalyst; forming a second ethylene interpolymer in a second solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a second catalyst. Petition 870250084786, dated 09 / 19 / 2025, page 72 / 154 64 / 123 homogeneous lysator, and form a third ethylene interpolymer in a third solution-phase polymerization reactor by polymerizing ethylene and at least one αolefin with a third homogeneous catalyst, wherein the first and second solution-phase reactors are configured in series with respect to each other, and the third solution-phase reactor is configured in parallel to the first and second reactors.
[0306] In one embodiment, the ethylene polymer composition of the present disclosure is produced by forming a first ethylene homopolymer in a first solution-phase polymerization reactor by polymerizing ethylene with a first homogeneous catalyst; forming a second ethylene interpolymer in a second solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a second homogeneous catalyst; and forming a third ethylene interpolymer in a third solution-phase polymerization reactor by polymerizing ethylene and at least one α-olefin with a third homogeneous catalyst, wherein the first and second solution-phase reactors are configured in series with respect to each other, and the third solution-phase reactor is configured in parallel to the first and second reactors.
[0307] In one embodiment, the solution-phase polymerization reactor used as a first solution-phase reactor, a second solution-phase reactor, or a third solution-phase reactor is a continuously stirred tank reactor or a tubular reactor.
[0308] In one embodiment, the solution-phase polymerization reactor used as a first solution-phase reactor, a second solution-phase reactor, or a third solution-phase reactor is a continuously stirred tank reactor. Petition 870250084786, dated 09 / 19 / 2025, page 73 / 154 65 / 123
[0309] In one embodiment, the solution-phase polymerization reactor used as a first solution-phase reactor, a second solution-phase reactor, or a third solution-phase reactor is a tubular reactor.
[0310] In one embodiment, the solution-phase polymerization reactor used as a first solution-phase reactor and a second solution-phase reactor is a continuously stirred tank reactor, and the solution-phase polymerization reactor used as a third solution-phase reactor is a tubular reactor.
[0311] In solution polymerization, monomers are dissolved / dispersed in the solvent before being fed into the reactor (or, for gaseous monomers, the monomer may be fed into the reactor so that it dissolves in the reaction mixture). Before mixing, the solvent and monomers are generally purified to remove potential contaminants from the catalyst, such as water, oxygen, or metallic impurities. Purification of the raw material follows standard practices in the art, for example, molecular sieves, alumina beds, and oxygen removal catalysts are used for monomer purification. The solvent itself (e.g., methyl pentane, cyclohexane, hexane, or toluene) is preferably treated in a similar manner.
[0312] The raw material can be heated or cooled before being fed into the reactor.
[0313] Generally, the catalyst components can be premixed in the solvent for the reaction or fed as separate streams to the reactor. In some cases, premixing may be desirable to provide a reaction time for the catalyst components before they enter the reaction. This in-line mixing technique is described in several patents in the name of DuPont Canada Inc. (e.g., U.S. Patent No. 5,589,555, issued December 31, 1996). Petition 870250084786, dated 09 / 19 / 2025, page 74 / 154 66 / 123
[0314] Solution polymerization processes for the polymerization or copolymerization of ethylene are well known in the art (see, for example, US Patents Nos. 6,372,864 and 6,777,509). These processes are conducted in the presence of an inert hydrocarbon solvent. In a solution-phase polymerization reactor, a variety of solvents can be used as process solvents; non-limiting examples include linear, branched, or cyclic C5 to C12 alkanes. Non-limiting examples of α-olefins include propene-1, butene-1, pentene-1, hexene-1, and octene-1. Suitable solvents for catalyst components include aliphatic and aromatic hydrocarbons. Non-limiting examples of aliphatic solvents for catalyst components include linear, branched or cyclic C5-12 aliphatic hydrocarbons, for example, pentane, methylpentane, hexane, heptane, octane, cyclohexane, cyclopentane, methylcyclohexane, hydrogenated naphtha or combinations thereof.Non-limiting examples of solvents for aromatic catalyst components include benzene, toluene (methylbenzene), ethylbenzene, xylene (1,2-dimethylbenzene), m-xylene (1,3-dimethylbenzene), p-xylene (1,4-dimethylbenzene), mixtures of xylene isomers, hemelitene (1,2,3-trimethylbenzene), pseudocumene (1,2,4-trimethylbenzene), mesitylene (1,3,5-trimethylbenzene), mixtures of trimethylbenzene isomers, prehenitene (1,2,3,4-tetramethylbenzene), durene (1,2,3,5-tetramethylbenzene), mixtures of tetramethylbenzene isomers, pentamethylbenzene, hexamethylbenzene, and combinations thereof.
[0315] The polymerization temperature in a conventional solution process can range from about 80 °C to about 300 °C. In one embodiment of the disclosure, the polymerization temperature in a solution process is from about 120 °C to about 250 °C. The polymerization pressure in a solution process can 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). In one embodiment of the disclosure, the polymerization pressure in a solution process Petition 870250084786, dated 09 / 19 / 2025, p. 75 / 154 67 / 123 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).
[0316] In one embodiment of the disclosure, the ethylene polymer composition has at least 1 mole percent of at least one α-olefin.
[0317] In one embodiment of the disclosure, the ethylene polymer composition has at least 3 mole percent of at least one α-olefin.
[0318] In one embodiment of the disclosure, the ethylene polymer composition has from about 1 to about 10 mole percent of at least one α-olefin.
[0319] In one embodiment of the disclosure, the ethylene polymer composition has from about 3 to about 10 mole percent of at least one α-olefin.
[0320] In one embodiment of the disclosure, the ethylene polymer composition has from about 3 to about 8 mole percent of at least one αolefin.
[0321] In one embodiment of the disclosure, the ethylene polymer composition comprises ethylene and at least one α-olefin selected from the group comprising butene-1, hexene-1, octene-1 and mixtures thereof.
[0322] In one embodiment of the disclosure, the ethylene polymer composition comprises ethylene and at least one α-olefin selected from the group comprising hexene-1, octene-1 and mixtures thereof.
[0323] In one embodiment of the disclosure, the ethylene polymer composition comprises ethylene and octene-1.
[0324] In one embodiment of the disclosure, the ethylene polymer composition comprises ethylene and at least 1 mol percent octene-1.
[0325] In one embodiment of the disclosure, the ethylene polymer composition comprises ethylene and from 1 to 10 mole percent of octene-1. Petition 870250084786, dated 09 / 19 / 2025, page 76 / 154 68 / 123
[0326] In one embodiment of the disclosure, the ethylene polymer composition comprises ethylene and from 3 to 8 mole percent of octene-1.
[0327] In some embodiments of the disclosure, the ethylene polymer composition has a density that is from about 0.900 g / cm3 to about 0.920 g / cm3, or from about 0.902 g / cm3 to about 0.919 g / cm3. In some preferred embodiments, the ethylene polymer composition has a density of from 0.903 to 0.916 g / cm3, preferably from 0.903 to 0.914 g / cm3, preferably from 0.905 to 0.912 g / cm3, preferably from 0.905 to 0.910 g / cm3.
[0328] In some embodiments of the disclosure, the melting index (I2) of the ethylene polymer composition is from about 0.1 dg / min to about 10.0 dg / min, or from about 0.3 dg / min to about 10.0 dg / min, or from about 0.5 dg / min to about 10.0 dg / min, or from about 0.7 dg / min to about 10.0 dg / min, or from about 1.0 dg / min to about 8.0 dg / min, or from about 1.5 dg / min to about 6.0 dg / min, or from about 2.0 dg / min to about 5.0 dg / min, or from 2.0 dg / min to about 6.0 dg / min, or from about 2.0 dg / min to about 8.0 dg / min, or from about 2.0 dg / min to about 10.0 dg / min, or from about 2.5 dg / min to about 10.0 dg / min, or from about 3.0 dg / min to about 10.0 dg / min, or from about 3.0 dg / min to about from 8.0 dg / min, or from about 3.0 dg / min to about 6.0 dg / min, or from about 3.0 dg / min to about 5.0 dg / min.
[0329] In some embodiments, the high-charge melt index (I21) of the ethylene polymer composition is from about 10 dg / min to about 10,000 dg / min, or from about 10 dg / min to about 1,000 dg / min, or from about 10 dg / min to about 500 dg / min, or from about 10 dg / min to about 250 dg / min, or from about 10 dg / min to about 150 g / min. Petition 870250084786, dated 09 / 19 / 2025, p. 77 / 154 69 / 123
[0330] In some embodiments, the melt flow ratio (I21 / I2) of the ethylene polymer composition is from about 15 to about 1,000, or from about 15 to about 100, or from about 15 to about 75, or from about 15 to about 50, or from about 15 to about 40, or from about 18 to about 50, or from about 20 to about 75, or from about 20 to about 50, or from about 20 to about 45, or from about 20 to about 40, or from about 20 to about 38, or from about 20 to about 35, or from about 24 to about 48, or from about 27 to about 45, or from approximately 30 to approximately 42. In some embodiments, the melt flow ratio (I21 / I2) of the ethylene polymer composition is 20 to 50.In some embodiments, the melt flow ratio (I21 / I2) of the ethylene polymer composition is less than about 45, or less than about 40, or less than about 35.
[0331] In some embodiments, the ethylene polymer composition has a weighted average molecular weight (Mw) from about 50 kg / mol to about 200 kg / mol, or from about 50 kg / mol to about 180 kg / mol, or from about 60 kg / mol to about 160 kg / mol, or from about 65 kg / mol to about 100 kg / mol, or from about 70 kg / mol to about 100 kg / mol, or from about 70 kg / mol to about 95 kg / mol, or from about 70 kg / mol to about 90 kg / mol.
[0332] In some embodiments, the ethylene polymer composition has a number average molecular weight (Mw) from about 5 kg / mol to about 35 kg / mol, or from about 10 kg / mol to about 35 kg / mol, or from about 10 kg / mol to about 30 kg / mol, or from about 15 kg / mol to about 30 kg / mol, or from about 15 kg / mol to about 25 kg / mol.
[0333] In embodiments of the disclosure, the ethylene polymer composition has a lower bound molecular weight (Mw / Mn) distribution of 2.3, or 2.4, or Petition 870250084786, dated 09 / 19 / 2025, p. 78 / 154 70 / 123 2.5, or 2.6. In embodiments of the disclosure, the ethylene polymer composition has an upper bound molecular weight (Mw / Mn) distribution of 6.0, or 5.5, or 5.0, or 4.5, or 4.0, or 3.75, or 3.5.
[0334] In embodiments of the disclosure, the ethylene polymer composition has a molecular weight (Mw / Mn) distribution of 2.3 to 6.0, or 2.3 to 5.5, or 2.3 to 5.0, or 2.3 to 4.5, or 2.3 to 4.0, or 2.3 to 3.75, or 2.3 to 3.5, or 2.4 to 5.5, or 2.4 to 5.0, or 2.4 to 4.5, or 2.4 to 4.0, or 2.4 to 3.75, or 2.4 to 3.5, or 2.5 to 5.5, or 2.5 to 5.0, or from 2.5 to 4.5, or from 2.5 to 4.0, or from 2.5 to 3.75, or from 2.5 to 3.5, or from 2.6 to 3.3. In some embodiments, the ethylene polymer composition has a molecular weight distribution (Mw / Mn) from 2.3 to 5.0.
[0335] In the disclosure embodiments, the ethylene polymer composition has a mean molecular weight distribution z, Mz / Mw of < 4.0, or < 4.0, or < 3.5, or < 3.5, or < 3.0, or < 3.0, or < 2.75, or < 2.75, or < 2.50, or < 2.50. In the disclosure embodiments, the ethylene polymer composition has a mean molecular weight distribution z, Mz / Mw, of from 1.5 to 4.0, or from 1.5 to 3.5, or from 1.75 to 3.5, or from 1.75 to 3.0, or from 1.75 to 2.5, or from 2.0 to 4.0, or from 2.0 to 3.5, or from 2.0 to 3.0, or from 2.0 to 2.75.
[0336] In one embodiment of the disclosure, the ethylene polymer composition exhibits a unimodal profile on a gel permeation chromatograph generated according to the ASTM D6474-99 method. The term unimodal is defined here as meaning that there will be only one significant peak or maximum evident in the GPC curve. A unimodal profile includes a broad unimodal profile. In contrast, the use of the term bimodal means that, in addition to a first peak, there will be a secondary peak or shoulder representing a component of higher or lower molecular weight (i.e., it can be said that the molecular weight distribution has two Petition 870250084786, dated 09 / 19 / 2025, page 79 / 154 71 / 123 maxima in a molecular weight distribution curve). Alternatively, the term bimodal denotes the presence of two maxima in a molecular weight distribution curve generated according to the ASTM D6474-99 method. The term multimodal denotes the presence of two or more, typically more than two, maxima in a molecular weight distribution curve generated according to the ASTM D6474-99 method.
[0337] In one embodiment of the disclosure, the ethylene polymer composition has a normal comonomer distribution profile as measured using GPC-FTIR. As used in this document, if the comonomer incorporation decreases monotonically with molecular weight, as measured using GPC-FTIR, the distribution is described as “normal”.
[0338] In one embodiment of the disclosure, the ethylene polymer composition exhibits a partially normal comonomer distribution profile, as measured by GPC-FTIR. As used herein, if comonomer incorporation decreases with increasing molecular weight and then increases with increasing molecular weight, as measured by GPC-FTIR, the distribution is described as “partially normal”. A partially normal comonomer distribution will exhibit a minimum.
[0339] In one embodiment of the disclosure, the ethylene polymer composition exhibits a partially reversed comonomer distribution profile, as measured by GPC-FTIR. As used herein, if comonomer incorporation increases with increasing molecular weight and then decreases with increasing molecular weight, as measured by GPC-FTIR, the distribution is described as “partially reversed”. A partially reversed comonomer distribution will exhibit a maximum.
[0340] The terms “normal” and “reverse” are used here in contrast to the term “flat”. If the incorporation of the comonomer is approximately constant Petition 870250084786, dated 09 / 19 / 2025, page 80 / 154 72 / 123 te with the molecular weight, as measured by GPC-FTIR, the comonomer distribution is described as planar or uniform.
[0341] In one embodiment, the ethylene polymer composition exhibits a comonomer distribution profile in a GPC-FTIR analysis, wherein the comonomer distribution profile exhibits a secant slope greater than or equal to (>) -55 short-chain branches per 1000 carbons and less than or equal to (>) -20 short-chain branches per 1000 carbons. The secant slope is defined herein as the number of short-chain branches per 1000 carbons at a molecular weight of 300,000 g / mol minus the number of short-chain branches per 1000 carbons at a molecular weight of 30,000 g / mol.In other embodiments of the disclosure, the ethylene polymer composition has a comonomer distribution profile in a GPC-FTIR analysis, wherein the comonomer distribution profile has a secant slope greater than or equal to (>) -50 short-chain branches per 1000 carbons and less than or equal to (>) -20 short-chain branches per 1000 carbons, or greater than or equal to (>) -45 short-chain branches per 1000 carbons and less than or equal to (>) -20 short-chain branches per 1000 carbons, or greater than or equal to (>) -40 short-chain branches per 1000 carbons and less than or equal to (>) -20 short-chain branches per 1000 carbons, or greater than or equal to (>) -35 short-chain branches per 1000 carbons and less than or equal to (>) -25 short-chain branches per 1000 carbons.
