Low odor olefin-based polymer compositions for flooring applications

Abstract

A composition comprising of: A) a first ethylene / alpha-olefin interpolymer with a melt index I2 measured at 190° C and 2.16 kg from 0.5 to 100 dg / min; B) a second ethylene / alpha-olefin interpolymer with a Brookfield viscosity BV measured at 177° C from 3700 cP to 22000 cP; C) ≥ 50 wt%, a filler, based on the total weight of the composition; and D) ≤ 7.5 wt% of a tackifier, based on the total weight of the composition.

Description

LOW ODOR OLEFIN-BASED POLYMER COMPOSITIONS FOR FLOORING APPLICATIONSBACKGROUND

[0001] Typically, flooring applications, such as carpet backings, comprise of approximately 19-21% of a polymer resin, approximately 7% of a tackifier, approximately 2% of a process oil and a filler. Accordingly, the filler predominately makes up the formulation contributing to approximately 70% of the total weight of the formulation. There is an increasing demand for recyclable, low-viscosity filled polymer compositions, as alternatives to the traditional bitumen carpet backing. Moreover, there remains a need for formulations with reduced odor that still maintain the good mechanical and rheological properties required for flooring applications. These needs have been met by the following invention.SUMMARY

[0002] The embodiments of this disclosure relate compositions containing a first ethylene / alpha-interpolymer and a second ethylene / alpha-olefin interpolymer, a filler, and a tackifier. The compositions described herein are particularly useful for flooring applications including carpet tiles and carpet backing materials.

[0003] Certain embodiments of this disclosure include a composition comprising of: A) a first ethylene / alpha-olefin interpolymer with a melt index 12 measured at 190° C and 2.16 kg from 0.5 to 100 dg / min; B) a second ethylene / alpha-olefin interpolymer with a Brookfield viscosity BV measured at 177° C from 3700 cP to 22000 cP; C) > 50 wt%, a filler, based on the total weight of the composition; and D) < 7.5 wt% of a tackifier, based on the total weight of the composition.BRIEF DESCRIPTION OF THE DRAWINGS

[0004] Figure 1 shows the TD-GCxGC-TOF MS plot for the direct desorption IE1 to IE3 and CE1 to CE3.DETAILED DESCRIPTIONDefinitions

[0005] All references to the Periodic Table of the Elements herein shall refer to the Periodic Table of the Elements, published and copyrighted by CRC Press, Inc., 2003. Also, any references to a Group or Groups shall be to the Group or Groups reflected in this Periodic Table of the Elements using the IUPAC system for numbering groups.

[0006] Unless stated to the contrary, implicit from the context, or customary in the art, all parts and percents are based on weight.

[0007] For purposes of United States patent practice, the contents of any patent, patent application, or publication referenced herein are hereby incorporated by reference in their entirety (or the equivalent US version thereof is so incorporated by reference) especially with respect to the disclosure of synthetic techniques, definitions (to the extent not inconsistent with any definitions provided herein) and general knowledge in the art.

[0008] The numerical ranges disclosed herein include all values from, and including, the lower and upper value. For ranges containing explicit values (e.g., 1, or 2, or 3 to 5, or 6, or 7), any subrange between any two explicit values is included (e.g., 1 to 2; 2 to 6; 5 to 7; 3 to 7; 5 to 6; etc.). The numerical ranges disclosed herein further include the fractions between any two explicit values.

[0009] The terms “comprising,” “including,” “having” and their derivatives are not intended to exclude the presence of any additional component, step or procedure, whether or not the same is specifically disclosed. In contrast, the term “consisting essentially of’ excludes from the scope of any succeeding recitation any other component, step, or procedure, excepting those that are not essential to operability. The term “consisting of’ excludes any component, step, or procedure not specifically delineated or listed. The term “or,” unless stated otherwise, refers to the listed members individually as well as in any combination.

[0010] The term “composition,” as used herein, includes a material or mixture of materials which comprise the composition, as well as reaction products and decomposition products formed from the materials of the composition. Typically, any reaction products and / or decomposition products are present in trace amounts.

[0011] The term “polymer” refers to a material prepared by reacting (i.e., polymerizing) a set of monomers, wherein the set is a homogenous (i.e., only one type) set of monomers or a heterogeneous (i.e., more than one type) set of monomers. The term polymer as used herein includes the term “homopolymer,” which refers to polymers prepared from a homogenous set of monomers, and the term “interpolymer” as defined below. Trace amounts of impurities, for example, catalyst residues, may be incorporated into and / or within the polymer.

[0012] The term “interpolymer” refers to a polymer prepared by the polymerization of at least two different types of monomers. This term includes both “copolymers,” i.e., polymers prepared from two different types of monomers, and polymers prepared from more than two different types of monomers, e.g., terpolymers, tetrapolymers, etc. This term also embraces all forms of interpolymers, such as random, block, homogeneous, heterogeneous, etc.

[0013] An “olefin-based polymer” refers to a polymer that comprises, in polymerized form, 50 wt% or a majority of an olefin monomer, for example, ethylene or propylene, (based on the weight of the polymer), and optionally, may contain at least one comonomer.Nonlimiting examples of an olefin-based polymer include an ethylene-based polymer and a propylene-based polymer.

[0014] A “propylene-based polymer,” refers to a polymer that comprises, in polymerized form, a majority amount of propylene monomer (based on the weight of the polymer), and optionally may comprise one or more comonomers.

[0015] An “ethylene-based polymer” refers to a polymer that comprises, in polymerized form, a majority amount of ethylene monomer (based on the weight of the polymer), and optionally may comprise one or more comonomers.

