Films containing post-consumer resins
Films containing PCR, formulated with low-density polyethylene and ethylene/carbon monoxide copolymers, and modifiers, address the variability of PCR to achieve sustainable films with maintained properties.
Patent Information
- Application Number
- JP2022556193
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- Priority Date
- 2020-04-10
- Filing Date
- 2021-04-07
- Publication Date
- 2025-09-26
- Estimated Expiration
- 2041-04-07
AI Technical Summary
The variability of post-consumer resins (PCRs) in composition and properties poses challenges in producing films with uniform characteristics, leading to issues such as elastic recovery, stiffness, and photodegradability, making it difficult to effectively incorporate PCR into consumer goods.
Films are formulated with 10-70% PCR, 10-87% low-density polyethylene or ethylene/carbon monoxide copolymer, and 3-25% modifiers like ethylene-based plastomers or elastomers to maintain or minimize the reduction of elastic recovery, stiffness, or photodegradability.
The formulation provides sustainable films with effective performance by maintaining desired properties while incorporating significant amounts of PCR, offering alternatives with improved elastic recovery and stiffness.
Smart Images

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Abstract
Description
[Technical Field]
[0001] FIELD OF THE DISCLOSURE Embodiments of the present disclosure generally relate to films made from polymer blends that include post-consumer resin (PCR).
[0002] Introduction Post-consumer resins (PCRs) are playing an increasingly important role in environmental sustainability initiatives and efforts in today's world. PCRs offer a way to reprocess and reincorporate materials into consumer goods, limiting the consumption of new resources, allowing for the reuse of old materials, and sustainably generating new goods. The novelty and inherent variability of PCRs present challenges to industries constantly striving to use them effectively. PCRs typically consist of heterogeneous mixtures of materials (e.g., polymer blends, organic materials, or inorganic materials). As a result, PCRs and their properties can be highly variable from lot to lot, batch to batch, or individual resin, often resulting in variations in their exact components, composition, and corresponding characteristics and properties. Therefore, it can be difficult to determine or predict how polymer blends incorporating PCRs will function or react, and therefore, it can be challenging to effectively incorporate PCRs to produce consumer goods with uniform, validated, or desired characteristics. For example, polymer-rich polymeric materials such as PCR are prime candidates for film or sheet applications, but such films or sheets may suffer from properties such as elastic recovery, stiffness, or photodegradability when formed from polymer blends containing PCR.
[0003] Thus, there remains a need for films that contain PCR that are sustainably and efficiently produced while maintaining or minimizing the reduction in other desired properties such as elastic recovery, stiffness, or photodegradability. Summary of the Invention
[0004] Embodiments of the present disclosure provide films that include significant amounts of PCR (e.g., 10% to 70% by weight) and, in aspects, maintain or minimize the reduction of other properties such as elastic recovery, stiffness, or photodegradability. For example, films according to embodiments of the present disclosure include PCR that can vary in percent crystallinity. While this variation can adversely affect film properties (e.g., elastic recovery), certain formulations of the disclosed films, including modifiers (e.g., ethylene-based plastomers or elastomers) and ethylene / carbon monoxide copolymers (ECO copolymers) and / or low-density polyethylene, maintain these film properties or minimize the reduction of these film properties. Such films promote sustainability while providing effective performance.
[0005] Disclosed herein are films formed from polymer blends. In particular, films made from polymer blends comprising: (i) 10-70 wt. % post-consumer resin (PCR); (ii) 10-87 wt. % low-density polyethylene, ethylene / carbon monoxide copolymer (ECO copolymer), or a combination thereof; and (iii) 3-25 wt. % modifier.
[0006] Additional features and advantages of the embodiments will be set forth in the detailed description that follows, and in part will be readily apparent to those skilled in the art from that description, or will be learned by practicing the embodiments described herein, including the following detailed description, claims, and accompanying drawings.
[0007] It is to be understood that both the foregoing and the following descriptions are intended to describe various embodiments and provide an overview or framework for understanding the nature and character of the claimed subject matter. The accompanying drawings are included to provide a further understanding of the various embodiments, and are incorporated in and constitute a part of this specification. [Brief explanation of the drawings]
[0008] [Figure 1] This is the second heating curve of the DSC of the PCR sample. [Figure 2] This is the second heating curve of a different PCR sample obtained by DSC. DETAILED DESCRIPTION OF THE INVENTION
[0009] Aspects of the disclosed films or sheets are described in more detail below. Films according to embodiments of the present disclosure are films or sheets (i.e., as used herein, the term film or films includes a sheet or sheets). Films containing PCR can be used to form unitizing films, shrink films, lamination films, liner films, shopping bags, agricultural films, food packaging films, beverage packaging films, or shipping bags. It should be noted, however, that this is merely an exemplary implementation of the embodiments disclosed herein. The embodiments are also applicable to other technologies prone to problems similar to those described above.
[0010] As used herein, the terms "comprising," "including," "having," and their derivatives are not intended to exclude the presence of any additional component, step, or procedure, whether specifically disclosed or not. For the avoidance of doubt, all compositions claimed through the use of the term "comprising" may include any additional additive, adjuvant, or compound, whether polymeric or otherwise, unless otherwise stated to the contrary. In contrast, the term "consisting essentially of" excludes from the scope of any subsequent description any other component, step, or procedure, except those that are not essential to operability. The term "consisting of" excludes any component, step, or procedure not specifically delineated or listed.
[0011] As used herein, the term "polymer" refers to a polymeric compound prepared by polymerizing monomers, whether of the same or different types. Thus, the term polymer encompasses the term homopolymer (used to refer to a polymer prepared from only one type of monomer, with the understanding that trace amounts of impurities may be incorporated into the polymer structure), as well as the terms copolymer or interpolymer. Trace amounts of impurities (e.g., catalyst residues) may be incorporated into and / or within the polymer. The polymer may be a single polymer or a polymer blend.
[0012] As used herein, "LDPE" or "low density polyethylene" refers to an ethylene homopolymer prepared using free radical high pressure (≧100 MPa (e.g., 100-400 MPa)) polymerization.
[0013] As used herein, the term "peak melting temperature (Tm)" refers to the melting temperature peak with the highest heat flow as indicated by the y-axis on the second heating curve of a DSC.
[0014] As used herein, the term "modifier" refers to an ethylene-based plastomer or elastomer, or ethylene-vinyl acetate, or a combination thereof.
[0015] Component (i) of the polymer blend - PCR The term "post-consumer resin" (or "PCR"), as used herein, refers to polymeric materials, including materials previously used in consumer or industrial applications. PCR is typically collected from recycling programs and recycling plants. PCR may include one or more of polyethylene, polypropylene, polyester, poly(vinyl chloride), polystyrene, acrylonitrile butadiene styrene, polyamide, ethylene vinyl alcohol, ethylene vinyl acetate, or polyvinyl chloride. PCR may contain one or more contaminants. The contaminants may be the result of the use of the polymeric material before it is slightly modified for reuse. For example, the contaminants may include paper, ink, food residue, or other recycled materials in addition to the polymers that may result from the recycling process.