[0342] In one embodiment of the present invention, the ethylene polymer composition has a strain exponent, defined as log10 (I6 / I2) / log10 (6.48 / 2.16), which is < 1.60. In other embodiments of the present invention, the ethylene polymer composition has a strain exponent, log10 (I6 / I2) / log10 (6.48 / 2.16), less than 1.55, or less than 1.50, or less than 1.45, or less than 1.40. Petition 870250084786, dated 09 / 19 / 2025, page 81 / 154 73 / 123
[0343] In some embodiments, the ethylene polymer composition has a dimensionless long chain branching factor (LCBF) greater than or equal to (>) 0.001.
[0344] In some embodiments, the ethylene polymer composition has a dimensionless long chain branching factor (LCBF) greater than or equal to (>) 0.001 and less than or equal to (<) 0.01.
[0345] In some alternative embodiments, the ethylene polymer composition has a VICAT softening temperature, measured using ASTM 1525-17 (August 1, 2017), greater than 85 °C or greater than 88 °C. Manufactured Flexible Articles
[0346] The ethylene polymer compositions disclosed herein can be converted into manufactured flexible articles, such as single-layer or multi-layer films.
[0347] A non-limiting example of a process for preparing single-layer or multi-layer films includes blowing processes.
[0348] In the blown film extrusion process, an extruder heats, melts, mixes, and conveys a thermoplastic or a mixture of thermoplastics. Once melted, the thermoplastic 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 determined primarily by the thermoplastic or thermoplastic mixture being processed, for example, the melting temperature or glass transition temperature of the thermoplastic and the desired viscosity of the melt. In the case of polyolefins, typical extrusion temperatures are 166°C to 288°C (330°F to 550°F). Upon exiting the annular die, the thermoplastic tube is inflated with air, cooled, solidified, and pulled through a pair of pressure rollers. Due to the air inflation, the tube increases in diameter, forming a bubble of the desired size. Due to the action of Petition 870250084786, dated 09 / 19 / 2025, p. 82 / 154 74 / 123 traction of the pressure rollers, the bubble is stretched in the machine direction. Thus, the bubble is stretched in two directions: the transverse direction (TD), where the inflated air increases the bubble diameter; and the machine direction (MD) where the pressure rollers stretch the bubble. As a result, the physical properties of blown films are typically anisotropic, i.e., the physical properties differ in the MD and TD directions; for example, the tear resistance and tensile properties of the film typically differ in the MD and TD directions. In some prior art documents, the terms “transverse direction” or “CD” are used; these terms are equivalent to the terms “transverse direction” or “TD” used in this disclosure.
[0349] In the blown film process, air is also blown into the outer circumference of the bubble to cool the thermoplastic as it exits the annular die. The final width of the film is determined by controlling the inflation air or the internal pressure of the bubble; in other words, increasing or decreasing the diameter of the bubble. The thickness of the film is mainly controlled by increasing or decreasing the speed of the pressure rollers to control the extraction rate. After exiting the pressure rollers, the bubble or tube is collapsed and can be cut in the direction of the machine, thus creating a film. Each sheet can be wound onto a roll of film. Each roll can then be cut to create a film of the desired width. Each roll of film is subsequently processed into a variety of consumer products, as described below.
[0350] Another example of a process for preparing single-layer or multi-layer films includes fused film processes.
[0351] The cast film process is similar in that one or more extruders may be used; however, the various thermoplastic materials are fed into a flat die and extruded into a single-layer or multi-layer sheet, rather than a tube. In the cast film process, the extruded sheet is solidified on a cooled roll. Petition 870250084786, dated 09 / 19 / 2025, page 83 / 154 75 / 123
[0352] In the cast film process, films are extruded from a flat die onto a cooled roll or a compressed roll, optionally with a vacuum box and / or air knife. Cast films can be single-layer or multi-layer co-extruded films, obtained by multiple extrusions through one or multiple dies. The resulting films can be used as is or can be laminated to other films or substrates, for example, by thermal lamination, adhesive lamination or direct extrusion onto a substrate. The resulting films and laminates can be subjected to other forming operations such as stamping, stretching and thermoforming. Surface treatments such as corona can be applied and the films can be printed.
[0353] Other examples of processes for preparing single-layer or multi-layer films include laminations and coatings, in which single-layer or multi-layer films containing the disclosed ethylene polymer composition are extrusion-laminated, adhesive-laminated, or extrusion-coated. In extrusion lamination or adhesive lamination, two or more substrates are joined with a thermoplastic or an adhesive, respectively. In extrusion coating, a thermoplastic is applied to the surface of a substrate. These processes are well known to those skilled in the art.Adhesive lamination or extrusion lamination is frequently used to join dissimilar materials; non-limiting examples include bonding a paper web to a thermoplastic web, or bonding a web containing aluminum foil to a thermoplastic web, or bonding two chemically incompatible thermoplastic webs, for example, bonding a web containing an ethylene interpolymer product to a polyester or polyamide web. Prior to lamination, the web containing the disclosed ethylene interpolymer product(s) may be single-layer or multi-layer. Prior to lamination, the individual webs may receive surface treatment to improve bonding; a non-limiting example of surface treatment is corona treatment. Petition 870250084786, dated 09 / 19 / 2025, page 84 / 154 76 / 123 The primary web or film may be laminated on its top, bottom, or both top and bottom surfaces with a secondary web. A secondary web and a tertiary web may be laminated to the primary web; the secondary and tertiary webs differing in chemical composition. As non-limiting examples, secondary or tertiary webs may include: polyamide, polyester, and polypropylene, or webs containing barrier resin layers such as EVOH. Such webs may also contain a vapor-deposited barrier layer; for example, a thin layer of silicon dioxide (SiOx) or aluminum oxide (AlOx). Multilayer webs (or films) may contain three, five, seven, nine, eleven, or more layers.
[0354] Depending on the final application, the disclosed ethylene polymer composition can be converted into single-layer or multi-layer films covering a wide range of thicknesses. Non-limiting examples include films for food packaging, whose thicknesses can range from about 0.5 mil to about 10 mil.
[0355] The ethylene polymer composition disclosed herein may be used in monolayer films; wherein the monolayer film may contain more than one ethylene polymer composition as described herein, and / or additional ethylene or non-ethylene polymers. The lower limit for the weight percent of the ethylene polymer composition in a monolayer film may be about 3% by weight, in other cases about 10% by weight, and in other cases about 30% by weight. The upper limit for the weight percent of the ethylene polymer composition in the monolayer film may be 100% by weight, in other cases about 90% by weight, and in other cases about 70% by weight.
[0356] The ethylene polymer composition disclosed herein may also be used in one or more layers of a multilayer film structure; non-limiting examples of multilayer films include three, five, seven, nine, eleven or Petition 870250084786, dated 09 / 19 / 2025, page 85 / 154 77 / 123 more layers. The thickness of a specific layer (containing the ethylene polymer composition) within a multilayer film structure may be about 5%, in other cases about 13.5%, in other cases about 15%, in other cases about 20%, and in other cases about 25% of the total thickness of the multilayer film. In other embodiments, the thickness of a specific layer (containing the ethylene polymer composition) within a multilayer film structure may be about 95%, in other cases about 80%, and in other cases about 65% of the total thickness of the multilayer film structure. Each individual layer of a multilayer film structure may contain more than one ethylene polymer composition and / or additional polyethylenes.
[0357] The ethylene polymer composition disclosed herein may be used in a wide range of manufactured articles comprising one or more films or film layers (single layer or multilayer). A non-limiting example of such manufactured articles includes films for food packaging (fresh and frozen foods, liquids, powdered and granulated foods).
[0358] The films used in the manufactured articles described in this section may optionally include, depending on the intended use, additives and adjuvants. Non-limiting examples of additives and adjuvants include antiblocking agents, antioxidants, heat stabilizers, slip agents, processing aids, antistatic additives, colorants, inks, fillers, light stabilizers, light absorbers, lubricants, pigments, plasticizers, nucleating agents and combinations thereof.
[0359] One embodiment of the disclosure is a film layer made entirely of polyethylene comprising the ethylene polymer composition described in this document.
[0360] In one embodiment, a layer of film made entirely of polyethylene comprises greater than or equal to 90%, or 93%, or 95%, or 97%, or 99%, or Petition 870250084786, dated 09 / 19 / 2025, page 86 / 154 78 / 123 100% of one or more ethylene polymers based on the total weight of the film layer.
[0361] In one embodiment, a layer of film made entirely of polyethylene is a film formed via a blow molding system.
[0362] In one embodiment, a layer of film made entirely of polyethylene is a melt film.
[0363] In one embodiment, a layer of film made entirely of polyethylene has a thickness from 0.5 to 10 mil.
[0364] In one embodiment, a layer of all-polyethylene film additionally comprises linear low-density polyethylene (LLDPE) having a density from 0.910 g / cm3 to 0.940 g / cm3 and a melt index I2 from 0.1 to 10 dg / min.
[0365] In one embodiment, a film layer made entirely of polyethylene comprises from 10 to 40 percent by weight of linear low-density polyethylene (LLDPE) and from 60 to 90 percent by weight of the ethylene polymer composition described in this document.
[0366] In one embodiment of the present disclosure, a linear low-density polyethylene (LLDPE) is an ethylene interpolymer comprising at least one α-olefin.
[0367] In embodiments of the disclosure, a linear low-density polyethylene is an ethylene interpolymer comprising at least one C3C20 α-olefin.
[0368] In embodiments of the disclosure, a linear low-density polyethylene is an ethylene interpolymer comprising at least one of butene-1, hexene-1 and octene-1.
[0369] In one embodiment of the disclosure, a linear low-density polyethylene is an ethylene interpolymer of ethylene and octene-1. Petition 870250084786, dated 09 / 19 / 2025, page 87 / 154 79 / 123
[0370] In embodiments of the disclosure, a linear low-density polyethylene is an ethylene interpolymer of ethylene and at least one C3-C20 α-olefin and comprises at least 70 percent by weight of ethylene, or at least 80 percent by weight of ethylene, or at least 90 percent by weight of ethylene.
[0371] In embodiments of the disclosure, a linear low-density polyethylene is an ethylene-octene-1 interpolymer and comprises at least 70 percent by weight of ethylene, or at least 80 percent by weight of ethylene, or at least 90 percent by weight of ethylene.
[0372] In embodiments of the disclosure, a linear low-density polyethylene has a density from 0.910 g / cm3 to 0.940 g / cm3, or from 0.910 g / cm3 to 0.939 g / cm3, or from 0.910 g / cm3 to 0.936 g / cm3, or from 0.910 g / cm3 to 0.932 g / cm3, or from 0.912 g / cm3 to 0.940 g / cm3, or from 0.912 g / cm3 to 0.939 g / cm3, or from 0.912 g / cm3 to 0.936 g / cm3, or from 0.912 g / cm3 to 0.932 g / cm3, or from 0.914 g / cm3 to 0.930 g / cm3, or from 0.914 g / cm3 to 0.939 g / cm3, or from 0.914 g / cm3 to 0.936 g / cm3, or from 0.914 g / cm3 to 0.932 g / cm3, or from 0.916 g / cm3 to 0.940 g / cm3, or from 0.916 g / cm3a 0.939 g / cm3, or from 0.916 g / cm3a 0.936 g / cm3, or from 0.916 g / cm3a 0.932 g / cm3, or from 0.910 g / cm3a 0.930 g / cm3, or from 0.910 g / cm3a 0.928 g / cm3, or from 0.910 g / cm3a 0.926 g / cm3, or from 0.910 g / cm3 to 0.924 g / cm3, or from 0.912 g / cm3 to 0.930 g / cm3, or from 0.912 g / cm3a 0.928 g / cm3, or from 0.912 g / cm3a 0.926 g / cm3, or from 0.912 g / cm3a 0.924 g / cm3, or from 0.914 g / cm3a 0.930 g / cm3, or from 0.914 g / cm3a 0.928 g / cm3, or from 0.914 g / cm3a 0.926 g / cm3, or from 0.914 g / cm3a 0.924 g / cm3.
[0373] In the embodiments of the disclosure, a linear low-density polyethylene has a melting index, I2 of from 0.01 dg / min to 100 dg / min, or from 0.1 dg / min to 50 dg / min, or from 0, 1 dg / min, or from 0.1 dg / min, or from 10 dg / min 0.1 Petition 870250084786, dated 09 / 19 / 2025, page 88 / 154 80 / 123 dg / min to 5 dg / min, or from 0.5 dg / min to 5 dg / min, or from 0.1 dg / min to 3 dg / min, or from 0.5 dg / min to 3 dg / min.
[0374] In one embodiment, the linear low-density polyethylene of the present disclosure may be a homogeneous ethylene interpolymer or a heterogeneous ethylene interpolymer.
[0375] In terms of dissemination methods, linear low-density polyethylene can be unimodal or multimodal.
[0376] In embodiments of the disclosure, linear low-density polyethylene has a molecular weight distribution, Mw / Mn less than 10.0, or less than 9.0, or less than 7.0, or less than 6.0, or less than 5.5, or less than 5.0, or less than 4.5, or less than 4.0, or less than 3.8. In some embodiments of the disclosure, linear low-density polyethylene has an Mw / Mn ratio of 2.0 to 10.0, or 2.0 to 8.0, or 2.0 to 6.0, or 2.0 to 5.5, or 2.0 to 5.0, or 2.0 to 4.5, or 2.0 to 4.0, or 2.2 to 6.0, or 2.2 to 5.5, or 2.2 to 5.0, or 2.2 to 4.5, or 2.2 to 4.0, or 2.5 to 6.0, or 2.5 to 5.5, or 2.5 to 5.0, or 2.5 to 4.5, or from 2.5 to 4.0.In further details of the disclosure, linear low-density polyethylene has an Mw / Mn ratio of 3.0 to 5.5, or 3.0 to 4.5, or 3.0 to 4.0, or 3.2 to 5.5, or 3.2 to 5.0.
[0377] In embodiments of the disclosure, linear low-density polyethylene has a mean molecular weight distribution z, Mz / Mw, of from 1.5 to 6.0. In further embodiments of the disclosure, linear low-density polyethylene has an Mz / Mn of from 1.5 to 5.5, or from 1.5 to 5.0, or from 1.5 to 4.0, or from 1.5 to 3.5, or from 1.5 to 3.0, or from 1.5 to 2.5.
[0378] In disclosure embodiments, linear low-density polyethylene can be made using a gas-phase polymerization process, in the phase of Petition 870250084786, dated 09 / 19 / 2025, page 89 / 154 81 / 123 solution or paste, or any combination thereof, using any type of reactor or reactor configuration known in the art, for example, fluidized bed gas phase reactors, loop reactors, stirred tank reactors, parallel batch reactors, series reactors and / or any combination thereof.
[0379] In one embodiment of the disclosure, linear low-density polyethylene is produced in a solution-phase polymerization process.
[0380] In one embodiment of the disclosure, linear low-density polyethylene is produced with a Ziegler-Natta catalyst.
[0381] In one embodiment of the disclosure, linear low-density polyethylene is produced with a Ziegler-Natta catalyst in a solution-phase polymerization process.
