Patent Description:
Pipes made with polyethylene have been used for water pipes, sewage pipes, industrial pipes, and the like, and have greater resistance to sagging and resistance to slow crack growth to be applicable to large-diameter pipes, and the use thereof is gradually diversifying.

When processing large-diameter pipes, resistance to sagging caused by the weight of pipe itself is indispensable, and this may improve by reducing melt index of a polyethylene resin.

Methods of reducing the melt index may include changing physical properties of the polyethylene resin itself, changing extrusion conditions as a post-treatment method, or adding peroxide upon extrusion.

The reducing of the melt index with the addition of peroxide significantly increases the resistance to sagging but tends to decrease resistance to slow crack growth and increase odor level. Meanwhile, the changing of the physical properties of the polyethylene resin itself or the reducing of the melt index only through extrusion conditions has limitations in increasing the resistance to sagging.

<CIT> relates to polyethylene resin compositions suitable for use as pipe with good resistance to sagging and slow crack growth. However, this document is silent about specific extrusion conditions, in particular in term of the extrusion rate and a specific range of extrusion temperature.

<CIT> discloses the polymerization of ethylene in a multistep reactor using organic peroxide, but it is silent about specific extrusion conditions.

An aspect of the present invention provides a polyethylene resin composition for pipe, which is all superior in resistance to sagging of pipe, resistance to slow crack growth, and an odor level.

An aspect of the present invention provides a method of preparing the polyethylene resin composition for pipe.

Another aspect of the present invention provides a molded article prepared from the polyethylene resin composition for pipe.

The invention is as defined in the attached claims.

According to the invention as claimed in the attached claims, a polyethylene resin composition for pipe has a melt index (under a load of <NUM>, at <NUM>) of <NUM>/<NUM> to <NUM>/<NUM>, and is prepared by passing through a two stage reactor, passing through an extruder, and adding peroxide, wherein a rate of change in the melt index (MI) (under a load of <NUM>, at <NUM>) by the extruder is <NUM>% to <NUM>% according to Equation <NUM> below, and a rate of change in the melt index (MI) (under a load of <NUM>, at <NUM>) by the peroxide is <NUM>% to <NUM>% according to Equation <NUM> below. <MAT> <MAT>.

The polyethylene resin composition has a zero shear viscosity (η0) of <NUM>,<NUM>,<NUM> poise to <NUM>,<NUM>,<NUM> poise.

The polyethylene resin composition may have a melt strength of <NUM> mN to <NUM> mN.

A rate of reduction in drop time in the presence of sagging versus drop time in the absence of sagging upon extrusion of the polyethylene resin composition may be <NUM>% to <NUM>%, and the drop time may be measured using a single screw extruder.

The polyethylene resin composition has a strain hardening modulus of <NUM> MPa to <NUM> MPa.

According to the invention as claimed in the attached claims, the method of preparing a polyethylene resin composition for pipe includes passing through a two stage reactor to obtain a polyethylene resin, and adding peroxide to the polyethylene resin and passing through an extruder to obtain a polyethylene resin composition, wherein the extruder is operated at a temperature of <NUM> to <NUM> and a rate of <NUM>,<NUM> rpm to <NUM>,<NUM> rpm.

The peroxide may be added in an amount of <NUM> parts by weight to <NUM> parts by weight with respect to <NUM> parts by weight of the polyethylene resin.

The melt index (under a load of <NUM>, at <NUM>) of the polyethylene resin after passing through the two stage reactor is <NUM>/<NUM> to <NUM>/<NUM>.

The melt index (under a load of <NUM>, at <NUM>) of the polyethylene resin composition after passing through the extruder before adding the peroxide is <NUM>/<NUM> to <NUM>/<NUM>.

The melt index (under a load of <NUM>, at <NUM>) of the polyethylene resin composition after adding the peroxide and passing through the extruder is <NUM>/<NUM> to <NUM>/<NUM>.

According to another embodiment, provided is a molded article prepared from the polyethylene resin composition for pipe.

Hereinafter, embodiments will be described in detail, and may be readily performed by those who have common knowledge in the related art. However, embodiments may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.

The polyethylene resin composition for pipe according to the invention has a melt index (under a load of <NUM>, at <NUM> ° C) of <NUM>/<NUM> to <NUM>/<NUM>, for example, <NUM>/<NUM> to <NUM>/<NUM>. When the melt index of the polyethylene resin composition is within the above range, processing load and surface roughness of products are reduced upon pipe processing, and resistance to sagging of pipe and strain hardening modulus thereof may be increased. Accordingly, a polyethylene resin composition which is superior in both resistance to sagging of pipe and resistance to slow crack growth may be obtained.