[0016] PCR differs from virgin polymeric materials. Virgin polymeric materials do not include materials previously used in consumer or industrial applications. Virgin polymeric materials have not been subjected to or otherwise undergone heating or molding processes like typical PCR. The physical, chemical, and flow properties of PCR resins are different compared to virgin polymeric resins, which can present challenges in incorporating PCR into formulations for commercial use.
[0017] In embodiments, the PCR comprises low-density polyethylene, linear low-density polyethylene, or a combination thereof. In embodiments, the PCR further comprises residues from its original use, such as paper, adhesives, ink, nylon, ethylene vinyl alcohol (EVOH), polyamide (PA), polyethylene terephthalate (PET), and other organic or inorganic materials. Examples of PCRs include AVANGARD™ NATURA PCR-LDPCR-100 ("AVANGARD™ 100") and AVANGARD™ NATURA PCR-LDPCR-150 ("AVANGARD™ 150") (PCRs commercially available from Avangard Innovative LP, Houston, Texas).
[0018] In embodiments, the polymer blend comprises 10 to 70 weight percent (wt %) PCR, based on the total weight % of the polymer blend. All individual values and subranges between 10 and 70 wt% are disclosed and included herein, for example, a polymer blend may include 10-70 wt%, 15-70 wt%, 20-70 wt%, 45-70 wt%, 50-70 wt%, 55-70 wt%, 60-70 wt%, 65-70 wt%, 35-70 wt%, 10-60 wt%, 20-60 wt%, 30-60 wt%, 35-60 wt%, 40-60 wt%, 45-60 wt%, 50-60 wt%, 55-60 wt%, 10-50 wt%, 20-50 wt%, 30-50 wt%, 35-50 wt%, 40-50 wt%, 45-50 wt%, 30-40 wt%, or 35-40 wt% PCR, based on the total weight percent of the polymer blend.
[0019] In embodiments, the PCR has a heat of fusion in the range of 130-170 Joules per gram (J / g), as measured according to the DSC test method described below. All individual values and subranges between 130 and 170 J / g are disclosed and incorporated herein; for example, the heat of fusion of the PCR can be 130-170 J / g, 130-160 J / g, 130-150 J / g, 130-140 J / g, 140-170 J / g, 140-160 J / g, 140-150 J / g, 150-170 J / g, or 155-170 J / g, as measured according to the DSC test method described below.
[0020] In embodiments, the PCR has a peak melting temperature (Tm) of 105° C. to 127° C., as measured according to the DSC test method described below. All individual values and subranges between 105° C. and 127° C. are disclosed and incorporated herein, for example, the peak melting temperature (Tm) of the PCR, as measured according to the DSC test method described below, may be 105° C. to 125° C., 107° C. to 125° C., 109° C. to 125° C., 111° C. to 125° C., 113° C. to 125° C., 115° C. to 125° C., 117° C. to 125° C., 105° C. to 123° C., 116° C. to 125° C., 117° C. to 125° C., 118° C. to 125° C., 119° C. to 125° C., 119° C. to 125° C., 125 ... °C, 107°C to 123°C, 109°C to 123°C, 111°C to 123°C, 113°C to 123°C, 115°C to 123°C, 117°C to 123°C, 119°C to 123°C, 121°C to 123°C, 119°C to 127°C, 119°C to 125°C, 119°C to 123°C, 119°C to 121°C, 121°C to 125°C, 123°C to 127°C, 123°C to 125°C, or 125°C to 127°C.
[0021] Referring now generally to FIG. 1, there is shown a second DSC thermal curve of a PCR sample according to one embodiment of the present disclosure. The polymer blends disclosed herein can include a PCR having a DSC curve as shown in FIG. 1, where the PCR has a peak melting temperature (Tm) of 120.08°C. Referring now generally to FIG. 2, there is shown a second DSC thermal curve of a different PCR sample according to one embodiment of the present disclosure. The polymer blends disclosed herein can include a PCR sample having a second DSC thermal curve as shown in FIG. 2, where the PCR has a peak melting temperature (Tm) of 122.87°C. One of skill in the art will understand how the differences in the second DSC thermal curve shown in FIG. 1 compared to FIG. 2 demonstrate, in part, variability in the composition and heat flow of the PCR material.
[0022] Component (ii) of the polymer blend—LDPE and / or ECO copolymer In embodiments, the polymer blend comprises 10-87 wt% low-density polyethylene, ethylene / carbon monoxide copolymer (ECO copolymer), or a combination thereof, where the wt% is based on the total weight of the polymer blend. All individual values and subranges between 10-87 wt% are disclosed and included herein, for example, the polymer blend may comprise 10-87 wt%, 20-87 wt%, 30-87 wt%, 40-87 wt%, 50-87 wt%, 60-87 wt%, 10-67 wt%, 20-67 wt%, 30-67 wt%, 40-67 wt%, 50-67 wt%, 10-60 wt%, 20-60 wt%, 30-60 wt%, 40-60 wt%, or 50-60 wt% low-density polyethylene, ethylene / carbon monoxide copolymer (ECO copolymer), or a combination thereof, where the wt% is based on the total weight of the polymer blend.
[0023] In further embodiments, the polymer blend comprises 10-87 wt% low density polyethylene alone (i.e., component (ii) is low density polyethylene). In other embodiments, the polymer blend comprises 10-87 wt% ECO copolymer alone (i.e., component (ii) is ECO copolymer). In still further embodiments, the polymer blend comprises a combination of low density polyethylene and ECO copolymer. For example, in one embodiment, the polymer blend comprises 10-87 wt% of a combination of 1-99 wt% low density polyethylene and 1-99 wt% ECO copolymer, the weight percentages of low density polyethylene and ECO copolymer being based on the total weight percentage of the combination. All individual values and subranges from 1 to 99 wt% are disclosed and included herein. For example, in one embodiment where the polymer blend comprises 10-87 wt % of a combination of low density polyethylene and ECO copolymer, the combination of low density polyethylene and ECO copolymer comprises 1-45 wt % low density polyethylene and 55-99 wt % ECO copolymer, the wt % of the low density polyethylene and ECO copolymer being based on the total weight of the combination.
[0024] In an embodiment, the low density polyethylene of the polymer blend has a density of 0.915 g / cm 3 ~0.935g / cm 3 The density can be measured according to ASTM D792. 3 ~0.935g / cm 3 All individual values and subranges of are included and disclosed herein, for example, the density of low density polyethylene is 0.915 g / cm 3 ~0.935g / cm 3 , 0.915g / cm 3 ~0.933g / cm 3 , 0.915g / cm 3 ~0.930g / cm 3 , 0.915g / cm 3 ~0.925g / cm 3 , 0.915g / cm 3 ~0.920g / cm 3, 0.925g / cm 3 ~0.925g / cm 3 , 0.920g / cm 3 ~0.930g / cm 3 , or 0.925 g / cm 3 ~0.930g / cm 3 and the density can be measured according to ASTM D792.