[0016] An “ethylene-based interpolymer” refers to an interpolymer that comprises, in polymerized form, 50 wt% or a majority amount of ethylene monomer (based on the weight of the interpolymer), and at least one comonomer.

[0017] An “ethylene-based copolymer,” refers to a copolymer that comprises, in polymerized form, 50 wt% or a majority amount of ethylene monomer (based on the weight of the copolymer), and a comonomer, as the only two monomer types.

[0018] An “ethylene / alpha-olefin interpolymer,” refers to an interpolymer that comprises, in polymerized form, 50 wt% or a majority amount of ethylene monomer (based on the weight of the interpolymer), and at least one alpha-olefin. The ethylene / alpha-olefin interpolymer may be a random or block interpolymer.

[0019] An “ethylene / alpha-olefin copolymer,” refers to a copolymer that comprises, in polymerized form, 50 wt% or a majority amount of ethylene monomer (based on the weight of the copolymer), and an alpha-olefin, as the only two monomer types. The ethylene / alpha- olefin copolymer does not exclude residual amounts of other components. The ethylene / alpha-olefin copolymer may be a random or block copolymer.

[0020] Unless stated to the contrary, all test methods are current as of the filing date of this disclosure.Compositions

[0021] Traditional flooring applications, such as carpet backings, comprise of approximately 19-21% of a polymer resin, approximately 7% of a tackifier, approximately 2% of a process oil and the remainder comprises of about 70% filler. These components must work in harmony to ensure that the formulation is securely bound together and has goodprocessibility. Some key performance requirements of flooring formulations are” a low preblend viscosity of less than 30,000 cP at 165° C, a high elongation at break (greater than 15 %) and a tensile modulus below 400 MPa.

[0022] In addition to good binding and processibility of formulations, a key area of focus in flooring applications is the reduction of odor. Depending on the processing conditions, which average temperatures of about 145-205° C, significant amounts of volatile organic compounds or (“VOCs”) can be generated due to degradation of the formulation components and / or release of adsorbed molecules. These VOCs which include oxygenated species result in quality concerns for consumers. One known source of VOCs is the tackifier component which has been identified as a key contributor to odor, with -60-70% of the total volatile organic compounds originating from these additives. Despite this shortcoming, tackifiers play a crucial role in supporting good rheological properties during processing and mechanical properties in application. Thus, any proposed solution to odor that impacts the concentration of the tackifier must not sacrifice on the overall carpet backing formulation performance.

[0023] As eluded to above, one potential solution to reducing odor is to lower the tackifier content while increasing the filler content. High filler loading provides both dimensional stabilities as well cost reduction to the overall formulation. However, increasing the filler content to above 70 wt% results in the system viscosity increasing significantly, which is detrimental to processability. Also, the use of high filler loadings in carpet backing applications results in the deterioration of mechanical properties of the formulation, especially the tensile “elongation at break”. Thus, it is not advantageous to simply lower the tackifier content by increasing the filler content.

[0024] Recently, the inventors of W02020010052A1 disclosed the use of polyolefin elastomer (POE) blends comprising of ethylene / alpha-olefin interpolymers in formulations for flooring applications. POEs are well-known for their high melt index (“MI”) properties and there use in hot melt adhesive applications. The introduction of POE into the carpet backing formulation provides a viable, alternative route to ensuring good carpet backing performance. Continuing the success of the formulations featuring POE blends described in W02020010052A1, the inventors of the instant application endeavored to determine if blends of POE could help maintain the desired mechanical and rheological properties when the tackifier is reduced to account for odor.

[0025] As a result, the inventors developed formulation comprising of blends of high MI ethylene / alpha-olefin interpolymers with reduced tackifier amounts, which are describedherein. The inventors found that these formulations provided the needed mechanical and rheology properties in the formulations with reduced tackifier content. In addition, the inventors surprisingly found that the formulation comprising of an ethylene / alpha-olefin interpolymer with a Brookfield viscosity BV from 3700 cP to 22000 cP, measured at 177° C has enhanced odor reduction properties for formulations with reduced tackifier. This result was determined from an odor panel and confirmed by a thermal desorption with GCxGC- TOF MS methodology described herein on samples that have been aged for 21 days at 80° C. In comparison to the traditional formulation with standard tackifier level (7 wt%, CE 1), the inventive ethylene / alpha-olefin interpolymer blended formulations (with less than 7.5 wt% tackifier present) improved upon the baseline performance of the traditional formulation in both rheological and mechanical properties.First Ethylene / Alpha-Ole fm Interpolymer (EAO-1)

[0026] In one embodiment, or a combination of embodiments described herein, the compositions of the present disclosure may include a first ethylene / alpha-olefin interpolymer (“EAO-1”) in the amount from 1 wt% to 20 wt%, from 1 wt% to 15 wt%, from 5 wt% to 12 wt%, or from 8 wt% to 14 wt%, based on the total weight of the composition. The first ethylene / alpha-olefin interpolymer is derived from ethylene and at least one of a C3 to C10 alpha-olefin. For example, the first ethylene / alpha-olefin interpolymer may be an ethylenepropylene copolymer, an ethyl ene-butylene copolymer, an ethylene-hexene copolymer, and / or an ethyl ene-octene copolymer.