[0382] In embodiments of the disclosure, linear low-density polyethylene may contain conventional additives, including (1) primary antioxidants (such as, for example, hindered phenols, including vitamin E); (2) secondary antioxidants (such as, for example, phosphites and phosphonites); and (3) processing aids (such as, for example, fluoroelastomer and / or processing aid linked to polyethylene glycol).
[0383] Other additives that can be added to linear low-density polyethylene in disclosure embodiments include nitrones, antacids, UV absorbers, metal deactivators, pigments, dyes, fillers and reinforcing agents, nanoscale organic or inorganic materials, antistatic agents, lubricating agents such as calcium stearates, and slip additives such as erucimide and behenamide.
[0384] One embodiment of the disclosure is a multilayer film structure made entirely of polyethylene comprising at least one surface layer A comprising the ethylene polymer composition described in this document. Petition 870250084786, dated 09 / 19 / 2025, pp. 90 / 154 82 / 123
[0385] In one embodiment, a multilayer film structure made entirely of polyethylene comprises greater than or equal to 90%, or 93%, or 95%, or 97%, or 99%, or 100% of one or more ethylene polymers based on the total weight of the multilayer film structure, excluding non-thermoplastic layers (if present).
[0386] In one embodiment, a multilayer structure of all-polyethylene film comprises a sublayer B adjacent to the skin layer A; the sublayer B comprising a high-density polyethylene HDPE having a density of at least 0.945 g / cm3 and a melt index I2 from 0.1 to 10 dg / min.
[0387] In embodiments of the disclosure, a high-density polyethylene has a density greater than 0.940 g / cm3, or at least 0.941 g / cm3, or at least 0.945 g / cm3, or at least 0.949 g / cm3, or at least 0.950 g / cm3, or at least 0.955 g / cm3, or at least 0.960 g / cm3, or at least 0.965 g / cm3.
[0388] In embodiments of the disclosure, a high-density polyethylene has a density from 0.945 to 0.975 g / cm3, or from 0.945 to 0.970 g / cm3, or from 0.945 to 0.967 g / cm3, or from 0.949 to 0.975 g / cm3, or from 0.949 to 0.970 g / cm3, or from 0.949 to 0.967 g / cm3, or from 0.950 to 0.975 g / cm3, or from 0.950 to 0.970 g / cm3, or from 0.950 to 0.967 g / cm3, or from 0.955 to 0.975 g / cm3, or from 0.955 to 0.970 g / cm3, or from 0.955 to 0.967 g / cm3, or from 0.960 to 0.975 g / cm3, or from 0.960 to 0.970 g / cm3, or from 0.960 to 0.967 g / cm3.
[0389] In embodiments of the disclosure, a high-density polyethylene has a melt index, I2, of from 0.01 to 100 dg / min, or from 0.1 to 50 dg / min, or from 0.1 to 10 dg / min, or from 0.1 to 8 dg / min, or from 0.5 to 10 dg / min, or from 0.8 to 8 dg / min, or from 0.5 to 8 dg / min, or from 0.1 to 5 dg / min, or from 0.5 to 5 dg / min. Petition 870250084786, dated 09 / 19 / 2025, pp. 91 / 154 83 / 123
[0390] In terms of dissemination methods, high-density polyethylene can be unimodal or multimodal.
[0391] In one embodiment of the disclosure, a high-density polyethylene has a molecular weight distribution, Mw / Mn, from about 3.0 to about 20.0.
[0392] In one embodiment of the disclosure, a high-density polyethylene has a molecular weight distribution, Mw / Mn, from about 7.0 to about 18.0.
[0393] In embodiments of the disclosure, high-density polyethylene can be produced using any of the well-known catalysts capable of generating high-density polyethylene, such as chromium catalysts, Ziegler-Natta catalysts and the so-called “homogeneous catalysts” such as but not limited to metallocene catalysts, restricted geometry catalysts, and phosphinimine catalysts.
[0394] In embodiments of the disclosure, high-density polyethylene can be made using a gas-phase, solution-phase or paste-phase polymerization process, or any combination thereof, using any type of reactor or reactor configuration known in the art, for example, fluidized bed gas-phase reactors, loop reactors, stirred tank reactors, parallel batch reactors, series reactors and / or any combination thereof.
[0395] In one embodiment of the disclosure, a high-density polyethylene comprises from greater than 0 percent by weight to 1 percent by weight of a nucleating agent or a mixture of nucleating agents.
[0396] In one embodiment of the disclosure, a high-density polyethylene comprises from 100 ppm (parts per million) to 3,000 ppm (parts per million) of a nucleating agent or a mixture of nucleating agents. Petition 870250084786, dated 09 / 19 / 2025, page 92 / 154 84 / 123
[0397] In one embodiment, a high-density polyethylene HDPE is a mixture of at least two ethylene homopolymer blend components; the mixture comprising: from 30 to 95 percent by weight of a first ethylene homopolymer blend component having a density from 0.950 to 0.975 g / cm3; and from 5 to 70 percent by weight of a second ethylene homopolymer blend component having a density from 0.950 to 0.975 g / cm3; wherein the ratio of the melt index I2 of the second ethylene homopolymer blend component to the melt index I2 of the first ethylene homopolymer blend component is at least 10.
[0398] In one embodiment, at least one surface layer A additionally comprises linear low-density polyethylene (LLDPE) having a density from 0.910 g / cm3 to 0.940 g / cm3 and a melt index I2 from 0.1 to 10 dg / min.
[0399] In one embodiment, at least one surface layer A comprises from 10 to 40 percent by weight of an LLDPE and from 60 to 90 percent by weight of the ethylene polymer composition described in this document.
[0400] In one embodiment, a multilayer structure of all-polyethylene film has a sealing start temperature from greater than or equal to 70°C to 115°C, wherein the sealing start temperature is the minimum sealing temperature at which the film structure has a sealing strength greater than 3.4 N per 25.4 mm sealing width.
[0401] In some embodiments, the film structure has a sealing strength from 3.4 to 15.0 N per 25.4 mm sealing width at a sealing temperature from SIT to SIT + 40°C.
[0402] In some embodiments, the film structure has a sealing strength of 3.4 to 15.0 N per 25.4 mm sealing width at a sealing temperature of SIT to SIT + 25°C. Petition 870250084786, dated 09 / 19 / 2025, p. 93 / 154 85 / 123 General Testing Procedures
[0403] Prior to testing, each specimen was conditioned for at least 24 hours at 23 ± 2 °C and 50 ± 10% relative humidity, and subsequent tests were conducted at 23 ± 2 °C and 50 ± 10% relative humidity. In this document, the term “ASTM conditions” refers to a laboratory maintained at 23 ± 2 °C and 50 ± 10% relative humidity; and the 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
[0404] The density of the ethylene polymer composition in the solid state was determined using the ASTM D792-13 standard (November 1, 2013). Merger Index
[0405] The melt index of the ethylene polymer composition was determined using ASTM D1238 (August 1, 2013). Melt indices, I2, were measured at 190 °C using a weight of 2.16 kg. Vicat Softening Temperature
[0406] The VICAT softening temperature of the disclosed Examples and Comparative Examples was measured using ASTM 1525-17 (August 1, 2017) under a load of 10 ± 0.2 N and a heating rate of 120 ± 10 °C / h. The initial temperature of the heat transfer medium (DOW Corning 710) was 20 to 23 °C. In the present disclosure, unless otherwise indicated, VICAT softening temperature measurements were performed on compression-molded specimens at 140 °C and a cooling rate of 15 degrees per minute. Melt Resistance
[0407] The resistance to fusion is measured on a Rosand RH-7 capillary rheometer (cylinder diameter = 15 mm) with a 2 mm diameter flat die, ratio Petition 870250084786, dated 09 / 19 / 2025, pp. 94 / 154 86 / 123 L / D of 10:1 at 190 °C. Pressure Transducer: 10,000 psi (68.95 MPa). Piston Speed: 5.33 mm / min. Drag Angle: 52°. Incremental Drag Speed: 50 - 80 m / min² or 65 ± 15 m / min². A molten polymer sample is extruded through a capillary die at a constant rate, and then the polymer filament is extracted at an increasing drag speed until it breaks. The maximum stable force value in the plateau region of a force versus time curve is defined as the polymer's melt strength. Differential Scanning Calorimetry
[0408] Melt endotherms were obtained by differential scanning calorimetry (DSC) as follows: the instrument was first calibrated with indium; after calibration, a polymer sample was equilibrated at 0 °C and then the temperature was increased to 200 °C at a heating rate of 10 °C / min; the melt was then held isothermally at 200 °C for five minutes; the melt was then cooled to 0 °C at a cooling rate of 10 °C / min and held at 0 °C for five minutes; the sample was then heated to 200 °C at a heating rate of 10 °C / min. The heat flux signal obtained during the second heating cycle was then plotted as a function of temperature. Small Amplitude Oscillatory Shear Rheology
[0409] Oscillatory shear measurements under small strain amplitudes were performed to obtain linear viscoelastic functions at 190 °C under a nitrogen atmosphere, with a strain amplitude of 10% and in a frequency range of 0.02 to 126 rad / s a 5-point decade. Frequency sweep experiments were performed with a TA Instruments DHR3 strain-controlled rheometer, using a cone-plate geometry with a cone angle of 5°, truncation of 137 μm, and a diameter of 25 mm. In this experiment, a sinusoidal strain wave was applied, and the stress response was analyzed in terms of function Petition 870250084786, dated 09 / 19 / 2025, page 95 / 154 87 / 123 linear viscoelastic properties. The viscosity at zero shear rate (η0) based on small-amplitude oscillatory shear measurements was determined by fitting a four-parameter Carreau-Yasuda (CY) viscosity model to the complex viscosity versus angular frequency defined by: ni ΙηΊ = 7o[1 + (υω)α]~ eq.(1) where |n*| is the complex viscosity measured as a function of the angular frequency ω, a (or CY-a, as mentioned in the EXAMPLES section) is a parameter that determines the amplitude of the transition from a Newtonian plateau to a shear-thinning region with a slope of n - 1 on a log-log graph. In this publication, the parameter n is defined as a constant value of 2 / 11 and the other model parameters were adjusted by the least squares method. Long Chain Branching Factor (LCBF)
[0410] The LCBF (dimensionless) was determined for the ethylene polymer composition using the method described in U.S. Patent Application Publication No. 2018 / 0305531, which is incorporated herein by reference.
[0411] In this disclosure, a long-chain branch has a molecular weight equal to or greater than the entanglement molecular weight, Me. Me is a well-known concept in polymer physics (e.g., reported as being about 1 kg / mol for polyethylenes, see Fetters et al., Macromolecules 1999, 32, 6847). In this disclosure, long-chain branches have been characterized as rheologically active. The term rheologically active means that the presence of long-chain branches in a sample was evident after comparison of rheological test results with a comparative sample that did not contain long-chain branches. Non-limiting examples of rheological test results include flow activation energy (Ea), viscosity ratios Petition 870250084786, dated 09 / 19 / 2025, p. 96 / 154 88 / 123 of or shear thinning, melt flow ratios (I21 / I2, I10 / I2, etc.), melt strength and long chain branching factor (LCBF), etc.
[0412] The LCBF calculation involved calculating a polydispersity-corrected zero shear viscosity (ZSVc) and a SCB-corrected intrinsic viscosity (IVc). The polydispersity correction applied to the zero shear viscosity, ZSVc, had Poise dimensions and was performed as shown in equation eq.(2): = 1.8389 X ηθc2.4110Ln(Pd)eq.(2) where η0, the zero shear viscosity (Poise), was measured by a dynamic mechanical analysis test procedure (see the test procedure under the heading “Small Amplitude Oscillating Shear Rheology”); Pd was the dimensionless polydispersity (i.e., Mw / Mn) measured using conventional SEC (see the test procedure under the heading “Conventional Size Exclusion Chromatography”); 1.8389 and 2.4110 were dimensionless constants.
[0413] The calculation of the SCB-corrected intrinsic viscosity IVc (with dimensions in dL / g) was performed as shown in equation (3), AX SCB X Mθ·725 1000000 eq.(3) wherein the intrinsic viscosity [n] (dL / g) was measured using 3D-SEC (see test procedure under the heading “Size Exclusion Chromatography with Triple Detection”), SCB with dimensions of (CH3 / 1000 C) which was determined using FTIR (see test procedure under the heading “Comonomer Coefficient: Fourier Transform Infrared Spectroscopy”), and the average molar mass of the viscosity Mv (g / mol) was determined using 3D-SEC (see test procedure under the heading “Size Exclusion Chromatography with Triple Detection”). The comonomer-dependent constant A was defined above in Petition 870250084786, dated 09 / 19 / 2025, page 97 / 154 89 / 123 context of equation (3). In the case of an ethylene homopolymer, no correction is needed for the Mark-Houwink constant, i.e., SCB is zero.
[0414] Non-long chain branched ethylene polymer compositions (i.e., ethylene polymer compositions that do not contain LCB or have undetectable levels of LCB) fall within a “reference line” as defined by the following equation. LogGK) = 0.2100 x Log(ZSVc) - 0.7879 eq.(4)
[0415] The LCBF calculation was based on the horizontal (Sh) and vertical (Sv) displacements of the linear reference line described above, as established by the following equations: 5h= Log(ZSVc) - 4.7619 x Log(IVc) - 3.7519 eq.(5) 5v= 0.2100 x Log(ZSVc) - Log)!-) - 0.7879 eq.(6)
[0416] In equations (5) and (6), it was necessary that the polydispersity-corrected zero shear viscosity, ZSVc, and the SCB-corrected intrinsic viscosity, IVc, had dimensions of Poise and dL / g, respectively. The horizontal displacement factor (Sh) was a displacement in ZSVc at a constant IVc. If we remove the Log function, its physical meaning is apparent, i.e., a ratio of two ZSVcs, i.e., the ZSVc of the sample under test relative to the ZSVc of a linear ethylene polymer composition with the same IVc. The horizontal displacement factor (Sh) was dimensionless.
[0417] The vertical displacement (Sv) was a displacement in IVc at a constant ZSVc. Again, if we remove the Log function, its physical meaning is apparent, that is, a ratio of two IVcs of an ethylene polymer composition. Petition 870250084786, dated 09 / 19 / 2025, page 98 / 154 90 / 123 linear with the same ZSVc in relation to the IVc of the sample under test. The vertical displacement factor (Sv) was dimensionless.