[0025] In an embodiment, the low density polyethylene has a melt index (I2) of 0.15 to 70 grams per 10 minutes (g / 10 min), and the melt index (I2) can be measured according to ASTM D1238 (190°C / 2.16 kg). All individual values and subranges of the melt index from 0.15 to 70 g / 10 min are disclosed and included herein, for example, a low density polyethylene may have a melt index from a lower limit of 0.15, 0.20, 0.25, 0.50, 1, 2, 5, 10, 20, 30, 40, 50, or 60 g / 10 min to an upper limit of 0.20, 0.25, 0.50, 1, 2, 5, 10, 20, 30, 40, 50, 60, or 70 g / 10 min, where the melt index (I2) can be measured according to ASTM D1238 (190°C / 2.16 kg).
[0026] In an embodiment, the ECO copolymer has a viscosity of 0.910 to 0.990 g / cm 3 The density can be measured according to ASTM D792 in the range of 0.910 to 0.990 g / cm 3 All individual values and subranges of density are disclosed and included herein, for example, ECO copolymer has a density of 0.910 to 0.990 g / cm 3 , 0.920~0.990g / cm 3 , 0.930~0.990g / cm 3 , 0.940~0.990g / cm 3 , 0.950~0.990g / cm 3 , 0.960~0.990g / cm 3 , 0.970~0.990g / cm 3 , 0.980~0.990g / cm 3, 0.910~0.970g / cm 3 , 0.920~0.970g / cm 3 , 0.930~0.970g / cm 3 , 0.940~0.970g / cm 3 , 0.950~0.970g / cm 3 , 0.960~0.970g / cm 3 , 0.910~0.950g / cm 3 , 0.920~0.950g / cm 3 , 0.930~0.950g / cm 3 , 0.940~0.950g / cm 3 , 0.910~0.950g / cm 3 , 0.920~0.950g / cm 3 , 0.930~0.950g / cm 3 , 0.940~0.950g / cm 3 , 0.910~0.930g / cm 3 , 0.920~0.930g / cm 3 , 0.925~0.935g / cm 3 , or 0.910 to 0.930 g / cm 3 The density may range from 0.01 to 0.01, and the density may be measured according to ASTM D792.
[0027] In embodiments, the ECO copolymer has a melt index (I2) in the range of 0.15 to 100 g / 10 minutes (g / 10 min), where the melt index (I2) can be measured according to ASTM D1238 (190°C / 2.16 kg). All individual values and subranges of the melt index from 0.15 to 100 g / 10 min are disclosed and included herein, for example, the ECO copolymers can have a melt index (I2) from a lower limit of 0.15, 0.20, 0.25, 0.50, 1, 2, 3, 4, 5, 10, 20, 30, 40, 50, 60, 70, 80, or 90 g / 10 min to an upper limit of 0.20, 0.25, 0.50, 1, 2, 3, 4, 5, 10, 20, 30, 40, 50, 60, 70, 80, 90, or 100 g / 10 min, where the melt index (I2) can be measured according to ASTM D1238 (190°C / 2.16 kg).
[0028] In embodiments, the ECO copolymer has a carbon monoxide content of 0.5 to 10 wt %, where wt % is based on the total weight of the ECO copolymer, and the carbon monoxide content can be determined as disclosed in U.S. Pat. No. 9,523,015. 13 All individual values and subranges from 0.5 to 10 wt% are disclosed and included herein, for example, the ECO copolymer may be present in an amount of 0.5 to 10 wt%, 0.5 to 8 wt%, 0.5 to 6 wt%, 0.5 to 4 wt%, 0.5 to 2.0 wt%, 0.5 to 1.5 wt%, 0.7 to 1.5 wt%, 0.9 to 1.5 wt%, 1.1 to 1.5 wt%, 1.3 to 1.5 wt%, based on the total weight of the ECO copolymer. %, 0.7-1.3 wt%, 0.9-1.3 wt%, 1.1-1.3 wt%, 0.5-1.1 wt%, 0.7-1.1 wt%, 0.9-1.1 wt%, 0.5-0.9 wt%, 0.5-0.7 wt%, 0.7-0.9 wt%, 0.6-1.0 wt%, or 0.5-1.1 wt%, wherein the carbon monoxide content is as disclosed in U.S. Pat. No. 9,523,015. 13 It can be measured by C NMR.
[0029] In embodiments, ethylene / carbon monoxide (ECO) is formed by high pressure free radical polymerization.
[0030] In an embodiment, the LDPE is 13 Contains an amyl (C5) group level of 0.5 amyl groups per 1000 carbon atoms or greater as determined by C NMR. The amyl (C5) group level is defined as being equal to or greater than 0.5 amyl groups per 1000 carbon atoms, as disclosed in U.S. Pat. No. 9,523,015. 13 It can be measured by C NMR.
[0031] In embodiments, the ECO copolymer is 13 Contains an amyl (C5) group level of 0.5 amyl groups per 1000 carbon atoms or greater as determined by C NMR. The amyl (C5) group level is defined as being equal to or greater than 0.5 amyl groups per 1000 carbon atoms, as disclosed in U.S. Pat. No. 9,523,015. 13It can be measured by C NMR.
[0032] Component (iii) of the polymer blend - modifier In embodiments, the polymer blend includes 3 to 25 wt. % of a modifier. The modifier is an ethylene-based plastomer or elastomer, or ethylene-vinyl acetate, or a combination thereof. In certain embodiments, the modifier is an ethylene-based plastomer or elastomer, and the polymer blend includes 3 to 25 wt. % of a modifier having a viscosity of 0.857 to 0.910 g / cm. 3 In another embodiment, the modifier is ethylene-vinyl acetate and the polymer blend comprises 3 to 25 weight percent ethylene-vinyl acetate. In yet a further embodiment, the modifier is a combination of an ethylene-based plastomer or elastomer and ethylene-vinyl acetate and the polymer blend comprises 3 to 25 weight percent of the combination of an ethylene-based plastomer or elastomer and ethylene-vinyl acetate.
[0033] All individual values and subranges of polymer blends comprising 3 to 25 wt% modifier are disclosed and included herein, for example, the polymer blends may comprise 3 to 25 wt%, 5 to 25 wt%, 7 to 25 wt%, 10 to 25 wt%, 3 to 20 wt%, 5 to 20 wt%, 7 to 20 wt%, 10 to 20 wt%, 3 to 15 wt%, 5 to 15 wt%, 7 to 15 wt%, 10 to 15 wt%, 3 to 12 wt%, 5 to 12 wt%, 7 to 12 wt%, or 10 to 12 wt% modifier, based on the total weight of the polymer blend.
