Patent Description:
Adhesive compositions and/or functionalized polymers are described in the following references: <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, <CIT>, ; International Application <CIT> and International Application <CIT>. However, as discussed above, there is a need for new HMA formulations that have improved adhesion to such "hard to bond" substrates. This need has been met by the following invention.

A composition comprising an acid and/or anhydride grafted ethylene/alpha-olefin interpolymer that comprises the following properties:.

<FIG> depicts a schematic of the test samples and test configuration for the Heat Stress test method.

New adhesive compositions have been discovered that have improved adhesion to UV varnished (UV cured coating) substrate and dense corrugated cardboard, as compared to conventional EVA based formulations, or conventional HMA formulations based on functionalized or non-functionalized ethylene/alpha olefin interpolymers.

As discussed above, a composition is provided that comprises an acid and/or anhydride grafted ethylene/alpha-olefin interpolymer that comprises the following properties:.

The composition may comprises a combination of two or more embodiments described herein.

The acid and/or anhydride grafted ethylene/alpha-olefin interpolymer may comprises a combination of two or more embodiments described herein.

In one embodiment, or a combination of embodiments described herein, the acid and/or anhydride grafted ethylene/alpha-olefin interpolymer is an acid and/or anhydride grafted ethylene/alpha-olefin copolymer. Suitable α-olefins include C<NUM>-C<NUM> α-olefins, further C<NUM>-C<NUM> α-olefins, and further propylene, <NUM>-butene, <NUM>-hexene and <NUM>-octene, or <NUM>-butene, <NUM>-hexene and <NUM>-octene.

In one embodiment, or a combination of embodiments described herein, the acid and/or anhydride grafted ethylene/alpha-olefin interpolymer, and further copolymer, has a density ≥ <NUM>/cc, or ≥ <NUM>/cc, or ≥ <NUM>/cc, or ≥ <NUM>/cc (<NUM> cc = <NUM><NUM>). Suitable α-olefins include C<NUM>-C<NUM> α-olefins, further C<NUM>-C<NUM> α-olefins, and further propylene, <NUM>-butene, <NUM>-hexene and <NUM>-octene, or <NUM>-butene, <NUM>-hexene and <NUM>-octene.

In one embodiment, or a combination of embodiments described herein, the acid and/or anhydride grafted ethylene/alpha-olefin interpolymer, and further copolymer, has a density ≤ <NUM>/cc, or ≤ <NUM>/cc, or ≤ <NUM>/cc, or ≤ <NUM>/cc (<NUM> cc = <NUM><NUM>). Suitable α-olefins include C<NUM>-C<NUM> α-olefins, further C<NUM>-C<NUM> α-olefins, and further propylene, <NUM>-butene, <NUM>-hexene and <NUM>-octene, or <NUM>-butene, <NUM>-hexene and <NUM>-octene.

In one embodiment, or a combination of embodiments described herein, the acid and/or anhydride grafted ethylene/alpha-olefin interpolymer, and further copolymer, has a density from <NUM> to <NUM>/cc, or from <NUM> to <NUM>/cc, or from <NUM> to <NUM>/cc. Suitable α-olefins include C<NUM>-C<NUM> α-olefins, further C<NUM>-C<NUM> α-olefins, and further propylene, <NUM>-butene, <NUM>-hexene and <NUM>-octene, or <NUM>-butene, <NUM>-hexene and <NUM>-octene.

In one embodiment, or a combination of embodiments described herein, the acid and/or anhydride grafted ethylene/alpha-olefin interpolymer, and further copolymer, has a melt viscosity (<NUM>) ≥ <NUM>,<NUM> mPa·s, or ≥ <NUM>,<NUM> mPa·s, or ≥ <NUM>,<NUM> mPa. s, or ≥ <NUM>,<NUM> mPa. s, ≥ <NUM>,<NUM> mPa·s, or ≥ <NUM>,<NUM> mPa·s, or ≥ <NUM>,<NUM> mPa. Suitable α-olefins include C<NUM>-C<NUM> α-olefins, further C<NUM>-C<NUM> α-olefins, and further propylene, <NUM>-butene, <NUM>-hexene and <NUM>-octene, or <NUM>-butene, <NUM>-hexene and <NUM>-octene.

In one embodiment, or a combination of embodiments described herein, the acid and/or anhydride grafted ethylene/alpha-olefin interpolymer, and further copolymer, has a melt viscosity (<NUM>) ≤ <NUM>,<NUM> mPa·s, or ≤ <NUM>,<NUM> mPa·s, or ≤ <NUM>,<NUM> mPa·s, or ≤ <NUM>,<NUM> mPa. s, or ≤ <NUM>,<NUM> mPa. Suitable α-olefins include C<NUM>-C<NUM> α-olefins, further C<NUM>-C<NUM> α-olefins, and further propylene, <NUM>-butene, <NUM>-hexene and <NUM>-octene, or <NUM>-butene, <NUM>-hexene and <NUM>-octene.

In one embodiment, or a combination of embodiments described herein, the acid and/or anhydride grafted ethylene/alpha-olefin interpolymer, and further copolymer, has a melt viscosity (<NUM>) ≤ <NUM>,<NUM> mPa. s, or ≤ <NUM>,<NUM> mPa·s, or ≤ <NUM>,<NUM> mPa·s, or ≤ <NUM>,<NUM> mPa. Suitable α-olefins include C<NUM>-C<NUM> α-olefins, further C<NUM>-C<NUM> α-olefins, and further propylene, <NUM>-butene, <NUM>-hexene and <NUM>-octene, or <NUM>-butene, <NUM>-hexene and <NUM>-octene.