[0027] In one or more embodiments, the first ethylene / alpha-olefin interpolymer may have a density (according to ASTM D792) of from 0.87 g / cm3to 0.911 g / cm3. For example, the first ethylene / alpha-olefin interpolymer may have a density of from 0.87 g / cm3to 0.875 g / cm3, from 0.875 g / cm3to 0.88 g / cm3, from 0.88 g / cm3to 0.885 g / cm3, from 0.885 g / cm3to 0.90 g / cm3, from 0.90 g / cm3to 0.905 g / cm3, from 0.905 g / cm3to 0.911 g / cm3, or any combination of these ranges.

[0028] In one embodiment, or a combination of embodiments, the first ethylene / alpha-olefin interpolymer may have a melt index 12 (measured at 190°C and 2.16 kg) of at least 0.3 dg / min, such as from 0.3 dg / min to 500 dg / min. For example, the ethylene / alpha-olefin interpolymer may have a melt index 12 of from 0.3 dg / min to 500 dg / min, from 0.3 dg / min to 250 dg / min, from 0.5 dg / min to 100 dg / min, from 0.5 dg / min to 80 dg / min, from 0.5 dg / min to 75 dg / min, from 0.5 dg / min to 50 dg / min, from 0.5 dg / min to 30 dg / min, from 0.5 dg / min to 25 dg / min, from 0.5 dg / min to 15 dg / min, from 0.5 dg / min to 10 dg / min, or any combination of these ranges. In one embodiment, or a combination of embodimentsdescribed herein, the first interpolymer has a melt index 12 < 90 dg / min, or < 80 dg / min, or < 70 dg / min, or < 60 dg / min, or < 50 dg / min, or < 40 dg / min, or < 35 dg / min, or < 30 dg / min, or < 25 dg / min, or < 20 dg / min, or < 15 dg / min, or < 10 dg / min, or < 5.0 dg / min.

[0029] In one embodiment, or a combination of embodiments, the first ethylene / alpha-olefin interpolymer may have a melting point of from 65° C. to 100° C. For example, the first ethylene / alpha-olefin interpolymer may have a melting point of from 65° C. to 70° C., from 70° C. to 75° C., from 75° C. to 80° C., from 80° C. to 85° C., from 85° C. to 90° C., from 90° C. to 95° C., from 95° C. to 100° C., or any combination of these ranges.

[0030] In one embodiment, or a combination of embodiments described herein, the first ethylene / alpha-olefin interpolymer has a molecular weight distribution (MWD) > 1.5, or >

[0031] 1.6, or > 1.7, or > 1.8. In one embodiment, or a combination of embodiments described herein, the first ethylene / alpha-olefin interpolymer has a molecular weight distribution (MWD) < 2.5, or < 2.4, or < 2.3, or < 2.2.

[0032] Some exemplary first ethylene / alpha-olefin interpolymers for use in the compositions of the instant disclosure include ethylene-octene polyolefin elastomers available as ENGAGE™ 8100, 8003, 8400, 8401, 8411, 8480, 8842, 8200, 7447, or 7467 from the Dow Chemical Company.Second Ethylene / Alpha-Ole fin Interpolymer (EAO-2)

[0033] In one embodiment, or a combination of embodiments described herein, the compositions of the present disclosure may include a second ethylene / alpha-olefin interpolymer (EAO-2) in the amount from 1 wt% to 20 wt%, from 1 wt% to 15 wt%, from 5 wt% to 12 wt%, or from 8 wt% to 14 wt% of, based on the total weight of the composition. The second ethylene / alpha-olefin interpolymer has a high melt flow interpolymer derived from ethylene and at least one of a C3 to C10 alpha-olefin. For example, the second ethylene / alpha-olefin interpolymer may be an ethyl ene-propylene copolymer, an ethylenebutylene copolymer, an ethyl ene-hexene copolymer, and / or an ethylene-octene copolymer.

[0034] The second ethylene / alpha-olefin interpolymer has a relatively high melt index such that the melt index is from 10.0 dg / min to 200.0 dg / min, according to ASTM D1238 and at 190° C / 2.16 kg. For example, the melt index may be from 10 dg / min to 150 dg / min, 20 dg / min to 120 dg / min, 30 dg / min to 70 dg / min, and / or 40 dg / min to 60 dg / min.

[0035] The second ethylene / alpha-olefin interpolymer has a relatively low density, according to ASTM D792, such that the density is from 0.860 g / cc to 0.900 g / c, preferably from 0.860 g / cc to 0.885 g / cc, and more preferably from 0.860 g / cc to 0.875 g / cc.

[0036] The second ethylene / alpha-olefin interpolymer may have a Brookfield viscosity (177° C) from 1,000 cP to 30,000 cP, from 2500 cP to 25,000 cP, from 3700 cP to 22,000 cP, from 5000 cP to 20,000 cP, and / or from 10,000 cP to 15,000 cP.

[0037] The second ethylene / alpha-olefin interpolymer may have a molecular weight distribution (MWD) of < 5, < 4, or < 3.

[0038] Some exemplary second ethylene / alpha-olefin interpolymers for use in the compositions of the instant disclose include a high melt flow ethylene-octene polyolefin elastomer AFFINITY™ GA 1875, 1900, and 1950 available from The Dow Chemical Company.Grafted Ethylene-Based Polyolefin (GEBP-1 and GEBP-2)

[0039] In one embodiment, or a combination of embodiments described herein, the compositions of the present disclosure may include a functionalized or grafted ethylene-based polyolefin (GEBP-1 and GEBP-2) in the amount from 1 wt% to 5 wt%, from 1 wt% to 3 wt%, from 2 wt% to 4 wt%, from 2 wt% to 3wt%, based on the total weight of the composition.