In the polyethylene resin composition, the melt index may change by stage in the preparation process before obtaining a final melt index. According to an embodiment, a polyethylene resin is obtained through ethylene polymerization while being subjected to passing through a two stage reactor, and then a polyethylene resin composition may be prepared while being subjected to passing through an extruder together with the addition of peroxide to the polyethylene resin. In this case, a melt index (MI1) of the polyethylene resin right after passing through the two stage reactor, a melt index (MI2) of the polyethylene resin composition right after passing through the extruder before the addition of peroxide, and a melt index (MI3) after passing through the extruder together with the addition of peroxide, which corresponds to the melt index of a final polyethylene resin composition, may be different in each stage. That is, the melt index right after passing through the two stage reactor may change its value after passing through the extruder having predetermined operating conditions (change from MI1 to MI2), and also the melt index after passing through the extruder without the addition of peroxide may change its value after passing through the extruder having predetermined operating conditions and adding peroxide (change from MI2 to MI3).

A rate of change in the melt index (MI) (under a load of <NUM>, at <NUM> ° C) by the extruder, which corresponds to the rate of change from MI1 to MI2, may be <NUM>% to <NUM>% according to Equation <NUM> below, for example, <NUM>% to <NUM>%.

In addition, a rate of change in the melt index (MI) (under a load of <NUM>, at <NUM> ° C) by the peroxide, which corresponds to the rate of change from MI2 to MI3, may be <NUM>% to <NUM>% according to Equation <NUM> below, for example, <NUM>% to <NUM>%.

When the rate of change in the melt index by the extruder and the rate of change in the melt index by the peroxide are each within the above ranges, a polyethylene resin composition which is all superior in the resistance to sagging of pipe, the resistance to slow crack growth and the odor level may be obtained.

The polyethylene resin composition has a zero shear viscosity (η0) of <NUM>,<NUM>,<NUM> poise to <NUM>,<NUM>,<NUM> poise, for example, <NUM>,<NUM>,<NUM> poise to <NUM>,<NUM>,<NUM> poise. The zero shear viscosity may be obtained by measuring storage modulus and loss modulus according to shear rate (unit rad/sec). When the zero shear viscosity of the polyethylene resin composition is within the above range, resistance to sagging upon pipe processing, specifically large-diameter pipe processing, may be excellent, and the polyethylene resin composition may thus be usefully used for large-diameter pipes.

The polyethylene resin composition may have a melt strength of <NUM> mN to <NUM> mN, for example, <NUM> mN to <NUM> mN. The melt strength may be obtained by measuring force for stabilization with an increase in the pulling rate of the resin at a resin temperature of <NUM> and a chamber temperature of <NUM>. When the melt strength of the polyethylene resin composition is within the above range, resistance to sagging upon pipe processing, specifically large-diameter pipe processing, may be excellent, and the polyethylene resin composition may thus be usefully used for large-diameter pipes.

In the polyethylene resin composition, a rate of reduction in drop time in the presence of sagging versus drop time in the absence of sagging upon extrusion may be <NUM>% to <NUM>%, for example, <NUM>% to <NUM>%. The drop time may be measured using a single screw extruder. Specifically, under the conditions of a temperature of <NUM> , an extrusion amount of <NUM>/min, and an initial linear velocity of an extruded resin of <NUM>/sec upon extrusion, when the height to the ground is <NUM> and the extruded resin does not sag, with respect to a case where the time to reach the ground is <NUM> seconds, time that the polyethylene resin composition reaches the ground may be measured to determine reduction rate relative to the case where the above sagging is not caused. When the reduction rate of drop time is within the above range, resistance to sagging upon pipe processing, specifically large-diameter pipe processing, may be excellent, and the polyethylene resin composition may thus be usefully used for large-diameter pipes.

The polyethylene resin composition has a strain hardening modulus of <NUM> MPa to <NUM> MPa, for example, <NUM> MPa to <NUM> MPa. When the strain hardening rate of the polyethylene resin composition is within the above range, the resistance to slow crack growth is excellent to allow long term use of pipes and provide large-diameter pipes having excellent durability.

Hereinafter, a method of preparing the polyethylene resin composition for pipe according to another embodiment will be described.

The polyethylene resin composition is prepared by passing through a two stage reactor to obtain a polyethylene resin, and adding peroxide to the polyethylene resin and passing through an extruder. In this case, the extruder may be operated at a temperature of <NUM> to <NUM>, for example, a temperature of <NUM> to <NUM>, and a rate of <NUM>,<NUM> rpm to <NUM>,<NUM> rpm, for example, a rate of <NUM>,<NUM> rpm to <NUM>,<NUM> rpm.