[0034] In embodiments, the polymer blend comprises 3 to 25 weight percent of a modifier that is an ethylene-based plastomer or elastomer. All individual values and subranges of the polymer blend comprising 3 to 25 weight percent of the ethylene-based plastomer or elastomer are disclosed and included herein, for example, the polymer blend may comprise 3 to 25 weight percent, 5 to 25 weight percent, 7 to 25 weight percent, 10 to 25 weight percent, 3 to 20 weight percent, 5 to 20 weight percent, 7 to 20 weight percent, 10 to 20 weight percent, 3 to 15 weight percent, 5 to 15 weight percent, 7 to 15 weight percent, 10 to 15 weight percent, 3 to 12 weight percent, 5 to 12 weight percent, 7 to 12 weight percent, or 10 to 12 weight percent of the ethylene-based plastomer or elastomer, based on the total weight of the polymer blend.
[0035] In embodiments where the modifier is an ethylene-based elastomer or plastomer, the ethylene-based elastomer or plastomer comprises 10 to 45 weight percent of units derived from one or more α-olefin comonomers. All individual values and subranges between 10 and 45 weight percent are included herein and disclosed herein; for example, the ethylene-based elastomer or plastomer may comprise 10 to 40 weight percent, 10 to 35 weight percent, 10 to 30 weight percent, 10 to 25 weight percent, 10 to 20 weight percent, or 10 to 15 weight percent of units derived from one or more α-olefin comonomers. The α-olefin comonomers typically have 20 or fewer carbon atoms. For example, the α-olefin comonomers may preferably have 3 to 10 carbon atoms, more preferably 3 to 8 carbon atoms. Exemplary α-olefin comonomers include, but are not limited to, propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, and 4-methyl-1-pentene. The one or more α-olefin comonomers may be selected from the group consisting of, for example, propylene, 1-butene, 1-hexene, and 1-octene, or alternatively, from the group consisting of 1-hexene and 1-octene.
[0036] In embodiments, the ethylene-based elastomer or plastomer comprises 55 to 90 weight percent units derived from ethylene. All individual values and subranges between 55 and 90 weight percent are included and disclosed herein; for example, the ethylene-based elastomer or plastomer can comprise 55 to 90 weight percent, 55 to 80 weight percent, 55 to 70 weight percent, or 55 to 60 weight percent units derived from ethylene. The ethylene-based elastomer or plastomer can be homogeneously branched, as described in U.S. Pat. No. 3,645,992, incorporated herein by reference, or linear or substantially linear, as described in U.S. Pat. Nos. 5,272,236 and 5,278,272, incorporated herein by reference.
[0037] In an embodiment, the ethylene-based plastomer or elastomer has a viscosity of 0.857 to 0.910 g / cm 3 The density can be measured according to ASTM D792 in the range of 0.857 to 0.910 g / cm 3 All individual values and subranges of density are disclosed and included herein, for example, ethylene-based plastomers or elastomers from 0.857 to 0.910 g / cm 3 , 0.860~0.900g / cm 3 , 0.860~0.890g / cm 3 , 0.860~0.880g / cm 3 , 0.860~0.870g / cm 3 , 0.870~0.910g / cm 3 , 0.870~0.900g / cm 3 , 0.870~0.890g / cm 3 , 0.870~0.880g / cm 3 , 0.880~0.910g / cm 3 , 0.880~0.900g / cm 3 , 0.880~0.890g / cm 3 , 0.890~0.910g / cm 3 , 0.890~0.900g / cm 3 , or 0.900 to 0.910 g / cm 3The density may range from 0.01 to 0.01, and the density may be measured according to ASTM D792.
[0038] In embodiments, the ethylene-based plastomer or elastomer has a melt index (I2) in the range of 0.50 to 50 g / 10 minutes (g / 10 min), where the melt index (I2) can be measured according to ASTM D1238 (190°C / 2.16 kg). All individual values and subranges from 0.50 to 50 g / 10 min are disclosed and included herein, for example, the ethylene-based plastomer or elastomer can have a melt index ranging from a lower limit of 0.50, 1, 2, 5, 10, 20, 30, or 40 g / 10 min to an upper limit of 1, 2, 5, 10, 20, 30, 40, or 50 g / 10 min, where the melt index (I2) can be measured according to ASTM D1238 (190°C / 2.16 kg).
[0039] Examples of commercially available ethylene-based plastomers or elastomers that can be used in some embodiments of the present invention include ethylene-based plastomers or elastomers available from The Dow Chemical Company under the designation ENGAGE™ and AFFINITY™, ethylene-based plastomers or elastomers available from ExxonMobil Chemical Co. under the designation EXACT™, and ethylene-based plastomers or elastomers available from Mitsui under the designation TAFMER™.
[0040] In embodiments, the ethylene-based plastomer or elastomer is an ethylene-based plastomer. In such embodiments, the ethylene-based plastomer has a viscosity of 0.885 to 0.910 g / cm 3 The density can be measured in accordance with ASTM D729 in the range of 0.885 to 0.910 g / cm 3 All individual values and subranges of density are disclosed and included herein, for example, ethylene-based plastomers have a density of 0.885 to 0.910 g / cm 3 , 0.890~0.910g / cm3 , 0.895~0.910g / cm 3 , 0.900~0.910g / cm 3 , 0.905~0.910g / cm 3 , or 0.890 to 0.900 g / cm 3 The density may range from 0.01 to 0.01, and the density may be measured according to ASTM D729.
[0041] In embodiments, the ethylene-based plastomer or elastomer is an ethylene-based elastomer. In such embodiments, the ethylene-based elastomer has a viscosity of 0.857 to 0.885 g / cm 3 The density can be measured in accordance with ASTM D729 in the range of 0.857 to 0.885 g / cm 3 All individual values and subranges of density are disclosed and included herein, for example, ethylene-based elastomers have a density of 0.857 to 0.885 g / cm 3 , 0.860~0.875g / cm 3 , 0.860~0.885g / cm 3 , 0.870~0.885g / cm 3 , 0.875~0.885g / cm 3 , or 0.880 to 0.885 g / cm 3 The density may range from 0.01 to 0.01, and the density may be measured according to ASTM D729.
[0042] In embodiments, the ethylene-based elastomer has a molecular weight distribution (M) (measured according to conventional GPC methods) in the range of 1.5 to 3.0, e.g., 1.6 to 2.5. w / M n )
[0043] In other embodiments, the modifier is ethylene vinyl acetate. In such embodiments, the polymer blend comprises 3 to 25 wt% ethylene vinyl acetate. All individual values and subranges from 3 to 25 wt% ethylene vinyl acetate are disclosed and included herein, for example, the polymer blend may comprise 3 to 25 wt%, 5 to 25 wt%, 7 to 25 wt%, 10 to 25 wt%, 3 to 20 wt%, 5 to 20 wt%, 7 to 20 wt%, 10 to 20 wt%, 3 to 15 wt%, 5 to 15 wt%, 7 to 15 wt%, 10 to 15 wt%, 3 to 12 wt%, 5 to 12 wt%, 7 to 12 wt%, or 10 to 12 wt%, based on the total weight of the polymer blend.
