# Patent

## Title
Bags made from ethylene copolymer films, and films and uses of such copolymers for making such bags

## Abstract

The invention relates to bags with a heat seal zone formed by a composition comprising an interpolymer of ethylene and an alpha-olefin having an MI of from 1.5 to 4.5 g/10 min, preferably from 1.7 to 3.5 g/10 min, and especially from 1.8 to 2.5 g/ 10 min, and a density of from 0.88 to 0.94 g/cm3, preferably from 0.91 to 0.93 g/cm3 and especially from 0.912 to 0.922 g/cm3,and a CDBI of at least 50%, preferably at least 55% and especially at least 60%, and less than 20 wt % of LDPL; and to uses of films for making such bags.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority from Great Britain Application No. 03/8019.7, filed Aug. 1, 2003, hereby incorporated by reference.
FIELD OF THE INVENTION
The invention relates to bags made with improved sealing performance made from ethylene copolymer films, and such films and uses of such interpolymers for making such films, for use especially but not exclusively in high speed packaging lines.
BACKGROUND
It is known to convert ethylene based copolymers made using a metallocene catalyst, such as in gas phase or solution or high pressure polymerization, into film by blown film extrusion and cast film extrusion in either a mono or multilayer structure. Such copolymers are sold under the trade name EXACT or EXCEED by ExxonMobil Chemical Company. The composition for the film may comprise a single polymer with the usual additives (anti-oxidant, anti-block additive etc.) It is also known to blend different polymers. An example of that is the use of varying amounts of low density polyethylene made in a high pressure free radical initiated process, referred to as LDPE, with ethylene based copolymers, whether made using metallocene catalyst or the conventional catalyst types produced using titanium chloride as the transition metal component. In the LDPE'S have broad molecular weight distributions and contain significant long chain branching (LCB). In the density range of from 0.91 g/cm3 to 0.94 g/cm3 such copolymers are often referred to as linear low-density polymers, LLDPE's for short.
The conversion of the copolymer composition into film can proceed by two principal routes: A) blown film extrusion, which requires melt strength to sustain the bubble formed as it cools and the polymer composition solidifies; and B) cast film where the molten polymer is cooled on a chilled metal roll. Melt strength is influenced by the molecular weight (the lower the Melt Index (MI) the higher the melt strength at the same extrusion temperature) and LCB. Low MI's of around 1 g/10 min have been favored to achieve bubble stability in blown film extrusion. MI's of over 2.5 g/10 min are favored in cast extrusion to achieve good flowability and reduced neck in. The films produced are frequently converted on the packaging line into some sort of containment structure referred to herein as a bag, which may be a pouch, a bread bag or any other type of bag. A form, fill and seal machine may be used to form the bag.
Once the film has been formed, a critical performance factor is the speed at which the packaging line can be operated. On most bag producing machines, the bottleneck that limits further speed increases of the packaging line is the speed at which the film can be sealed to form the bag. The most important indicators for high line-speed potential are:
A) the heat seal strength (HSS) at different temperatures;
B) the hot tack, which influences the time taken before the product to be packed can be dropped on the freshly made seal and ensure package integrity; and
C) the seal initiation temperature (SIT), which determines the lowest temperature at which sufficient heat seal strength is developed to keep the bag closed.
A higher heat seal strength and/or a broader hot tack would provide a broader operating window, lowering the SIT and decreasing the heat seal cycle time and so increase the line speed with which the machine can reliably bag the products. It is among the objects of the invention to broaden the operating window while maintaining a reasonable balance of other properties for processability and film formation.
SUMMARY
We have found surprisingly that small differences in the molecular weight of the ethylene interpolymers can have favorable influence on the sealing behavior of films composition comprising metallocene derived ethylene interpolymers. Such differences are less pronounced to the point of having been ignored in the past using interpolymers derived from classical titanium chloride based catalyst systems.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 plots the heat seal strength data from Table 3A for 50 μm thick films.
FIG. 2 plots the hot tack data from Table 3A for 50 μm thick films.
FIG. 3 plots the heat seal strength for the blends with 20 wt % LDPE.