When the polyethylene resin composition is prepared through an extruder operating within the temperature and rate ranges, the rate of change in the melt index (MI) (under a load of <NUM>, at <NUM> ° C) of the polyethylene resin composition by the extruder may be obtained within the range of <NUM>% to <NUM>%, and accordingly, a polyethylene resin composition which is all superior in the resistance to sagging of pipe, the resistance to slow crack growth and the odor level may be obtained. The rate of change in the melt index by the extruder may be obtained according to Equation <NUM> as described above.

Specifically, the melt index (under a load of <NUM>, at <NUM>) of the polyethylene resin after passing through the two stage reactor is <NUM>/<NUM> to <NUM>/<NUM>, for example, <NUM>/<NUM> to <NUM>/<NUM>. In addition, the melt index (under a load of <NUM>, at <NUM>) of the polyethylene resin composition after passing through the extruder before adding the peroxide is <NUM>/<NUM> to <NUM>/<NUM>, for example, <NUM>/<NUM> to <NUM>/<NUM>.

In addition, since the polyethylene resin composition is prepared by passing through the extruder together with the addition of peroxide, the rate of change in the melt index (MI) (under a load of <NUM>, at <NUM> ° C) of the polyethylene resin composition by the peroxide may be obtained within the range of <NUM>% to <NUM>%, and accordingly, a polyethylene resin composition which is all superior in the resistance to sagging of pipe, the resistance to slow crack growth and the odor level may be obtained.

Specifically, the melt index (under a load of <NUM>, at <NUM> ° C) of the polyethylene resin composition after passing through the extruder before the addition of peroxide, and the melt index of the polyethylene resin composition after passing through the extruder together with the addition of peroxide, that is, the melt index of a final polyethylene resin composition, are each as described above.

The peroxide may be added in an amount of <NUM> parts by weight to <NUM> parts by weight with respect to <NUM> parts by weight of the polyethylene resin, for example, <NUM> parts by weight to <NUM> parts by weight or, as specifically claimed in claim <NUM>, <NUM> parts by weight to <NUM> parts by weight. When peroxide is added within the above amount range, a polyethylene resin composition which is all superior in the resistance to sagging of pipe, the resistance to slow crack growth, and the odor level may be obtained.

In the stage of obtaining the polyethylene resin composition, an additive including an antioxidant, a neutralizing agent, or a combination thereof may be further included. The additive may be included in an amount of <NUM> parts by weight to <NUM> parts by weight with respect to <NUM> parts by weight of the polyethylene resin composition.

The antioxidant may include <NUM>,<NUM>,<NUM>-trimethyl-<NUM>,<NUM>,<NUM>-tris(<NUM>,<NUM>-di-tert-butyl-<NUM>-hydroxybenzyl)benzene, <NUM>,<NUM>-bis[<NUM>-(<NUM>,<NUM>)-di-tert-butyl-<NUM>-hydroxyphenyl)propionamido]hexane, <NUM>,<NUM>-bis[<NUM>-(<NUM>,<NUM>-di-tert-butyl-<NUM>-hydroxyphenyl)propionamido]propane, tetrakis[methylene(<NUM>,<NUM>-di-tert-butyl-<NUM>-hydroxyhydrocinnamate)]methane, bis(<NUM>,<NUM>-di-tert-butyl-<NUM>-methylphenyl)pentaerythritol-di-phosphite , bis(<NUM>,<NUM>-di-tert-butylphenyl)pentaerythritol-di-phosphite, or a combination thereof.

The antioxidant may be included in an amount of <NUM> parts by weight to <NUM> parts by weight, or, as specifically as claimed in claim <NUM>, <NUM> parts by weight to <NUM> parts by weight, with respect to <NUM> parts by weight of the polyethylene resin composition. When the antioxidant is added within the above amount range, a polyethylene resin composition which is all superior in the resistance to sagging of pipe, the resistance to slow crack growth, and the odor level may be obtained.

The neutralizing agent may include calcium stearic acid, zinc stearic acid, magnesium aluminum hydroxy carbonate, zinc oxide, magnesium hydroxy stearic acid, or a combination thereof.

The neutralizing agent may be included in an amount of <NUM> parts by weight to <NUM> parts by weight, or, as specifically claimed in claim <NUM>, <NUM> parts by weight to <NUM> parts by weight, with respect to <NUM> parts by weight of the polyethylene resin composition. When neutralizing agent is added within the above amount range, a polyethylene resin composition which is all superior in the resistance to sagging of pipe, the resistance to slow crack growth, and the odor level may be obtained.