In one embodiment, or a combination of embodiments described herein, the acid and/or anhydride grafted ethylene/alpha-olefin interpolymer, and further copolymer, has a melt viscosity (<NUM>) from <NUM>,<NUM> to <NUM>,<NUM> mPa·s, or from <NUM>,<NUM> to <NUM>,<NUM> mPa. s, or from <NUM>,<NUM> to <NUM>,<NUM> mPa·s, or from <NUM>,<NUM> to <NUM>,<NUM> mPa·s, or from <NUM>,<NUM> to <NUM>,<NUM> mPa·s. Suitable α-olefins include C<NUM>-C<NUM> α-olefins, further C<NUM>-C<NUM> α-olefins, and further propylene, <NUM>-butene, <NUM>-hexene and <NUM>-octene, or <NUM>-butene, <NUM>-hexene and <NUM>-octene.

In one embodiment, or a combination of embodiments described herein, the acid and/or anhydride grafted ethylene/alpha-olefin interpolymer, and further copolymer, is an anhydride grafted ethylene/alpha-olefin interpolymer, and further copolymer. Suitable α-olefins include C<NUM>-C<NUM> α-olefins, further C<NUM>-C<NUM> α-olefins, and further propylene, <NUM>-butene, <NUM>-hexene and <NUM>-octene, or <NUM>-butene, <NUM>-hexene and <NUM>-octene.

In one embodiment, or a combination of embodiments described herein, the acid and/or anhydride grafted ethylene/alpha-olefin interpolymer, and further copolymer, is a maleic anhydride grafted ethylene/alpha-olefin interpolymer, and further copolymer. Suitable α-olefins include C<NUM>-C<NUM> α-olefins, further C<NUM>-C<NUM> α-olefins, and further propylene, <NUM>-butene, <NUM>-hexene and <NUM>-octene, or <NUM>-butene, <NUM>-hexene and <NUM>-octene.

In one embodiment, or a combination of embodiments described herein, the acid and/or anhydride grafted ethylene/alpha-olefin interpolymer, and further copolymer, is present in an amount ≥ <NUM> wt%, or ≥ <NUM> wt%, or ≥ <NUM> wt% based on the weight of the composition. In one embodiment, or a combination of embodiments described herein, the acid and/or anhydride grafted ethylene/alpha-olefin interpolymer, and further copolymer, is present in an amount ≤ <NUM> wt%, or ≤ <NUM> wt%, or ≤ <NUM> wt%, or ≤ <NUM> wt%, based on the weight of the composition. Suitable α-olefins include C<NUM>-C<NUM> α-olefins, further C<NUM>-C<NUM> α-olefins, and further propylene, <NUM>-butene, <NUM>-hexene and <NUM>-octene, or <NUM>-butene, <NUM>-hexene and <NUM>-octene.

In one embodiment, or a combination of embodiments described herein, the acid and/or anhydride grafted ethylene/alpha-olefin interpolymer, and further copolymer, has ≥ <NUM>, or ≥ <NUM>, or ≥ <NUM>, or ≥ <NUM> grafts per polymer chain. Here the term "grafts" refer to the grafted acid and/or anhydride functionalization agent. In one embodiment, or a combination of embodiments described herein, the acid and/or anhydride grafted ethylene/alpha-olefin interpolymer, and further copolymer, has ≤ <NUM> or ≤ <NUM>, or ≤ <NUM> or ≤ <NUM> grafts per polymer chain. Suitable α-olefins include C<NUM>-C<NUM> α-olefins, further C<NUM>-C<NUM> α-olefins, and further propylene, <NUM>-butene, <NUM>-hexene and <NUM>-octene, or <NUM>-butene, <NUM>-hexene and <NUM>-octene.

In one embodiment, or a combination of embodiments described herein, the acid and/or anhydride grafted ethylene/alpha-olefin interpolymer, and further copolymer, has ≥ <NUM>, or ≥ <NUM>, or ≥ <NUM> or ≥ <NUM> wt% grafted acid and/or anhydride groups, based on the total weight of the interpolymer, or copolymer. In one embodiment, or a combination of embodiments described herein, the acid and/or anhydride grafted ethylene/alpha-olefin interpolymer, and further copolymer, has ≤ <NUM> or ≤ <NUM>, or ≤ <NUM> or ≤ <NUM> grafted acid and/or anhydride, based on the total weight of the interpolymer, or copolymer. Suitable α-olefins include C<NUM>-C<NUM> α-olefins, further C<NUM>-C<NUM> α-olefins, and further propylene, <NUM>-butene, <NUM>-hexene and <NUM>-octene, or <NUM>-butene, <NUM>-hexene and <NUM>-octene.

In one embodiment, or a combination of embodiments described herein, the acid and/or anhydride grafted ethylene/alpha-olefin interpolymer, and further copolymer, has a number average molecular weight (Mn) ≥ <NUM>,<NUM>/mole, or ≥ <NUM>,<NUM>/mole, or ≥ <NUM>,<NUM>/mole, or ≥ <NUM>,<NUM>/mole, ≥ <NUM>,<NUM>/mole, or ≥ <NUM>,<NUM>/mole. Suitable α-olefins include C<NUM>-C<NUM> α-olefins, further C<NUM>-C<NUM> α-olefins, and further propylene, <NUM>-butene, <NUM>-hexene and <NUM>-octene, or <NUM>-butene, <NUM>-hexene and <NUM>-octene.

In one embodiment, or a combination of embodiments described herein, the acid and/or anhydride grafted ethylene/alpha-olefin interpolymer, and further copolymer, has a number average molecular weight (Mn) ≤ <NUM>,<NUM>/mole, or ≤ <NUM>,<NUM>/mole, or ≤ <NUM>,<NUM>/mole, or ≤ <NUM>,<NUM>/mole, or ≤ <NUM>,<NUM>/mole, or ≤ <NUM>,<NUM>/mole, or ≤ <NUM>,<NUM>/mole, or ≤ <NUM>,<NUM>/mole. Suitable α-olefins include C<NUM>-C<NUM> α-olefins, further C<NUM>-C<NUM> α-olefins, and further propylene, <NUM>-butene, <NUM>-hexene and <NUM>-octene, or <NUM>-butene, <NUM>-hexene and <NUM>-octene.