[0040] Generally, the grafted polyolefin is a compatibilizer. The functionalized polyolefin may be a polyethylene grafted with ethylenically unsubstituted dicarboxylic acid or derivative thereof or may be a polyolefin copolymerized with ethylenically unsubstituted dicarboxylic acid or a derivative thereof. The grafted polyolefin may comprise at least one a- olefin, such as a C2-C14 a-olefin. Contemplated C2-C14 a-olefins include, by way of example and not limitation, C2, C3, C4, C5, Ce, C7, Cs, C9, C10, Cn, C12, C13, or C14. In embodiments, the a-olefin may be ethylene and the grafted polyolefin may comprise functionalized polyethylene.

[0041] The polyolefin may be functionalized with an ethylenically unsubstituted dicarboxylic acid or derivative thereof. The functionalized polyolefin may be formed by co-polymerizing the a-olefin with the ethylenically unsubstituted dicarboxylic acid or by grafting the ethylenically unsubstituted dicarboxylic acid onto the already formed polyolefin. The ethylenically unsubstituted dicarboxylic acid or derivative thereof may be selected from maleic anhydride, itaconic anhydride, maleic acid diesters, fumaric diesters, maleic acid monoesters or fumaric acid monoesters, esters of Ci to C4 alcohols, maleic acid, itaconic acid, fumaric acid, or mixtures thereof. For example, the functionalized polyolefin, such as a functionalized polyethylene, may include an anhydride functionalized polyolefin, such as maleic anhydride functionalized polyolefin, such as maleic anhydride functionalized polyethylene, such as maleic anhydride grafted polyolefin. The polyolefin may have afunctionalization level of 0.5 to 3.0 wt. %, such as from 1.0 to 2.0 wt. %, from 0.5 to 1.0 wt. %, from 1.0 to 1.5 wt. %, from 1.5 to 2.0 wt. %, from 2.0 to 2.5 wt. %, from 2.5 to 3.0 wt. %, or any combination of two or more of these ranges, of the ethylenically unsubstituted dicarboxylic acid or derivative thereof. Preferred ethylene-based polymers for use as the grafted ethylene-based polyolefin include low density polyethylene (LDPE), high density polyethylene (HDPE), heterogeneously branched linear low density polyethylene (LLDPE), homogeneously branched linear ethylene polymers and substantially linear ethylene polymers.

[0042] The grafted polyolefin may have a density of from elastomer may have a density of from 0.850 to 0.925 g / cc, such as from 0.855 to 0.920 g / cc, from 0.865 to 0.915 g / cc, from 0.875 to 0.910 g / cc, from 0.885 to 0.905 g / cc, from 0.895 to 0.900 g / cc, or any combination of two or more of these ranges. Preferred host ethylene polymers have a polymer density greater than or equal to 0.915 g / cc and most preferably greater than or equal to 0.920 g / cc.

[0043] Some exemplary functionalized ethylene-based polyolefins include FUSABOND™ E204 and E528 available from The Dow Chemical Company, Midland MITackifiers

[0044] In one embodiment, or a combination of embodiments described herein, the composition of the instant disclosure may include a tackifier in the amount of from less than 7 wt%, from less than 6 wt%, from less than 5 wt%, from less than 4 wt%, or from less than 3 wt% of the total weight of the composition. In one embodiment, or a combinations of embodiments the composition contains a tackifier in the amount of from 1 to 7 wt %, from 1 to 5 wt% from 1 to 4 wt%, from 5 wt% to 7 wt%, from 3 wt% to 5 wt%, from 2 wt% to 4 wt% or from 1 wt% to 3 wt% of the total weight of the composition.

[0045] The compositions disclosed herein comprise a tackifier or tackifying resin or tackifier resin. The tackifier may modify the properties of the composition such as viscoelastic properties (e.g., tan delta), rheological properties (e.g., viscosity), and tackiness (z.e., ability to stick).

[0046] Any tackifier known to a person of ordinary skill in the art may be used in the adhesion composition disclosed herein. Tackifiers suitable for the compositions disclosed herein can be solids, semi-solids, or liquids at room temperature. Non-limiting examples of tackifiers include (1) natural and modified rosins (e.g., gum rosin, wood rosin, tall oil rosin, distilled rosin, hydrogenated rosin, dimerized rosin, and polymerized rosin); (2) glycerol and pentaerythritol esters of natural and modified rosins (e.g., the glycerol ester of pale, wood rosin, the glycerol ester of hydrogenated rosin, the glycerol ester of polymerized rosin, thepentaerythritol ester of hydrogenated rosin, and the phenolic-modified pentaerythritol ester of rosin); (3) copolymers and terpolymers of natured terpenes (e.g., styrene / terpene and alpha methyl styrene / terpene); (4) polyterpene resins and hydrogenated polyterpene resins; (5) phenolic modified terpene resins and hydrogenated derivatives thereof (e.g., the resin product resulting from the condensation, in an acidic medium, of a bicyclic terpene and a phenol); (6) aliphatic or cycloaliphatic hydrocarbon resins and the hydrogenated derivatives thereof (e.g., resins resulting from the polymerization of monomers consisting primarily of olefins and diolefins); (7) aromatic hydrocarbon resins and the hydrogenated derivatives thereof; (8) aromatic modified aliphatic or cycloaliphatic hydrocarbon resins and the hydrogenated derivatives thereof; and combinations thereof.