[0044] In embodiments where the modifier is ethylene-vinyl acetate (EVA), the EVA may contain from 7 to about 20% by weight vinyl acetate. All individual values and subranges between 7 and 20 wt% are disclosed and included herein, for example, the EVA can comprise 7-20 wt%, 9-20 wt%, 11-20 wt%, 13-20 wt%, 15-20 wt%, 17-20 wt%, 7-19 wt%, 9-19 wt%, 11-19 wt%, 13-19 wt%, 15-19 wt%, 17-19 wt%, 7-17 wt%, 9-17 wt%, 11-17 wt%, 13-17 wt%, 7-15 wt%, 9-15 wt%, 11-15 wt%, 13-15 wt%, 7-11 wt%, 9-11 wt%, or 7-9 wt% vinyl acetate, based on the total weight of the EVA.
[0045] In embodiments, the EVA has a melt index (I2) in the range of 0.2 to 50 g / 10 minutes (g / 10 min), where the melt index (I2) can be measured according to ASTM D1238 (190°C / 2.16 kg). All individual values and subranges from 0.2 to 50 g / 10 min are disclosed and included herein, for example, the EVA can have a melt index ranging from a lower limit of 0.2, 0.5, 1, 2, 5, 10, 20, 30, or 40 to an upper limit of 10, 20, 30, 40, or 50 g / 10 min, where the melt index (I2) can be measured according to ASTM D1238 (190°C / 2.16 kg).
[0046] Other components of the polymer blend In embodiments, the polymer blend may contain additional components, such as one or more additives. Possible additives may include, but are not limited to, antistatic agents, color enhancers, dyes, lubricants, fillers, pigments, primary antioxidants, secondary antioxidants, processing aids, UV stabilizers, antiblocking agents, slip agents, tackifiers, flame retardants, antimicrobial agents, odor reducers, antifungal agents, and combinations thereof. The polymer blend may contain 0.01, 0.1, 1 to 5, 10, or 15 wt. % of such additives, based on the total weight of the polymer blend.
[0047] film Films are made from the polymer blends according to the embodiments described herein. Useful films according to the embodiments of the present disclosure include cast, blown, and calendered films, including multilayer films, greenhouse films, shrink films including transparent shrink films, lamination films, biaxially oriented films, extrusion coatings, liners, transparent liners, overlap films, and agricultural films. Monolayer and multilayer films may be made according to the film and manufacturing methods described in U.S. Patent No. 5,685,128.
[0048] When formed into a film, the polymer blends of the present disclosure can be a more sustainable way to manufacture films and can also provide several other advantages. For example, while providing a sustainable formulation for forming films, in some embodiments of the present disclosure, the films maintain or minimize the reduction of film properties such as elastic recovery, stiffness, or photodegradability. The advantage of a sustainable film with effective performance is, for example, providing an alternative to existing film structures where elastic recovery is a desired property.
[0049] In embodiments, films formed from polymer blends have a thickness in the range of 1 to 20 mils. All individual values and subranges from 1 to 20 mils are disclosed and included herein, for example, films formed from polymer blends may have thicknesses of 1 to 20 mils, 1 to 18 mils, 1 to 16 mils, 1 to 14 mils, 1 to 12 mils, 1 to 10 mils, 1 to 8 mils, 1 to 6 mils, 5 to 20 mils, 5 to 18 mils, 5 to 16 mils, 5 to 14 mils, 5 to 12 mils, 5 to 10 mils, 5 to 8 mils, 5 to 6 mils, It may have a thickness of 8 to 20 mils, 8 to 18 mils, 8 to 16 mils, 8 to 14 mils, 8 to 12 mils, 8 to 10 mils, 10 to 20 mils, 10 to 18 mils, 10 to 16 mils, 10 to 14 mils, 10 to 12 mils, 12 to 20 mils, 12 to 18 mils, 12 to 16 mils, 12 to 14 mils, 14 to 20 mils, 14 to 18 mils, 14 to 16 mils, 16 to 20 mils, 16 to 18 mils, or 18 to 20 mils.
[0050] In embodiments where the polymer blend comprises an ethylene-based plastomer or elastomer, films formed from the polymer blend may exhibit a 1% secant modulus in the cross direction (CD) in the range of 9,000 to 16,000 psi, when measured according to the test method described below. All individual values and subranges of 1% secant modulus in CD in the range of 9,000 to 16,000 psi are disclosed and included herein, for example, a film formed from the polymer blends may have a 1% secant modulus of elasticity of 9,000 to 16,000 psi, 10,000 to 16,000 psi, 11,000 to 16,000 psi, 12,000 to 16,000 psi, 13,000 to 16,000 psi, 14,000 to 16,000 psi, 15,000 to 16,000 psi, 9,000 to 15,000 psi, 10,000 to 15,000 psi, 11,000 to 15,000 psi, 12,000 to 15,000 psi, 13,000 to 16,000 psi, and 14,000 to 16,000 psi, when measured according to the test methods described below. 0~15,000psi, 14,000~15,000psi, 9,000~14,000psi, 10,000~14,000psi, 11,000~14,000p si, 12,000~14,000psi, 13,000~14,000psi, 9,000~13,000psi, 10,000~13,000psi, 11,000 The 1% secant modulus in CD may be in the range of 13,000 psi, 12,000 to 13,000 psi, 9,000 to 12,000 psi, 10,000 to 12,000 psi, 11,000 to 12,000 psi, 9,000 to 11,000 psi, 10,000 to 11,000 psi, or 9,000 to 10,000 psi.
[0051] In embodiments where the polymer blend comprises an ethylene-based plastomer or elastomer, a film formed from the polymer blend may exhibit a 1% secant modulus in the machine direction (MD) in the range of 9,000 to 14,800 psi, when measured according to the test methods described below. All individual values and subranges of the 1% secant modulus in MD in the range of 9,000 to 14,800 psi are disclosed and included herein, for example, a film formed from the polymer blend may exhibit a 1% secant modulus in the range of 9,000 to 14,800 psi, 10,000 to 14,800 psi, 11,000 to 14,800 psi, 12,000 to 14,800 psi, 13,000 to 14,800 psi, 140,000 to 14,800 psi, 9,000 to 14,000 psi, 10,000 to 14,000 psi, when measured according to the test methods described below. psi, 11,000-14,000 psi, 12,000-14,000 psi, 13,000-14,000 psi, 9,000-13,000 psi, 10,000-13,000 psi, 11,000-13,000 psi, 12,000-13,000 psi, 9,000-12,000 psi, 10,000-12,000 psi, 11,000-12,000 psi, 9,000-11,000 psi, 10,000-11,000 psi, or 9,000-10,000 psi.