In one embodiment, or a combination of embodiments described herein, the acid and/or anhydride grafted ethylene/alpha-olefin interpolymer, and further copolymer, has a molecular weight distribution (Mw/Mn) ≥ <NUM>, or ≥ <NUM>, or ≥ <NUM>, or ≥ <NUM>. Suitable α-olefins include C<NUM>-C<NUM> α-olefins, further C<NUM>-C<NUM> α-olefins, and further propylene, <NUM>-butene, <NUM>-hexene and <NUM>-octene, or <NUM>-butene, <NUM>-hexene and <NUM>-octene.

In one embodiment, or a combination of embodiments described herein, the acid and/or anhydride grafted ethylene/alpha-olefin interpolymer, and further copolymer, has a molecular weight distribution (Mw/Mn) ≤ <NUM>, or ≤ <NUM>, or ≤ <NUM>, or <NUM>. Suitable α-olefins include C<NUM>-C<NUM> α-olefins, further C<NUM>-C<NUM> α-olefins, and further propylene, <NUM>-butene, <NUM>-hexene and <NUM>-octene, or <NUM>-butene, <NUM>-hexene and <NUM>-octene.

In one embodiment, or a combination of embodiments described herein, the acid and/or anhydride grafted ethylene/alpha-olefin interpolymer, and further copolymer, is present in an amount ≥ <NUM> wt%, or ≥ <NUM> wt%, or ≥ <NUM> wt% based on the weight of the composition. Suitable α-olefins include C<NUM>-C<NUM> α-olefins, further C<NUM>-C<NUM> α-olefins, and further propylene, <NUM>-butene, <NUM>-hexene and <NUM>-octene, or <NUM>-butene, <NUM>-hexene and <NUM>-octene.

In one embodiment, or a combination of embodiments described herein, the composition further comprises a tackifier. The tackifier includes, but not limited to, aliphatic, cycloaliphatic and aromatic hydrocarbons and modified hydrocarbons and hydrogenated versions; terpenes and modified terpenes and hydrogenated versions; and rosins and rosin derivatives and hydrogenated versions; and mixtures of two or more of these tackifiers.

In one embodiment, or a combination of embodiments described herein, the composition further comprises a wax. The wax includes, but not limited to, paraffin wax, microcrystalline wax, high density, low molecular weight polyethylene wax, polypropylene wax, thermally degraded wax, by-product polyethylene wax, Fischer-Tropsch wax, oxidized Fischer-Tropsch wax, and functionalized wax, such as hydroxyl stearamide wax and fatty amide wax or a mixture thereof.

In one embodiment, or a combination of embodiments described herein, the composition further comprises a non-functionalized ethylene/alpha-olefin interpolymer, and further a non-functionalized ethylene/alpha-olefin copolymer.

In one embodiment, the composition further comprises a second acid and/or anhydride grafted ethylene/alpha-olefin interpolymer, and further copolymer, and wherein the two interpolymers (or copolymers) differ in one or more properties, such as melt viscosity (177C), density, Mn, or Mw/Mn.

In one embodiment, or a combination of embodiments described herein, the composition has a melt viscosity (<NUM>) ≥ <NUM> mPa·s, or ≥ <NUM> mPa·s, or ≥ <NUM> mPa. s, or ≥ <NUM> mPa·s, ≥ <NUM> mPa·s, or ≥ <NUM>,<NUM> mPa·s. In one embodiment, or a combination of embodiments described herein, the composition has a melt viscosity (<NUM>) ≤ <NUM>,<NUM> mPa·s, or ≤ <NUM>,<NUM> mPa·s, or ≤ <NUM>,<NUM> mPa·s, or ≤ <NUM>,<NUM> mPa·s, or ≤ <NUM>,<NUM> mPa·s, or ≤ <NUM>,<NUM> mPa·s, or ≤ <NUM>,<NUM> mPa·s, or ≤ <NUM>,<NUM> mPa·s.

In one embodiment, or a combination of embodiments described herein, the composition has a Heat Stress ≥ <NUM>, or ≥ <NUM>, or ≥ <NUM>, or ≥ <NUM>, ≥ <NUM>. In one embodiment, or a combination of embodiments described herein, the composition has a Heat Stress ≤ <NUM>, or ≤ <NUM>, or ≤ <NUM>, or ≤ <NUM>, or ≤ <NUM>.

In one embodiment, or a combination of embodiments described herein, the composition has a Fiber Tear (at -<NUM>) from <NUM>% to <NUM>%, or from <NUM>% to <NUM>%, or from <NUM>% to <NUM>%, or from <NUM>% to <NUM>%, or from <NUM>% to <NUM>%.

In one embodiment, or a combination of embodiments described herein, the composition has a Fiber Tear (at <NUM>) from <NUM>% to <NUM>%, or from <NUM>% to <NUM>%, or from <NUM>% to <NUM>%.

In one embodiment, or a combination of embodiments described herein, the composition has a Fiber Tear (at <NUM>) from <NUM>% to <NUM>%, or from <NUM>% to <NUM>%, or from <NUM>% to <NUM>% or from <NUM>% to <NUM>%, or from <NUM>% to <NUM>%.

In one embodiment, or a combination of embodiments described herein, the composition has a Fiber Tear (at -<NUM>) from <NUM>% to <NUM>%, or from <NUM>% to <NUM>%, or from <NUM>% to <NUM>%, or from <NUM>% to <NUM>%, or from <NUM>% to <NUM>%, when bonded to a UV varnished substrate or a dense corrugated cardboard.

In one embodiment, or a combination of embodiments described herein, the composition has a Fiber Tear (at <NUM>) from <NUM>% to <NUM>%, or from <NUM>% to <NUM>%, or from <NUM>% to <NUM>%, when bonded to a UV varnished substrate or a dense corrugated cardboard.