[0047] In some embodiments, the tackifier is an aliphatic hydrocarbon resin having at least five carbon atoms (e.g. PICCOTAC™ 1095 from Synthomer Chemicals Company, Essex U.K.). In other embodiments, the tackifiers include rosin-based tackifiers (e.g. AQUATAC® 9027, AQUATAC® 4188, SYLV ALITE®, SYLVATAC® and SYLVAGUM® rosin esters from Arizona Chemical, Jacksonville, FL). In other embodiments, the tackifiers include polyterpenes or terpene resins (e.g., SYLV ARES® terpene resins from Arizona Chemical, Jacksonville, FL). In other embodiments, the tackifiers include aliphatic hydrocarbon resins such as resins resulting from the polymerization of monomers consisting of olefins and diolefins (e.g., ESCOREZ® 1310LC, ESCOREZ® 2596 from ExxonMobil Chemical Company, Houston, Tex.) and the hydrogenated derivatives thereof; alicyclic petroleum hydrocarbon resins and the hydrogenated derivatives thereof (e.g. ESCOREZ® 5300 and 5400 series from ExxonMobil Chemical Company; EASTOTAC® resins from Eastman Chemical, Kingsport, Tenn.). In further embodiments, the tackifiers are modified with tackifier modifiers including aromatic compounds (e.g., ESCOREZ® 2596 from ExxonMobil Chemical Company.) and low softening point resins (e.g., AQUATAC 5527 from Arizona Chemical, Jacksonville, FL).Oils

[0048] In one embodiment, or a combination of embodiments described herein, the composition of the instant disclosure may include an oil in the amount from 1 wt% to 5 wt%, from 1 wt% to 3 wt%, from 2 wt% to 4 wt%, from 2 wt% to 3wt%, based on the total weight of the composition. Oils useful in embodiments of the invention include, for example, a paraffinic oil, aromatic oil, napththenic oil, hydrogenated (white) oil (such as, Kaydol oil), vegetable and animal oil and their derivatives, petroleum derived oils or a combination thereof.Filler

[0049] In one embodiment, or a combination of embodiments described herein, the composition of the instant disclosure may include a filler in the amount of from less than 70 wt %, less than 60 wt%, less than 50 wt%, less than 40 wt%, or from 10 wt% to 50 wt %, or from 20 wt% to 60 wt %, or from 30 wt% to 70 wt% of the total weight of the composition. In further embodiments, the compositions disclosed herein optionally can comprise a filler. Any filler known to a person of ordinary skill in the art may be used in the adhesion composition disclosed herein. Non-limiting examples of suitable fillers include sand, talc, dolomite, calcium carbonate, clay, silica, mica, wollastonite, feldspar, aluminum silicate, alumina, hydrated alumina, glass bead, glass microsphere, ceramic microsphere, thermoplastic microsphere, barite, and combinations thereof. In one embodiment the filler is selected from talc, carbon black, or calcium carbonate, further carbon black, or calcium carbonate, further calcium carbonate (CaCCE).Compositions and Articles

[0050] In one embodiment, or a combination of embodiments described herein, the composition comprises one or more additives. Additives include, but are not limited to, antioxidants, ultraviolet absorbers, antistatic agents, colorants (e.g., titanium dioxide, carbon black and pigments), viscosity modifiers, flame retardants, odor modifiers / absorbents, and any combination thereof. In one embodiment, or a combination of embodiments described herein, the composition further comprises a thermoplastic polymer, different in one or more properties from the first ethylene / alpha-olefin interpolymer and the second ethylene / alpha- olefin interpolymer. Illustrative polymers, include, but not limited to, propylene-based polymers, ethylene-based polymers, and olefin multi-block interpolymers. Suitable ethylenebase polymers include, but are not limited to, high density polyethylene (HDPE), linear low- density polyethylene (LLDPE), very low-density polyethylene (VLDPE), ultra-low density polyethylene (ULDPE), homogeneously branched linear ethylene polymers, and homogeneously branched substantially linear ethylene polymers (that is homogeneously branched long chain branched ethylene polymers).

[0051] The compositions of the present disclosure may be used to prepare a variety of articles, or their component parts or portions. The inventive compositions may be converted into a finished article of manufacture by any one of a number of conventional processes and apparatus. Illustrative processes include, but are not limited to, adhesives, injection molding, extrusion, calendaring, compression molding, and other typical thermoset material forming processes. Articles include, but are not limited to, sheets, foams, molded goods, and extrudedparts. Additional articles include flooring materials such as resilient tiles and sheets, rigid planks and laminates, tiles, carpet tiles, carpets and carpet backing material.

[0052] Specific Embodiments of the present disclosure include but are not limited to the following:

[0053] A composition comprising ofA) a first ethylene / alpha-olefin interpolymer with a melt index 12 measured at 190° C and 2.16 kg from 0.5 to 100 dg / min;B) a second ethylene / alpha-olefin interpolymer with a Brookfield viscosity BV measured at 177° C from 3700 cP to 22000 cP;C) > 50 wt% of a filler, and wherein the filler, based on the total weight of the composition;D) < 7.5 wt% of a tackifier, based on the total weight of the composition.

[0054] The composition of any one of the embodiments, wherein the first ethylene alphaolefin interpolymer has a density of from 0.860 g / cc to 0.910 g / cc and the second ethylene alpha-olefin interpolymer has a density of from 0.860 g / cc to 0.910 g / cc.

[0055] The composition of any one of the embodiments, wherein the first ethylene / alpha- olefin interpolymer is selected from the group consisting of an ethyl ene / butene interpolymer, an ethyl ene / hexene interpolymer, or an ethylene / octene interpolymer.