DETAILED DESCRIPTION
Various aspects of the invention are more clearly identified in the claims. The invention generally provides in one aspect a bag with a heat seal zone formed by a composition comprising an interpolymer of ethylene and an alpha-olefin having an MI of from 1.5 to 4.5 g/10 min, preferably from 1.7 to 3.5 g/10 min, and especially from 1.8 to 2.5 g/10 min and a density of from 0.88 to 0.94 g/cm3, preferably from 0.91 to 0.93 g/cm3, and especially from 0.912 to 0.922 g/cm3 and a CDBI of at least 50, preferably at least 55% and especially at least 60%, and less than 20 wt % of LDPE. Within the scope of the invention, more than one interpolymer may be used, preferably differing by less than 0.5 in MI g/10 min and less than 0.01 g/cm3 in density.
The interpolymer is preferably of the type containing short chain branches derived from an alpha-olefin comonomer having from 4 to 8 carbon atoms, and preferably from butene-1, hexene-1 and/or octene-1. Such inter-polymers may be made in solution processes, high-pressure processes and heterogeneous processes such as gas phase or slurry polymerization using a transition metal catalyst. The inter-polymers are preferably obtained through processes using single site transition metal catalysts such as metallocene which may be used with activating systems of various types such as aluminum alkyl derivatives, including alumoxane, and/or non-co-ordinating anions such as various boranes or borates. Such catalysts preferably are associated with the presence of Zr or Hf catalyst residues.
It is believed that the effect will be most pronounced by using homogeneous polymer compositions as far as possible. Suitably the heat seal zone is formed by a composition comprising a composition comprising from 85 wt % to 100% of the ethylene interpolymer, preferably at least 90% of the ethylene interpolymer, and especially at least 95 wt % and, a balance of an interpolymer of ethylene and an alpha-olefin having a CDBI less than 50% and/or LDPE. Some long chain branching may be present. However preferably the composition of the heat seal zone contains less than 5 wt % of an LDPE material made in an autoclave or tubular reactor, which generally have a broad molecular weight distribution and significant levels of long chain branches that lead to shear sensitive behavior.
Processing into film of compositions referred to above can be facilitated in blown film extrusion by extruding at a lower temperature to compensate for the lower melt strength resulting from the higher MI. Where the machinery permits, the extrusion temperature can be maintained and the output increased. Use of LDPE as a processing aid can then be reduced or avoided, minimizing the associated disadvantageous effect on the film properties such as reduction in impact strength.
Suitably the bags are made of films having a heat seal strength of more than 50% of the maximum heat seal strength at less than 105° C. and/or a maximum hot tack force at a temperature of less than 110° C.
Film can be adapted for use in making bags according to the invention by providing a heat seal zone extending over at least one surface of the film. The film may then be a mono-layer film consisting substantially of the inter-polymer throughout or it may be a multi-layer film, with three or five or more layers, formed by coextrusion or lamination so as to provide a heat zone face on one or both sides.
In another aspect of the invention there is provided the use of an interpolymer of ethylene and an alpha-olefin having an MI of from 1.5 to 4.5 g/10 min, preferably from 1.7 to 3.5 g/10, and especially from 1.8 to 2.5 g/10 and a density of from 0.88 to 0.94 g/cm3, preferably from 0.910 to 0.93 g/cm3, and especially from 0.912 to 0.922 g/cm3 and a CDBI of at least 50, preferably at least 55% and especially at least 60%, and less than 20 wt % of LDPE for improving the hot tack and/or seal strength of a film having a heat seal zone made from such inter-polymer, and preferably so that the film has a heat seal strength of more than 50% of the maximum heat seal strength at less than 105° C. and/or a maximum hot tack force at a temperature at less than 110° C. Such use can help speed up the packaging line speed without significant disadvantage for film properties or film extrusion capacity.
Measurements
Calculations involved in the characterization of polymers by C13 NMR for comonomer content follow the work of F. A. Bovey in “Polymer Confirmation and Configuration” Academic Press, New York, 1969. For example hexene content was determined using C13 NMR integrating the 2B4 peak at 23.4 ppm.
The Melt Index was determined according to ASTM-1238 Condition E 190° C., 2.16 kg.