In one embodiment, or a combination of embodiments described herein, the composition has a Fiber Tear (at <NUM>) from <NUM>% to <NUM>%, or from <NUM>% to <NUM>%, or from <NUM>% to <NUM>% or from <NUM>% to <NUM>%, or from <NUM>% to <NUM>%, when bonded to a UV varnished substrate or a dense corrugated cardboard.

In one embodiment, or a combination of embodiments described herein, the composition is in a pellet form (for example, a single pellet).

In one embodiment, or a combination of embodiments described herein, the composition has a gel content (GI200) of ≤ <NUM>, or ≤ <NUM>, or ≤ <NUM>, or ≤ <NUM>, or ≤ <NUM>, or ≤ <NUM>, or ≤ <NUM>, or ≤ <NUM>, or ≤ <NUM>, or ≤ <NUM><NUM> per <NUM><NUM> of film.

In one embodiment, or a combination of embodiments describe herein, the composition comprises < <NUM> wt%, or < <NUM> wt%, or < <NUM> wt% of EVA, based on the weight of the composition. In a further embodiment, the composition does not comprise EVA.

In one embodiment, or a combination of embodiments describe herein, the composition comprises < <NUM> wt%, or < <NUM> wt%, or < <NUM> wt% of a propylene-based polymer, based on the weight of the composition. In a further embodiment, the composition does not comprise a propylene-based polymer.

In one embodiment, or a combination of embodiments describe herein, the composition comprises < <NUM> wt%, or < <NUM> wt%, or < <NUM> wt% of a polymer containing, in polymerized form, styrene, based on the weight of the composition. In a further embodiment, the composition does not comprise a polymer containing, in polymerized form, styrene.

In one embodiment, or a combination of embodiments describe herein, the composition comprises < <NUM> wt%, or < <NUM> wt%, or < <NUM> wt% of a fluoro-containing polymer, based on the weight of the composition. In a further embodiment, the composition does not comprise a fluoro-containing polymer.

In one embodiment, or a combination of embodiments describe herein, the composition comprises < <NUM> wt%, or < <NUM> wt%, or < <NUM> wt% of a polyurethane, based on the weight of the composition. In a further embodiment, the composition does not comprise a polyurethane.

In one embodiment, or a combination of embodiments described herein, the composition further comprises one or more additives. Additives include, but are not limited to, anti-oxidants, fire retardants, UV stabilizers, plasticizers, colorants, fillers (e.g., inorganic fillers), and slip agents. In one embodiment, the composition comprises from greater than zero, or ≥ <NUM> wt%, or ≥ <NUM> wt%, or ≥ <NUM> wt% to ≤ <NUM> wt%, or ≤ <NUM> wt%, or ≤ <NUM> wt%, or ≤ <NUM> wt% of the combined weight of one or more additives, based on the weight of the final composition.

Also is provided an article that comprises at least one component formed from the composition of one or more embodiments described herein.

In one embodiment, or a combination of embodiments described herein, the article is selected from a package structure, an adhesive primer composition, a dispersion, an automotive part, or a building or construction part. In one embodiment, or a combination of embodiments described herein, the article is selected from a film structure comprising one or more layers.

In one embodiment, or a combination of embodiments described herein, the ethylene/ alpha-olefin interpolymer, and further copolymer, comprises greater than, or equal to, <NUM> wt%, further greater than, or equal to, <NUM> wt%, further greater than, or equal to, <NUM> wt%, further greater than, or equal to, <NUM> wt%, or equal to, <NUM> wt% polymerized ethylene, based on the weight of the interpolymer. In one embodiment, the ethylene/alpha-olefin interpolymer is an ethylene/alpha-olefin copolymer. Suitable α-olefins include, but are not limited to, C<NUM>-C<NUM> α-olefins, and preferably C<NUM>-C<NUM> α-olefins. More preferred α-olefins include propylene, <NUM>-butene, <NUM>-pentene, <NUM>-hexene, <NUM>-heptene and <NUM>-octene, further include propylene, <NUM>-butene, <NUM>-hexene and <NUM>-octene, and further <NUM>-butene, <NUM>-hexene and <NUM>-octene.

In one embodiment, or a combination of embodiments described herein, the ethylene/alpha-olefin interpolymer, and further copolymer, has a density ≥ <NUM>/cc, or ≥ <NUM>/cc, or ≥ <NUM>/cc, or ≥ <NUM>/cc (<NUM> cc = <NUM><NUM>). In one embodiment, or a combination of embodiments described herein, the ethylene/alpha-olefin interpolymer, and further copolymer, has a density ≤ <NUM>/cc, or ≤ <NUM>/cc, or ≤ <NUM>/cc, or ≤ <NUM>/cc, or ≤ <NUM>/cc. Suitable α-olefins are described above.

In one embodiment, or a combination of embodiments described herein, the ethylene/alpha-olefin interpolymer, and further copolymer, has a melt index (I<NUM>, <NUM>, <NUM>) ≥ <NUM> dg/min , ≥ <NUM> dg/min, or ≥ <NUM> dg/min, or ≥ <NUM> dg/min, or ≥ <NUM> dg/min, or ≥ <NUM> dg/min,. In one embodiment, ethylene/alpha-olefin interpolymer, and further copolymer, the ethylene/alpha-olefin interpolymer, and further copolymer, has a melt index (I<NUM>, <NUM>, <NUM>) ≤ <NUM> dg/min, or ≤ <NUM> dg/min, or ≤ <NUM> dg/min, or ≤ <NUM> dg/min, or ≤ <NUM> dg/min. Suitable α-olefins are described above.

The ethylene-based interpolymer, or copolymer, may comprise a combination of two or more embodiments as described herein.

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

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.

The term "polymer," as used herein, refers to a polymeric compound prepared by polymerizing monomers, whether of the same or a different type. The generic term polymer thus embraces the term homopolymer (employed to refer to polymers prepared from only one type of monomer, with the understanding that trace amounts of impurities can be incorporated into the polymer structure), and the term interpolymer as defined hereinafter. Trace amounts of impurities, for example, catalyst residues, may be incorporated into and/or within the polymer.