[0056] The composition of any one of the embodiments, wherein the second ethylene / alpha- olefin interpolymer is selected from the group consisting of an ethyl ene / butene interpolymer, an ethyl ene / hexene interpolymer, or an ethylene / octene interpolymer.

[0057] The composition of any one of the embodiments, wherein weight ratio of the first ethylene / alpha-olefin interpolymer to the second ethylene / alpha-olefine interpolymer is from 9: 1 to 1 :9.

[0058] The composition of any one of the embodiments, wherein weight ratio of the first ethylene / alpha-olefin interpolymer to the second ethylene / alpha-olefine interpolymer is from 1 : 1 to 1 : 1.

[0059] The composition of any one of the embodiments, wherein weight ratio of the first ethylene / alpha-olefin interpolymer to the second ethylene / alpha-olefine interpolymer is from 6:4 to 4:6.

[0060] The composition of any one of the embodiments, wherein weight ratio of the first ethylene / alpha-olefin interpolymer to the second ethylene / alpha-olefine interpolymer is from 7:3 to 3:7.

[0061] The composition of any one of the embodiments, wherein the composition further comprises from 0.5 wt% to 5 wt% of a maleic anhydride grafted ethylene-based polymer, based on the total weight of the composition.

[0062] The composition of any one of the embodiments, wherein the composition further comprises from 0.5 wt% to 5 wt% of a paraffin oil, based on the total weight of the composition.

[0063] The composition of any one of the embodiments, wherein the composition has a complex shear viscosity at 100 rad / s shear rate and 190° C from 250 Pa s to 1000 Pa s, from 300 Pa s to 950 Pa s, from 400 Pa S to 800 Pa s, or from 500 Pa s to 800 Pa s.

[0064] The composition of any one of the embodiments, wherein the composition has a volatile organic compound concentration less than 2000 pg / g measured by TD-GOGC- TOF MS.

[0065] An article comprising the composition of any one of the embodiments.

[0066] A flooring structure comprising the article of any one of the embodiments.

[0067] In one embodiment, or a combination of embodiments described herein, the composition has a growth tension at 40° C of less than 50 PSI, less than 45 PSI, less than 40 PSI, less than 35 PSI, or less than 30 PSI. In one embodiment, or a combination of embodiments described herein, the composition has a growth tension at 40° C from 10 PSI to 50 PSI, from 20 PSI to 40 PSI, or from 30 PSI to 40 PSI.

[0068] In one embodiment, or a combination of embodiments described herein, the composition has a rheology ratio greater than 160, greater than 170, greater than 180, greater than 190, greater than 200, or greater than 250. In one embodiment, or a combination of embodiments described herein, the composition has a rheology ratio from 175 to 300, from 180 to 275, or from 190 to 300, wherein the rheology ratio is defined as the ratio of complex shear viscosity at 0.1 rad / s divided by complex shear viscosity at 100 rad / s.

[0069] In one embodiment, or a combination of embodiments described herein have an average hardness (Shore A) of greater than 75, greater than 80, greater than 85, greater than 90, greater than 95, greater than 97, or greater than 100. In one embodiment, or a combination of embodiments described herein have an average hardness (Shore A) of 75- 100, of 80 to 99, of 85 to 97, of 90 to 97, or of 90 to 100.

[0070] In one embodiment, or a combination of embodiments described herein, the composition has a tensile elongation at break of greater than or equal to 10%, or greater than or equal to 20%, or greater than or equal to 25%, or greater than or equal to 30%, or greater than or equal to 40%, or greater than or equal to 50%. In one embodiment, or a combinationof embodiments described herein, the composition has a tensile elongation at break from 10% to 45%.TEST METHODSDensity

[0071] Density was measured in accordance with ASTM D-792.Melt Index (I ) and Melt Flow rate (MFR)

[0072] Melt index (2.16 kg, 190°C) for an ethylene-based polymer was measured in accordance with ASTM D-1238.GPC Molecular Weight and Molecular Weight Distribution

[0073] Molecular weight is determined using gel permeation chromatography (GPC), on a Waters 150°C high temperature chromatographic unit, equipped with three mixed porosity columns (Polymer Laboratories 103, 104, 105, and 106), operating at a system temperature of 140°C. The solvent is 1, 2, 4-tri chlorobenzene, from which 0.3 percent by weight solutions of the samples are prepared for injection. The flow rate is 1.0 mL / min and the injection size is 100 microliters.

[0074] The molecular weight determination is deduced by using narrow molecular weight distribution, polystyrene standards (from Polymer Laboratories), in conjunction with their elution volumes. The equivalent polyethylene molecular weights are determined by using appropriate Mark-Houwink coefficients for polyethylene and polystyrene (as described by T. Williams & I.M. Ward, The Construction of a Polyethylene Calibration Curve for Gel Permeation Chromatography Using Polystyrene Fractions, 6 J. Polymer Sci. Pt. B: Polymer Letter 621, 621-624 (1968)) to derive the following equation:^polyethylene u X Mpoiystyrene')this equation, a 0.4316 and b 1.0.Number average molecular weight, Mn, of a polymer is expressed as the first moment of a plot of the number of molecules in each molecular weight range, against the molecular weight. In effect, this is the total molecular weight of all molecules, divided by the number of molecules, and is calculated in the usual matter, according to the following formula:where ni = number of molecules with molecular weight Mi , wi = weight fraction of material having molecular weight Mi,and Xni= total number of molecules.Weight average molecular weight, Mw, is calculated, in the usual manner, according to the following formula: Mw =wi x Mi, where wi and Mi are the weight fraction and molecular weight, respectively, of the ith fraction eluting from the GPC column. The ratio of these two averages, the molecular weight distribution (MWD or Mw / Mn), defines the breadth of the molecular weight distribution.Microtensile Test