Density was determined according to ASTM D4883 on plaques prepared according to ASTM D1928.
Composition Distribution Breadth Index (CDBI) is measured by the procedure described in PCT publication WO93/03093, published Feb. 18, 1993. Fractions having a molecular weight (Mw) less than 15,000 were ignored.
Mw and Mn were measured by GPC (Gel Permeation Chromatography) on a Waters 150 gel permeation chromatograph equipped with a differential refractive index (DRI) detector and Chromatix KMX-6 on line light scattering photometer. The system was used at 135° C. with 1,2,4-trichlorobenzene as the mobile phase. Shodex (Showa Denko America, Inc) polystyrene gel columns 802, 803, 804 and 805 were used. This technique is discussed in “Liquid Chromatography of Polymers and Related Materials III”, J. Cazes, editor, Marcel Dekker. 1981, p. 207, which is incorporated herein by reference. No corrections for column spreading were employed; however, data on generally accepted standards, e.g. National Bureau of Standards Polyethylene 1484 and anionically produced hydrogenated polyisoprenes (an alternating ethylene-propylene copolymer) demonstrated that such corrections on Mw/Mn (=MWD) were less than 0.05 units. Mw/Mn was calculated from elution times. The numerical analyses were performed using the commercially available Beckman/CIS customised LALLS software in conjunction with the standard Gel Permeation package.
The heat seal strength (and energy if required) determine the firmness of the seal established at the end of the packaging line after the seal has cooled and stabilized. The procedure for testing it is as follows. Seals were made on a J&B instruments sealing machine. The film was folded between TEFLONTM film and inserted between the sealing bars. At various temperatures, the sealing bars were closed with a pressure of 0.5 MPa for 0.5 seconds. The film was removed from the J&B machine and conditioned for a minimum of 12 hours at 23° C. +/−3° C. and 50% +/−5% humidity.
Seal strength was tested according to the following procedure. After conditioning for a minimum of 12 hours at 23° C. +/−3° C. and 50% +/−5% humidity, the seal strength of 15 mm wide sample was measured in a Zwick tensile instrument under the following conditions: speed 500 mm/min, load cell-200N, and clamp distance 50 mm. The film was placed between the clamps and the clamps were moved apart at a speed of 500 mm/min. During the test the force (N) was recorded as a function of elongation (%). Four test specimens were measured and the average seal strength curve was recorded. The seal strength was the force at which the test specimen registered the maximum force. This is reported in N/15 mm. The seal energy is the integration of the stress/strain curve. The seal energy is the amount of energy (J) necessary to break a seal reportable in J/15 mm.
The hot tack determines the initial seal strength before the film has had much opportunity to cool and represents the force that holds the seals of a bag together on a packaging line after initial sealing for the remainder of the operations on the packaging line. It was measured in the Examples as follows. Seals were made on a J&B instruments sealing machine. The films are laminated to a PET backing tape to prevent stickiness to the sealing bars. Taped films are conditioned at 23±3° C. and 50±5% humidity during a minimum of 12 hours before measuring the hot tack force. Samples were cut into strips of 30±0.5 mm width with a minimum length of 40 cm using a 30 mm Karl Frank cutter. At various temperatures, the sealing bars are closed with a pressure of 0.5 MPa for 0.5 seconds. The seals are allowed to cool down during 0.4 seconds after which the hot tack force is measured by applying a force to opposed sides of the seal according to the following conditions: speed 200 mm/min, a load cell of a piëzo crystal with a sensitivity between 0-100 N. During the test the force (N) was recorded as a function of elongation (%). Four test specimens were measured and the average maximum seal force was recorded. The hot tack strength is the force at which the test specimen registered the maximum force. This is reported in N/30 mm.
The information from the seal strength and hot tack measurements can be used to assess the seal initiation temperature (SIT). A threshold seal strength can be defined and the temperature at which that threshold is reached. A realistic assessment is possible using the heat seal strength data as obtained above and by setting a fixed threshold such as 4 N/15 mm or a threshold expressed as a fraction of the maximum seal strength such as 50% depending on the application.
EXAMPLES
The starting compositions for the films are as follows:














TABLE 1








Comonomer
Melt






Grade
Monomer
content
Index

Density


Sample
Designation
types
wt %
g/10 min
Mw/Mn
g/cm3
CDBI %







A
Exceed
E-H1)
5.1
2.0
2.3
0.927
59



MX2027ED*


B
Exceed
E-H
4.7
1.0
2.3
0.927
59



ML1027FE*


C
Exceed
E-H
8.0
1.0
2.3
0.918
67



1018CA*


D
Exceed
E-H
8.6
2.0
2.3
0.918
67



ECD357*


E
Exceed
E-H
8.8
2.5
2.3
0.918
67



2518CB*


F
Exceed
E-H
9.1
3.5
2.3
0.918
67



3418CB*


G
Escorene
LDPE
N/A
2.0
4.9
0.922
N/A



LD 185



BW**


H
ExxonMobil
E-B2)
8.0
1.0
3.5
0.918
N/A



LL1001XV***


I
ExxonMobil
E-B
8.5
2.8
3.5
0.918
N/A



LL1004YB***


J
ExxonMobil
E-B
8.8
2.0
3.5
0.918
N/A



LL1002YB***





EXCEED TM is a trade name owned by ExxonMobil Chemical Company.


E-H indicates ethylene hexene-1 copolymer.


E-B indicates ethylene butene-1 copolymer.


These grades are produced using a non-bridged bis cyclopentadienyl metallocene catalyst and alumoxane supported on silica in a gas phase process.


**This grade is produced in high-pressure polymerization using free-radical initiation on a tubular reactor.


***These grades are produced using a titanium chloride based catalyst and aluminum alkyl supported on silica in a gas phase process.






In the table FE stands for grades containing a blown film additive package containing 1250 ppm erucamide, 750 ppm anti-block additive and anti-oxidant package and polymer processing aid. CA stands for a blown film additive package containing only anti-oxidant and polymer processing aid. CB and YB stand for cast film additive packages containing an anti-oxidant package only and acid scavenger. XV stand for blown film additive package, anti-oxidant package and acid scavenger. BW stands for a blown film additive package containing an anti-oxidant package only.
Mono-Layer Films
Mono-layer films were blown on an Alpine extruder under the conditions in Table 2A (50 μm thick) and Table 2B (25 μm thick). Test data for the resulting films are reported in Table 3 to 9. The comparative examples, not according to the invention are marked with an asterisk.







TABLE 2A







50 μm mono-layer films:

















H*
J*
I*
C
D
E
F




Polymer
MI = 1.0
MI = 2.0
MI = 2.8
MI = 1.0
MI = 2.0
MI = 2.5
MI = 3.5
K = 80%


Sample
D = 0.918
D = 0.918
D = −0.918
D = 0.918
D = 0.918
MI = 0.918
D = 0.918
C + 20% G
L = 80% D + 20% G





Film Sample
I
II
III
IV
V
VI
VII
VIII
IX


Barrell Temp Settings


(° C.)


Zone 1
180
180
180
180
180
175
175
190
190


Zone 2
180
180
180
180
180
175
175
190
190


Zone 3
180
180
180
180
180
175
175
190
190


Zone 4
180
180
180
180
180
175
175
190
190


Zone 6
180
180
180
180
180
175
175
190
190


Zone 7
180
180
180
180
180
175
175
195
195


Zone 8
180
180
180
180
180
175
175
195
195


Zone 9
180
180
180
180
180
175
175
195
195


Zone 10
190
180
180
190
180
175
175
200
200


Zone 11
190
180
180
190
180
175
175
200
200


Zone 12
200
180
180
200
190
175
175
200
200


Diegap (mm)
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1
1


Cooling Air
21
21
23
22
22
20
20
16
16


Temp (° C.)