The term "interpolymer," as used herein, refers to polymers prepared by the polymerization of at least two different types of monomers. The generic term interpolymer thus includes copolymers (employed to refer to polymers prepared from two different types of monomers), and polymers prepared from more than two different types of monomers.

The term "olefin-based polymer," as used herein, refers to a polymer that comprises, in polymerized form, <NUM> wt% or a majority amount of an olefin monomer, for example, ethylene or propylene, based on the weight of the polymer, and optionally may comprise one or more comonomers. In one embodiment, the olefin-based polymer comprises a majority amount of the olefin monomer (based on the weight of the polymer) and optionally may comprise one or more comonomers.

The term "propylene-based polymer," as used herein, 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.

The term, "ethylene-based polymer," as used herein, refers to a polymer that comprises, in polymerized form, at least <NUM> wt% or a majority amount of ethylene monomer (based on the weight of the polymer), and optionally may comprise one or more comonomers. In one embodiment, the ethylene-based polymer comprises a majority amount of ethylene monomer (based on the weight of the ethylene-based polymer), and optionally may comprise one or more comonomers.

The term, "ethylene/α-olefin interpolymer," as used herein, refers to an interpolymer that comprises, in polymerized form, at least <NUM> wt% or a majority amount of ethylene monomer (based on the weight of the interpolymer), and at least one α-olefin. In one embodiment, the ethylene/α-olefin interpolymer comprises a majority amount of ethylene monomer (based on the weight of the ethylene-based copolymer) and at least one α-olefin.

The term, "ethylene/α-olefin copolymer," as used herein, refers to a copolymer that comprises, in polymerized form, at least <NUM> wt% or a majority amount of ethylene monomer (based on the weight of the copolymer), and an α-olefin, as the only two monomer types. In one embodiment, the ethylene/α-olefin copolymer comprises a majority amount of ethylene monomer (based on the weight of the ethylene-based copolymer) and an α-olefin as the only monomer types.

The term "acid and/or anhydride grafted ethylene/alpha-olefin interpolymer," and similar terms, as used herein, refer to an ethylene/alpha-olefin interpolymer comprising, in graft form, bonded carboxylic acid groups and/or bonded anhydride groups.

The term "anhydride grafted ethylene/alpha-olefin interpolymer," and similar terms, as used herein, refer to an ethylene/alpha-olefin interpolymer comprising, in graft form, bonded anhydride groups. As understood in the art, trace amounts of anhydride groups may form carboxylic acid groups due to reaction with water, for example, in an atmosphere.

The term "functionalization agent," as used herein, refers to a compound containing at least one functional group which may be bonded into (for example, incorporated) and/or onto (for example, grafted) a polymer (i.e., an ethylene-based polymer).

The term "functional group," as used herein, refers to a chemical group comprising at least one heteroatom (e.g., O, N, Si, Cl). A functional group may additionally contain unsaturation. Exemplary functional groups include, but are not limited to, acid and anhydrides.

The term "free-radical initiator," as used herein, refers to a compound that produces radical species for radical reactions.

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 order to avoid any doubt, all compositions claimed through use of the term "comprising" may include any additional additive, adjuvant, or compound, whether polymeric or otherwise, unless stated to the contrary. 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.

Density was measured in accordance with ASTM D792, Method B. The result was recorded in grams (g) per cubic centimeter (g/cc or g/cm<NUM>).

The concentration of maleic anhydride is determined by the ratio of peak heights of the maleic anhydride at wave number <NUM>-<NUM> to the polymer reference peak, which, in case of polyethylene, is at wave number <NUM>-<NUM>. Maleic anhydride content is calculated by multiplying this ratio with the appropriate calibration constant. The equation used for maleic grafted olefin-based polymer (with reference peak for polyethylene) has the following form, as shown in Equation <NUM>.

The calibration constant A can be determined using C13 NMR standards. The actual calibration constant may differ slightly, depending on the instrument and polymer. The second component at wave number <NUM>-<NUM> accounts for the presence of maleic acid, which is negligible for freshly grafted material. Over time, however, maleic anhydride is readily converted to maleic acid in the presence of moisture. Depending on surface area, significant hydrolysis can occur in just a few days under ambient conditions. The acid has a distinct peak at wave number <NUM>-<NUM>. The constant B in Equation <NUM> is a correction for the difference in extinction coefficients between the anhydride and acid groups.

The sample preparation procedure begins by making a pressing, typically <NUM> to <NUM> millimeters in thickness, in a heated press, between two protective films, at <NUM>-<NUM> for one hour. MYLAR and TEFLON are suitable protective films to protect the sample from the platens. Aluminum foil must never be used (maleic anhydride reacts with aluminum). Platens should be under pressure (~<NUM> ton) for about five minutes. The sample is allowed to cool to room temperature, placed in an appropriate sample holder, and then scanned in the FTIR. A background scan should be run before each sample scan, or as needed. The precision of the test is good, with an inherent variability of less than ± <NUM>%. Samples should be stored with desiccant to prevent excessive hydrolysis. Moisture content in the product has been measured as high as <NUM> weight percent. The conversion of anhydride to acid however is reversible with temperature, but may take up to one week for complete conversion. The reversion is best performed in a vacuum oven at <NUM>; a good vacuum (><NUM> inches Hg) is required. If the vacuum is less than adequate, the sample tends to oxidize resulting in an infrared peak at approximately <NUM>-<NUM>, which will cause the values for the graft level to be too low. Maleic anhydride and acid are represented by peaks at about <NUM> and <NUM>-<NUM>, respectively.