[0075] Microtensile tests measure the properties of a specimen when tested under uniaxial extension. Properties include yield strength and yield strain, tensile strength and tensile strength at break, strain at break, energy to break (sometimes referred to as toughness) and elastic modulus (from the initial portion of the stress-strain curve, often referred to as the young’s Modulus). The Microtensile test was conducted using an INSTRON 5565, equip with a “100 load cell”. In preparation, the test sample is compression molded according to ASTM D4703 (Procedure C, Annex Al). 24 hours after molding the microtensile specimens are cut with a NAEF Punch Press with ASTM die D1708. The test specimens are conditioned for at least 40 hours at 23° C (+ / - 2° C) and 50% R.H (+ / - 10) as per ASTM standards. Standard testing conditions are 23° C (+ / - 2° C) and 50% R.H (+ / - 10) as per ASTM standards. During the test, the prepared sample is subjected to a strain rate of 5 in / min. From this measurement, the average stress at break is reported here; the reported value is an average of five measurements at maximum.Shore A Hardness

[0076] The test material was compressed to a plaque for micro-tensile test. Compression molding is conducted based on ASTM D4703 to prepare a 4” x 4” x 0.125” plaque. The molding temperature is 190° C with controlled cooling at 15° C / min. The Shore A hardness test was conducted in accordance with ASTM D2240 with a durameter. For each measurement, the indenter was held against the sample for 5 seconds prior to recording the hardness value. The Shore A hardness values reported here for each sample is an average of 5 measurements.Brookfield Viscosity

[0077] A Brookfield Digital Viscometer Model LVDV-1 Prime, with a thermosel, was used, in accordance with ASTM DI 986 Standard Test for Apparent Viscosity of Hot Melt Adhesives and Coating Materials. Compositions containing filler were measured with spindle SC4-27. Compositions without filler were measured with spindle SC4-31.Capillary Rheology

[0078] Capillary testing is conducted on either Rheotester 2000 or Rheograph 25 capillary rheometers, both which are manufactured by Gbttfert. The die used for testing has a diameter of 1mm and an entry angle of 180 degrees (also known as a “flat die”). The length of the die used in the Rheograph 25 capillary is 30mm (active length is 20mm), whereas the Rheotester uses a 20mm length (active length is 20mm as well). Each test was performed isothermally at a temperature of 190° C.

[0079] Prior to initiating the test, a sample, in preferably pellet form, is loaded into the capillary barrel and allowed to equilibrate at the testing temperature for lOmin. After the 10 min. wait period, the test is initiated. During the test, the piston inside the barrel applies a force on the molten sample to achieve apparent shear rates ranging from approximately 150 to 10,000s'1. As this test proceeds, the pressure drop across the capillary die is measured by the transducer. This pressure drop is used to determine the apparent shear stress near the wall with respect to apparent shear rate. Additional calculations provided by the capillary test include the apparent viscosity, Rabinowitsch-modified shear rate and the Rabinowitsch- modified viscosity. The apparent viscosity is obtained by dividing the apparent wall shear stress by the corresponding apparent shear rate. The Rabinowitsch-modified shear rate obtained by applying the Weissenberg-Rabinowitsch correction to the apparent shear rate and shear stress dataset. In turn, the Rabinowitsch-modified viscosity is calculated by dividing the apparent wall shear stress by the Rabinowitsch-modified shear rate. Note: the Bagley correction was not utilized in the calculations.

[0080] The software used to facilitate the capillary measurements and calculations are Lab Rheo and Win Rheo. These software packages were developed by Gbttfert.Growth Tension

[0081] Growth tension is a key parameter meter for gaining understanding of the stress relaxation of the test sample. It is measured using a TA Instrument Rheometric Solids Analyzer III. Compression molded sheets of “0.8-1 mm” thickness are cut into “12.7 mm” width rectangular shape and loaded into the instrument. During the test, the strain and tension are set so that the clamp distance is fixed at 20 mm. A temperature ramp was programmed, at 20 C / min, to run from room temperature until melting. The force is recorded during the temperature ramp, from which the growth tension, as defined according to the Equation 1 below is calculated., F F(gf) X 0.0098 (N / gf)Growth Tension (MPa) = - = .Area Hmm) X w(mm) ,,Equation 1

[0082] In Equation 1, F is the growth force, “Area” is the cross-sectional area of the test sample, t is the thickness of the test samples, and w is the width of the test sample. At one point, a growth tension value at 40C was used throughout the study to provide for easier comparison at an elevated temperature sometimes seen in the application. At least three repetitions were conducted on each composition, and the average reported. The molding conditions for growth tension sample preparation are 130 C for 15 minutes warm up, and 3,000 lbs for 3 minutes, 10,000 lbs for 3 minutes, and 20,000 lbs for 1 minute, then cooling for 1 to 2 minutes at 20,000 lbs pressure.Odor Panel

[0083] In preparation, each sample in this study are placed in two separate 20 mL vials. One vial is subjected to oven aging at 80° C for 21 days. A panel of 5 participants was gathered for qualitative odor comparison of the formulations produced in study. The panelists were instructed to subjectively rank the test samples on a scale from 1 to 5, where 5 has the strongest odor and 1 has the weakest odor.Thermal Desorption with Two-Dimensional Gas Chromatosraphy-TOF-MS

[0084] Thermal desorption coupled with comprehensive two-dimensional gas chromatography and time-of-flight mass spectrometry (TD-GC*GC-TOF MS) was conducted on the compositions to determine the amount of VOCs present in each composition. A Markes Centri™ 360 autosampler coupled with an Agilent™ 8860 GC and a Markes benchtop TOF mass spectrometer were used for this analysis. ChromSpace® (SepSolve Analytical) version 2.1.7 software was used for data acquisition and analysis.