[0052] In embodiments where the polymer blend includes ethylene-vinyl acetate, the secant modulus at 1% can be maintained and there is no significant decrease in the secant modulus even in the presence of PCR and / or ethylene-vinyl acetate.
[0053] In embodiments, films formed from the polymer blends of the present disclosure exhibit a Peak Load in the cross direction (CD) of less than 17.5 lbf at a thickness of 13 mils when measured according to the test method described below. All individual values and subranges less than 17.5 lbf at a thickness of 13 mils are disclosed and included herein, for example, films formed from the polymer blends may have a Peak Load in the CD of less than 17.5 lbf at a thickness of 13 mils, less than 17.0 lbf, or less than 16.5 lbf, or a range of 12-17.5 lbf, 12-17 lbf, 14-17.5 lbf, 14-17 lbf, 15-17 lbf, 16-17.5 lbf, or 16-17 lbf at a thickness of 13 mils when the Peak Load in the CD is measured according to the test method described below.
[0054] In embodiments, films formed from the polymer blends of the present disclosure exhibit a percent peak load achieved in the cross direction (CD) at 0 seconds (s) of the second hold of greater than 23.5%, as measured according to the test method described below. All individual values and subranges greater than 23.5% are included and disclosed herein, for example, a film formed from the polymer blend can have a percent Peak Load in CD at 0 seconds (s) of second hold greater than 23.5%, greater than 24.0%, greater than 25.0%, greater than 26.0%, greater than 27.0%, greater than 28.0%, or greater than 28.5%, or a percent Peak Load in CD at 0 seconds (s) of second hold from 23.5% to 40.0%, 23.5% to 35.0%, 23.5% to 30.0%, 23.5% to 25.0%, 25.0% to 40.0%, 25.0% to 35.0%, 25.0% to 30.0%, 28.5% to 40.0%, 28.5% to 35.0%, or 28.5% to 30.0%.
[0055] In embodiments, films formed from the polymer blends of the present disclosure exhibit a percent peak load achieved in the cross direction (CD) at 1 second (s) of the second hold of greater than 31.0%, as measured according to the test method described below. All individual values and subranges greater than 31.0% are included and disclosed herein; for example, a film formed from the polymer blend may have a percent Peak Load in CD at 1 second (s) of second hold of greater than 31.0%, greater than 32.0%, greater than 33.0%, greater than 34.0%, or greater than 35.0%, or a percent Peak Load in CD at 1 second (s) of second hold of 31.0% to 45.0%, 31.0% to 40.0%, 31.0% to 35.0%, 32.0% to 45.0%, 32.0% to 40.0%, 32.0% to 36.0%, 33.0% to 45.0%, 33.0% to 40.0%, 33.0% to 36.0%, or 34.0% to 36.0%, when measured according to the test methods described below.
[0056] In embodiments, films formed from the polymer blends of the present disclosure exhibit a percent peak load achieved in the cross direction (CD) at 2 seconds (s) of the second hold of greater than 33.0%, as measured according to the test method described below. All individual values and subranges greater than 33.0% are included and disclosed herein, for example, a film formed from the polymer blend may have a percent Peak Load in CD at 2 seconds (s) of second hold of greater than 33.0%, greater than 34.0%, greater than 35.0%, greater than 36.0%, or greater than 37.0%, or a percent Peak Load in CD at 2 seconds (s) of second hold of 33.0% to 45.0%, 33.0% to 40.0%, 33.0% to 38.0%, 35.0% to 45.0%, 35.0% to 40.0%, 35.0% to 38.0%, 36.0% to 45.0%, 36.0% to 40.0%, 36.0% to 38.0%, or 37.0% to 38.0%, when measured according to the test methods described below.
[0057] In embodiments, films formed from the polymer blends of the present disclosure exhibit a percent peak load achieved in the cross direction (CD) at 5 seconds (s) of the second hold of greater than 36.0%, as measured according to the test method described below. All individual values and subranges greater than 36.0% are included and disclosed herein; for example, a film formed from the polymer blend may have a percent Peak Load in CD at 5 seconds (s) of second hold of greater than 36.0%, greater than 36.5%, greater than 37.0%, greater than 38.0%, or greater than 39.0%, or a percent Peak Load in CD at 5 seconds (s) of second hold of 36.0% to 45.0%, 36.0% to 40.0%, 36.0% to 39.0%, 37.0% to 45.0%, 37.0% to 40.0%, 37.0 to 38.0%, 37.0% to 39.0%, 38.0 to 45.0%, 38.0% to 43.0%, or 38.0% to 40.0%, when measured according to the test methods described below.
[0058] In embodiments, films formed from the polymer blends of the present disclosure exhibit a percent peak load achieved in the cross direction (CD) at 10 seconds (s) of the second hold of greater than 38.0%, as measured according to the test method described below. All individual values and subranges greater than 38.0% are included and disclosed herein, for example, a film formed from the polymer blend may have a percent Peak Load in CD at 10 seconds (s) of second hold of greater than 38.0%, greater than 39.0%, greater than 40.0%, or greater than 40.5%, or a percent Peak Load in CD at 10 seconds (s) of second hold of 38.0% to 50.0%, 38.0% to 45.0%, 38.0% to 42.0%, 39.0% to 50.0%, 39.0% to 45.0%, 39.0% to 42.0%, or 39.0% to 41.0%, when measured according to the test methods described below.
[0059] In embodiments, films formed from the polymer blends of the present disclosure exhibit a percent (%) strain at break at 100 exposure hours of greater than 100%, as measured according to the test method described below. All individual values and subranges greater than 100% are disclosed and included herein, for example, the polymer blends may exhibit a % strain at break at 100 hours of exposure of greater than 100%, greater than 150%, greater than 200%, greater than 250%, greater than 300%, greater than 350%, greater than 400%, or greater than 450%, or a % strain at break at 100 hours of exposure in the range of 100% to 700%, 100% to 600%, 100% to 500%, 100% to 450%, 100% to 400%, 100% to 350%, 100% to 300%, 100% to 250%, 100% to 200%, or 100% to 150%, where the % strain at break at 100 hours of exposure can be measured according to the test methods described below.
[0060] In embodiments, films formed from polymer blends of the present disclosure exhibit a percent (%) strain at break at 100 exposure times greater than 100% and a % strain at break at 292 exposure times less than 20%, when measured according to the test methods described below. All individual values and subranges less than 20% are disclosed and included herein, for example, polymer blends may exhibit a % strain at break at 100 exposure times greater than 100% and a % strain at break at 292 exposure times less than 20%, less than 18%, less than 12%, less than 10%, or less than 8%, or a % strain at break at 292 exposure times in the range of 5% to 20%, 8% to 20%, 10% to 20%, 12% to 20%, or 15% to 20%, where the % strain at break at 292 exposure times can be measured according to the test methods described below.