[0418] Finally, in the present disclosure, a dimensionless long chain branching factor (LCBF) was defined by equation (7): $hxSv2 LCBF = eq.(7) Comonomer Tror: Infrared spectroscopy Fourier Transform Infrared (FTIR)
[0419] The comonomer quantity in an ethylene polymer composition was determined by FTIR and reported as the Short Chain Branching (SCB) content with dimensions of CHa / 1000 C (number of methyl branches per 1000 carbon atoms). This test was performed according to ASTM D6645-01 (2001) using a compression-molded polymer plate and a Thermo-Nicolet 750 Magna-IR spectrophotometer. The polymer plate was prepared using a compression molding device (Wabash-Genesis Series press) according to ASTM D4703-16 (April 2016). Triple Detection Size Exclusion Chromatography (3D-SEC)
[0420] Polymer solutions (1 to 3 mg polymer / mL) were prepared by heating the ethylene polymer composition sample in 1,2,4-trichlorobenzene (TCB) and rotating it 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 to stabilize the polymer sample against oxidative degradation. The BHT concentration was 250 ppm. The sample solutions were chromatographed at 140 °C in a PL 220 high-temperature chromatography unit equipped with a differential refractive index (DRI) detector, a dual-angle light scattering detector (15 and 90 degrees), and a differential viscometer. The SEC columns used were four SHODEX® columns (HT803, HT804, HT805, and HT806) or four Petition 870250084786, dated 09 / 19 / 2025, page 99 / 154 91 / 123 PL Mixed ALS or BLS columns. TCB was the mobile phase with a flow rate of 1.0 mL / minute, BHT was added to the mobile phase at a concentration of 250 ppm to protect the SEC columns from oxidative degradation. The sample injection volume was 200 μL. The raw SEC data were processed using CIRRUS® GPC software to produce absolute molar masses, intrinsic viscosity ([η]), and viscosity-average molar mass (Mv). The term absolute molar mass was used to distinguish the absolute molar masses determined by 3D SEC from the molar masses determined by conventional SEC. The viscosity-average molar mass (Mv) and intrinsic viscosity ([η]) determined by 3D SEC were used in the calculations to determine the long-chain branching factor (LCBF). Conventional Size Exclusion Chromatography (SEC)
[0421] Polymer solutions (1 to 3 mg / mL) were prepared by heating the polymer in 1,2,4-trichlorobenzene (TCB) and rotating it 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 to stabilize the polymer against oxidative degradation. The BHT concentration was 250 ppm. The polymer solutions were chromatographed at 140 °C in a PL 220 high-temperature chromatography unit equipped with four Shodex columns (HT803, HT804, HT805, and HT806) using TCB as the mobile phase at 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 the GPC columns from oxidative degradation. The sample injection volume was 200 μL. The GPC columns were calibrated with narrow-distribution polystyrene standards.The molecular weights of polystyrene were converted to polyethylene molecular weights using the Mark-Houwink equation, as described in the ASTM D6474-12 standard test method (December 2012). The raw GPC data were processed with CIRRUS GPC software to produce molar mass averages (Mn, Mw, Mz) and distribution of... Petition 870250084786, dated 09 / 19 / 2025, pp. 100 / 154 92 / 123 molar mass (e.g., Polydispersity, Mw / Mn). In polyethylene technology, a term commonly used as an equivalent to SEC is GPC, or Gel Permeation Chromatography. GPC-FTIR
[0422] Polymer solutions were prepared by heating 2 to 4 mg / mL of the ethylene polymer composition sample in 1,2,4-trichlorobenzene (TCB) and rotating on a wheel for 4 hours at 150°C in an oven. The antioxidant 2,6-di-tert-butyl-4-methylphenol (BHT) was added to the mixture to stabilize the polymer against oxidative degradation. The BHT concentration was 250 ppm. Sample solutions were chromatographed at 140 °C in a Waters GPC 150C chromatography unit equipped with four SHODEX columns (HT803, HT804, HT805, and HT806) using TCB as the mobile phase at a flow rate of 1.0 mL / minute, with an FTIR spectrometer and a heated FTIR stream through the cell coupled to the chromatography unit via a heated transfer line as the detection system. BHT was added to the mobile phase at a concentration of 250 ppm to protect the SEC columns from oxidative degradation. The sample injection volume was 300 μL.Raw FTIR spectra were processed using OPUS FTIR software, and polymer concentration and methyl content were calculated in real time using Chemometric Software (PLS technique) associated with OPUS. Subsequently, polymer concentration and methyl content were acquired and corrected to baseline using CIRRUS GPC software. SEC columns were calibrated with narrow-distribution polystyrene standards. Polystyrene molecular weights were converted to polyethylene molecular weights using the Mark-Houwink equation, as described in ASTM Standard Test Method D6474. Comonomer content was calculated based on the polymer concentration and methyl content predicted by the PLS technique, as described in Paul J. DesLauriers, Polymer 43, pages 159-170 (2002); incorporated herein by reference. Petition 870250084786, dated 09 / 19 / 2025, pp. 101 / 154 93 / 123
[0423] The GPC-FTIR method measures the total methyl content, which includes methyl groups located at the ends of each macromolecular chain, i.e., terminal methyl groups. Thus, the raw GPC-FTIR data must be corrected by subtracting the contribution of terminal methyl groups. To clarify, the raw GPC-FTIR data overestimate the amount of short-chain branching (SCB), and this overestimation increases as the molecular weight decreases. In this publication, the raw GPC-FTIR data were corrected using the 2-methyl correction. For a given molecular weight (M), the number of terminal methyl groups (NE) was calculated using the following equation: NE = 28000 / M, and NE (dependent on M) was subtracted from the raw GPC-FTIR data to yield the SCB per 1000 carbon atoms (GPC-FTIR data corrected for 2-methyl).
[0424] The slope of the comonomer distribution is determined by GPCFTIR and is defined by SCB per 1000 Cs at a molecular weight of 300,000 (g / mol) SCB per 1000 Cs at a molecular weight of 30,000 g / mol, where “-” is a minus sign, SCB per 1000 Cs is the comonomer content corrected for 2-methyl, determined as the number of short-chain branches per thousand carbons at the corresponding molecular weight (i.e., the absolute molecular weight) on a GPCFTIR chromatograph. Heat Sealing Resistance of the Film
[0425] In this disclosure, the “Hot Seal Resistance Test” (also known as the “cold seal test”) was performed as follows. Hot seal data were generated using a conventional Instron Tensile Tester. In this test, two film samples are sealed within a temperature range where the two film samples were cut from the same roll. The following parameters were used in the hot seal resistance test (or cold seal test): film sample width, 1 inch (25.4 mm); film sealing time, 0.5 seconds; film sealing pressure, 40 psi (0.28 N / mm2); Petition 870250084786, dated 09 / 19 / 2025, pp. 102 / 154 94 / 123 temperature range, 212 °F to 302 °F (100 °C to 150 °C) and temperature increment, 9 °F (5 °C). After aging for at least 24 hours under ASTM conditions, the seal strength was determined using the following tensile parameters: pull speed (crosshead); 12 inches / min (2.54 cm / min); pull direction of 90 ° to seal; and 5 film samples were tested at each temperature increment. EXAMPLES Solution Polymerization Process
[0426] The ethylene polymer compositions of the reactor mixture in Examples 1 to 3 were produced in a pilot multireactor solution polymerization process “in series”, where the ethylene polymer composition was produced by forming the first ethylene polymer in a first reactor (R1); forming a second ethylene interpolymer in a second reactor (R2); and forming a third ethylene interpolymer in a third reactor (R3), where R1, R2 and R3 were configured in series with each other. A multireactor, series solution-phase polymerization process was described in U.S. Patent Application Publication No. 2019 / 0135958.
[0427] In a series reactor system, the outlet stream from a first polymerization reactor (R1) flows directly into a second polymerization reactor (R2). The pressure of R1 varied from about 14 MPa to about 18 MPa; while R2 was operated at a lower pressure to facilitate continuous flow from R1 to R2. Both R1 and R2 were continuous stirred reactors (CSTRs). The third reactor, R3, was a tubular reactor configured in series with the second reactor, R2 (i.e., the contents of reactor 2 flowed into reactor 3). The process was operated continuously by feeding the first and second reactors with fresh process solvent, ethylene, octene-1, and hydrogen, and by removing the product. Methylpentane was used as the process solvent (a commercial mixture of meth isomers). Petition 870250084786, dated 09 / 19 / 2025, pp. 103 / 154 95 / 123 tilpentane). The volume of the first CSTR reactor (R1) was 12 L (3.2 gallons), and the volume of the second CSTR reactor (R2) was 22 L (5.8 gallons). The volume of the tubular reactor (R3) was 18 L (4.755 gallons). The monomer (ethylene) and comonomer (octene-1) were purified before addition to the reaction using conventional feed preparation systems (such as contact with various absorption media to remove impurities like water, oxygen, and polar contaminants). The reactor feeds were pumped into the reactors in the proportions shown in Table 1.
[0428] Table 1 shows the reactor conditions used to produce each of the ethylene polymer compositions of Examples 1 to 3. Table 1 includes process parameters such as ethylene and octene-1 splits between reactors (R1, R2 and R3), reactor temperatures, ethylene conversions, hydrogen amounts, ethylene and octene-1 concentration in fresh feed to the reactors, total fresh feed dissolution rates, agitation speeds of the CSTR reactors (R1 and R2), etc.
[0429] In Examples 1 and 2, the following unbridged single-site catalyst components were used to prepare the first ethylene polymer in the first CSTR reactor (R1): component C, cyclopentadienyl tri(butyl tertiary)phosphinimine titanium dichloride {Cp[(t-Bu)3PN]TiCl2}; component M, methylaluminoxane (MMAO-07); component B, trityl tetrakis(pentafluorophenyl)borate; and; component P, 2,6-di-tert-butyl-4-ethylphenol. The following solvents for the catalyst components were used: methylpentane for components M and P; and xylene for components C and B. The efficiency of the unbridged single-site catalyst formulation was optimized by adjusting the amount of component C added to R1 [catalyst R1 (ppm) as described in Table 1], the molar ratios of the catalyst components — i.e., [M] / [C], [P] / [M] and [B] / [C], as tabulated in Table 1 — and the inlet temperature of catalyst R1. Petition 870250084786, dated 09 / 19 / 2025, pp. 104 / 154 96 / 123
[0430] In Examples 1 and 2, the following metallocene bridge catalyst components were used to prepare the second ethylene interpolymer in the second CSTR reactor (R2): component A, diphenylmethylene(cyclopentadienyl)(2,7-di-t-butylfluoroenyl)hafnium dimethide [(2,7-tBu2Flu)Ph2C(Cp)HfMe2]; component M, methylaluminoxane (MMAO-07); component B, trityl tetrakis(pentafluorophenyl)borate (trityl borate); and component P, 2,6-di-tert-butyl-4-ethylphenol (BHEB). Methylaluminoxane (MMAO-07); 2,6-di-tert-butyl-4-ethylphenol are premixed in-line and then combined with diphenylmethylene(cyclopentadienyl)(2,7-di-t-butylfluoroenyl)hafnium dimethide and trityl tetrakis(pentafluorophenyl)borate immediately before entering the polymerization reactor (R2). The following catalyst component solvents were used: methylpentane for components M and P; and xylene for components A and B.The efficiency of the metallocene bridge catalyst formulation was optimized by adjusting the amount of component A added to R2 [catalyst R2 (ppm) as described in Table 1], the molar ratios of the catalyst components — i.e., [M] / [A], [P] / [M] and [B] / [A] as tabulated in Table 1 — and the inlet temperature of catalyst R2.
[0431] In Example 3, the following metallocene bridge catalyst components were used to prepare the first ethylene polymer in the first CSTR reactor (R1) and to prepare the second ethylene interpolymer in the second CSTR reactor (R2): component A, diphenylmethylene(cyclopentadienyl)(2,7di-t-butylfluoroenyl)hafnium dimethide [(2,7-tBu2Flu)Ph2C(Cp)HfMe2]; component M, methylaluminoxane (MMAO-07); component B, trityl tetrakis(pentafluorophenyl)borate (trityl borate); and component P, 2,6-di-tert-butyl-4-ethylphenol (BHEB). Methylaluminoxane (MMAO07); 2,6-di-tert-butyl-4-ethylphenol and 2,6-di-tert-butyl-4-ethylphenol are premixed in-line and then combined with diphenylmethylene(cyclopentadienyl)(2,7-di-t-butylfluoroenyl)hafnium dimethide and trityl tetrakis(pentafluorophenyl)borate immediately before entering the polymerization reactors (R1 and R2). The following solvents are components of the catalyst. Petition 870250084786, dated 09 / 19 / 2025, pp. 105 / 154 97 / 123 were used: methylpentane for components M and P; and xylene for components A and B. The efficiency of the metallocene bridge catalyst formulation was optimized by adjusting the amount of component A added to R1 and R2 [catalyst R1 (ppm) and catalyst R2 (ppm), as described in Table 1], the molar ratios of the catalyst components — i.e., [M] / [A], [P] / [M] and [B] / [A], as tabulated in Table 1 — and the inlet temperatures of catalysts R1 and R2.
[0432] In the continuous solution polymerization process shown in Table 1, the total amount of ethylene supplied to the process was portioned or divided among the three reactors R1, R2, and R3. In Table 1, this operational variable was termed ethylene split (ES), i.e., ESR1, ESR2, and ESR3, referring to the percentage by weight of ethylene injected into R1, R2, and R3, respectively; with the condition that ESR1 + ESR2 + ESR3 = 100%. Octene-1 was also added to the continuous solution polymerization process and was portioned or divided among R1, R2, and R3. In Table 1, this operational variable was termed octene-1 split (OS), i.e., OSR1, OSR2, and OSR3, referring to the percentage by weight of the octene-1 comonomer that was injected into R1, R2, and R3, respectively; with the condition that OSR1 + OSR2 + OSR3 = 100%.
[0433] In Examples 1 to 3, no fresh ethylene, octene-1, hydrogen, and catalyst were pumped into the third reactor—for example, ESR3 and OSR3 were zero. The residual ethylene, residual octene-1, and residual active catalyst(s) that entered the third reactor (R3) from the upstream reactors R1 and R2 formed the third ethylene interpolymer in these Examples.
[0434] When operating the continuous solution polymerization process shown in Table 1, the total amount of ethylene converted in each reactor is monitored. The term QR1 refers to the percentage of ethylene added to R1 that was converted into a first ethylene polymer by the catalyst formulation. Similarly Petition 870250084786, dated 09 / 19 / 2025, pp. 106 / 154 98 / 123 form, QR2 and QR3 represent the percentage of ethylene added to R2 and the residual ethylene transported from R1 and R2 to R3, which were converted into the second and third ethylene interpolymers, respectively.
[0435] In Table 1, the term QT represents the total or overall conversion of ethylene throughout the continuous solution polymerization plant; that is, QT = 100 χ [weight of ethylene in the ethylene polymer mix] / ([weight of ethylene in the ethylene polymer mix] + [weight of unreacted ethylene]).
[0436] The polymerization in the continuous solution polymerization process was terminated by adding a catalyst deactivator to the third outlet stream of the tubular reactor (R3). The catalyst deactivator used was octanoic acid (caprylic acid), commercially available from P&G Chemicals, Cincinnati, OH, USA. The catalyst deactivator was added in such a way that the moles of fatty acid added corresponded to 50% of the total molar amount of catalytic metal and aluminum added to the polymerization process; to clarify, the moles of octanoic acid added = 0.5 χ (moles of hafnium + moles of aluminum).
