IMPROVED ADHESION OF POLYOLEFINS TO POLYESTERS

Abstract

The use of a block copolymer of the following structure. Wherein R and R.sup.1 may be the same or different and each independently represents an alkyl or aryl group, X may be hydrogen or C.sub.1 to C.sub.20 alkyl group which may be branched or linear and wherein the aromatic ring substituent joined to polymer B is positioned meta or para to the aromatic ring substituent joined to polymer A and, wherein polymer A is a polymer (or copolymer) of ethylene and polymer B is a polymer of monomers selected from vinyl acetate, C.sub.1-C.sub.9 acrylate esters, acrylic acid and mixtures thereof as an additive in polyethylene or polyethylene terephthalate to improve the adhesion between co-extruded layers of the polyethylene and the polyethylene terephthalate and laminated films derived from such use.

##STR00001##

Claims

1. A block copolymer of the following structure: ##STR00012## wherein R and R.sup.1 may be the same or different and each independently represents an alkyl or aryl group, and X may be hydrogen or C.sub.1 to C.sub.20 alkyl group which may be branched or linear; wherein the aromatic ring substituent joined to polymer B is positioned meta or para to the aromatic ring substituent joined to polymer A; and wherein polymer A is a polymer (or copolymer) of ethylene and polymer B is a polymer of vinyl acetate.

2-26. (canceled)

27. Polyethylene or polyethylene terephthalate containing from 0.1 wt % to 15 wt % of a block copolymer of the following structure: ##STR00013## wherein R and R.sup.1 may be the same or different and each independently represents an alkyl or aryl group, and X may be hydrogen or C.sub.1 to C.sub.20 alkyl group which may be branched or linear; wherein the aromatic ring substituent joined to polymer B is positioned meta or para to the aromatic ring substituent joined to polymer A; and wherein polymer A is a polymer (or copolymer) of ethylene and polymer B is a polymer of monomers selected from vinyl acetate, C.sub.1-C.sub.9 acrylate esters, acrylic acid, and mixtures thereof.

28. The polyethylene or polyethylene terephthalate according to claim 27, wherein each R and R.sup.1 group independently represents an alkyl group having from 1 to 4 carbon atoms.

29. The polyethylene or polyethylene terephthalate according to claim 27, wherein the aromatic ring substituent joined to polymer B is positioned meta to the aromatic ring substituent joined to polymer A.

30. The polyethylene or polyethylene terephthalate according to claim 27, wherein block A of the block copolymers is produced by the metallocene catalyzed polymerization of ethylene optionally together with other alkene-1 compounds.

31. The polyethylene or polyethylene terephthalate according to claim 27, wherein block A has a number average molecular weight (Mn) in the range 1000 to 10,000.

32. The polyethylene or polyethylene terephthalate according to claim 27, wherein block B is produced by the free radical catalyst polymerization of vinyl acetate.

33. The polyethylene or polyethylene terephthalate according to claim 27, wherein block B has a molecular weight (Mn) in the range of 1000 to 20,000, preferably in the range 3000 to 6000.

34. A laminate comprising a layer of polyethylene or paper bonded to a layer of polyethylene terephthalate, wherein at least one layer contains a block copolymer of the following structure: ##STR00014## wherein R and R.sup.1 may be the same or different and each independently represents an alkyl or aryl group, and X may be hydrogen or C.sub.1 to C.sub.20 alkyl group which may be branched or linear; wherein the aromatic ring substituent joined to polymer B is positioned meta or para to the aromatic ring substituent joined to polymer A; and wherein polymer A is a polymer (or copolymer) of ethylene and polymer B is a polymer of monomers selected from vinyl acetate, C.sub.1-C.sub.9 acrylate esters, acrylic acid, and mixtures thereof.

35. The laminate according to claim 34, wherein the inherent viscosity (IV) of the polyethylene terephthalate used in the laminate is in the range of 0.72 to 0.88 dL/g.