[0085] The samples were prepared by adding 1.00 g of resin composition to a weighed headspace vial. The VOCs were extracted using a Markes Centri 360 autosampler (Markes International) operated in headspace mode with multiple headspace extraction, the samples were heated to for an incubation period of 45 minutes at the desorption temperature of 120° C. The desorbed VOCs were collected / concentrated on a -30° C cold trap and injected onto an Agilent 8890 gas chromatograph for separation (ID Column: Phase VF-200ms, dimensions 30 m x 250 pm x 1 pm, carrier gas helium; 2D column: Phase VF-lms, dimensions 2.5m x 320 pm x 0.5 pm, carrier gas helium). The gas chromatograph was operated in in GCxGC mode with a reversed fi 11 / flush modulator (modulation period (Pm) = 1.8s). Samples were quantified using internal standard calibration with a 1 parts per million(ppm; pg / mL) deuterated toluene gas standard that was added to the cold trap after collection and concentration of the sample, and detected on a Markes BenchTOF2 time of flight mass spectrometer (Mass Range: m / z 30-600).

[0086] The resulting 2D-GC chromatogram is provided in FIG 1. As scheme in FIG 1, the aliphatic compounds are retained longer in the second-dimension column, thus eluting in a band of intense peaks along the top of the plot. Contrastingly, the odor-active compounds (such as oxygenated species or VOCs) elute earlier in the second dimension, separating these compounds from the aliphatics. This region is defined in FIG 1 as the Integrated Region and is defined by the upper hydrocarbon and the lower column bleed regions. A minimum peak area for integration was set at 10,000 peak area and the total peak area in the “Integrated Region” was used to determine the concentration of the oxygenated species in parts per million (ppm; pg / g).EXAMPLES

[0087] The following examples are intended to illustrate some embodiments of the invention and should not be interpreted as limiting the scope of the invention set forth in the claims.Materials

[0088] Materials used in this section are shown in Table 1 below. Polymer properties are shown in Table 2.

[0089] Table 1 :Table 1. Materials

[0090] Table 2:Table 2: Summary of Polymer CharacteristicsCompoundingCompounding (with Filler):

[0091] The compounding of all sample formulations (compositions) with filler was performed on a rotating Haake Rheomix 3000, at 180°C. The raw materials, excluding filler, were added sequentially, and mixed at 180°C, at 20 rpm, until uniformly mixed (about five minutes). Then the filler was added over a five-minute period. The material was mixed for 35 minutes, at 35 rpm, after the final addition of filler.Samples and Results

[0092] Table 3: Inventive and Comparative Examples with 70 wt% Filler

[0093] Table 4: Physical Properties of Examples*units of 2D-GC data are pg / g volatiles in polymer eluting in integrated region

[0094] As shown, the inventive blends IE 1-3 had enhanced rheological properties with good growth tension, and comparable hardness properties to traditional formulation CE 1. Further IE 1-3 which all contain a second ethylene / alpha-olefin interpolymer with a Brookfield viscosity BV from 3700 cP to 22000 cP, measured at 177° C had enhanced odor reduction properties for formulations with reduced tackifier when compared to CE 2 and CE 3. Theseformulations also had good growth tension and comparable hardness to incumbent formulation.

Claims

Claims:

1. A composition comprising of:A) a first ethylene / alpha-olefin interpolymer with a melt index 12 measured at 190° C and 2.16 kg from 0.5 to 100 dg / min;B) a second ethylene / alpha-olefin interpolymer with a Brookfield viscosity BV measured at 177° C from 3700 cP to 22000 cP;C) > 50 wt% of a filler, and wherein the filler, based on the total weight of the composition;D) < 7.5 wt% of a tackifier, based on the total weight of the composition.

2. The composition of claim 1, wherein the first ethylene alpha-olefin interpolymer has a density of from 0.860 g / cc to 0.910 g / cc and the second ethylene alpha-olefin interpolymer has a density of from 0.860 g / cc to 0.910 g / cc.

3. The composition of any one of the previous claims, wherein the first ethylene / alpha- olefin interpolymer is selected from the group consisting of an ethyl ene / butene interpolymer, an ethylene / hexene interpolymer, or an ethyl ene / octene interpolymer.

4. The composition of any one of the previous claims, wherein weight ratio of the first ethylene / alpha-olefin interpolymer to the second ethylene / alpha-olefine interpolymer is from 9:1 to 1 :9.

5. The composition of any one of the previous claims, wherein the composition further comprises from 0.5 wt% to 5 wt% of a maleic anhydride grafted ethylene-based polymer, based on the total weight of the composition.

6. The composition of any one of the previous claims, wherein the composition further comprises from 0.5 wt% to 5 wt% of a paraffin oil, based on the total weight of the composition.

7. The composition of any one of the previous claims, wherein the composition has a complex shear viscosity from 250 Pa s to 1000 Pa s at 100 rad / s shear rate and 190° C.

8. The composition of any one of the previous claims, wherein the composition has a volatile organic compound concentration less than 2000 pg / g measured by TD- GCxGC-TOF MS.

9. An article comprising the composition of any one of the previous claims.

10. A flooring structure comprising the article of claim 9.

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