[0437] A two-stage devolatilization process was employed to recover the ethylene polymer composition from the process solvent, i.e., two vapor / liquid separators were used, and the second bottom stream (from the second V / L separator) was passed through a gear pump / granulator combination. The gear pump was a Vacorex 45 / 45 pump with a capacity of 191 liters per hour, steam-coated with 270#. The ethylene polymer composition exiting the gear pump was then passed through a 10 cm diameter static mixer before entering the pelletizer, where it was forced through holes in the die plate from top to bottom. There were 32 holes in the die, with a diameter of 0.31 cm. The aspect ratio (i.e., length-to-diameter ratio) for each hole was 6.3:1, and the die had a thickness of 4.1 cm and a diameter of 30 cm. There were 6 cutting blades — 8.6878” in diameter ex Petition 870250084786, dated 09 / 19 / 2025, pp. 107 / 154 99 / 123 dies with an internal diameter of 6.2418 inches — located on the side of the die facing the cooling water system. There were internal heating channels inside the die plate, and the die body and plate were heated with 600# or 270# steam. The cooling water system had a temperature range of 10 to 80°C and a flow rate of 7500-9500 kg / h.
[0438] DHT-4V (hydrotalcite), supplied by Kyowa Chemical Industry Co. LTD, Tokyo, Japan, can be used as a passivator, or acid remover, in the continuous solution process. A suspension of DHT-4V in the process solvent can be added before the first V / L separator.
[0439] Prior to pelleting, the ethylene polymer composition was stabilized by adding 500 ppm of IRGANOX® 1076 (a primary antioxidant) and 500 ppm of IRGAFOS® 168 (a secondary antioxidant), based on the weight of the ethylene polymer composition. The antioxidants were dissolved in the process solvent and added between the first and second V / L separators.
[0440] The Mw, Mn, Mw / Mn, weight percent, and SCB per 1000 carbon atoms of each component produced in R1, R2, and R3 were calculated and presented in Table 2a using a reactor model simulation using the inlet conditions that were employed for real pilot-scale operating conditions. For references on relevant reactor modeling methods, see “Copolymerization” by A. Hamielec, J. MacGregor, and A. Penlidis in Comprehensive Polymer Science and Supplements, volume 3, Chapter 2, page 17, Elsevier, 1996 and “Copolymerization of Olefins in a Series of Continuous Stirred-Tank Slurry-Reactors using Heterogeneous Ziegler-Natta and Metallocene Catalysts I. General Dynamic Mathematical Model” by JBP Soares and AE Hamielec in Polymer Reaction Engineering, 4(2&3), p153, 1996.
[0441] The model takes as input the flow of various reactive species (e.g., catalyst, monomer such as ethylene, comonomer such as octene-1, hydro Petition 870250084786, dated 09 / 19 / 2025, pp. 108 / 154 100 / 123 (genus and solvent) going to each reactor, the temperature (in each reactor) and the monomer conversion (in each reactor) and calculates the polymer properties (of the polymer made in each reaction zone) using a terminal kinetic model for continuously stirred tank reactors (CSTRs) connected in series. The “terminal kinetic model” assumes that the kinetics depend on the monomeric unit within the polymer chain in which the active catalytic site is located — see “Copolymerization” by A. Hamielec, J. MacGregor and A. Penlidis in Comprehensive Polymer Science and Supplements, Volume 3, Chapter 2, page 17, Elsevier, 1996. In the model, it is assumed that the copolymer chains have a reasonably large molecular weight to ensure that the insertion statistics of the monomer / comonomer unit into the active catalytic center are valid and that the monomers / comonomers consumed in routes other than propagation are negligible. This is known as the "long chain" approximation.
[0442] The terminal kinetic model for polymerization includes reaction rate equations for the activation, initiation, propagation, chain transfer, and deactivation pathways. This model solves the steady-state conservation equations (e.g., the total mass balance and heat balance) for the reactive fluid comprising the reactive species identified above. The total mass balance for a generic CSTR with a given number of inputs and outputs is given by: = ^^ i (eq. 8) where mi represents the mass flow rate of individual streams with index i indicating the inflow and outflow. Equation 8 can be expanded to show the individual species and reactions: Petition 870250084786, dated 09 / 19 / 2025, pp. 109 / 154 101 / 123 mxΛLi / μ, = ------7T-1+RJ / ' Pmix P mix^ (eq. 9) where Mi is the average molar mass of the inlet or outlet fluid i, xij is the mass fraction of species j in stream i, pmix is the molar density of the reactor mixture, V is the reactor volume, Rj is the reaction rate for species j, which has units of kmol / m3s. The overall heat balance is solved for an adiabatic reactor and is given by: °=(Σ miAH- + qRxV + W (eq. 10) where, mi is the mass flow rate of stream i (inlet or outlet), ΔH is the enthalpy difference of stream i relative to a reference state, qRx is the heat released by the reaction(s), V is the reactor volume, W is the input work (i.e., stirrer), Q' is the heat input / loss. The inlet catalyst concentration in each reactor is adjusted to match the experimentally determined ethylene conversion and reactor temperature values in order to solve the kinetic model equations (e.g., propagation rates, heat balance, and mass balance). The inlet H2 concentration in each reactor can be adjusted similarly so that the calculated molecular mass distribution of a polymer produced in all reactors (and therefore the molecular mass of the polymer produced in each reactor) matches that observed experimentally.
[0443] The percentage values by weight reported in Table 2a are such that the sum of the percentage values by weight of the material produced in R1, R2 and R3 is 100%.
[0444] The degree of polymerization (dpn) for a polymerization reaction is given by the ratio between the rate of chain propagation reactions and the rate of chain transfer / termination reactions: Petition 870250084786, dated 09 / 19 / 2025, pp. 110 / 154 102 / 123 dpn_________________kplφ^τη^ + k^ 0![m2]+ Ρρ^ΦΑΑ________________ k tmll[ml]Φl+ktm22[m2](li+ / Clm[l[m[]Φ[+^tsl^l+^ts202+^ / Hl[^] +^ίΗ2[^]=Rp R t (eq. 11) where kl22 is the propagation rate constant for adding monomer 2 (octene-1) to a growing polymer chain terminating with monomer 1 (ethylene), [m1] is the molar concentration of monomer 1 in the reactor, [m2] is the molar concentration of monomer 2 in the reactor, ktm12 is the termination rate constant for chain transfer to monomer 2 for a growing chain terminating with monomer 1, kts1 is the rate constant for spontaneous chain termination for a chain terminating with monomer 1, ktH1 is the rate constant for hydrogen chain termination for a chain terminating with monomer 1. Φ1 and Φ2 are the fraction of catalyst sites occupied by a chain terminating with monomer 1 or monomer 2, respectively. TABLE 1: Continuous solution polymerization process Parameters by examples 1-3. Example 1 Example 2 Example 3 Catalyst R1 (ppm) 0.11 0.17 0.26 Catalyst R1 PIC* PIC* CpFt Molar ratio R1 ([M] / [A]) — — 51 Molar ratio R1 ([P] / [M]) — — 0.43 Molar ratio R1 ([B] / [A]) — — 1.31 Molar ratio R1 ([M] / [C]) 50 50 — Molar ratio R1 ([P] / [M]) 0.54 0.49 — Molar ratio R1 ([B] / [C]) 1.30 1.31 — Temperature of catalyst diluent R1 (°C) 29.6 34.1 36.3 Catalyst R2 (ppm) 0.86 0.78 0.56 Catalyst R2 CpFt CpFt CpFt Molar ratio R2 ([M] / [A]) 50 50 50 Molar ratio R2 ([P] / [M]) 0.3 0.40 0.40 Molar ratio R2 ([B] / [A]) 1.30 1.30 1.30 Catalyst diluent temperature R2 (°C) 38.4 35.8 37.8 Petition 870250084786, dated 09 / 19 / 2025, pp. 111 / 154 103 / 123 ESR1 (%) 45.0 45.0 45.0 ESR2 (%) 55.0 55.0 55.0 Ethylene concentration R1 (% by weight) 11.2 10.6 10.8 Ethylene concentration R2 (% by weight) 12.5 11.3 11.9 Octene-1 to ethylene ratio R1 (weight fraction) 0 0 0 Octene-1 to ethylene ratio R2 (weight fraction) 1.16 0.948 0.87 Octene-1 to ethylene ratio (total weight fraction) 0.634 0.520 0.480 Polymer production rate (kg / h) 68.6 61.9 73.2 R1 total solution rate (kg / h) 273.8 263.9 272.7 R2 Total solution rate (kg / h) 276.2 286.1 277.3 Total solution rate (kg / h) 550.0 550.0 550.0 OSR1 (%) 0.0 0.0 0.0 OSR2 (%) 100.0 100.0 100.0 H2 concentration in R1 (ppm) 2.50 2.50 5.00 H2 concentration in R2 (ppm) 1.00 1.00 1.00 R1 Fresh feed temperature (°C) 35.0 40.0 40.0 R2 Fresh feed temperature (°C) 35.0 42.0 42.4 R1 Average temperature (°C) 159.7 163.2 165.2 R2 Average temperature (°C) 184.9 175.0 180.1 R3 Outlet temperature (°C) 192.1 184.3 190.7 R3 Volume (L) 18 18 18 QR1 (%) 89.9 89.9 90.0 QR2 (%) 77 730 74.0 QR3 (%) 50 61.9 66.2 QT (%) 93.1 93.9 94.8 R1 Stirrer speed (rpm) 325.0 325.0 646.0 R2 Stirrer speed (rpm) 260.0 260.0 260.0 *Cp[(t-Bu)3PN]TiCl2; et(2,7-tBu2Flu)Ph2C(Cp)HfMe2.
[0445] The number-average molecular weight (Mn) for a polymer is derived from the degree of polymerization and the molecular weight of a monomeric unit. Starting from the number-average molecular weight of the polymer in a given reactor, and assuming a Flory-Schulz distribution for a single-site catalyst, the molecular weight distribution is determined for the polymer using the following relationships. Petition 870250084786, dated 09 / 19 / 2025, pp. 112 / 154 104 / 123 w(η) = m2eτη(eq. 12) where n is the number of monomeric units in a polymer chain, w(n) is the weight fraction of polymer chains having a chain length n, and τ is calculated using the equation below: Rt τ = = “ dp ηRp (eq. 13) where dp is the degree of polymerization, Rp is the propagation rate and Rt is the termination rate. The Flory-Schulz distribution can be transformed into common logarithmic scale gel permeation chromatography, trace GPC by applying: dW ,sn2( _) ---------= / n(T0)-----e' ^Pn·' dlog(M)O)dpn2 (eq. 14) where diogÇM^)éa fractional weight differential of the polymer with a chain length n (n = — where 28 is the molecular weight of the polymer segment ' 28 ~ which corresponds to the C2H4 unit) and dpné is the degree of polymerization.
[0446] Assuming a Flory-Schultz model, different molecular weight distribution moments can be calculated using the following: í , _ . . μl= I nlW)n)dn J ο (eq. 15) Thus, μο= 1, μ1= dpn, and μ2= 2 dpn2; only: μ1 Μη = Mwmonomer = Wmonomer ^Ρη μ ο μ 2 Mw = MWmonomer = 2MWmonomer dpnμ ι (eq. 16) where Mwmonomer is the molecular weight of the polymer segment corresponding to the C2H4 monomer unit. Finally, when a site catalyst Petition 870250084786, dated 09 / 19 / 2025, pp. 113 / 154 105 / 123 single produces long chain branching, the molecular weight distribution is determined for the polymer using the following relationships (see “Polyolefins with Long Chain Branches Made with Single-Site Coordination Catalysts: A Review of Mathematical Modeling Techniques for Polymer Microstructure” by JBP Soares in Macromolecular Materials and Engineering, volume 289, Issue 1, Pages 70-87, Wiley-VCH, 2004 and “Polyolefin Reaction Engineering” by JBP Soares and TFL McKenna Wiley-VCH, 2012). (1 - α) τB6~τ^ / BBnJã\w (n)=---n λ---;i 2 ~T7— (1 + cr) y 1 + cl ] (eq. 17) where n is the number of monomeric units in a polymer chain, ( ) is the weight fraction of polymer chains having a chain length n, and bbe a are calculated using the equations below: _1_Rt + RlbbT B= Bp= = R„ R LCBa= (eq. 18) where dpB is the degree of polymerization, Rpé is the propagation rate, Rté is the termination rate, and RLBB is the branching rate of long chain formation calculated using the equation below: R LCB = ^1301^3] (eq. 19) where kp33 is the propagation rate constant for adding monomer 3 (macromonomer formed in the reactor) to a growing polymer chain terminating with monomer 1, [m3] is the molar concentration of the macromonomer in the reactor. The weight distribution can be transformed into the common logarithmic scale GPC trace by applying: Petition 870250084786, dated 09 / 19 / 2025, pp. 114 / 154 106 / 123 dW (1 — a) rBeτBη7 TBmfã\ =ln(10)(1+^φvd (eq. 20) where ——- is the differential weight fraction of the polymer with a chain length log(MW)v n (n = — where 28 is the molecular weight of the polymer segment ' 28 ~ which corresponds to the C2H4 unit). From the weight distribution, different molecular weight distribution moments can be calculated using the following: Mn Mw-monomer d-Pn Mw2 MwmOeômero dpn+ a — a + a (1 — u)2(eq. 21) where dpé is the degree of polymerization, and a is calculated as explained.
[0447] Assuming that the addition of the 2-monomer unit (octene-1) to a chain terminating in a terminal octene unit is negligible, the number of octenes after the ethylene steps will be equivalent to the number of ethylenes after the octene steps. The branching rate of the resulting polymer per thousand carbon atoms of the main chain (500 monomeric units), BrF, will be the ratio between the rate of addition of monomer 1 (ethylene) and the rate of addition of monomer 2 (octene). 1). rate of addition of monomer 2 after monomer 1 [m2]%i2 BrF = 7 η h - h----------17-----:-----Ãx 500= rP x 500rate of addition of monomer 1 after monomer 1 [mj kpl(eq. 22) where kpl2 is the propagation rate constant for adding the monomer (octene-1) to a growing polymer chain ending with monomer 1 (ethylene), kp11 is the propagation rate constant for adding the monomer (ethylene) to a growing polymer chain ending with monomer 1 1, [m1] is the molar concentration of monomer 1 in the reactor and [m2] is the molar concentration of monomer 2 in the reactor. Petition 870250084786, dated 09 / 19 / 2025, pp. 115 / 154 107 / 123
[0448] With reference to Table 2a, Example 1 contained 38.9 percent by weight of a first ethylene polymer having a weight-average molecular weight Mw of 114.2 kg / mol, a comonomer content of 0 SCB per 1000 carbons and a polydispersity index Mw / Mn of 2.00; 56.9 percent by weight of a second ethylene interpolymer having a weight-average molecular weight Mw of 39.1 kg / mol, a number of short-chain branches per thousand carbon atoms of 42, and a polydispersity index Mw / Mn of 2.06; and 4.2 percent by weight of a third ethylene interpolymer having a weight-average molecular weight Mw of 25.6 kg / mol, a number of short-chain branches per thousand carbon atoms of 47, and a polydispersity index Mw / Mn of 2.26.
[0449] Example 2 contained 41.5 percent by weight of a first ethylene polymer having a weight-average molecular weight Mw of 110.2 kg / mol, a comonomer content of 0 SCB per 1000 carbons, and a polydispersity index Mw / Mn of 2.00; 53.7 percent by weight of a second ethylene interpolymer having a weight-average molecular weight Mw of 58.9 kg / mol, a number of short-chain branches per thousand carbon atoms of 3, and a polydispersity index Mw / Mn of 2.04; and 4.8 percent by weight of a third ethylene interpolymer having a weight-average molecular weight Mw of 43.2 kg / mol, a number of short-chain branches per thousand carbon atoms of 32, and a polydispersity index Mw / Mn of 2.23.