Die Diameter (mm)
200
200
200
200
200
200
200
200
200


Melt Temp (° C.)


T1
193
191
185
205
197
193
185
212
206


T2
201
194
188
207
201
200
190
219
211


T3
203
196
190
208
203
203
191
224
214


T4
200
194
188
207
200
200
189
219
210


T5
191
190
184
201
195
191
183
210
204


T Melt
189
188
181
202
193
188
181
208
202


Melt Pressure (Bar)


P1
250
191
154
90
88
75
121
620
447


P2
288
223
191
250
190
189
191
530
533


P3
291
244
217
312
150
166
212
420
281


P4
413
309
289
475
350
293
277
641
471


P5
418
303
286
489
333
309
275
643
474


P6
269
274
257
453
312
288
253
360
367


Screw Speed (RPM)
38
40
44
38
44
44
40
52
56


Output (Kg/H)
78
78
82
80
80
78
78
121
122


Lay-Flat (mm)
781
785
786
785
785
789
777
785
785


BUR
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5


Haul-off Speed
18
18
18
18
18
18
19.7
28
28


(m/min)


Thickness (μm)
50
50
50
50
50
50
46
50
50
















TABLE 2B







25 μm mono-layer films:











Polymer
C MI = 1.0
D MI = 2.0
B MI = 1.0
A MI = 2.0


Sample
D = 0.918
D = 0.918
D = −0.927
D = 0.927





Film Sample
X
XI
XII
XIII


Barrell Temp


Settings (° C.)


Zone 1
180
190
170
175


Zone 2
190
180
175
180


Zone 3
190
175
175
180


Zone 4
190
180
175
180


Zone 6
190
180
185
185


Zone 7
190
180
185
185


Zone 8
190
180
185
185


Zone 9
190
180
190
190


Zone 10
190
180
190
190


Zone 11
200
190
200
200


Zone 12
200
190
200
200


Diegap (mm)
1.5
1.5
1.5
1.5


Cooling Air
20
19
19
19


Temp (° C.)


Die Diameter
200
200
200
200


(mm)


Melt Temp


(° C.)


T1
224
213
200
199


T2
238
225
206
196


T3
243
229
211
199


T4
237
224
205
196


T5
221
210
198
200


T Melt
213
203
197
193


Melt Pressure


(Bar)


P1
278
107
N/A
N/A


P2
358
N/A
114
245


P3
119
N/A
113
46


P4
471
345
589
531


P5
524
396
625
533


P6
209
192
246
328


Screw Speed
61
71
49
46


(RPM)


Output (Kg/H)
121
123
121
122


Lay-Flat (mm)
785
785
785
785


BUR
2.5
2.5
2.5
2.5


Haul-off Speed
56
56
56
56


(m/min)


Thickness (μm)
25
25
25
25









The sealing behavior was as follows:








TABLE 3A







50 μm film

















H
J
I
C
D
E
F




Polymer
MI = 1.0
MI = 2.0
MI = 2.8
MI = 1.0
MI = 2.0
MI = 2.5
MI = 3.5


Sample
D = 0.918
D = 0.918
D = −0.918
D = 0.918
D = 0.918
MI = 0.918
D = 0.918
K = 80% C + 20% G
L = 80% D + 20% G





Film Sample
I
II
III
IV
V
VI
VII
VIII
IX


Hot Tack


Force


90
0.2
0.3
0.2
0
0
0
0
0
0


(all in C)