36. The laminate according to claim 34, wherein the polyethylene is medium-density polyethylene, low-density polyethylene, or linear low-density polyethylene.

37. The laminate according to claim 34, wherein the laminate comprises a layer of polyethylene provided on both surfaces with a layer of polyethylene terephthalate.

38. A laminate comprising the laminate of claim 34 laminated to paper or board.

39. The laminate according to claim 37, wherein the inherent viscosity (IV) of the polyethylene terephthalate used in the laminate is in the range of 0.72 to 0.88 dL/g.

40. The laminate according to claim 37, wherein the polyethylene is medium-density polyethylene, low-density polyethylene, or linear low-density polyethylene.

41. Packaging material for foods and beverages comprising the laminate according to claim 28.

42. A process for the production of the laminate of polyethylene and polyethylene terephthalate according to claim 34, comprising: co-extruding layers of polyethylene and polyethylene terephthalate, wherein at least one of the layers contains a block copolymer of the structure. ##STR00015## wherein R and R.sup.1 may be the same or different and each independently represents an alkyl or aryl group, and X may be hydrogen or C.sub.1 to C.sub.20 alkyl group which may be branched or linear; wherein the aromatic ring substituent joined to polymer B is positioned meta or para to the aromatic ring substituent joined to polymer A; and wherein polymer A is a polymer (or copolymer) of ethylene and polymer B is a polymer of monomers selected from vinyl acetate, C.sub.1-C.sub.9 acrylate esters, acrylic acid, and mixtures thereof.

43. A masterbatch comprising polyethylene or polyethylene terephthalate containing from 30 to 70 wt % of the block copolymer according to claim 1.

Description

DETAILED DESCRIPTION

[0031] The block copolymer of this invention may be prepared by [0032] a) in a first step, polymerising ethylene, and optionally one or more 1-alkene co-monomers higher than ethylene such as C.sub.2 to C.sub.8 olefines particularly hexene and octene, preferably in the presence of a metallocene catalyst system to form polymer A, being a chain consisting of ethylenic structural units optionally bearing pendent alkyl groups originating from the 1-alkene comonomer(s), the reaction being carried out in the presence of a compound of the formula (I):

##STR00010## [0033] in a reaction vessel wherein, in the course of the reaction, the compound (I) is terminally incorporated onto polymer A resulting in the formation of a terminally unsaturated intermediate of the formula (II):

##STR00011## [0034] b) in an optional second step, recovering the intermediate (II) from the reaction mixture of the first step; and [0035] c) in a third step, reacting the intermediate (II) at its terminal double bond with a monomer selected from vinyl acetate, C.sub.1-C.sub.9 acrylate esters and acrylic acid and mixtures thereof in a subsequent radical polymerisation reaction to form polymer B.

[0036] where R, R1 and X are as previously defined.

[0037] Optionally step a) may be performed under hydrogen pressure in order to control the characteristics of polymer A.

[0038] In this specification, the word terminal when used in relation to a polymer chain (or block) simply refers to the end of the polymer chain (or block), and does not convey any additional mechanistic requirement that the chain (or block) end in question be the end at which the polymerisation reaction terminated. References to terminally shall be construed analogously.

[0039] Polymer A may have a backbone chain of polyethylenic structural units optionally incorporating in the backbone chain, units derived from 1-alkenes higher than ethylene, such that the resulting polymer chain remains an uninterrupted sequence of saturated aliphatic carbon atoms, the residual alkyl groups of the 1-alkene residues being borne as saturated alkyl substituents pendant from the polymer chain.

[0040] It is important that polymer A be terminally joined to polymer B, so as to leave polymer A exposed for interacting with the polyethylene or polyethylene terephthalate with which it is used. As such, it is important that the linkage between polymer A and polymer B be positioned at the end of the polymeric chain of polymer A.