[0061] Films according to embodiments of the present disclosure can maintain their structural integrity for up to or greater than about 100 exposure hours and can achieve photodegradation at or about 292 exposure hours.
[0062] In embodiments, the film is a monolayer film. In such embodiments, the components of the polymer blend are blended with each other and optionally with other components (e.g., other polymers or additives) in any conventional manner (e.g., dry blending the individual components, followed by melt mixing, either directly in the extruder to produce a film, or pre-melt mixing in a separate extruder, and processing into a film, such as a blown film or a cast film, using any film production process).
[0063] In embodiments, the film may contain carbon monoxide levels greater than 0.1% by weight. For example, the film may contain carbon monoxide levels greater than 0.1, 0.2, 0.5, or 1.0% by weight. In further embodiments, the film may contain: 13 The film may contain amyl groups (C5) levels of 0.1 amyl groups per 1000 carbon atoms or greater as determined by C NMR. For example, the film may contain 13 It may contain amyl group (C5) levels of greater than or equal to 0.1, 0.2, 0.3, 0.4, or 0.5 amyl groups per 1000 carbon atoms as determined by C NMR.
[0064] Films according to embodiments of the present disclosure have many utilities and can be formed into a variety of articles, for example, films according to embodiments of the present disclosure can be overwrapping films such as tissue overwraps, overwraps for bound bottled water, transparent films such as confectionery bags, bread bags, envelope window films, food packaging films and specialty packaging films such as produce bags, meat wraps, cheese wraps, beverage containers, pouches such as milk pouches or bag-in-boxes for wine, etc.
[0065] As noted above, the films of the present invention may be made by conventional manufacturing techniques, such as simple bubble extrusion, biaxial orientation processes (such as tenter frame or double bubble processes), simple cast / sheet extrusion, coextrusion, lamination, and the like.
[0066] Extrusion coating is another technique for producing films. Like cast film, extrusion coating is a flat die technique. Films can be extrusion coated or laminated onto a substrate in either the form of a monolayer film or a coextruded film.
[0067] Test Method density Density is measured in grams / cm according to ASTM D792 3 (g / cm 3 )
[0068] Melt Index (I2) Melt index is measured according to ASTM D 1238-10, Method B, at 190 degrees Celsius and 2.16 kg, and is expressed in grams dissolved / 10 minutes (g / 10 min).
[0069] photodegradable Photodegradability is measured according to ASTM D3826-18. Five specimens per example are tested at a given time and the corresponding mean and standard deviation are calculated therefrom.
[0070] Elastic recovery A 4 inch by 1 inch specimen of an exemplary film is prepared. The specimen is mounted in an Instron with a 2 inch gauge length. The specimen is first extended to 100% strain at 20 inches / minute and held for 15 seconds (s). The specimen is then returned to 75% strain at 20 inches / minute, and the load is monitored for 90 seconds after returning to 75% strain. The load on the specimen from 0 seconds to 90 seconds of the second hold is normalized by the maximum load achieved by the specimen to yield the % recovery of maximum load at each given time. This value is an indication of the specimen's ability to elastically recover.
[0071] Secant modulus of elasticity A 6 inch by 1 inch sample is prepared and mounted in the Instron with a 4 inch gauge length. The sample is elongated at 2 inches / minute and the secant modulus is calculated at 1% tensile strain. Five samples per example are tested and the corresponding mean and standard deviation are calculated therefrom.
[0072] DSC method Differential scanning calorimetry (DSC) is a common technique that can be used to study the melting and crystallization of semicrystalline polymers. The general principles of DSC measurements and the use of DSC to study semicrystalline polymers are described in standard texts (e.g., E A Turi, ed., Thermal Characterization of Polymeric Materials, Academic Press, 1981).
[0073] DSC analysis is determined using a TA Instruments, Inc. DSC. DSC calibration is performed as follows: First, the instrument baseline must be calibrated using the standard DSC procedure. Approximately 5-7 milligrams of fresh indium sample are then analyzed by heating the sample to 180°C, cooling the sample to 140°C at a cooling rate of 10°C / min, isothermally holding the sample at 140°C for 1 minute, and then heating the sample from 140°C to 180°C at a heating rate of 10°C / min. The heat of fusion and onset of melting of the indium sample are determined and checked to be within 0.5°C of 156.6°C for the onset of melting and within 0.5 J / g of 28.57 J / g for the heat of fusion.
[0074] The polymer sample is pressed into a thin film at a temperature of 190°C. Approximately 5-8 mg of sample is weighed and placed in a DSC pan. A lid is crimped onto the pan to ensure a sealed atmosphere. The sample pan is placed in the DSC cell and then heated at a rate of approximately 100°C / min to a temperature of 190°C. The sample is held at this temperature for approximately 3 minutes. The sample is then cooled to -40°C at a rate of 10°C / min and held isothermally at that temperature for 3 minutes. As a result, the sample is heated to 170°C at a rate of 10°C / min. This step is referred to as the second heating. The resulting enthalpy curve is analyzed to determine the peak melting temperature, the onset and peak crystallization temperatures, and the heat of fusion (also known as the heat of fusion), ΔH. f The heat of fusion is measured in Joules / gram by integrating the area under the melting endotherm (second heat) between -20°C and the end of melting using a linear reference line. The heat of fusion of 100% crystalline polyethylene is taken to be 292 Joules / gram (J / g) for purposes of calculating the weight percent crystallinity. [Example]
[0075] The following materials are used in the examples:
[0076] AVANGARD™ NATURA PCR-LDPCR-150 ("AVANGARD™ 150") is a PCR commercially available from Avangard Innovative LP (Houston, Texas). AVANGARD™ 150 contains LDPE and LLDPE, and as a PCR, each batch number, lot number, and resin may have a different heat of fusion (J / g from DSC) and peak melting temperature (Tm). The heat of fusion of AVANGARD™ 150 is in the range of 130-170 J / g, and the peak melting temperature (Tm) of AVANGARD™ 150 is in the range of 105°C-127°C.
[0077] DOW™ 458I low density polyethylene resin (or DOW™ 458I) has a target melt index (I2) of 0.52 g / 10 min and a viscosity of 0.930 g / cm 3The copolymer is an ECO copolymer available from The Dow Chemical Company (Midland, MI) with a target density of 1000 .mu.m.
[0078] DOW™ LDPE 959s Low Density Polyethylene Resin (or DOW™ 959s) has a target melt index (I²) of 55 g / 10 min and a viscosity of 0.923 g / cm³. 3 The polyethylene is a commercially available low density polyethylene from The Dow Chemical Company (Midland, MI) having a density of 100 .mu.m.