The chromatographic system consists of a PolymerChar GPC-IR (Valencia, Spain) high temperature GPC chromatograph, equipped with an internal IR5 infra-red detector (IR5). The autosampler oven compartment is set at <NUM>, and the column compartment is set at <NUM>. The columns used are <NUM> Agilent "Mixed A" <NUM> <NUM>-micron linear mixed-bed columns, and a <NUM>-um pre-column. The chromatographic solvent is <NUM>,<NUM>,<NUM>-trichlorobenzene, which contains <NUM> ppm of butylated hydroxytoluene (BHT). The solvent source is nitrogen sparged. The injection volume used is <NUM> microliters and the flow rate is <NUM> milliliters/minute.

Calibration of the GPC column set is performed with <NUM> narrow molecular weight distribution polystyrene standards, with molecular weights ranging from <NUM> to <NUM>,<NUM>,<NUM>/mol, and which are arranged in six "cocktail" mixtures, with at least a decade of separation between individual molecular weights. The standards are purchased from Agilent Technologies. The polystyrene standards are prepared at "<NUM> grams in <NUM> milliliters of solvent" for molecular weights equal to, or greater than, <NUM>,<NUM>,<NUM>/mol, and at "<NUM> grams in <NUM> milliliters of solvent" for molecular weights less than <NUM>,<NUM>,<NUM>/mol. The polystyrene standards are dissolved at <NUM>, with gentle agitation, for <NUM> minutes. The polystyrene standard peak molecular weights are converted to ethylene-based polymer molecular weights, using Equation <NUM> (as described in <NPL>)): <MAT> where M is the molecular weight, A has a value of <NUM> and B is equal to <NUM>.

A fifth order polynomial is used to fit the respective ethylene-based polymer -equivalent calibration points. A small adjustment to A (from approximately <NUM> to <NUM>) is made to correct for column resolution and band-broadening effects, such that NIST standard NBS <NUM> is obtained at a molecular weight of <NUM>,<NUM>/mol.

The total plate count of the GPC column set is performed with EICOSANE (prepared at "<NUM> in <NUM> milliliters of TCB," and dissolved for <NUM> minutes with gentle agitation). The plate count (Equation <NUM>) and symmetry (Equation <NUM>) are measured on a <NUM> microliter injection according to the following equations: <MAT> where RV is the retention volume in milliliters, the peak width is in milliliters, the peak max is the maximum height of the peak, and half height is one half of the height of the peak maximum; <MAT> where RV is the retention volume in milliliters, and the peak width is in milliliters, peak max is the maximum height of the peak, one tenth height is one tenth of the height of the peak maximum, and where rear peak refers to the peak tail at later retention volumes than the peak max, and where front peak refers to the peak front at earlier retention volumes than the peak max. The plate count for the chromatographic system should be greater than <NUM>,<NUM>, and symmetry should be between <NUM> and <NUM>.

Samples are prepared in a semi-automatic manner with the PolymerChar "Instrument Control" Software, wherein the samples are weight-targeted at <NUM>/ml, and the solvent (contained 200ppm BHT) is added to a pre nitrogen-sparged septa-capped vial, via the PolymerChar high temperature autosampler. The samples are dissolved for three hours at <NUM>, under "low speed" shaking.

The calculations of Mn(GPC), Mw(GPC), and Mz(GPC) are based on the GPC results, using the internal IR5 detector (measurement channel) of the PolymerChar GPC-IR chromatograph according to Equations <NUM>-<NUM>, using PolymerChar GPCOne™ software, the baseline-subtracted IR chromatogram at each equally-spaced data collection point i (IRi), and the ethylene-based polymer equivalent molecular weight obtained from the narrow standard calibration curve for the point i (Mpolyethylene,i in g/mol) from Equation <NUM>. Subsequently, a GPC molecular weight distribution (GPC-MWD) plot (wtGPC(lgMW) vs. IgMW plot, where wtGPC(lgMW) is the weight fraction of ethylene-based polymer molecules with a molecular weight of IgMW) for the ethylene-based polymer sample can be obtained. Molecular weight is in g/mol and wtGPC(lgMW) follows: ∫wtGPC(lg MW)d lg MW = <NUM> (Equation <NUM>).

Number-average molecular weight Mn(GPC), weight-average molecular weight Mw(GPC) and z-average molecular weight Mz(GPC) can be calculated as the following equations: <MAT><MAT> <MAT>.

In order to monitor the deviations over time, a flow rate marker (decane) is introduced into each sample via a micropump controlled with the PolymerChar GPC-IR system. This flow rate marker (FM) is used to linearly correct the pump flow rate (Flowrate(nominal)) for each sample by RV alignment of the respective decane peak within the sample (RV(FM Sample)) to that of the decane peak within the narrow standards calibration (RV(FM Calibrated)). Any changes in the time of the decane marker peak are then assumed to be related to a linear-shift in flow rate (Flowrate(effective)) for the entire run. To facilitate the highest accuracy of a RV measurement of the flow marker peak, a least-squares fitting routine is used to fit the peak of the flow marker concentration chromatogram to a quadratic equation. The first derivative of the quadratic equation is then used to solve for the true peak position. After calibrating the system based on a flow marker peak, the effective flow rate (with respect to the narrow standards calibration) is calculated as Equation <NUM>. Processing of the flow marker peak is done via the PolymerChar GPCOne™ Software. Acceptable flow rate correction is such that the effective flowrate should be within <NUM>% of the nominal flowrate.

The grafts per chain are calculated using the following Formula A: <MAT> where <NUM> is the MAH molecular weight. The number average molecular weight (Mn) of the grafted polymer was measured using the GPC test method (outlined above).

Fiber Tear (%) Percent fiber tear (FT) of compositions using UV varnished substrates or dense corrugated cardboard was determined according to a standardized method. A bead of sample composition (<NUM>. 00014lb/in) was applied on to a cardboard coupon (<NUM> x <NUM>) using an Olinger Bond Tester, and a second coupon was quickly placed on top of the sample composition. Light finger pressure, for about <NUM> seconds, was applied to hold the bond in place. Samples were conditioned for at least <NUM> hours at room temperature and <NUM> % relative humidity. Next, samples were conditioned at the test temperatures for <NUM> hours to <NUM> hours. Samples (n=<NUM>) were pulled apart by hand and the failure mode (fiber tear, cohesive failure, adhesive failure), and the average result was recorded.