[0450] Example 3 contained 39.4 percent by weight of a first ethylene polymer having a weight-average molecular weight Mw of 142.9 kg / mol, a comonomer content of 0 SCB per 1000 carbons, and a polydispersity index Mw / Mn of 2.29; 53.6 percent by weight of a second ethylene interpolymer having a weight-average molecular weight Mw of 50.3 kg / mol, a number of short-chain branches per thousand carbon atoms of 36.3, and a polydispersity index Mw / Mn of 2.07; and 7.0 percent by weight of a third ethylene interpolymer. Petition 870250084786, dated 09 / 19 / 2025, pp. 116 / 154 108 / 123 of a weight-average molecular weight Mw of 26.0 kg / mol, a number of short-chain branches per thousand carbon atoms of 46, and a polydispersity index Mw / Mn of 2.18.
[0451] It is observed that, in Examples 1 to 3, the second ethylene interpolymer (component R2) had a lower weight-average molecular weight than the first ethylene polymer (component R1). The ratio between the weight-average molecular weight of the first ethylene polymer and the weight-average molecular weight of the second ethylene interpolymer was approximately 2.67, 2.05, and 2.64 for Examples 1, 2, and 3, respectively.
[0452] As can be seen from the data in Table 2a, the first ethylene polymer produced in the first reactor (R1) was a first ethylene homopolymer. This result was a direct consequence of applying a 0% OSR1 in Examples 1 to 3.
[0453] It is also noteworthy that, in Examples 1-3, the second ethylene interpolymer had a weight-average molecular weight that was lower than the weight-average molecular weight of the first ethylene polymer and higher than the weight-average molecular weight of the third ethylene interpolymer.
[0454] In Table 2b, the R1, R2, and R3 components for the simulated Examples S1, S2, and S3 are tabulated, in which the octene-1 splitting ratios of reactors R1 and R2 in the experimentally produced Examples 1, 2, and 3 were changed to OSR1 = 5.0% and OSR2 = 95.0%. All other polymerization process variables were kept constant between simulated Examples S1 to S3 and their corresponding experimentally produced Examples 1 to 3. To clarify, for example, the R1, R2, and R3 components for the simulated Example S1 were simulated using the same polymerization process variables as Example 1, with the only difference being the octene-1 splitting ratios for reactors R1 and R2. As can be seen from the data in Table 2b, in Examples S1 Petition 870250084786, dated 09 / 19 / 2025, p. 117 / 154 109 / 123 In S3, a first ethylene / octene-1 interpolymer was synthesized in the first reactor (R1), that is, the first ethylene polymer presented a comonomer content of (<) 0 SCB per 1000 carbons and (<) 6 SCB per 1000 carbons.
[0455] As shown in Table 3, Examples 1 and 2 contained undetectable levels of long-chain branching, as characterized by an LCBF less than 0.001. Example 3, on the other hand, contained detectable levels of long-chain branching, as characterized by an LCBF greater than or equal to 0.001. This latter structural characteristic of Example 3 in relation to Examples 1 and 2 can be examined in more detail by comparing its observed values for I21 / I2, strain exponent, ηα, CY-a, and G' at G = 500 Pa.
[0456] As noted by experts in the art, in Examples 1 and 2, the bridging metallocene catalyst that produces the second ethylene interpolymer in the second reactor (abbreviated as CpF in Table 1) would generate long-chain branched species. However, its contribution to the melt rheological measurements discussed above would be completely masked by the presence of the first, higher molecular weight, LCB-free polymer produced in R1 using the unbridged single-site catalyst (abbreviated as PIC in Table 1). TABLE 2a: Deconvolution of the ethylene polymer composition of examples 1-3 into a first ethylene polymer, a second ethylene interpolymer, and a third ethylene interpolymer made in R1, R2, and R3, respectively. R1 R2 R3 Example 1 Weight percent (%) 38.9 56.9 4.2 Mn (g / mol) 57.051 18.935 11.292 Mw (g / mol) 114.163 39.141 25.552 Polydispersity (Mw / Mn) 2.00 2.06 2.26 SCB per 103 carbons 0 42 47 Example 2 Weight percent (%) 41.5 53.7 4.8 Mn (g / mol) 55.058 28.775 19.360 Mw (g / mol) 110.215 58.939 43.199 Polydispersity (Mw / Mn) 2.00 2.04 2.23 Petition 870250084786, dated 09 / 19 / 2025, pp. 118 / 154 110 / 123 SCB per 103 carbons 0 33 32 Example 3 Weight percent (%) 39.4 53.6 7.0 Mn (g / mol) 62.331 24.277 11.892 Mw (g / mol) 142.864 50.330 25.989 Polydispersity (Mw / Mn) 2.29 2.07 2.18 SCB per 103 carbons 0 36 46 TABLE 2b: Deconvolution of the ethylene polymer composition of Simulated Examples S1-S3 into a first ethylene polymer, a second ethylene interpolymer, and a third ethylene interpolymer produced in R1, R2, and R3, respectively. R1 R2 R3 Example S1 Mn (g / mol) 54.781 19.005 11.335 Mw (g / mol) 109.677 39.315 25.756 Polydispersity (Mw / Mn) 2.00 2.07 2.27 SCB per 103 carbons 1 42 46 Example S2 Mn (g / mol) 53.079 28.886 19.481 Mw (g / mol) 106.311 59.186 43.573 Polydispersity (Mw / Mn) 2.00 2.05 2.24 SCB per 103 carbons 1 33 31 Example S3 Mn (g / mol) 61.574 24.553 11.662 Mw (g / mol) 116.466 51.044 25.696 Polydispersity (Mw / Mn) 2.26 2.08 2.20 SCB per 103 carbons 6 35 46 TABLE 3: Physical, molecular, thermal, and rheological melting characteristics of Examples 1-3. Example 1 Example 2 Example 3 Density 0.9094 0.9072 0.9080 Melting Index I2 (dg / min) 3.73 3.09 3.77 Melting Index I6 (dg / min) 15.47 12.70 17.38 Melting Index I21 (dg / min) 107.01 84.50 124.78 Melting Ratio I21 / I2 (-) 28.73 27.35 33.10 Stress Exponent (-) 1.30 1.29 1.39 Petition 870250084786, dated 09 / 19 / 2025, pp. 119 / 154 111 / 123 Comonomer content (% by mol) 5.0 5.2 5.2 Comonomer content (% by weight) 17.4 18.1 17.9 Comonomer type octene-1 octene-1 octene-1 Number of SCBs per 1000 carbons 25.0 26.1 25.9 Mn (kg / mol) 22.41 19.83 23.05 Mw (kg / mol) 78.87 71.15 73.52 Mz (kg / mol) 197.20 150.54 170.03 Mw / Mn (-) 3.52 3.59 3.19 GPC MWD conventional Unimodal Unimodal Unimodal Zero shear viscosity (kPa.s) 2.79 3.60 5.40 CY-a 0.4769 0.4415 0.2909 τ (ms) 9.55 9.83 10.06 G' in G” = 500 Pa (Pa) 31.90 35.21 74.79 Melting strength (cN) not tested 1.40 1.51 Strain ratio (-) not tested 1637.8 1115.1 LCBF (-) 4.19x10-4 1.68x10-5 8.06x10-3 Low temperature melt peak, Tmlow (°C) 76.9 75.1 78.0 High temperature melt peak, Tmhigh (°C) 129.5 128.8 125.3 GPCFTIR slope (SCB per 1000 carbons) -31.9 -31.0 -28.3 Vicat Softening Temperature (°C) 64.0 69.0 69.0
[0457] With reference to the GPC-FTIR profiles shown in Figures 1a, 2a and 3a, it can be understood that the ethylene polymer compositions prepared in Examples 1-3 had a normal comonomer distribution where the low MW species contained a short-chain branching frequency greater than about 30 short-chain branches per 1000 carbon atoms at lower MWs. Petition 870250084786, dated 09 / 19 / 2025, pp. 120 / 154 112 / 123 that approximately 30 kg / mol and the high MW species had a short-chain branching frequency approaching small (almost zero) SCB contents in MWs greater than approximately 300 kg / mol. Specifically, the GPC-FTIR comonomer distribution of Example 1 showed a slope of -31.9 SCB per 1000 carbons, the GPC-FTIR comonomer distribution of Example 2 showed a slope of -31.0 SCB per 1000 carbons, and the GPC-FTIR comonomer distribution of Example 3 showed a slope of -28.3 SCB per 1000 carbons.
[0458] Based on the second DSC heating thermograms shown in Figures 1b, 2b, and 3b, and the low / high temperature melting peaks tabulated in Table 3, it is possible to recognize that Examples 1 to 3 included two distinct melting peaks: a low temperature melting peak around 75-78 °C and a high temperature melting peak around 125-130 °C. In all Examples, the heat flux signal, in a temperature range of about 85 °C to about 100 °C, returned almost to an imaginary baseline drawn between 20 °C and the end of melting. In the examples shown in Figures 1b, 2b, and 3b, the maximum distance between the second heating heat flux curves and the imaginary baseline, in a temperature range of about 85 °C to about 100 °C, was less than 0.07 W / g. Peelable and Easy-Open Film Structures
[0459] Examples 1F to 3F were all polyethylene film structures prepared from the ethylene polymer compositions disclosed in Examples 1 to 3 on a three-layer coextrusion film blowing line manufactured by Brampton Engineering with a blow ratio of 2.5, a total film thickness of 2.85 mils, a freeze line height of 18.0 inches, a production rate of 100.0 pounds per hour, and a die opening of 35 mils. Examples 1F to 3F had an A / B / C structure with a layer thickness ratio Petition 870250084786, dated 09 / 19 / 2025, pp. 121 / 154 113 / 123 of 20 / 40 / 40 and were produced at a melting temperature of 409-413°F, 417-418°F and 431-432°F for layers A, B and C, respectively. The sealing layer (the surface layer here identified as layer A) in Film Examples 1F, 2F and 3F was prepared from the ethylene polymer composition disclosed in Examples 1, 2 and 3, respectively. The sealing layer in these film examples also contained 2.0% (by weight) of a fluoroelastomer-type process aid masterbatch, commercially available from Ingenia Polymers under the trade name Ingenia 1150. The Ingenia 1150 masterbatch contains 5% (by weight) of 3M DYNAMAR® FX 5920A in an LLDPE carrier resin with a melt index I2 of 1.0 and a density of 0.920 g / cm3. Coating layer C contained 98% (by weight) of a commercially available HDPE homopolymer from NOVA Chemicals Corporation under the trade name SCLAIR® 19A and 2.0% (by weight) of Ingenia 1150.SCLAIR 19A is a commercially available HDPE homopolymer from NOVA Chemicals Corporation and has a melt index I2 of 0.72 dg / min and a density of 0.962 g / cm3. Core layer B was prepared with 100% (by weight) of a commercially available HDPE homopolymer from NOVA Chemicals under the trade name SURPASS® HPs167-AB. SURPASS HPs167-AB has a nominal melt index I2 of 1.2 dg / min and a nominal density of 0.967 g / cm3.
[0460] The film structure in Example 1FB was a multilayer A / B / C film prepared under identical conditions to those used in Examples 1F-3F, except that the sealing layer A was prepared from a mixture containing 78% (by weight) of the ethylene polymer composition produced in Example 1, 20% (by weight) of SCLAIR FP120-C, and 2% (by weight) of Ingenia 1150. SCLAIR FP120-C is a commercially available ethylene / octene-1 LLDPE copolymer from NOVA Chemicals Corporation and has a nominal melt index I2 of 1.0 and a nominal density of 0.920 g / cm3. Petition 870250084786, dated 09 / 19 / 2025, pp. 122 / 154 114 / 123
[0461] The film structure in Example 2FB was a multilayer A / B / C film prepared under identical conditions to those used in Examples 1F-3F, except that the sealing layer A was prepared from a mixture containing 49% (by weight) of the ethylene polymer composition produced in Example 1, 49% (by weight) of the ethylene polymer composition produced in Example 2, and 2% (by weight) of Ingenia 1150.
[0462] The film structure in Comparative Example 1F was a multilayer A / B / C film prepared under identical conditions to those used in Examples 1F3F, except that the sealing layer A was prepared from a mixture containing 77% (by weight) ELVAX® 3165, 20% (by weight) TOPPYL® PB 8640M, and 3% (by weight) Ingenia 1150. ELVAX 3165 is an ethylene vinyl acetate (EVA) copolymer, commercially available from Dow Chemical Company, containing 18% by weight of vinyl acetate comonomer and having a nominal melt index I2 of 0.7 dg / min and a nominal density of 0.94 g / cm3. TOPPYL PB 8640M is a low-ethylene random copolymer of butene-1, commercially offered by LyondellBasell Industries. TOPPYL PB 8640M has a nominal melting point (I2) of 1.0 dg / min and a nominal density of 0.906 g / cm3.
[0463] Comparative Example 3F was a multilayer film A / B / C prepared under identical conditions to those used for Examples 1F-3F, except that the sealing layer A was prepared from a mixture containing 70% (by weight) NOVAPOL® HB-L354-A, 28% (by weight) QUEO® 8230 and 2% (by weight) Ingenia 1150. NOVAPOL HB-L354-A is a high-density polyethylene (HDPE) commercially offered by NOVA Chemicals Corporation that is an ethylene / hexene-1 copolymer and has a nominal melt index I2 of 0.3 dg / min and a nominal density of 0.955 g / cm3. QUEO 8230 is an ethylene-based octene-1 plastomer produced in a solution process using a metallocene catalyst and has a nominal melting index I2 of 30 dg / min and a nominal density of Petition 870250084786, dated 09 / 19 / 2025, pp. 123 / 154 115 / 123 0.883 g / cm3. The film blowing process conditions in the case of Comparative Example 3F were also different from those applied in Examples 1F-3F, since Comparative Example 3F was produced with a total film thickness of 2.79 mil at a melting temperature of 406 °F, 417 °F and 433 °F for layers A, B and C, respectively.
[0464] Comparative Example 4F was a multilayer A / B / C film prepared under identical conditions to those used in Examples 1F to 3F, except that sealant layer A was prepared from a mixture containing 70% (by weight) QUEO 8230, 28% (by weight) NOVAPOL HB-L354-A and 2% (by weight) Ingenia 1150. The film blowing process conditions in the case of Comparative Example 4F were also different from those applied in Examples 1F to 3F, since Comparative Example 4F was produced with a total film thickness of 2.79 mil at a melting temperature of 415°F, 416°F and 432°F for layers A, B and C, respectively.