[0041] To achieve this terminal positioning of the linkage between polymer A and polymer B, the process by which the copolymer is made should be specific for terminal functionalization of polymer A. Equally, it is important that the terminal functionalization formed on polymer A be sufficiently reactive to enable the subsequent formation of polymer B under radical polymerisation conditions that are industrially practical, whilst at the same time not being so highly reactive that unwanted side reactions occur to a significant extent.

[0042] The block A of the block copolymers of this invention is preferably produced by the metallocene catalysed polymerisation of ethylene optionally together with other alkene-1 compounds and the structure and molecular weight of block A can be tailored according to the nature of the polyethylene and the polyethylene terephthalate. We prefer however that it be substantially linear and have a number average molecular weight (Mn) in the range 1000 to 10,000. Such polymers preferably have a molecular weight distribution Mw/Mn from about 1 to about 3 preferably about 2.

[0043] The block B of the block copolymer is preferably produced by the free radical polymerisation. It is preferred that block B has a molecular weight (Mn) in the range of 1000 to 20,000 preferably in the range 3000 to 6000. Such polymers preferably have a molecular weight distribution (Mw/Mn) in the range 1.5 to 3.5 more preferably 2 to 3.

[0044] Block B may be prepared by the polymerisation of vinyl acetate or one or more C.sub.1-C.sub.9 acrylate esters or acrylic acid or mixtures thereof. Methyl acrylate, butyl acrylate and hexyl acrylate being preferred.

[0045] The heat sealable laminate of polyethylene and polyethylene terephthalate of the present invention can be formed without the use of an anchor coating agent or an adhesive. Thus, the laminate can be free from an odor problem due to a residual solvent or the like. Thus, a possible problem ascribed to a heat seal layer of polyolefin, such as adsorption of an olefin odor and fragrance components, is avoided, and excellent aroma retaining properties are ensured. Moreover, the polyethylene terephthalate layer has heat sealability.

[0046] The laminate of the present invention is also excellent in water vapor barrier properties and gas barrier properties. Moreover, the polyethylene terephthalate layer has heat sealability. Thus, the laminate can be formed into a container or the like by heat sealing, and the resulting container or the like is excellent in the long-term storage characteristics required of a food or beverage packaging material.

[0047] In one embodiment the laminate may comprise a layer of polyethylene provided on both surfaces with a layer of polyethylene terephthalate. In this embodiment either the polyethylene can contain the block copolymer used in the invention or both layers of polyethylene terephthalate may contain the block copolymer. Such a laminate is particularly useful for lamination to paper to produce packaging materials where one of the layers of polyethylene terephthalate can secure the adhesion of the laminate to the paper and the other layer provides a heat sealable surface for the ultimate closing of the packaging material. Thus, paper/polyethylene/polyethylene terephthalate can be laminated without the use of an anchor coating agent or an adhesive between the polyethylene and the polyethylene terephthalate.

[0048] In another embodiment of the present invention, polyethylene may be coated on at least one surface of a paper substrate, and polyethylene terephthalate containing the block copolymer is coated on the polyethylene surface by melt extrusion lamination, and again a strong laminate may be produced without an adhesive or the like being interposed.

[0049] The polyethylene terephthalate used in this invention (may hereinafter be referred to as PET) consists essentially of a polyester which is formed by dehydration condensation of ethylene glycol as a diol component and terephthalic acid as a dicarboxylic acid component, and which has ester bonds connected together.

[0050] The polyethylene terephthalate for use in the present invention may be homopolyethylene terephthalate or a copolymer formed from a mixture of phthalic acids. Homopolyethylene terephthalate is formed by polycondensation of ethylene glycol as a diol component and terephthalic acid as a dicarboxylic acid component, and which does not positively contain any other copolymerization component. The polyethylene terephthalate may include impurity components which occur as by-products during preparation of polyethylene terephthalate.