Heat stress resistance (Heat Stress) was measured according to the "Suggested Test Method for Determining the Heat Stress Resistance of Hot Melt Adhesives," method T-<NUM>, prepared by the Institute of Packaging Professions (IoPP). To prepare one sample, two cardboard coupons available from Inland Corrugated Cardboard (cut with flutes running in the long direction) having dimensions of <NUM> inches (<NUM>) x <NUM>-<NUM>/<NUM> in (<NUM>) and <NUM> in (<NUM>) x <NUM>-<NUM>/<NUM> in (<NUM>) were bonded by applying <NUM>. 00014lb/in of the composition using an Olinger Bond Tester (application temperature <NUM>), and this tester was used to compress the coupons at a constant pressure, and without a further application of heat. The composition was applied perpendicular to the flutes in the center of the shorter coupon and the coupons were bonded such that the composition was ¾ in (<NUM>) from one end of the long coupon. Five replicates were made for each composition. Each coupon was stored for <NUM> hours, at <NUM>-<NUM>, and <NUM>% relative humidity. Samples (<NUM>) were then loaded into a sample holder (<NUM>), with the short coupon end aligned with the edge of the sample holder (<NUM>), as shown in <FIG>. The samples (<NUM>) were held in place with a wide plate (<NUM>) of the sample holder (<NUM>), and the plate (<NUM>) was secured by wingnuts (<NUM>) to the sample holder (<NUM>). A "<NUM>" weight (<NUM>) was attached to the coupon (<NUM>), at a distance of <NUM> in (<NUM>) from the bond. The weight (<NUM>) was secured by placing the peg attached to the weight into a hole made in the end of the longer coupon. The sample holder (<NUM>), containing the coupon (<NUM>) and the attached weight (<NUM>), was then placed into a convection oven (not shown), equilibrated at a set temperature, and remained in the oven for <NUM> hours. At the end of the <NUM> hours, if at least <NUM>% of the bonds (i.e., <NUM> bonds) do not fail, then the sample is considered to have passed heat resistance testing at the test temperature. The oven temperature was varied, until the maximum passing heat stress resistance (temperature) was determined. All new bonded coupon samples were used for each test temperature. Results are reported as heat stress temperature (°C).

Melt viscosity (at <NUM>, or noted temperature) was measured using a Brookfield Viscometer Model, and a Brookfield RV-DV-II-Pro viscometer spindle <NUM>. The sample was poured into an aluminum disposable tube-shaped chamber, which was, in turn, inserted into a Brookfield Thermosel, and locked into place. The sample chamber has a notch on the bottom that fits the bottom of the Brookfield Thermosel, to ensure that the chamber is not allowed to turn, when the spindle is inserted and spinning. The sample (approximately <NUM>-<NUM> grams) was heated to the required temperature, until the melted sample was one inch below the top of the sample chamber. The viscometer apparatus was lowered, and the spindle submerged into the middle of the sample chamber, wherein the spindle did not touch the sides of the chamber. Lowering was continued, until the brackets on the viscometer align on the Thermosel. The viscometer was turned on, and set to operate at a steady shear rate, which led to a torque reading in the range from <NUM> to <NUM> percent of the total torque capacity, based on the rpm output of the viscometer. Readings were taken every minute for <NUM> minutes, or until the values stabilize, at which point, a final reading was recorded.

Differential Scanning Calorimetry (DSC) can be used to measure the melting, crystallization, and glass transition behavior of a polymer over a wide range of temperature. For example, the TA Instruments Q1000 DSC, equipped with an RCS (refrigerated cooling system) and an autosampler was used to perform this analysis. During testing, a nitrogen purge gas flow of <NUM>/min was used. Each sample was melt pressed into a thin film at <NUM>; the melted sample was then air-cooled to room temperature (<NUM>). A "<NUM>-<NUM>," <NUM> diameter specimen was extracted from the cooled polymer, weighed, placed in a light aluminum pan (<NUM>), and crimped shut. Analysis was then performed to determine its thermal properties.

The thermal behavior of the sample was determined by ramping the sample temperature up and down to create a heat flow versus temperature profile. First, the sample was rapidly heated to <NUM> and held isothermal for <NUM> minutes, in order to remove its thermal history. Next, the sample was cooled to -<NUM>, at a <NUM>/minute cooling rate, and held isothermal at -<NUM> for <NUM> minutes. The sample was then heated to <NUM> (this is the "second heat" ramp) at a <NUM>/minute heating rate. The cooling and second heating curves were recorded. The values determined are extrapolated onset of melting, Tm, and extrapolated onset of crystallization, Tc.

The heat of fusion (Hf) and the peak melting temperature were reported from the second heat curve. Peak crystallization temperature was determined from the cooling curve.

Melting point, Tm, was determined from the DSC heating curve by first drawing the baseline between the start and end of the melting transition. A tangent line was then drawn to the data on the low temperature side of the melting peak. Where this line intersects the baseline is the extrapolated onset of melting (Tm). This is as described in <NPL>).

Crystallization temperature, Tc, was determined from a DSC cooling curve as above, except the tangent line was drawn on the high temperature side of the crystallization peak. Where this tangent intersects the baseline is the extrapolated onset of crystallization (Tc).

Glass transition temperature, Tg, was determined from the DSC heating curve, where half the sample has gained the liquid heat capacity as described in <NPL>). Baselines were drawn from below and above the glass transition region and extrapolated through the Tg region. The temperature at which the sample heat capacity was half-way between these baselines is the Tg.

Peel adhesion failure temperature (PAFT) was tested according to ASTM D <NUM>, with a "<NUM> gram weight" in the peel mode. The tests were started at room temperature (<NUM>/<NUM>°F), and the temperature was increased at an average rate of <NUM>/minute.