[0465] Comparative Example 5F was a multilayer film A / B / C prepared under identical conditions to those used for Examples 1F-3F, except that the sealing layer A was prepared from a mixture containing 70% (by weight) NOVAPOL HB-W952-A, 28% (by weight) QUEO 8230 and 2% (by weight) Ingenia 1150. NOVAPOL HB-W952-A is a high-density polyethylene (HDPE) commercially offered by NOVA Chemicals Corporation that is an ethylene / hexene-1 copolymer and has a nominal melt index I2 of 0.08 dg / min and a nominal density of 0.952 g / cm3. The film blowing process conditions in the case of Comparative Example 5F were even different from those applied in Examples 1F-3F, since Comparative Example 5F was produced with a total film thickness of 2.70 mil at a melting temperature of 421 °F, 417 °F and 432 °F for layers A, B and C, respectively. Petition 870250084786, dated 09 / 19 / 2025, pp. 124 / 154 116 / 123
[0466] Comparative Example 6F was a multilayer A / B / C film prepared under identical conditions to those used in Examples 1F-3F, except that the sealant layer A was prepared from a mixture containing 70% (by weight) of QUEO 8230, 28% (by weight) of NOVAPOL HB-W952-A and 2% (by weight) of Ingenia 1150. The film blowing process conditions in the case of Comparative Example 6F were also different from those applied in Examples 1F-3F, since Comparative Example 6F was produced with a total film thickness of 2.77 mil at a melting temperature of 407°F, 419°F and 432°F for layers A, B and C, respectively.
[0467] Figures 4a to 4c illustrate the seal strength profiles as a function of seal temperature for film structures prepared in Examples 1F-3F and 1FB-2FB, and Comparative Examples 1F and 3F-6F. Skilled in the art would recognize that, from a design-for-performance perspective, all polyethylene film structures prepared in Examples 1F-3F and 2FB provided removable seals exhibiting constant (or nearly constant) seal strength values within a desired seal strength range for easy-open applications (e.g., a seal strength of about 3.4 N / 25 mm to about 15 N / 25 mm) over a wide seal temperature window. To clarify, Example 1F exhibited a SIT of 101.8 °C and a sealing strength of approximately 3.4 N / 25 mm to approximately 15 N / 25 mm over a temperature range from SIT to SIT + 29.8 °C.Example 2F exhibited a SIT of 70.2 °C and a sealing strength of approximately 3.4 N / 25 mm to approximately 15 N / 25 mm over a temperature range from SIT to SIT + 26.9 °C. Example 3F exhibited a SIT of 92.9 °C and a sealing strength of approximately 3.4 N / 25 mm to approximately 15 N / 25 mm over a temperature range from SIT to SIT + 32.7 °C. Example 2FB exhibited a SIT of ~75 °C and a sealing strength of approximately 3.4 N / 25 mm to approximately 15 N / 25 mm over a temperature range. Petition 870250084786, dated 09 / 19 / 2025, pages 125 / 154 117 / 123 from SIT to ~SIT + 35.0 °C. Example 1FB further demonstrated that the addition of 20% (by weight) of an LLDPE component did not have a pronounced effect on the observed seal strength-seal temperature behavior. Comparative Example 1F presented a SIT of 81.8 °C and a seal strength of approximately 3.4 N / 25 mm to approximately 15 N / 25 mm in a temperature range from SIT to SIT + 29.2 °C. In the seal temperature windows described above, the seal temperatures corresponding to a seal strength of 3.4 N and / or 15 N were estimated by a linear interpolation routine if they were not part of the experimentally determined data points.
[0468] It is important to emphasize that the range of the sealing temperature window, which corresponded to a sealing resistance of about 3.4 to about 15 N / 25 mm (represented by the dashed lines in Figures 4a-4c) in Examples 1F-3F and 2FB, was comparable to or wider than that of Comparative Example 1F, which contained non-polyethylene materials. This last observation is of particular importance for applications where easy-open, single-material packaging systems are desired.
[0469] With reference to Figure 4c, it is noteworthy that the advantageous properties described above are not attainable in the case of film structures prepared in Comparative Examples 3F-6F which, in their sealing layer, contained post-reactor physical mixtures of a high molecular weight comonomer-poor mixing component (i.e., a low melting index, high density mixing component) and a low molecular weight comonomer-rich mixing component (i.e., a high melting index plastomeric mixing component). Ethylene Polymer Compositions of Reactor Mixture with Enhanced VICAT
[0470] The ethylene polymer compositions in reactor mixture in Examples 4 to 6 were each produced in the same pilot polymerization process. Petition 870250084786, dated 19 / 09 / 2025, page 126 / 154 118 / 123 solution in a multireactor in series, used in Examples 1 to 3, with adjustments to the process conditions to obtain ethylene polymer compositions in reactor mixtures with a target density higher than the ethylene polymer compositions in reactor mixtures in Examples 1 to 3. Table 4 shows the reactor conditions used to produce each of the ethylene polymer compositions in Examples 4 to 6. TABLE 4: Continuous Solution Polymerization Process Parameters for Examples 4 to 6. Ex. 4 Ex. 5 Ex. 6 Catalyst R1 (ppm) 0.24 0.26 0.24 Catalyst R1 CpFt CpP CpFt Molar ratio R1 ([M] / [A]) 50 50 50 Molar ratio R1 ([P] / [M]) 0.48 0.40 0.44 Molar ratio R1 ([B] / [A]) 1.30 1.30 1.30 Catalyst diluent temperature R1 (°C) 34.9 30.0 30.0 Catalyst R2 (ppm) 0.30 0.36 0.28 Catalyst R2 CpFt CpP CpFt Molar ratio R2 ([M] / [A]) 50 52 50 Molar ratio R2 ([P] / [M]) 0.40 0.40 0.40 Molar ratio R2 ([B] / [A]) 1.30 1.36 1.30 Catalyst diluent temperature R2 (°C) 33.9 30.6 31.6 ESR1 (%) 40.0 45.0 37.0 ESR2 (%) 60.0 55.0 63.0 Ethylene concentration R1 (% by weight) 14.2 13.1 13.7 Ethylene concentration R2 (% by weight) 17.0 17.3 16.5 Octene-1 to ethylene ratio R1 (weight fraction) 0 0 0 Octene-1 to ethylene ratio R2 (weight fraction) 0.589 0.728 0.623 Octene-1 to ethylene ratio 0.325 0.367 0.354 (weight fraction, total) 62.7 68.2 69.2 Polymer Production Rate (kg / h) 220.0 272.9 228.2 Total Solution Rate R1 (kg / h) 280.0 277.0 321.7 R2 Total solution rate (kg / h) 500.0 550.0 550.0 Total solution rate (kg / h) 0.0 0.0 0.0 OSR1 (%) 100.0 100.0 100.0 OSR2 (%) 8.59 8.18 7.50 Petition 870250084786, dated 09 / 19 / 2025, pp. 127 / 154 119 / 123 H2 concentration at R1 (ppm) 7.00 4.01 9.00 H2 concentration at R2 (ppm) 40.0 39.9 40.0 R1 Fresh feed temperature (°C) 45.0 45.0 45.0 R2 Fresh feed temperature (°C) 165.2 164.8 165.2 R1 Average temperature (°C) 178.9 178.9 179.1 R2 Average temperature (°C) 188.8 188.2 189.9 R3 Outlet temperature (°C) 18 18 18 R3 Volume (L) 91.0 91.0 91.0 QR1 (%) 74.0 73.6 74.0 QR2 (%) 56.7 58.2 58.8 QR3 (%) 92.8 93.4 92.9 QT (%) 875.0 875.0 800.0 R1 Stirrer speed (rpm) 260.0 270.9 260.0 t(2,7-tBu2Flu)Ph2C(Cp)HfMe2.
[0471] In Examples 4-6, the following metallocene bridge catalyst components were used to prepare the first ethylene polymer in the first CSTR reactor (R1) and to prepare the second ethylene interpolymer in the second CSTR reactor (R2): component A, diphenylmethylene(cyclopentadienyl)(2,7-di-t-butylfluoroenyl)hafnium dimethide [(2,7-tBu2Flu)Ph2C(Cp)HfMe2]; component M, methylaluminoxane (MMAO-07); component B, trityl tetrakis(pentafluorophenyl)borate (trityl borate); and component P, 2,6-di-tert-butyl-4-ethylphenol (BHEB). Methylaluminoxane (MMAO-07); and 2,6-di-tert-butyl-4-ethylphenol are premixed in-line and then combined with diphenylmethylene(cyclopentadienyl)(2,7-di-t-butylfluoroenyl)hafnium dimethide and tetrakis(pentafluorophenyl)tritylborate immediately before entering the polymerization reactors (R1 and R2).The following solvent components of the catalyst were used: methylpentane for components M and P; and xylene for components A and B. The efficiency of the metallocene bridge catalyst formulation was optimized by adjusting the amount of component A added to R1 and R2 [catalyst R1 (ppm) and catalyst R2 (ppm), as described in Table 4], the molar ratios of the catalyst components — i.e., [M] / [A], [P] / [M] and [B] / [A], as tabulated in Table 4 — and the inlet temperatures of catalysts R1 and R2. Petition 870250084786, dated 09 / 19 / 2025, pp. 128 / 154 120 / 123
[0472] Based on the reactor model simulation scheme disclosed above, using the inlet conditions employed for actual pilot-scale operating conditions, Examples 4 to 6 contained 30 to 70 percent by weight of a first ethylene polymer produced in R1 and 30 to 70 percent by weight of a second ethylene interpolymer produced in R2. In Examples 4 to 6, the first ethylene polymer contained zero short-chain branches per thousand carbon atoms—that is, the first ethylene polymer was an ethylene homopolymer. The first ethylene polymer in Examples 4 to 6 had a weight-average molecular weight, Mw, of about 100 kg / mol and an Mw / Mn of about 2.0. In Examples 4 to 6, the second ethylene interpolymer contained 26 to 30 short-chain branches per thousand carbon atoms. The second ethylene interpolymer in Examples 4 to 6 had a weight-average molecular weight, Mw, of about 50 kg / mol and an Mw / Mn of about 2.1.
[0473] As shown in Table 5, Examples 4 to 6 contained detectable levels of long-chain branching, as characterized by an LCBF greater than or equal to 0.001. TABLE 5: Physical, Molecular, Thermal and Rheological Characteristics of Merging Examples 4 to 6. Example 4 Example 5 Example 6 Density 0.9182 0.9167 0.9163 Melting index I2 (dg / min) 3.58 3.68 3.41 Melting index I6 (dg / min) 15.4 15.94 14.85 Melting index I21 (dg / min) 93.6 98.67 91.17 Melting flow ratio I21 / I2 (-) 26.18 26.78 26.74 Stress exponent (-) 1.33 1.33 1.34 Comonomer content (% by mol) 3.6 3.9 3.8 Comonomer content (% by weight) 13.1 14.0 13.6 Comonomer type octene-1 octene-1 octene-1 Number of SCBs per 1000 carbons 18.1 19.6 19.0 Mn (kg / mol) 28.17 27.22 28.70 Mw (kg / mol) 69.03 79.09 69.80 Mz (kg / mol) 127.49 152.44 135.26 Mw / Mn (—) 2.45 2.91 2.43 Petition 870250084786, dated 09 / 19 / 2025, pp. 129 / 154 121 / 123 Conventional GPC MWD Unimodal Unimodal Unimodal Zero shear viscosity (kPa.s) 3.92 3.71 3.97 CY-a 0.3524 0.3543 0.3485 τ (ms) 7.80 7.68 7.80 G' in G” = 500 Pa (Pa) 45.33 46.01 46.52 Melting strength (cN) 1.43 1.37 1.46 Strain ratio (-) 1182.0 1251.1 1210.0 LCBF (-) 1.07 x 10-2 5.41 x 10-3 6.67 x 10-3 Low temperature melt peak, Tmlow (°C) 92.5 87.2 91.61 Peak High-temperature melting point, Tmalto (°C) 125.7 126.3 125.36 GPC-FTIR slope (SCB per 1000 carbons) -16.2 -15.1 -15.4 Vicat softening temperature (°C) 89.2 85.1 88.2
[0474] With reference to Tables 3 and 5, Examples 4 to 6 advantageously exhibited higher VICAT softening temperatures compared to Examples 1 to 3. Experts in the field will understand that the manufacturing process of ethylene polymer compositions with an improved VICAT softening temperature involves less propensity for pellet agglomeration in the finishing area of the polymerization plant, as well as during storage and transport.
[0475] With reference to Tables 3 and 5, the GPC-FTIR comonomer distribution of Examples 4, 5 and 6 showed a slope greater than -22 SCB per 1000 carbons; namely: -16.2, -15.1 and -15.4 SCB per 1000 carbons, respectively.
[0476] Figure 5 describes the seal strength profiles as a function of seal temperature for all 4F to 6F polyethylene film structures prepared from the reactor mixture ethylene polymer compositions disclosed in Examples 4 to 6.
[0477] The films produced in Examples 4F to 6F were produced on a three-layer coextrusion film blow molding line manufactured by Bramp. Petition 870250084786, dated 09 / 19 / 2025, pp. 130 / 154 The 122 / 123 ton Engineering, with a blow ratio of 3.0, a total film thickness of 1.54 mil, a freeze line height of 20.0 inches, a production rate of 100.0 pounds per hour, and a die opening of 35 mil. Examples 4F to 6F had an A / B / C structure with a layer thickness ratio of 13.5 / 65 / 21.5 and were produced at a melt temperature of 404-407 °F, 424-425 °F, and 415-417 °F for layers A, B, and C, respectively. The sealing layer (the surface layer here identified as layer A) in film Examples 4F, 5F, and 6F was prepared from the ethylene polymer composition described in Examples 4, 5, and 6, respectively. The sealant layer in these film examples also contained 2.0% (by weight) of a fluoroelastomer-type process aid masterbatch, commercially available from Ingenia Polymers under the trade name Ingenia 1150.The Ingenia 1150 masterbatch contains 5% (by weight) of 3M DYNAMAR FX 5920A in an LLDPE carrier resin with a melt index I2 of 1.0 and a density of 0.920 g / cm3. Coating layer C contained 98% (by weight) of a commercially available HDPE homopolymer from NOVA Chemicals Corporation under the trade name SCALIR 19A and 2.0% (by weight) of Ingenia 1150. SCALIR 19A is a commercially available HDPE homopolymer from NOVA Chemicals Corporation and has a melt index I2 of 0.72 dg / min and a density of 0.962 g / cm3.
[0478] In Examples 4 and 5, core layer B was prepared from 78% (by weight) of a commercially available HDPE homopolymer from NOVA Chemicals under the trade name SURPASS® HPs167-AB mixed with 22% (by weight) of SCLAIR 19A. SURPASS HPs167-AB has a nominal melt index I2 of 1.2 dg / min and a nominal density of 0.967 g / cm3. In Example 6, core layer B was prepared with 100% (by weight) of SURPASS HPs167-AB.