[0051] It is preferred that the inherent viscosity (IV) of the polyethylene terephthalate used in the laminate of the present invention be in the range of 0.72 to 0.88 dL/g, particularly 0.80 to 0.83 dL/g. If the inherent viscosity is lower than this range, the film-forming properties can be poor and the inherent viscosity is higher than this range, it may be difficult to extrude.

[0052] The polyethylene terephthalate used in the present invention can incorporate compounding agents for film such as anti-blocking agents, antistatic agents, lubricants, antioxidants, and ultraviolet absorbers.

[0053] The polyethylene used in this invention may be any commercial polyethylene such as high-density polyethylene (HDPE), medium-density polyethylene (MDPE), low-density polyethylene (LDPE), and linear low-density polyethylene (LLDPE). The use of medium-density polyethylene, low-density polyethylene or linear low density polyethylene is preferred, particularly when the laminate is to be further bonded to paper because of their easy lamination onto a paper substrate.

[0054] The thickness of the polyethylene layer is not limited, but generally, a thickness of 10 to 60 m is preferred.

[0055] The laminate of the present invention includes a polyethylene terephthalate surface which has heat sealability. Thus, it is possible to form the laminate into a predetermined shape by heat sealing polyethylene terephthalate surfaces to each other, without adding a further polyethylene layer. Furthermore it is possible to bond the polyethylene terephthalate to other substrates such as paper. Many packaging materials contain a layer of aluminum foil to provide barrier properties. It is believed that the present invention may enable polyethylene terephthalate to be used in place of aluminum to obtain the desirable barrier properties which also improves the recyclability of the packaging material.

[0056] Where a paper substrate is included any traditional paper substrates may be used in the laminate, paperboards conventionally used in paper containers can all be used. For example, ivory board, cup stock base paper, Manila board, cardboard, and synthetic paper can be used. The basis weight of the base paper or board used is not limited, but preferably, it is in the range of 180 to 500 g/m.sup.2. If the basis weight is less than this range, the mechanical strength of the resulting container may be inferior to that obtained using paper within this range. If the basis weight is greater than this range, on the other hand, the resulting container can become so heavy that its handle ability and formability may be inferior.

[0057] The laminate of the present invention is not limited to two or three polyethylene/polyethylene terephthalate layers or to the three layers, paper/polyethylene/polyethylene terephthalate. For example, polyethylene also may be coated on the other surface of the paper. The selection of additional layers that should be added can be selected optionally depending on uses.

[0058] The present invention is illustrated by reference to the following Examples.

EXAMPLE 1

[0059] Materials Used

[0060] Polyethylene Terephthalate Ramapet 180 a copolymer of terephthalic acid, isophthalic acid and mono-ethylene glycol obtainable from Informa Venturer having an Intrinsic viscosity of 0.800.02, density (D 1505) 1.4 g/cm.sup.3 Crystalline Peak melting point (D 3418) 2455 C., Glass Transition temperature (D 3418) 782 C. (referred to as PET).

[0061] Low density polyethylene LDPC 3020K available from Lyondell Basell having a Melt Flow Rate (190 C./2.16 Kg) of 4 g/10 minutes a density of 0.928 g/cm.sup.3, vicat softening point (A/50N) of 97 C. a DSC melting point of 114 C. (referred to as LDPE).

[0062] Experimental Block Copolymers (of the invention) known as BCX26 and Polarfin PRP027 which is a polyethylene-block-poly(vinyl acetate), PE-b-PVAc, block copolymer consisting of a polyethylene block of number average molecular weight (M.sub.n) 3200 and dispersity 2 as measured by high temperature gel permeation chromatography, terminally coupled to a polyvinyl acetate) (PVAc) block of approximately 20 monomer units (1700 M.sub.n) as measured by solution phase Nuclear Magnetic Resonance (NMR) spectroscopy.