According to another embodiment, a molded article prepared from the polyethylene resin composition described above is provided.

The molded article may be a pipe used for a water pipe, a sewage pipe, and an industrial pipe, specifically a large-diameter pipe having a large diameter.

The polyethylene resin composition for pipe is all superior in resistance to sagging of the pipe, resistance to slow crack growth, and an odor level, and may thus be usefully used for large-diameter pipes.

Hereinafter, specific examples of the present invention are presented. However, the following examples are merely used to illustrate or describe the present invention in more detail, and are not to be seen as limiting the present invention. Furthermore, what is not described herein may be sufficiently understood by those skilled in the art who have knowledge in this field, and thus are omitted.

Ethylene polymerization was performed using a ziegler-natta catalyst and a <NUM>-hexene co-monomer through a series polymerization method in which two reactors were connected in series.

The powder-type polyethylene resin obtained after the two stage reactor had a melt index (under a load of <NUM>, at <NUM>) of <NUM>/<NUM>.

<NUM> parts by weight of Irganox <NUM> and <NUM> parts by weight of Irgafos-<NUM> as antioxidants, <NUM> parts by weight of calcium stearic acid as a neutralizing agent, and <NUM> parts by weight of Trigonox <NUM> as peroxide were mixed to <NUM> parts by weight of the powdered polyethylene resin obtained above with a Henschel mixer to prepare a polyethylene resin composition in the form of pellets, using a twin screw extruder. In this case, a screw having a diameter of <NUM> and an L/D (screw length/diameter) of <NUM> was used as the twin screw extruder, and the twin screw extruder was operated at a temperature of <NUM> and a rate of <NUM>,<NUM> rpm.

The polyethylene resin composition in the form of pellets prepared therefrom had a melt index (under a load of <NUM>, at <NUM>) of <NUM>/<NUM> before adding the peroxide, and <NUM>/<NUM> after adding the peroxide. This is shown in Table <NUM> below.

A polyethylene resin composition was prepared in the same manner as in Example <NUM>, except that peroxide was not added in Example <NUM>.

The polyethylene resin composition in the form of pellets prepared therefrom had a melt index (under a load of <NUM>, at <NUM>) of <NUM>/<NUM>.

The powdered polyethylene resin obtained after the two stage reactor had a melt index (under a load of <NUM>, at <NUM>) of <NUM>/<NUM> instead of <NUM>/<NUM>, and a polyethylene resin composition was prepared in the same manner as in Example <NUM>, except that peroxide was not added.

A polyethylene resin composition was prepared in the same manner as in Example <NUM>, except that peroxide was not added in Example <NUM>, and the twin screw extruder was operated at a temperature of <NUM> and a rate of <NUM>,<NUM> rpm.

<NUM> parts by weight of Irganox <NUM> and <NUM> parts by weight of Irgafos-<NUM> as antioxidants, <NUM> parts by weight of calcium stearic acid as a neutralizing agent, and <NUM> parts by weight of Trigonox <NUM> as peroxide were mixed to <NUM> parts by weight of the powdered polyethylene resin obtained above with a Henschel mixer to prepare a polyethylene resin composition in the form of pellets, using a single screw extruder. In this case, a screw having a diameter of <NUM> and an L/D (screw length/diameter) of <NUM> was used as the single screw extruder, and the single screw extruder was operated at a temperature of <NUM> and a rate of <NUM> rpm.

The following physical properties were measured for the polyethylene resin compositions prepared in Examples <NUM> and <NUM> and Comparative Examples <NUM> to <NUM>, and the results are shown in Tables <NUM> and <NUM> below.

In according with ASTM D1238, the melt index was measured under a load of <NUM> at <NUM>.

The rate of change in the melt index by an extruder was obtained through Equation <NUM> below, and the rate of change in the melt index by peroxide was obtained through Equation <NUM> below. <MAT> <MAT>.

Using an advanced rheometer expansion system (ARES, <NUM>), storage modulus G' and loss modulus G" according to shear rate (unit rad/sec) were measured and zero shear viscosity η0 was calculated through Carreau model.

Force for stabilization with an increase in the pulling rate of a resin at a resin temperature of <NUM> and a chamber temperature of <NUM> was measured.

A HAAKE™ and Rheomex OS single screw extruder was used, and a die having a diameter of <NUM> in the form of a bar was used. Temperature was set to <NUM>, extrusion rate was maintained at <NUM>/min, and initial linear velocity of an extruded resin was <NUM>/sec. Height to the ground was <NUM>, and when the extruded resin did not sag, the time to reach the ground was <NUM> seconds. By measuring the time that each polyethylene resin composition reached the ground, the reduction rate relative to a case of no sagging was calculated.