Shear Adhesion Failure Temperature (SAFT) was measured according to ASTM D <NUM>, with a "<NUM> gram weight" in the shear mode. The tests were started at room temperature (<NUM>/<NUM>°F), and the oven temperature was ramped at an average rate of <NUM>/minute. The temperature at which the specimen failed was recorded.

Samples for PAFT and SAFT testing were prepared using two sheets of <NUM> pound Kraft paper, each of <NUM> x <NUM> in (<NUM> x <NUM>) dimensions. On the bottom sheet, lengthwise, and separated by a gap of <NUM> in (<NUM>), were adhered, in parallel fashion, two "<NUM> in or <NUM> in (<NUM> or <NUM>) wide" strips of a one sided, pressure-sensitive tape such as masking tape. The composition sample to be tested was heated to <NUM> (<NUM>°F), and drizzled in an even manner down the center of the gap formed between the tape strips. Then, before the composition could unduly thicken, two glass rods, one rod riding immediately upon the tapes, and shimmed on each side of the gap with a strip of the same tape, followed by the second rod, and (between the two rods) the second sheet of paper, were slid down the length of the sheets. This was done in a fashion, such that the first rod evenly spread the composition in the gap between the tape strips, and the second rod evenly compress the second sheet over the top of the gap, and on top of the tape strips. Thus, a single "<NUM> inch (<NUM>) wide" strip of sample sheet was created between the two tape strips, and bonding the paper sheets. The sheets so bonded were cut crosswise into strips of "width <NUM> inch (<NUM>)" and "length of <NUM> inches (<NUM>)," each strip having a "<NUM> in x <NUM> in (<NUM> x <NUM>)" adhesive sample bond in the center. The strips were then used in the PAFT and SAFT testing, as desired.

The reaction mixture consisted of the base polymer, maleic anhydride (MAH), and peroxide (POX) that was diluted with mineral oil (<NUM>:<NUM>), to facilitate ease of handling and feeding. The POX was <NUM>,<NUM>-dimethyl-<NUM>,<NUM>-di(tert-butylperoxy)hexane (DBPH, <NPL>); which can be obtained from Arkema or Akzo Nobel Corp. The MAH was obtained from MagnaKron Corporation. A "<NUM> SUS white mineral oil" was used to dilute the POX. See Table <NUM>. The grafting reaction was performed (extruder), and the grafted polymer was pelletized.

The grafting reaction was performed in two, <NUM>, co-rotating twin screw extruders, arranged in tandem. Each extruder was configured with <NUM> barrels (<NUM>/D), providing a total L/D ratio of <NUM>. For each extruder, the maximum screw speed for was <NUM> rpm, and the motor output was <NUM> HP. The extrusion set-up was equipped with "loss-in-weight feeders," and the POX and molten MAH were metered into the extruder at Barrel 4B and Barrel 3B of the first extruder respectively. The run rate was between <NUM> - <NUM> lbs/hr. Nitrogen gas was injected, at approximately five standard cubic foot per hour (SCFH), in the first barrel of Extruder <NUM>, to maintain an inert atmosphere and to minimize oxidation. A vacuum (<NUM>' Hg) was pulled on Barrel <NUM> of Extruder <NUM>. The operating conditions for Extruder <NUM> & Extruder <NUM> are shown in Table <NUM>. The "compounding set-up," downstream of Extruder <NUM>, included a gear pump, a screen changer, a water slide, a strand pelletizer.

A wet cut water slide, strand pelletizer consisted of a <NUM> hole die, with nominal <NUM>" die hole diameter opening. The water slide had eight spray zones (three spray nozzles per zone), and the resulting pellet/water slurry was separated using a spin dryer. The water temperature was maintained from <NUM>-<NUM>°F, and it was pumped at approximately <NUM> gpm to water slide. The cutter speed was about <NUM> t <NUM> rpm.

Materials used to produce compositions, further hot melt adhesive compositions, are shown in Table <NUM> below. The starting materials from Table <NUM> are weighed, and then melt blended at <NUM>, for <NUM> minute, at <NUM> rpm, using a small can mixer, equipped with temperature control. The compositions and their application performance data are provided in Tables <NUM>-<NUM> below.

The grafts per chain were calculated using Formula A. For example for EO <NUM> (MAH functionalized ethylene/octene copolymer <NUM>), substituting the MAH graft level <NUM> wt% and the Mn <NUM>/mol in Formula A (see above), the chains per graft = (<NUM>/<NUM>)/(<NUM>/<NUM>) = <NUM>.

Hot melt adhesive composition, and application performance data, for UV varnished substrate are listed in Table <NUM>. As shown in Table <NUM>, the compositions containing the MAH functionalized ethylene/octene copolymer (Ex. <NUM> and Ex. <NUM>) exhibit (i) higher Fiber Tear (≥ <NUM>%) in the range of -<NUM> to <NUM>, and (ii) higher a Heat Stress (≥ <NUM>) than the comparative compositions containing EVA (CS. <NUM>) or GA <NUM> only (CS. <NUM>) or GA <NUM> and GA 1000R (CS. <NUM> and CS. <NUM>), or GA <NUM> and the MAH grafted ethylene-based polymer, as noted, with lower grafts per chain (CS. <NUM>, and CS.

Claim 1:
A composition comprising an acid and/or anhydride grafted ethylene/alpha-olefin interpolymer that comprises the following properties:
A) number of grafts per polymer chain ≥ <NUM>, and
B) melt viscosity (at <NUM>) ≤ <NUM>,<NUM> mPa.s;
wherein the number of grafts per polymer chain is determined according to formula A: <MAT>
wherein the MAH wt% is determined in accordance with the method described in the description;
wherein the Mn is determined in accordance with the GPC method described in the description; and
wherein the melt viscosity is measured using a Brookfield Viscometer Model, and a Brookfield RV-DV-II-Pro viscometer spindle <NUM>.