[0063] The polyethylene used to produce BCX26 was produced in a 1 gallon reactor in a semi-batch fashion by feeding ethylene as required to maintain a constant reactor pressure. A catalyst (Dicyclopentadienyl Zirconium dichloride Cp2ZrCL2 in toluene) was pumped in as needed to maintain the ethylene uptake near 100% of the 10 slpm setting of the ethylene flow meter. The reactor temperature was controlled manually to be near 90 C. A constant feed rate of 0.4 slpm of hydrogen was held throughout the test. Liquid samples (50-100 grams) were collected periodically throughout the test at 20, 40, 60, 90 120, and 150 minutes. Gas samples (1 liter) were collected two minutes before each liquid sample.

[0064] The polyethylene was used to make the PE-b-PVAc block copolymer as follows, the PE was catalytically reacted with Diisopropenyl benzene to produce PE-DIB. The PE-DIB (X g) was added to a 1 L reactor, along with X mL of toluene. Overhead stirrer turned on and set to 500 rpm.

[0065] Vinyl acetate (VAc) monomer (X mL) was added to the dropping funnel.

[0066] Reactor and dropping funnel purged with N.sub.2 for 30 mins.

[0067] In separate round bottom flasks, VAc monomer (X mL) and Benzoyl peroxide (BP) stock solution (X g BP in X mL Toluene) were purged with N.sub.2 for 30 mins.

[0068] Whilst the system was purging the reactor was heated to 110 C.

[0069] After purging, the VAc was transferred to the PE-DI Bitoluene solution in the reactor, using a degassed syringe. This caused the internal temperature to drop to 94 C.

[0070] X mL of the BP solution was added to a degassed 50 mL syringe and placed on a syringe pump.

[0071] Addition from the syringe pump and dropping funnel was started at the same time. Feed Rates: VAc=X mL/hr, BP=X mL/hr.

[0072] The two solutions were added to the reactor over 2 hr and once completed the reaction was heated at 110 C. for a further 1 hr.

[0073] Volatiles were removed using a rotary evaporator leaving approximately 200 mL of slurry which was heated to 100 C. and precipitated into 2 L of stirred ethanol. The precipitate was left to settle, excess solvent decanted off and filtration used to yield the PE-b-PVAc block copolymer. The solid was collected from the filter and dried overnight in a vacuum oven to remove any residual solvent.

[0074] The material of the invention was compounded with the LDPE in an extruder at about 180 C. The material was then extruded from a three layer blown film die from an extruder consisting of three temperature zones. (Test 2). The material was compared with a similar material without the material of the invention (Test 1).

[0075] The inner layer was the compounded LDPE layer and the middle and outer layers were of the PET.

[0076] The layers were as follows.

TABLE-US-00001 Test Inner Middle Outer Number Layer Layer Layer 1 LDPE PET PET 2 LDPE + 10% BCX PET PET

[0077] The extrusion conditions were

TABLE-US-00002 Inner Layer Middle Layer Outer Layer () ( C.) ( C.) Feeding Zone 40 Not Controlled 65 Zone 2 160 240 230 Zone 3 190 270 270 Zone 4 190 270 270 Adapter 190 270 270 Die Zone 1 250 Die Zone 2 250 Screw Speed (RPM) 40 20 20

[0078] The Haul Off Speed (m/min) was 6.5.

TABLE-US-00003 Test Inner Layer Middle Layer Outer Layer Number (Bar) (Bar) (Bar) 1 80 46 46 2 52 37 45

[0079] The Interlayer adhesion was determined by assessing the force required to peel the LDPE inner layer away from the PET middle layer.

[0080] 30 mm wide strips of the films were cut to form test pieces for the assessment of adhesion employing a peel test.

[0081] The films were opened at the bubble to produce single layers of the film. The delamination at the PET/LDPE interface was started manually prior to testing, in order to provide parts of the sample to go into the grips. This delamination involved immersing the end of each of the test strips into water heated to 85 C. and the end 3-4 cm was immersed for a few minutes, removed, stressed in two directions within the plane of the film and re-immersed.

[0082] The Peel test results were as follows.