Strain hardening modulus was measured in accordance with ISO <NUM>.

<NUM> of the polyethylene resin composition and <NUM> of water were put into an airtight container, left in an oven at <NUM> for <NUM> hours, and then left at room temperature for <NUM> hour to evaluate odor level. The worse the odor level, the higher the score, and the score was rated on a scale of <NUM> to <NUM>.

Impact strength was measured through the charpy impact test at -<NUM> in accordance with ISO <NUM>-<NUM>.

Oxidation induction time was measured in accordance with ISO <NUM>-<NUM> at <NUM>.

Table <NUM> shows that in the polyethylene resin compositions according to Examples <NUM> and <NUM>, the final melt index, the rate of change in the melt index by the extruder, and the rate of change in the melt index by the peroxide satisfy the predetermined ranges according to an embodiment. For Examples <NUM> and <NUM>, it is seen that the resistance to sagging of pipe, the resistance to slow crack growth, and the odor level were all superior to those of Comparative Examples <NUM> to <NUM>.

On the other hand, in Comparative Example <NUM> in which peroxide was not added, the final melt index was out of the ranges according to an embodiment, and in this case, the resistance to slow crack growth and the odor level were slightly superior, but the zero shear viscosity and the melt strength were greatly reduced and the rate of reduction in drop time was greatly increased, indicating that the resistance to sagging of pipe was reduced. In addition, in Comparative Example <NUM>, the resistance to slow crack growth was increased, but as peroxide was not added, it is seen that the resistance to sagging of pipe was reduced.

For Comparative Example <NUM> as a case of excluding peroxide and passing through the extruder outside the predetermined temperature and rate conditions, it is seen that the resistance to sagging of pipe was slightly increased, but the odor level was increased due to high shear stress and the oxidation induction time was reduced.

The polyethylene resin composition of Comparative Example <NUM> was extruded under extrusion conditions of low shear stress using a single screw extruder to reduce the rate of change in the melt index by the extruder to <NUM>%, and greatly increase the rate of change in the melt index according to peroxide to <NUM>% by adding an excessive amount of peroxide. Accordingly, the resistance to sagging of pipe was greatly increased, but the resistance to slow crack growth and the oxidation induction time were greatly reduced due to the addition of high amount of peroxide, and the odor level was greatly increased.

Claim 1:
A polyethylene resin composition for use in manufacturing pipe, which has a melt index under a load of <NUM>, at <NUM> of <NUM>/<NUM> to <NUM>/<NUM>,
obtainable by polymerization performed using a Ziegler-Natta catalyst and a <NUM>-hexene co-monomer in a two stage reactor to obtain a polyethylene resin, adding peroxide to the polyethylene resin, and extruding the polyethylene resin mixture by a twin screw extruder to obtain a polyethylene resin composition
wherein the extrusion is performed at a temperature of <NUM> to <NUM> and a rate of <NUM>,<NUM> rpm to <NUM>,<NUM> rpm
wherein the melt index under a load of <NUM>, at <NUM>, measured according with ASTM D1238 of the polyethylene resin after passing a two stage reactor is <NUM>/<NUM> to <NUM>/<NUM>; wherein the melt index under a load of <NUM>, at <NUM>, measured according with ASTM D1238 of the polyethylene resin composition after adding the peroxide and passing through the extruder is <NUM>/<NUM> to <NUM>/<NUM>; and
wherein the polyethylene resin mixture comprises;
<NUM> parts by weight of the polyethylene resin,
peroxide in amount of <NUM> parts by weight to <NUM> parts by weight with respect to <NUM> parts by weight of the polyethylene resin,
an antioxidant in amount of <NUM> parts by weight to <NUM> parts by weight with respect to <NUM> parts by weight of the polyethylene resin; and
a neutralizing agent in amount of <NUM> parts by weight to <NUM> parts by weight with respect to <NUM> parts by weight of the polyethylene resin, and
wherein the polyethylene resin composition has Zero shear viscosity of <NUM>,<NUM>,<NUM> to <NUM>,<NUM>,<NUM> poise, determined by using an advanced rheometer expansion system (ARES, <NUM>), storage modulus G' and loss modulus G" according to shear rate (unit rad/sec) and calculated through Carreau model, and
wherein the polyethylene resin composition has a strain hardening modulus of <NUM> MPa to <NUM> MPa measured in accordance with ISO <NUM>.