[0479] With reference to Figure 5, it was observed that, in relation to the film structures of Examples 1F-3F and 2FB, the film structures prepared in Petition 870250084786, dated 09 / 19 / 2025, pp. 131 / 154 123 / 123 Examples 4F-6F exhibited a narrower sealing temperature window, corresponding to a sealing strength of approximately 3.4 to approximately 15 N / 25 mm. Without intending to be bound by any specific theory, this latter observation can be interpreted as a consequence of the reduction in the gradient intensity in the GPC-FTIR comonomer distribution observed in Examples 4-6 compared to Examples 1-3. INDUSTRIAL APPLICABILITY
[0480] The reactor-mixed ethylene polymer compositions disclosed herein have industrial applicability in a wide range of manufactured flexible articles; examples, not limited to, include single-layer or multi-layer films. Petition 870250084786, dated 09 / 19 / 2025, pp. 132 / 154
Claims
1 / 11 CLAIMS 1. Reactor mixture comprising ethylene polymer composition, CHARACTERIZED in that it comprises: from 30 to 70 percent by weight of a first ethylene polymer, the first ethylene polymer comprising ethylene and optionally at least one α-olefin, the first ethylene polymer having a weight-average molecular weight Mw of from 70 kg / mol to 250 kg / mol, a number of short-chain branches per thousand carbon atoms of from 0 to 6, and a polydispersity index Mw / Mn of from 1.7 to 2.3; and from 30 to 70 percent by weight of a second ethylene interpolymer, the second ethylene interpolymer comprising ethylene and at least one αolefin, the second ethylene interpolymer having a weight-average molecular weight Mw of from 20 kg / mol to 75 kg / mol, a number of short-chain branches per thousand carbon atoms of from 25 to 55, and a polydispersity index Mw / Mn of from 1.7 to 2.3;wherein the weight-average molecular weight of the second ethylene interpolymer is less than the weight-average molecular weight of the first ethylene polymer; and wherein the ethylene polymer composition is produced in a continuous solution polymerization process, the continuous solution polymerization process comprising: forming the first ethylene polymer in a first solution polymerization reactor by polymerizing ethylene and optionally at least one α-olefin with the first homogeneous catalyst formulation; and forming the second ethylene interpolymer in a second solution polymerization reactor by polymerizing ethylene and at least one α-olefin with a second homogeneous catalyst formulation. Petition 870250084786, dated 09 / 19 / 2025, pp. 133 / 154 2 / 11; 2. Ethylene polymer composition according to claim 1, CHARACTERIZED in that the ethylene polymer composition has a comonomer distribution profile in a GPC-FTIR analysis, wherein the comonomer distribution profile has a secant slope greater than or equal to -55 short-chain branches per 1000 carbons and less than or equal to -20 short-chain branches per 1000 carbons, wherein the secant slope is defined as the number of short-chain branches per 1000 carbons at a molecular weight of 300 kg / mol less the number of short-chain branches per 1000 carbons at a molecular weight of 30 kg / mol.
3. Ethylene polymer composition according to claim 2, CHARACTERIZED in that the comonomer distribution profile is a normal comonomer distribution profile.
4. Ethylene polymer composition, according to any one of claims 1-3, CHARACTERIZED in that one or both of the first homogeneous catalyst formulation and the second homogeneous catalyst formulation comprise a bridged metallocene catalyst having Formula (I): R1 QMQG (I) wherein M is a group 4 metal selected from titanium, zirconium or hafnium; G is a group 14 element selected from carbon, silicon, germanium, tin or lead; R1 is a hydrogen atom, a C1-20 hydrocarbyl radical, a C1-20 alkoxy radical or a C6-10 aryl oxide radical; R2 and R3 are independently selected from a hydrogen atom, a hydrocarbyl radical. Petition 870250084786, dated 09 / 19 / 2025, p.134 / 154 3 / 11 C1-20 carbyl, a C1-20 alkoxy radical or a C6-10 aryl oxide radical; R4 and R5 are independently selected from a hydrogen atom, an unsubstituted C1-20 hydrocarbyl radical, a substituted C1-20 hydrocarbyl radical, a C1-20 alkoxy radical or a C6-10 aryl oxide radical; and Q is independently an activatable leaving group ligand.
5. Ethylene polymer composition, according to any one of claims 1-4, CHARACTERIZED in that one or both of the first homogeneous catalyst and the second homogeneous catalyst comprise a phosphinimine catalyst.
6. Ethylene polymer composition, according to any one of claims 1-5, CHARACTERIZED in that the first ethylene polymer is a first ethylene homopolymer.
7. Ethylene polymer composition, according to any one of claims 1-6, CHARACTERIZED in that the ethylene polymer composition has a density from 0.880 g / cm3 to 0.920 g / cm3, as determined in accordance with ASTM D792-13.
8. Ethylene polymer composition, according to any one of claims 1-6, CHARACTERIZED in that the ethylene polymer composition has a density from 0.900 g / cm3 to 0.920 g / cm3, as determined in accordance with ASTM D792-13.
9. Ethylene polymer composition, according to any one of claims 1-8, CHARACTERIZED in that the ethylene polymer composition has a melt index I2 of from 2 dg / min to 10 dg / min, as determined in accordance with ASTM D1238-13 at 190°C using a weight of 2.16 kg.
10. Ethylene polymer composition, according to any one of claims 1-9, CHARACTERIZED in that the ethylene polymer composition Petition 870250084786, dated 09 / 19 / 2025, page 135 / 154 4 / 11 has a molecular weight distribution with a polydispersity index Mw / Mn from 2.3 to 6.
0.
11. Ethylene polymer composition, according to any one of claims 1-10, CHARACTERIZED in that the ethylene polymer composition has a molecular weight distribution with a polydispersity index Mw / Mn from 2.3 to 4.
5.
12. Ethylene polymer composition, according to any one of claims 10 or 11, CHARACTERIZED in that the ethylene polymer composition has a unimodal molecular weight distribution.
13. Ethylene polymer composition, according to any one of claims 1-12, CHARACTERIZED in that the ratio between the weight-average molecular weight of the first ethylene polymer and the weight-average molecular weight of the second ethylene interpolymer is greater than or equal to 1.5 and less than or equal to 6.
14. Ethylene polymer composition, according to any one of claims 1-12, CHARACTERIZED in that the ratio between the weight-average molecular weight of the first ethylene polymer and the weight-average molecular weight of the second ethylene interpolymer is greater than or equal to 2 and less than or equal to 4.
15. Ethylene polymer composition, according to any one of claims 1-14, CHARACTERIZED in that the ethylene polymer composition contains detectable levels of long-chain branching as characterized according to a long-chain branching factor, LCBF, of greater than or equal to 0.
001.
16. Ethylene polymer composition, according to any one of claims 1-15, CHARACTERIZED in that the second ethylene interpolymer is present in the ethylene polymer composition in an amount of from 50 to 65 percent by weight.
17. Ethylene polymer composition, according to any one of claims 1-16, CHARACTERIZED in that the first ethylene polymer is present in the ethylene polymer composition in an amount of from 35 to 50 percent by weight.
18. Ethylene polymer composition, according to any one of claims 1-17, CHARACTERIZED in that the ethylene polymer composition has a number average molecular weight Mn from 10 kg / mol to 35 kg / mol.
19. Ethylene polymer composition, according to any one of claims 1-18, CHARACTERIZED in that the ethylene polymer composition has a number average molecular weight Mn from 15 kg / mol to 30 kg / mol.
20. Ethylene polymer composition, according to any one of claims 1-19, CHARACTERIZED in that the ethylene polymer composition has a weight-average molecular weight Mw from 65 kg / mol to 100 kg / mol.
21. Ethylene polymer composition, according to any one of claims 1-19, CHARACTERIZED in that the ethylene polymer composition has a weight-average molecular weight Mw from 70 kg / mol to 95 kg / mol.
22. Ethylene polymer composition, according to any one of claims 1-21, CHARACTERIZED in that the second ethylene interpolymer has a number average molecular weight from 10 kg / mol to 38 kg / mol. Petition 870250084786, dated 19 / 09 / 2025, pp. 137 / 154 6 / 11 23. Ethylene polymer composition, according to any one of claims 1-21, CHARACTERIZED in that the second ethylene interpolymer has a number average molecular weight from 15 kg / mol to 34 kg / mol.
24. Ethylene polymer composition, according to any one of claims 1-23, CHARACTERIZED in that the second ethylene interpolymer has a weight-average molecular weight from 30 kg / mol to 65 kg / mol.
25. Ethylene polymer composition, according to any one of claims 1-24, CHARACTERIZED in that the second ethylene interpolymer has a number of short-chain branches per thousand carbon atoms from 27 to 48.
26. Ethylene polymer composition, according to any one of claims 1-25, CHARACTERIZED in that the first ethylene polymer has a weight-average molecular weight from 70 kg / mol to 160 kg / mol.
27. Ethylene polymer composition, according to any one of claims 1-25, CHARACTERIZED in that the first ethylene polymer has a weight-average molecular weight of from 100 kg / mol to 160 kg / mol.
28. Ethylene polymer composition, according to any one of claims 1-27, CHARACTERIZED in that the ethylene polymer composition has a melt flow ratio I21 / I2 of from 15 to 40, as determined in accordance with ASTM D1238-13 at 190°C using weights of 2.16 kg and 21.6 kg.
29. Ethylene polymer composition, according to any one of claims 1-28, CHARACTERIZED in that the ethylene polymer composition Petition 870250084786, dated 09 / 19 / 2025, page 138 / 154 7 / 11 additionally comprises from greater than 0 to 20 percent by weight of a third ethylene interpolymer comprising ethylene and at least one α-olefin, the third ethylene interpolymer having a polydispersity index Mw / Mn of from 1.7 to 2.3 and a weight-average molecular weight less than the weight-average molecular weight of the first ethylene polymer and the weight-average molecular weight of the second ethylene interpolymer.
30. Ethylene polymer composition according to claim 29, CHARACTERIZED in that the third ethylene interpolymer has a weight-average molecular weight from 20 kg / mol to 50 kg / mol and a number of short-chain branches per 1000 carbon atoms from 25 to 50.
31. Ethylene polymer composition, according to any one of claims 29-31, CHARACTERIZED in that the continuous solution polymerization process further comprises a step of forming the third ethylene interpolymer in a third solution polymerization reactor by polymerizing ethylene and at least one α-olefin with a third homogeneous catalyst formulation, wherein the first, second and third solution phase polymerization reactors are configured in series with respect to each other.
32. Ethylene polymer composition according to claim 31, CHARACTERIZED in that the third homogeneous catalyst formulation comprises a bridged metallocene catalyst having Formula (I): QMQG R5 (I) wherein M is a group 4 metal selected from titanium, zirconium or Petition 870250084786, dated 09 / 19 / 2025, p.139 / 154 8 / 11 hafnium; G is a group 14 element selected from carbon, silicon, germanium, tin, or lead; Ri is a hydrogen atom, a C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, or a C6-10 aryl oxide radical; R2 and R3 are independently selected from a hydrogen atom, a C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, or a C6-10 aryl oxide radical; R4 and R5 are independently selected from a hydrogen atom, an unsubstituted C1-20 hydrocarbyl radical, a substituted C1-20 hydrocarbyl radical, a C1-20 alkoxy radical, or a C6-10 aryl oxide radical; and Q is independently an activatable leaving group ligand.
33. Ethylene polymer composition according to claim 31, CHARACTERIZED in that the third homogeneous catalyst comprises a phosphinimine catalyst.
34. Ethylene polymer composition, according to any one of claims 1-33, CHARACTERIZED in that at least one α-olefin is selected from the group consisting of C3 to C10 α-olefins.
35. Ethylene polymer composition, according to any one of claims 1-33, CHARACTERIZED in that at least one αolefin is selected from the group consisting of hexene-1, octene-1, and a mixture of hexene-1 and octene-1.
36. Ethylene polymer composition according to any one of claims 1-33, CHARACTERIZED in that at least one αolefin is octene-1.
37. A film layer made entirely of polyethylene, CHARACTERIZED in that it comprises an ethylene polymer composition, according to any one of claims 1-36.
38. Film layer, according to claim 37, CHARACTERIZED in that the film layer is a film formed via a blowing system. Petition 870250084786, dated 09 / 19 / 2025, pp. 140 / 154 9 / 11 39. Film layer, according to claim 37, CHARACTERIZED in that the film layer is a cast film.
40. Film layer, according to any one of claims 3739, CHARACTERIZED in that the film layer additionally comprises a linear low-density polyethylene (LLDPE) having a density from 0.910 g / cm3 to 0.940 g / cm3 and a melt index I2 from 0.1 to 10 dg / min.
41. Film layer, according to claim 40, CHARACTERIZED in that the film layer comprises from 10 to 40 percent by weight of LLDPE and from 60 to 90 percent by weight of ethylene polymer composition, according to any one of claims 1-32.
42. Multilayer film structure made entirely of polyethylene, CHARACTERIZED in that the film structure has at least one surface layer comprising an ethylene polymer composition, according to any one of claims 1-36.
43. Film structure, according to claim 42, CHARACTERIZED in that the film structure has a sublayer adjacent to at least one surface layer; the sublayer comprising a high-density polyethylene HDPE having a density of at least 0.945 g / cm3 and a melt index I2 from 0.1 to 10 dg / min.
44. Film structure, according to claim 43, CHARACTERIZED in that the HDPE is a mixture of at least two ethylene homopolymer blend components; the mixture comprising: from 30 to 95 percent by weight of a first ethylene homopolymer blend component having a density from 0.950 to 0.975 g / cm3; and Petition 870250084786, dated 19 / 09 / 2025, pp. 141 / 154 10 / 11 from 5 to 70 percent by weight of a second ethylene homopolymer blend component having a density from 0.950 to 0.975 g / cm3; wherein the ratio of the melt index I2 of the second ethylene homopolymer blend component to the melt index I2 of the first ethylene homopolymer blend component is at least 10.
45. Film structure, according to any one of claims 43 or 44, CHARACTERIZED in that the HDPE comprises from 100 to 3000 parts per million of a nucleating agent or a mixture of nucleating agents.
46. Film structure, according to any of claims 4345, CHARACTERIZED in that the HDPE has a polydispersity index Mw / Mn of from 7 to 18.
47. Film structure, according to any one of claims 4246, CHARACTERIZED in that at least one surface layer additionally comprises a linear low-density polyethylene (LLDPE) having a density from 0.910 g / cm3 to 0.940 g / cm3 and a melt index I2 from 0.1 to 10.0 dg / min.
48. Film structure, according to claim 47, CHARACTERIZED in that at least one surface layer comprises from 10 to 40 percent by weight of LLDPE and from 60 to 90 percent by weight of the ethylene polymer composition, according to any one of claims 1-36.
49. Film structure, according to any of the claims in 4248, CHARACTERIZED in that the film structure comprises at least three layers. Petition 870250084786, dated 09 / 19 / 2025, pp. 142 / 154 11 / 11 50. Film structure, according to any one of claims 4248, CHARACTERIZED in that the film structure comprises between three and nine layers.
51. Film structure, according to any one of claims 4250, CHARACTERIZED in that at least one surface layer is a sealant layer.
52. Film structure, according to claim 51, CHARACTERIZED in that the film structure has a SIT sealing start temperature of greater than or equal to 70°C to 115°C, wherein the sealing start temperature is the minimum sealing temperature at which the film structure has a sealing strength greater than 3.4 N per 25.4 mm sealing width.
53. Film structure, according to claim 52, CHARACTERIZED in that the film structure has a sealing strength from 3.4 to 15.0 N per 25.4 mm sealing width at a sealing temperature from SIT to SIT + 40°C.
54. Film structure, according to claim 52, CHARACTERIZED in that the film structure has a sealing strength from 3.4 to 15.0 N per 25.4 mm sealing width at a sealing temperature from SIT to SIT + 25°C. Petition 870250084786, dated 19 / 09 / 2025, pp. 143 / 154