TABLE-US-00004 TEST 1 TEST 2 Force (N) 0.06 1.2 0.04 1.3 0.04 1.4 0.04 1.7 0.03 1.3 0.04 1.2 0.06 1.2 1.5 1.2 1.2 Average (N) 0.04 1.32

[0083] The areas over which steady state peeling took place were noted and used as the results. These areas are the parts of the test when the delamination is steady and the film is not curling around or folded back on itself.

[0084] In Test 2, the force required for peeling was sufficiently large to cause plastic deformation in the LDPE layer during the peel test as shown by stress whitening in the LDPE layer.

EXAMPLE 2

[0085] 40 g of the polyethylene diisopropyl benzene reactant prepared as in Example 1 of number average molecular weight by NMR of 1650 was fed into a reactor, fitted with a water condenser and nitrogen bubbler, with 300 ml toluene. The reactor was heated up to 100 C., and purged with N.sub.2 for 30 minutes. 5.76 g of V601 initiator (0.0250 mol, 2 eq.) was dissolved in 50 ml toluene purged for 30 minutes. 170 ml of Methyl Acrylate (density=0.956 g/ml, 1.89 mol, 150 eq.) was also purged for 30 minutes. The initiator solution and the monomer solution were transferred to syringes set to 50 ml/hour and 170 ml/hour delivery respectively. The reactor was left under nitrogen atmosphere and the syringe pumps started, leaving the reaction for 1 hour. After 1 hour the reflux divider tap was opened and the temperature was increased to boil off toluene and unreacted monomer. After an hour, a toluene/polymer mixture (275 ml total volume) was emptied from the reactor. The polymer was then precipitated into 1.25 litres of methanol (a antisolvent ratio of 4.5:1). The sample was left to settle overnight. The top clear layer of methanol was decanted, 750 ml fresh methanol was added, stirred for 1 hour, and left overnight to settle. The top layer of methanol was decanted, and the product was transferred to a 1 litre rotary evaporator and evaporated to dryness. The product was then dried in a vacuum oven overnight and analysed and found to have a molecular weight of 5750 by NMR.

[0086] The product was compounded with linear low density polyethylene at 1%, 5% and 10% of the block copolymer and blown into film on a Haake film line. The film blowing parameters were as follows:

[0087] Screw speed 30 rpm

[0088] Haul off 300 units

[0089] Air blow time 1 minute

[0090] Air blow quantity 1 L/min

[0091] The films were rolled up such that the first part of the extrudate was in the middle of the roll, and the last part at the outermost part of the roll.

[0092] Using a small white press the film samples were adhered to sheets of the polyester film Melinex. The film samples were preheated in hot plates for 20 seconds, after which the pressure was applied, at 10 Tonnes for 2 min 20 seconds. Several samples of film bonded to Melinex were produced for each batch.

[0093] The compression moulded samples were cut to strips of 40 mm wide. The delamination between the two components was manually started, and these two parts were fed into the grips of the tensile testing equipment, a Lloyds LR50k, fitted with a 50N load cell.

[0094] Peel testing was carried out at 100 mm/minute. The results for these samples are given in Table 3.

TABLE-US-00005 TABLE 3 Results of Peel Test of LLDPE Block Copolymer blend on Melinex polyester film Peel test (N/40 mm) LLDPE + 1% LLDPE + 5% LLDPE + 10% Block Block Block Sample LLDPE Copolymer Copolymer Copolymer 1 0.4 1.5 4 6.5* 2 0.6 2.0 4 6.5* 3 0.4 1.8 5 7* 4 0.45 2.0 5 7* 5 0.45 1.8 5 6 0.5 1.8 5 7 5 Average 0.5 1.8 4.7 6.8* *The film samples containing 10% Block Copolymer stretched during testing. This indicates that the adhesion to the Melinex was greater that the tensile strength of the film. The peel strength of the film is therefore greater than the measured 7 N/40 mm.