95
0.3
0.2
0.2
0.1
0
0.1
0.1
0
0.1


100
0.2
0.4
0.7
0.4
1
0.7
1.3
0.9
1.3


105
1.3
0.9
2.2
5
12.8
6
5.4
4.1
6.6


107
1.9
1.4
2
6.4
13.5
11.3
12.5
8.3
12.8


110
3.2
2.2
3
12.9
13.4
12.8
12.6
15.2
14.6


115
6.7
4.7
4.7
15.7
10.3
11.4
10.8
13.7
13.5


120
4.8
4.4
4.1
11.4
9.2
6.6
6.1
9.6
7


125
3.9
3
3.2
9.5
6.7
5.6
6.4
7.5
6.1


130
4.3
3.4
3.4
7.3
7.4
5.9
5.7
6.9
5.9


140
4.2
3.4
2.9
6.4
5.3
4.3
4.2
5.6
5.3


Heat Seal


Strength


95
0.4
0.3
0.3
0.1
0.1
0.2
0.2
0.2
0.1


100
0.7
0.6
0.6
0.3
7.2
5
3.5
0.4
0.3


105
1.8
1.3
1.8
8
8.2
7.9
7.6
8.5
8.9


110
8.5
7.2
8.2
9.8
8.9
8.8
8.5
12.1
11.8


115
9.6
9
9.4
10.9
9.5
9.7
10.5
13.5
13.0


120
10.7
10.1
10.6
12.3
10.7
11.1
12.2
16.4
14.5


125
12.9
10.9
11
11.8
11.3
11.6
11.7
15.7
15.0
















TABLE 3B







25 μm mono-layer films:












C

B
A



MI = 1.0
D MI = 2.0
MI = 1.0
MI = 2.0


Polymer Sample
D = 0.918
D = 0.918
D = 0.927
D = 0.927





Film Sample
X
XI
XII
XIII


Hot Tack Force


90 (all in C)


95


100
0.3
2.2


105
3.2
9.1
0.2
0.1


110
6.2
8.2
0.3
0.5


115


1.7
8.7


117



6.2


120
7.2
6.5
5.6
6.2


125


9.1
5.2


130
4.9
5
6.7
5.2


135


4.9
4.7


Heat Seal Strength


95
0
0.2


100
0.4
3.1


105
4
4.2


110
4.7
5
0.1
0.2


115
5.8
5.5
0.1
1.1


120
5.7
5.8
0.5
6.3


125


6.3
7.2


130


7.0
6.8


140


7.4
7.6









The hot tack and heat seal strength data are converted into graphs.
FIG. 1 plots the heat seal strength data from Table 3A for 50 μm thick films. Sufficient seal strength is developed at 100° C. and above. With LLDPE grades made from metallocene based catalyst systems, the plots vary with MI. A material improvement is provided by an MI of above 1.5 g/10 min. The Table 3B show that the effect is also observable for films of 25 μm. Table 3B also shows that the shift is observable at different densities.
FIG. 2 plots the hot tack data from Table 3A for 50 μm thick films. The 2.0 MI Exceed grade D provides significant hot tack forces below 105° C. The grade conventionally used for blown film extrusion is the 1.0 MI grade, which develops hot tack only above 105° C. Corresponding LL grades made using a titanium chloride based catalyst do not develop equivalent hot tack forces. Such LL grades do not show significant variations of hot tack with different MI.
FIG. 3 plots the heat seal strength for the blends with 20 wt % LDPE. Addition of such levels of LDPE reduces the beneficial effects of the invention.

## Claims

1. Bag with a heat seal zone, the heat seal zone formed by a composition consisting essentially of an interpolymer of ethylene and an alpha-olefin, wherein the interpolymer has an MI of from 1.5 to 3.5 g/10 min, and a density of from 0.910 to 0.93 g/cm3, and a CDBI of at least 50%, and LDPE in an amount less than 20 wt % based on the total weight of the composition; wherein the maximum hot tack force of the bag is at a temperature of less than 110° C.

2. Bag according to claim 1 in which the interpolymer contains short chain branches derived from an alpha-olefin comonomer having from 4 to 8 carbon atoms.

3. Bag according to claim 1 in which the ethylene interpolymer is characterized by the presence of Zr or Hf catalyst residues.

4. Bag according to claim 1, in which the bag is formed from a multi-layer film having a heat seal zone on at least one side.