[0079] ENGAGE™ 8200 is an ethylene-based elastomer commercially available from The Dow Chemical Company (Midland, MI). In particular, ENGAGE™ 8200 has a viscosity of 0.870 g / cm 3 a target density of 1000 .ANG., a target melt index (I2) of 5 g / 10 min, a DSC melting peak of about 59°C, a Mw from GPC (conventional) of about 72,000-73,000 Daltons or g / mol, and a molecular weight distribution (Mw / Mn) of approximately 2.2.
[0080] ELVAX™ 440 is an ethylene-vinyl acetate available from The Dow Chemical Company (Midland, MI). ELVAX™ 440 has a melt index of 30 g / 10 min and a vinyl acetate content of 17-19 wt %.
[0081] Film formation Examples are formed into films as follows: The compounded blends are compounded into pellets using a Haake Micro-18 twin-screw extruder (SN 44039) equipped with a mild mixing screw and a temperature of 140°C at the feed throat and 200°C at the die, as described below. The pellets are then processed into 7.5-inch wide rolls of 13 mil monolayer cast film using a Collin line using a standard 30 mm 30 L / D screw, a 25 mil die gap, a temperature of 250°C at the die, a 1.5 inch air gap, and a temperature of 25°C for the chill roll.
[0082] Comparative Example 1 is a film formed from a polymer blend of 55 wt% AVANGARD™ 150, 30 wt% DOW™ LDPE 458I low density polyethylene resin, and 15 wt% DOW™ LDPE 959S low density polyethylene resin. Inventive Example 1 is a film formed from a polymer blend of 55 wt% AVANGARD™ 150, 25 wt% DOW™ LDPE 458I low density polyethylene resin, 15 wt% DOW™ LDPE 959S low density polyethylene resin, and 5 wt% ENGAGE™ 8200. Inventive Example 2 is a film formed from a polymer blend of 55 wt% AVANGARD™ 150, 25 wt% DOW™ LDPE 458I low density polyethylene resin, and 10 wt% DOW™ LDPE 959S low density polyethylene resin, and 10 wt% ENGAGE™ 8200. Inventive Example 3 is a film formed from a polymer blend of 55 wt% AVANGARD™ 150, 25 wt% DOW™ LDPE 458I low density polyethylene resin, and 20 wt% ELVAX™ 440. Table 1 below provides the compositions of the polymer blends of the film examples with respect to components (i), (ii), and (iii), as described above.
[0083] [Table 1]
[0084] The elastic recovery of the film is measured according to the test method described above. Table 2 shows the results.
[0085] [Table 2]
[0086] The secant modulus of the film is measured at 1% in both the cross direction (CD) and machine direction (MD) according to the test method described above. Table 3 shows the results.
[0087] [Table 3]
[0088] Photodegradation is measured according to the test method described above. Table 4 shows the results of % strain at break at 0, 100, 172, 247, and 292 exposure times, with average (Ave.) and standard deviation (St. Dev.).
[0089] [Table 4]
[0090] All documents cited herein, including any cross-referenced or related patents or applications, if any, and any patent application or patent to which this application claims priority or benefit, are incorporated herein by reference in their entirety, unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein, or that it teaches, suggests, or discloses such invention, either alone or in any combination with any other reference. Furthermore, to the extent that the meaning or definition of any term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
[0091] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. Therefore, it is intended in the appended claims to cover all such changes and modifications that are within the scope of this invention. It should be noted that the present invention includes the following aspects. [Aspect 1] 1. A film made from a polymer blend, the polymer blend comprising: A film comprising: (i) 10 to 70 wt. % post-consumer resin (PCR); (ii) 10 to 87 wt. % low-density polyethylene, ethylene / carbon monoxide copolymer (ECO copolymer), or a combination thereof; and (iii) 3 to 25 wt. % modifier. [Aspect 2] 2. The film of embodiment 1, wherein the PCR has a heat of fusion in the range of 130 to 170 J / g. [Aspect 3] 3. The film of claim 1 or 2, wherein the PCR has a peak melting temperature (Tm) of 105°C to 127°C. [Aspect 4] Aspect 4. The film of any one of aspects 1 to 3, wherein the PCR comprises low density polyethylene, linear low density polyethylene, or a combination thereof. [Aspect 5] The modifier has a density of 0.857 to 0.910 g / cm 3 5. The film of any one of embodiments 1-4, wherein the film is an ethylene-based plastomer or elastomer having a density in the range of [Aspect 6] Aspect 6. The film of any one of aspects 1 to 5, wherein the modifier is ethylene vinyl acetate. [Aspect 7] The film of any one of embodiments 1-6, wherein (ii) is 10% to 87% by weight of ECO copolymer. [Aspect 8] A film according to any one of aspects 1 to 6, wherein (ii) is 10% to 87% by weight of low-density polyethylene. [Aspect 9] Aspect (ii) is a combination of low density polyethylene and ECO copolymer, from 1 to 99 wt. % of the low density polyethylene and from 1 to 99 wt. % of the ECO copolymer, based on the total weight percent of the combination. [Aspect 10] 10. The film of any one of the preceding claims, wherein the film has a thickness of 1 to 20 mils. [Aspect 11] 11. The film of any one of aspects 1 to 10, wherein the film is in the form of a bonding film, a shrink film, a lamination film, a liner film, a shopping bag, an agricultural film, a food packaging film, a beverage packaging film, or a shipping bag.
Claims
1. 1. A film made from a polymer blend, the polymer blend comprising, based on the total weight of the polymer blend: (i) 10 to 70 wt. % of a post-consumer resin (PCR) comprising low density polyethylene and linear low density polyethylene; (ii) 10 to 87 wt. % of an ethylene / carbon monoxide copolymer (ECO copolymer), or a combination of low density polyethylene and ECO copolymer; (iii) 3 to 25 wt. % of a modifier comprising an ethylene-based plastomer or elastomer having a density in the range of 0.857 to 0.910 g / cm 3 or ethylene-vinyl acetate; Including, the film.
2. 10. The film of claim 1, wherein the PCR has a heat of fusion in the range of 130 to 170 J / g.
3. 3. The film of claim 1 or 2, wherein the PCR has a peak melting temperature (Tm) of 105°C to 127°C.
4. The modifier has a density of 0.857 to 0.910 g / cm 3 4. The film of claim 1, wherein the film is an ethylene-based plastomer or elastomer having a density in the range of
5. The film of any one of claims 1 to 4, wherein the modifier is ethylene vinyl acetate.
6. A film according to any one of claims 1 to 5, wherein (ii) is from 10% to 87% by weight of ECO copolymer.
7. 7. The film of any one of claims 1 to 6, wherein (ii) is a combination of low density polyethylene and ECO copolymer, wherein the combination is 1 to 99 wt% of the low density polyethylene and 1 to 99 wt% of the ECO copolymer, based on the total weight percent of the combination.
8. The film of any one of claims 1 to 7, wherein the film has a thickness of 1 to 20 mils.
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